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1996 Group 00 - General

1997 Model Changes
1998 Model Changes
1999 Model Changes
2000 Model Changes
2001 Model Changes
Pub. No. TWSE9501-5
Service Manual
Table of Contents
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Model Year Changes
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For U.S.A. Pub. No. TWSE9501-5

MAY 2000
FE/FG
SERVICE MANUAL
FOREWORD GROUP INDEX
2001 MODEL CHANGES
This Service Manual contains maintenance and repair meth-

ods for personnel involved in the maintenance and repair of
GENERAL ...........................................
00
2001 model Mitsubishi Fuso Truck FE/FG series.
Read this manual carefully as an aid in providing correct,
efficient and fast maintenance.
MAINTENANCE SCHEDULE .............
01
Please note, however, that due to continuous improvements
on the specifications, numbers and description for mainte-
nance might be changed without prior notice.
ENGINE <4D34T3> ............................
11
If you have any questions, or encounter a problem, please
do not hesitate to contact your nearest Mitsubishi Fuso dealer
or distributor.
AUTOMATIC TRANSMISSION ...........
23
Mitsubishi Motors Corporation, May 2000 TRANSFER <FG> ..............................
24
ELECTRICAL .....................................
54
2001 MODEL CHANGES
i
2001 MODEL CHANGES
Item 01 Model 0 00 Model
Gr 00 General
Power Train Table and Vehicle Identifi- Gr 00
cation number have been updated.
Gr 01 Maintenance Schedule
The schedule for 4M50T2 engine has Gr 01
been added.
Gr 10 REMOVAL & INSTALLATION Removal and Installation of Engine
Removal and installation proce-
dures for 4M50T2 established
*
1
29529
P Removal sequence
1 Nut 3 Transmission assembly B Gr22 *: Wide cab vehicle only
2 Bolt 4 Engine assembly
WARNING k
When lifting the engine assembly 4, be sure to use a lifting gear or engine hoist
capable of lifting an engine of 3.9 to 4.7 kN {880 to 1060 lbs, 400 to 480 kg}.
P Installation sequence
Follow the removal sequence in reverse.
Tightening torque Unit: Nm{lbf.ft, kgfm}
Location Parts to be tightened Tightening torque Remarks

1 Nut (For attaching front mounting) 69 to 99 {51 to 65, 7 to 9}
2 Bolt (For attaching rear mounting) 125 to 175 {94 to 130, 13 to 18}
ii
Gr 11 Engine <4D34T3>
Gr 11
Flywheel power take-off added
Gr 11A ENGINE <4M50T2> B Gr 11A ENGINE <4M50T2>

Service procedure added Pub. No. TWSE9501-511A
Gr 12A LUBRICATION <4M50T2> B Gr 12A LUBRICATION <4M50T2>
iii
2001 MODEL CHANGES
Gr 13 Fuel and Engine Control <4D34T3>
Part No. and type of Read Only MK386562 MK344606
Memory (ROM) pack are different. (MRT-E7) (MRT-E6)
Newly introduced flywheel PTO-

equipped version has the engine
control provided with an engine
control cable and a lever & bracket
assembly. 3 1
4
*a
2
*b
41143
P Removal sequence
1 Accelerator pedal assembly P13-56 4 Emergency engine stop cable
2 Engine control cable
3 Accelerator pedal position sensor *a: Lever and bracket assembly
assembly *b: Injection pump assembly
R Service procedure
2 Installation of engine control cable
A Adjust the threaded section A of the engine

control cable 2 to thedimension shown in the
illustration and connect the cable to the le-
16 mm or less ver & bracket assembly *a.
2
*a
41144
iv
Electronic governor control unit addition- Con- Termi-
ally provided with torque limiting function Connected to
nector nal
CM 160 First/reverse check switch
30A 161 Transfer four-wheel drive switch
162 Transfer low switch
JAE
160 161 162
CM30A
41122
Gr 13A FUEL & ENGINE CONTROL B Gr 13A FUEL&ENGINE CONTROL <4M50T2>

<4M50T2> Pub. No. TWSE9501-513A
Service procedure added
Gr 13E Electronically Controlled Fuel B Gr 13E Electronically Controlled Fuel System <4M50T2>
System <4M50T2> Pub.No. TWSE9501-513E
Service procedure added
Gr 14A COOLING <4M50T2> B Gr 14A COOLING <4M50T2>
Gr 15A INTAKE&EXHAUST <4M50T2> B Gr 15A INTAKE&EXHAUST <4M50T2>
v
2001 MODEL CHANGES
Gr 23 Automatic Transmission Specifications
FE640 and FG639 introduced into
Vehicle model
lineup FE639 FE649 FE640 FG639
Item
Manufacturer Aisin Seiki Co., Ltd.
Transmission type M035A4
Torque Type 3-element, 1-stage, 2-phase (with lock-up clutch)

converter Stall torque ratio 1.82
Type Planetary gear type, 4 forward speeds, 1 reverse speed
1st 3.018
Automatic 2nd 1.548

transmission Gear ratio 3rd 1.000
4th 0.703 0.765
Rev. 2.678
Range selector pattern P-R-N-D-2-L (Engine starts in P and N position only)
Oil type DEXRON III type
Automatic Total oil capacity L {qts} 13 {14}
transmission
Quality of oil required in
fluid
automatic transmission Approximately 4.5 {4.8}
fluid change L {qts}
FG639 automatic transmission assembly Automatic Transmission Assembly

different in configuration
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 36806
1 Converter housing 9 2nd clutch 17 Overdrive input shaft
2 Torque converter 10 Rear clutch 18 Oil pump
3 Transmission case 11 Front planetary gear 19 Oil pan
4 Overdrive direct clutch 12 No. 2 one-way clutch 20 Valve body
5 Overdrive brake 13 1st and reverse brake 21 Input shaft
6 Overdrive one-way clutch 14 Rear planetary gear 22 Intermediate shaft
7 Overdrive planetary gear 15 Parking lock gear 23 Transfer case adapter
8 Front clutch 16 Output shaft
STRUCTURE AND OPERATION

Control system
Control block diagram
Chat of control items, inputs and outputs Gr 23
Self-diagnosis function
Vehicle speed sensor
Modified or additional descriptions incor-
porated in the above items.
vi
ROM pack for FE640 newly included in Tool name Read Only Memory (ROM) pack
special tool lineup
Part No. MK386562 (MRT-E7)
As a troubleshooting procedure for

FE640, Inspection Using MUT-II and Di- Gr23
agnosis code chart additionally shown
Stall speed standard values for FE640 Stall speed

and FG639 established as shown
FE640 2070 150 rpm
FG639 1890 150 rpm
As standard values for road tests of <FE640>

FE640 and FG639, vehicle speeds at P Shift-point vehicle speeds Unit: km/h {mph}
which shifting or locking up must take
place determined as shown Throttle opening Shifting Power mode
D1D2 7.2 to 9.9 {4.5 to 6.1}
Half throttle D2D3 21.3 to 24.0 {13.3 to 14.9}
D3D4 39.6 to 42.3 {24.6 to 26.3}
D1D2 20.5 to 23.2 {12.8 to 14.4}
Full throttle D2D3 44.0 to 46.7 {27.4 to 29.0}
D3D4 77.4 to 82.7 {48.1 to 51.4}
D1D2 5.3 to 8.0 {3.3 to 5.0}
Closed throttle D2D3 5.3 to 8.0 {3.3 to 5.0}
D3D4 28.8 to 31.5 {17.9 to 19.6}
P Lock-up vehicle speeds Unit: km/h {mph}
Throttle opening Shifting Power mode

2nd gear ON 36.0 to 38.7 {22.4 to 24.0}
Half throttle 3rd gear ON 47.8 to 50.4 {29.7 to 31.3}
4th gear ON 57.8 to 60.4 {35.9 to 37.6}
2nd gear ON 46.7 to 49.4 {29.0 to 30.7}
Full throttle 3rd gear ON 47.8 to 50.4 {29.7 to 31.3}
4th gear ON 77.4 to 82.7 {48.1 to 51.4}
2nd gear OFF 36.0 to 38.7 {22.4 to 24.0}
Closed throttle 3rd gear OFF 46.7 to 49.4 {29.0 to 30.7}
4th gear OFF 48.3 to 51.0 {30.0 to 31.7}
The above standard values are based on the following conditions.

5.285 differential gear ratio, 0.374 m tire radius (215/85R16)
If the differential gear ratio and/or the tire radius are different from the above, proper
standard values must be calculated based on the ratios of the differences and the
above figures.
vii
2001 MODEL CHANGES
<FG639>
P Shift-point vehicle speeds Unit: km/h {mph}

D1D2 9.7 to 12.3 {6.0 to 7.6}
Half throttle D2D3 25.5 to 28.1 {15.9 to 17.5}
D3D4 40.1 to 42.6 {24.9 to 26.5}
D1D2 22.2 to 24.8 {13.8 to 15.4}
Full throttle D2D3 47.5 to 50.0 {29.5 to 31.1}
D3D4 80.4 to 85.5 {50.0 to 53.2}
D1D2 5.1 to 7.7 {3.2 to 4.8}
Closed throttle D2D3 5.1 to 7.7 {3.2 to 4.8}
D3D4 27.3 to 29.9 {17.0 to 18.6}
P Lock-up vehicle speeds Unit: km/h {mph}

2nd gear ON 33.4 to 36.0 {20.8 to 22.4}
Half throttle 3rd gear ON 49.8 to 52.3 {30.9 to 32.5}
4th gear ON 58.4 to 60.9 {36.3 to 37.9}
2nd gear ON 45.4 to 48.0 {28.2 to 29.8}
Full throttle 3rd gear ON 54.9 to 57.4 {34.1 to 35.7}
4th gear ON 76.6 to 81.7 {47.6 to 50.8}
2nd gear OFF 34.5 to 37.0 {21.4 to 23.0}
Closed throttle 3rd gear OFF 44.7 to 47.2 {27.8 to 29.4}
4th gear OFF 44.7 to 47.2 {27.8 to 29.4}

5.714 differential gear ratio, 0.387 m tire radius (7.50R16)
If the differential gear ratio and/or the tire radius are different from the above, proper
standard values must be calculated based on the ratios of the differences and the
above figures.
viii
Breather cap on transmission case re-
Breather Breather cap
placed with new type breather
Automatic
Automatic transmission unit
Pipe
transmission unit
41134
41133
Sealant
Point of Outer periphery of
application breather pipe
Sealant Cemendyne 540
Quantity As required
REPLACEMENT OF AUTOMATIC Automatic Installation of oil seal

TRANSMISSION PARTS transmission unit CAUTION k
Oil seal installation method for FG639 Oil seal After the oil seal is removed, clean the surface
different from that for other model Extension of the extension housing of automatic trans-
housing mission unit to which oil seal is mounted.
end face
Apply grease on the lip section of oil seal.
Drive the oil seal into the automatic transmission
Oil seal
unit until its end face becomes flush with the end
face of the extension housing.
CAUTION k
Be sure to apply the installation force evenly
41443 on the entire periphery.
Do not damage or deform the shape of oil seal.
Gr. 24 Transfer <FG>

Transfer exclusively combined with
1st/reverse check switch
manual transmission additionally pro-
344.9 Nm {253.6 lbf.ft, 3.50.5 kgfm}
vided with 1st/reverse check switch
and dust plug
Dust plug
41093
Transfer for automatic transmission newly

Gr24
introduced
Gr. 27 Rear axle Vehicle model

Reduction gear ratio for FE640 is as Except FE640 FE640
Item
shown
Model D033H D033H
Type Single-reduction gear Single-reduction gear
Reduction
Tooth shape Hypoid gear Hypoid gear
Speed reduction ratio 5.714 5.285
ix
2001 MODEL CHANGES
Gr. 54 Electrical
1. POWER CHARGE AND GROUND Battery cable diameter is different between for 4D3 and 4M5.
Because of introduction of 4M5 engine For 4M5: 85 mm 0 For 4D3: 60 mm
and mirror heater, some descriptions
in 104 , 106 , 110 , 125 and 130 104 FUSE P54-7
subjected to change.
106 The alternator for 4M5 engine is different in pulley shape and B-terminal posi-
tion from that for 4D3 engine.
For 4M5 For 4D3
Pulley Pulley
B-terminal
B-terminal
41085
110 POWER CIRCUIT P54-8
125 BATTERY CHARGING CIRCUIT P54-10
130 GROUND P54-12
2. STARTING, PREHEATING AND

STOPPING ENGINE SPECIFICATIONS <4M5> P54-13
Because of introduction of 4M5 en-
gine, some descriptions in Specifica- STRUCTURE AND OPERATION <4M5> P54-14
tions, Structure and Operation, 201 ,
210 and 225 subjected to change. 201 STARTER P54-15
210 ENGINE STARTING CIRCUIT <4M5 Automatic Transmission> P54-28
x
2. STARTING, PREHEATING AND
STOPPING ENGINE 225 ENGINE WARMING CIRCUIT <4M5> P54-32
4. METER
Because of introduction of 4M5 en- 410 TACHOMETER CIRCUIT <4M5> P54-34
gine, the content of 410 changed.
6. CAB SIDE ELECTRICAL

Because of introduction of 4M5 engine 601 SWITCH P54-36
and mirror heater and addition of
torque limiting function to FG, 601 604 RELAY AND CONTROL UNIT P54-38
and 604 subjected to change.
629 added. 629 MIRROR HEATER CIRCUIT P54-38
7. CHASSIS ELECTRICS
Because of introduction of 4M5 en- 701 EXHAUST BRAKE CIRCUIT <4M5 Automatic Transmission> P54-40
gine, the content of 710 changed.
8. ENGINE AND TRANSMISSION

ELECTRICS 801 ENGINE ELECTRICS <4M5> P54-42
801 changed because of adoption of
4M5 engine. 802 TRANSMISSION ELECTRICS
802 provided with additional descrip-
tion about speed sensor installed on Speed sensor
FE640 automatic transmission.
41137
Inspection of speed sensor

Slowly rotate the speed sensor shaft A while
3 2 1
applying a voltage of 12VDC between termi-
nals 1 and 3.
A D Keeping the above condition, measure the
maximum voltage (high pulse voltage B) and
B the minimum voltage (low pulse voltage C) gen-
C
23607 erating between terminals 1 and 2.
D: Tester
Replace the speed sensor if the measurements
deviate from the standard values.
Standard Low puls 0.5V or less

value High puls 81V
xi
2001 MODEL CHANGES
8. ENGINE AND TRANSMISSION
ELECTRICS 1st/reverse check switch
802 additionally provided with some

descriptions about 1st/reverse check
switch installed on manual transmis-
sion-equipped FG.
41123
+0.25 +0.01
25.70.75 mm {1.01 0.03 in}
Inspection of 1st/reverse check switch
Perform the continuity test according to the fol-
lowing table.
OFF ON 1 2
OFF
16203 ON
There must be continuity between
the terminals.
Replace the switch if any abnormality is found.
810 revised because if newly incor- 810 FOUR WHEEL DRIVE CIRCUIT P54-46
porated torque limiting function.
9. OTHERS
910 changed because of adoption of 910 MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT <4M5> P54-48
4M5 engine.
xii
GROUP 00 GENERAL
POWER TRAIN TABLE ......................................................................... 00-2
VEHICLE IDENTIFICATION NUMBER ................................................ 00-3
ENGINE NUMBER ................................................................................ 00-3
PRECAUTIONS FOR MAINTENANCE OPERATION .......................... 00-4
00-1
POWER TRAIN TABLE
Final reduc-
Engine Clutch Transmission Propeller Rear axle
Model tion and
model model model shaft model
gear ratio
FE639C, E, 4D34T3 C4W30 M035S5 P3 R033T D033H

F G.V.W 145 HP/2900 rpm 5.380/0.722 5.714
5445 kg 275 lbf.ft/1600
{12000 lb} rpm (SAE, Gross)
Torque M035A4
converter 3.018/0.703
FE639C, E, C4W30 M035S5

F G.V.W. 5.380/0.722
6125 kg
{13500 lb}
Torque M035A4
FG639C,E 4D34T3 C4W30 M035S5+TF3 P2 D1H modi-

G.V.W. 145 HP/2900 rpm 5.380/0.722 (Front) fied
5445 kg 275 (253:*a) P3 5.714
{12000 lb} lbs.ft/1600 rpm (Rear) (Front)
(SAE, Gross) D033H
5.714
(Rear)
FG639E 4D34T3 Torque M035A4+TF3
G.V.W. 145 HP/2900 rpm converter 3.018/0.765
5445 kg 275 (253: *b)lbf.ft/
{12000 lb} 1600rpm (SAE,
Gross)
FE649C, E, 4D34T3 C4W30 M035S5 P3 D033H

F, H G.V.W. 145 HP/2900 rpm 5.380/0.722 5.714
6575 kg 275 lbf.ft/1600
FE649C, E, Torque M035A4

F G.V.W. converter 3.018/0.703
6375 kg
{14050 lb}
FE640C, E, 4M50T2 D033H

F, H G.V.W 175 HP/2700 rpm 5.285
6575 kg 347 lbt.ft/1600
*a: Torque cut when 1st/reverse is selected

*b: Torque cut when 4WD/Low is selected
00-2
VEHICLE IDENTIFICATION NUMBER/ENGINE NUMBER 00
VEHICLE IDENTIFICATION NUMBER
J W 6 A A C 1 H n 1 L n n n n n n
1 2 3 4 5 6 7 8 9 Q W E
1 Country J: Japan
2 Make W: Mitsubishi Fuso
3 Vehicle type 6: Incomplete Vehicle
7: Truck
4 Gross vehicle weight/Brake system A: 10001 to 14000 lbs/Hydraulic
B: 14001 to 16000 lbs/Hydraulic
5 Line A: FE639
B: FE649
G: FG639
H: FE640
6 Series (Wheel base) C: 2.6 to 2.89 m {8.53 to 9.48 ft.}
E: 3.2 to 3.49 m {10.49 to 11.44 ft}
F: 3.5 to 3.79 m {11.48 to 12.43 ft}
H: 4.1 to 4.39 m {13.45 to 14.40 ft}
7 Cab chassis type 1: Chassis cab
3: Mixer
8 Engine H: 3.907 , Diesel turbocharged and charge air cooled
S: 4.899 , Diesel turbocharged and charge air cooled
9 Check digit
Q Model year 1: 2001
W Plant K: Kawasaki-1
L: Kawasaki-2
M: Kawasaki-3
E Plant sequential number
ENGINE NUMBER
Engine number <4M50T2>
Engine number is stamped on the position as illustrated.
4M50-A12345
29747
00-3
PRECAUTIONS FOR MAINTENANCE OPERATION
DANGER k
This product contains or emits chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm.
00-4
GROUP 01 MAINTENANCE SCHEDULE
HOW TO READ THE MAINTENANCE SCHEDULE TABLES .............. 01-2
MAINTENANCE SCHEDULE TABLES ................................................ 01-3
MAINTENANCE OPERATIONS
Replacement of Oil Filter ............................................................. 01-4
Replacement of Fuel Filter .......................................................... 01-5
Bleeding of Air from Fuel Line .................................................... 01-6
Adjustment of V-ribbed Belt Tension .......................................... 01-6
Battery ........................................................................................... 01-8
Fuse ............................................................................................... 01-12
LUBRICATION ...................................................................................... 01-13

Engine Oil ...................................................................................... 01-14
01-1
HOW TO READ THE MAINTENANCE SCHEDULE TABLES
Example Table:
E: Exhaust emission items
N: Noise control items
Time of inspection and maintenance
New vehicle at 4000 km/

Inspection interval
Every 250000 km/

Inspection and Working procedures Remarks
Every 10000 km/
Every 20000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
2500 miles
6000 miles
ENGINE
1
Manifold bolts and nuts Check inlet and exhaust manifold bolts B Gr 15A
torque and nuts for looseness
2 ECheck and adjust Check valve clearance with feeler gauge B Gr 11A
valve clearance
3 EOil filter replacement Every 10000 km/6000 miles or Replace oil filter B Gr 12A
12 months
4 EInjection nozzle Check and clean injection nozzle B Gr 13A
N
5 EFuel injection timing Check fuel injection timing B Gr 13A
6 EFuel feed pump filter Every 40000 km/24000 miles or Clean gauze filter inside connector with B Gr 13A
24 months gas oil
Every 20000 km/12000 miles or Replace fuel filter
12 months
(1) This column contains the maintenance and inspection items.

(2) The periods between inspection and service and based on the assumption that the vehicle will be driven approximately
60000 kilometers (36000 miles) per year.
Inspection which must be made are indicated by an or by the appropriate period between servicing.
(3) This column provides a simplified explanation of the operational procedures involved for each inspection or mainte-
nance item.
(4) The Gr. No. refers to the group number in this vehicle Service Manual. For visual checks and simple inspections, see
the sections labelled Working Procedures.
01-2
MAINTENANCE SCHEDULE TABLES 01
E: Exhaust emission items
N: Noise control items

Inspection interval
Every 250000 km/

Inspection and Working procedures Remarks
Every 10000 km/
Every 20000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
2500 miles
6000 miles
ENGINE
1
Manifold bolts and nuts Check inlet and exhaust manifold bolts B Gr 15A
torque and nuts for looseness
2 ECheck and adjust Check valve clearance with feeler gauge B Gr 11A
valve clearance
3 EOil filter replacement Every 10000 km/6000 miles or Replace oil filter B Gr 12A
12 months
4 EInjection nozzle Check and clean injection nozzle B Gr 13A
N
5 EFuel filter replacement Every 20000 km/12000 milesor Replace fuel filter B Gr 13A
12 months
6 EFuel line Every 20000 km/12000 miles or Inspect fuel tank, cap and lines for dam- B Gr 13A
12 months age causing leakage
7 EV-ribbed belt tension Every 10000 km/6000 miles or Inspect V-ribbed belt for cracks, wear and B Gr 14A
N and damage 12 months tension
8 ECooling system Check radiator and radiator cap for seal- B Gr 15A
ing performance and mounting condition.
Inspect hoses for looseness, deteriora-
tion, damage causing leakage. Remove
dust and foreign deposits from radiator
and intercooler front.
9 Coolant replacement Every 24 months Replace coolant B Gr 15A
10 ETurbocharger rotor play Check turbocharger rotor play B Gr 15A
11 Air cleaner element Every 5000 km/3000 miles Clean air cleaner element by blowing B Gr 15A
clean compressed air through it.
12
EAir cleaner element Replace air cleaner element B Gr 15A
N replacement
13 EExhaust system Inspect exhaust system for damage, cor- B Gr 15A
N rosion and loose connection causing
leakage
01-3
Oil Filter Replacement
Lubricant
Location Points of application Specified lubricant Quantity
2 Oil filter Engine oil (API CD or higher) Approx.1 L {1.1 qts}
0 Special tools
Unit: mm {in.}
Location Tool name and shape Part No. Application
Oil Filter Element Socket MH061566
08550
Oil filter removal
107 to 120
Oil Filter Wrench MH063200
{4.21 to 4.72}
01503
WARNING k
Wipe up any spilled engine oil since it may cause a fire.
Do not touch oil when the engine is hot since it can inflict severe
burns.
2
CAUTION k
1
When pouring oil into the engine, take care not to spill any on the
V-ribbed belt. Contact with oil could make the V-ribbed belt slip,
rendering the cooling system less effective.
29367
Loosen oil filter drain plug 1 to drain the engine oil from inside the filter 2.
[Removal]
0: Oil Filter Element Socket or Filter Wrench
0
41054
[Installation]
Clean the surface of oil filter head 3 to which oil filter 2 is fitted.
Apply a thin coat of engine oil to the gasket A of oil filter 2.
3 Screw oil filter 2 into oil filter head 3 by hand until gasket A contacts the
A oil filter head. Then, tighten oil filter 2 further by giving it a 3/4 turn.
After installing the oil filter, start the engine and check gasket A for oil
2 leakage.
Check to see if the engine oil level is in the specified range.
29368
01-4
01
Replacing Fuel Filter
Lubricant
Location Parts to be tightened Specified lubricant Quantity
3 Gasket for fuel filter cartridge Engine oil As required
[Removal]
A: Filter Wrench
(Commercially available one: For filter diameter of approx. 90 mm {3.54
A in.})
1
WARNING k
Fuel is highly flammable. Keep it away from flames and sources
2 of heat.
To minimize the risk of fire, wipe up any spilled fuel.
37451
CAUTION k
The water level sensor 2 may be reused if it properly functions.
[Installation]
WARNING k
Use of an unsuitable fuel filter cartridge 1 can lead to fuel leaks
and fires. Be sure to use a genuine filter.
CAUTION k
To prevent injection failures, keep dust and dirt out of the fuel
filter cartridge 1 and the fuel pipe.
To fit the fuel filter cartridge 1, turn it until the gasket C touches seal
2 surface of the fuel filter head 2. Be sure to turn the filter by hand clock-
wise.
C Then, tighten the filter by 3/4 turn.
After fitting the filter, start the engine and check that no fuel leakage
occurs.
1 Bleed all air out of the fuel system. P.01-6
37452
01-5
Bleeding Air from Fuel System
Tightening torque Unit: Nm {lbf.ft, kgfm}

1 Air vent plug 61 {4.30.7, 0.61}
Loosen the fuel filter air vent plug 1.

Operate the priming pump 2 to pump up fuel.
2
Continue to pump fuel until no air bubbles are found in the fuel flowing
out from the air vent plug 1.
After ascertaining that air bubbles have completely disappeared, tighten
the air vent plug 1 securely.
1
Operate the priming pump 2 further until it feels heavy.
Wipe up all spilled fuel, then start the engine.
Check that no fuel leakage occurs.
37450
WARNING k
of heat.
Be sure to wipe up all spilled fuel. Unless it is wiped up, it could
catch fire.
V-ribbed belt tension

[Inspection]
C 5
NOTE
Before checking for tension, crank the engine one turn or more
B clockwise.
A Apply force of approximately 98 N {22.1 lbf, 10 kgt} to the span center of

E
D the V-ribbed belt 5, and measure the extent of belt deflection A.
B: Alternator pulley
29774 C: Air conditioner compressor pulley or tension pully
D: Fan pulley
E: Water pump pulley
01-6
01
G P Use of belt tension gauge
Set the upper O-ring G of the 0 Belt Tension Gauge to a push load of
H 98 N {22 lbf, 10 kgt} on scale H.
Set the lower O-RING J of the 0 Belt Tension Gauge to the belts
0
specified maximum deflection value on scale K.
K
03613
Apply the 0 Belt Tension Gauge to the center of the V-ribbed belt 5
and push L until the upper O-ring G reaches the flange M.
L G
0
M
5
03614
Measure the deflection A of the V-ribbed belt 5. If the measurement

A
does not comply with the standard value, adjust the tension in accor-
dance with the following procedure.
03615
[Adjustment]
(1) Tension adjustment of V-ribbed belt for water pump
CAUTION k
Excessive tension in the V-ribbed belt 5 may damage the belt and
related bearings.
Keep the V-ribbed belt 5 free of oil. If the belt becomes oily, it may
slip, resulting in overheating of the engine and insufficient charg-
ing of the battery.
<With air conditioner>

Loosen the alternator mounting nuts Q and R, then adjust the tension
Q 5 of the V-ribbed belt 5 using the adjustment bolt S.
When the adjustment is completed, securely tighten the nuts Q and R.
S
29778
01-7
<Without air conditioner>
Loosen the tension pully mounting sleeve N and adjust the tension of
the V-ribbed belt 6 using the adjusting belt P.
After the adjustment, tighten the sleeve N securely.
29777
Battery
DANGER k
Since flammable hydrogen gas is generated by the battery, be sure
to obey the following warnings:
Do not short-circuit the ! and @ terminals on the battery.
Keep sparks and lit cigarettes away from the battery.
Do not wear metal objects on your arms and lean over the battery.
Because the battery electrolyte is diluted sulfuric acid and is cor-
rosive, when handling the battery wear safety glasses and rubber
gloves to protect the eyes and hands.
Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands after handling.
WARNING k
To prevent a short-circuit be sure that disconnected the battery
cables do not accidentally touch the battery terminals.
CAUTION k
Make sure that you disconnect the battery cable @ first when you
disconnect the battery cables.
Make sure that all electrical switches of the vehicle are OFF be-
fore connecting the battery cables.
Make sure that you connect the battery cables ! before you con-
nect the battery cable @.
01-8
01
A Visual inspection
If terminal A is corroded, scrub off the corrosion from it using a wire
A brush.
If cracks or defects are found on battery 7, replace it because the
cracks or defects can cause liquid spills.
CAUTION k
Be sure to apply grease to the ! side of terminal A because it is
easily corroded.
41386
If the air bleed hole C of vent plug B is clogged, clean the hole.
C
41387
Inspection of fluid level

Confirm that the level of battery electrolyte is between UPPER and
B
LOWER LEVEL lines.
If the level is below LOWER LEVEL line, remove vent plug B and
replenish the distilled water or battery fluid to the UPPER LEVEL.
41388
Specific gravity measurement

You can tell the specific gravity of the battery electrolyte by the color
shown in indicator D.
Blue : Good
White : Charge or replace
41389
01-9
Charging
Although, as a rule, charging of the battery should be done with the
battery removed from the vehicle, if you have to charge the battery
while it is on the vehicle, make sure that you stop the engine and dis-
connect the battery cable @.
Remove vent plug B before charging the battery.
For the recommended charge time and current, see the following table
to avoid overcharging.
Good
Upper limit
Specific gravity of
battery electrolyte
1.280 Charge current Charge time (H) of fluid tem-

1.240 (A) perature
1.220
1.200 (C{F})
Charge
needed
1.160 value of 5-hour *Amount of
1.120 Normal rating capacity discharge (Ah) 45
charge 1.2
1.080 10 Charge {113}
(to 1.5)
0 10 20 30 40 50 60 70 80 90 100 current (A)
Amount of discharge (%)
Value of 5-hour
07789 Quick rating capacity 55
0.5
charge {131}
1.5
Amount of
discharge (%)
* Amount of discharge (Ah) = 5 hour rating capacity (Ah)
100
Use the graph shown on the left to calculate the amount of dis-
charge (%).
If electrolyte level is low add distilled water to raise level.
The specific gravity of fully-charged battery electrolyte is 1.280 with
the temperature at 20C {68F}.
DANGER k
Do not let the battery electrolyte level rise and overflow while charg-
ing the battery.
Keep unprotected lights away from the battery while charging it
or it might explode.
Be careful not to generate sparks while charging the battery be-
cause its dangerous.
After charging the battery, tighten vent plug B, wash away sulfu-
ric acid from the battery using water, and dry the surface.
Be sure to check the electrolyte level before charging the battery.
Charging with the electrolyte level below the lower limit (LOWER
LEVEL) can cause premature deterioration, heat generation and
explosion of the battery.
01-10
01
MEMO
01-11
Fuse
F18 to 34
F1 to 17
FH7
FH6
FH5
FH4
FH3
FH2
FH1
07998
1 Fuse box
2 High-current fuse box
CAUTION k
If a fuse blow, make sure you identify and remedy the cause, then replace the fuse.
Make sure that you replace the fuse with one having the same rating.
Make sure that you remove the @ terminal of the battery cable before removing high-current fuses FH1 to 7.
01-12
01
High-current fuse box
Fuse
Main load Capacity
No.
FH1 Fuse box (F1 to F4) 50A
FH3 ABS hydraulic unit 40A
FH5 Starter switch (Terminal B) 50A
FH7 Alternator 100A
Fuse box
Fuse Fuse
Main load Capacity Main load Capacity
No. No.
F1 Headlamp, LH 15A F18 Transmission neutral relay 10A
F2 Headlamp, RH 15A <Manual transmission>
Inhibitor switch
F3 Stop lamp, horn 15A <Automatic transmission>
F4 Turn signal lamp 15A F19 Backup lamp 10A
F5 !Engine control unit 20A F20 Meter cluster, DRL 10A
F6 Cab lamp 10A F21 Wiper 10A
F7 Reserve power (BATT) 10A F22 Reserve power (MAIN) 10A
F8 Power window 25A F23 Automatic transmission control unit 10A
F9 F24 Automatic transmission control unit 10A
F10 Automatic transmission fluid cooler 15A F25 Engine control (ACT) 10A
fan relay
F26
F11 Automatic transmission fluid cooler 20A
fan relay F27 Exhaust brake 10A
F12 F28 Engine control unit 10A
F13 Cigarette lighter 15A F29 ABS 10A
F14 Radio 10A F30 Mirror heater relay 10A
F15 Reserve power (ACC) 10A F31
F16 F32 !Condenser fan 15A
F17 Mirror heater relay 10A F33 Blower fan 25A
F34 Tail lamp 20A
! : Fuses are provided for these pieces of equipment only
where they are installed.
DRL: Daytime Running Lights
01-13
LUBRICATION
: Exhaust emission items
Inspection interval
Every 10000 km/
Every 20000 km/
Every 30000 km/
Every 40000 km/
Every 5000 km/

Items Lubricant specifications Remarks
12000 miles
18000 miles
24000 miles
30000 miles
2500 miles
6000 miles
1 Engine oil replacement Engine oil B Gr 12A
API classification, CD, CD/SF, CE,
CE/SF or CF-4
Over 30C {86F} SAE 40
40 to 5C {104 to 23F} SAE 30
15 to 15C {59 to 5F} SAE 20W-20
Over 15C {5F} SAE 15W-40
Below 0C {32F} SAE 10W-30
01-14
01
Engine Oil Replacement
Tightening torques
Unit: Nm {lbfft, kgfm}
2 Oil pan drain plug 34.3 to 43.1 {25 to 32, 3.5 to 4.4}
3 Oil filter drain plug 9.81.96 {7.21.4, 1.00.2}
Lubricant
Oil pan Engine oil (API CD or higher) Approx.9 L {9.5 qts}
Oil filter Engine oil (API CD or higher) Approx.1 L {1.1 qts}
1 WARNING k
Wipe up any spilled engine oil since it can cause a fire.
Do not touch oil when the engine is not since it can inflict severe
burns.
CAUTION k
29798
[Draining]
Warm up the engine, then remove oil filler cap 1.
Remove oil pan drain plug 2 and oil filter drain plug 3. Then, drain the
engine oil.
[Filling]
Tighten oil pan drain plug 2 and oil filter drain plug 3 to their specified
torques. Then, add new engine oil to the specified level.
2 07381
3 29717
01-15
GROUP 11 ENGINE
<4D34T3>
FLYWHEEL ........................................................................................... 11-2
FLYWHEEL POWER TAKE-OFF .......................................................... 11-6
11-1
FLYWHEEL
4 1
2
3
A
*1
6
5
*2
03591
P Disassembly sequence
1 Bolt 6 Flywheel
2 Plate
3 Bearing *1: Crankshaft B Gr.11
4 Flywheel assembly *2: Crankshaft power take-off pulley L P.11-6
5 Ring gear
A: Location Pin
P Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION k
After the flywheel assembly 4 is installed, be sure to check the flywheel 6 for runout.
11-2
11
Service standards Unit: mm (in.)
Location Maintenance item Standard value Limit Remedy

Height of friction surface 25 24 Correct or replace
Flywheel
4 Friction surface distortion 0.05 or less 0.2 Correct or replace
assembly
Friction surface runout (when fitted) 0.2 Correct or replace
Tightening torques Unit: Nm {lbf.ft, kgfm}

120 {90, 12.5} M12 bolt
1 Bolt (flywheel assembly installation)
175 {130, 18.0} M14 bolt
R Service procedure
4 Flywheel assembly
[Removal]
To remove the flywheel assembly 4, screw the mounting bolts 1 into
the removal holes A.
Loosen the bolt of the tensioner pulley assembly to remove the tension
A from the belt. L P.11-8
1
[Installation]
4 Adjust the belt tension after installing the flywheel assembly 4.
03347
L P.11-6
[Inspection]
(1) Runout
If runout exceeds the specified limit, check that the bolts 1 are tight-
ened correctly and inspect the surface in contact with the crankshaft
*1. Then, rectify or replace the flywheel assembly 4 as required.
1
03348
11-3
FLYWHEEL
(2) Height of friction surface
If the measurement is below the specified value, rectify or replace the
B B 4 flywheel assembly 4.
B: Height of friction surface
03349
(3) Distortion of friction surface

If distortion exceeds the specified limit, rectify or replace the flywheel
4 assembly 4.
CAUTION k
If any abnormality is evident on the ring gear 5, replace the ring
gear before making inspections.
5 03350
[Rectification]
Grind the friction surface such that its height B remains greater than the
B B
specified minimum. The friction surface must remain parallel with surface
C with a tolerance of 0.1 mm {0.0039 in.}.
C
03351
5 Ring gear
[Inspection]
Check the ring gear 5 for damage and abnormal wear, and replace the
ring gear if it is faulty.
[Removal]
Heat the ring gear 5 evenly with an acetylene torch or the like.
WARNING k
Be careful not to get burned.
03352
Remove the ring gear 5 from the flywheel by tapping around its entire
periphery.
11-4
11
5 [Installation]
A Using a piston heater or the like, heat the ring gear 5 to approximately
100C {212F} for 3 minutes.
WARNING k
Fit the ring gear 5 with the non-chamfered side of its teeth toward the
flywheel 6.
6
03353 A: Chamfered side of ring gear
11-5
FLYWHEEL POWER TAKE-OFF
5
6 1
7 *
17 8
18 9
P
20
21
16
23
Y
14 L A
A
22 29
4
10
3
2
11 25
24
12
27
26
41096
1 Bearing cover 13 Washer 25 Flywheel assembly L P11-2
2 Tension pulley cover 14 Power take-off joint 26 Bolt
3 Bolt 15 Bearing 27 Cover plate
4 Tension pulley assembly 16 Bearing case 28 Belt
5 Bearing 17 Power take-off shaft 29 Crankshaft power take-off pulley
6 Spacer 18 Key
7 Tension pulley 19 Bearing *: Flywheel housing B Gr.11
8 Bearing 20 Pulley flange A: Location pin
9 Tension lever 21 Power take-off pulley : Non-reusable part
10 Bolt 22 Bolt
11 Hanger plate 23 Cover plate
12 Power take-off pulley assembly 24 Bolt
P Assembly sequence
11-6
11

3 Bolt (for mounting tension pulley assembly) 82 {61, 8.4}
10 Bolt (for mounting power take-off pulley assembly) 44 {33, 4.5}
22 Bolt (for mounting cover plate) 54 {40, 5.5}
24 Bolt (for mounting flywheel assembly and power 175 {130, 18.0} M14
take-off pulley)
26 Bolt (for mounting cover plate) 55 {41, 5.6}
Lubricant and/or sealant Unit: g {oz}
Location Points of application Specified lubricant and/or sealant Quantity

6, 7 Between spacer and tension pulley Templex N-3 5 to 8 {0.18 to 0.28}
15 Between bearings Templex N-3 5 to 8 {0.18 to 0.28}
19 Between bearings Templex N-3 7 to 10 {0.25 to 0.35}
R Service procedure
5 8 Installation of bearings
Install the bearings with the sealing portion A directed as shown.
A 8 5 A 06233
67 Packing grease between spacer and tension pulley

7 6 Pack a specified amount of grease in the illustrated section A.
8 A 5 03564
A A YP Bearings
[Installation]
Install the bearings with the sealing section A directed as shown.
15 19
06234
11-7
FLYWHEEL POWER TAKE-OFF
[Grease packing]
B B
Pack a specified amount of grease in the illustrated section B.
19
15
03365
n L Adjustment of belt tension

Loosen the bolt 3 of the tension lever 9.
3 Attach a torque wrench A to the n section of the tension lever 9.
Apply a torque of 9.8 Nm {7.2 lbf.ft, 1.0 kgfm} to the torque wrench
A in the arrowed direction. Keeping this condition, tighten the bolt 3
to the specified torque.
A
9
03566
11-8
GROUP 23 AUTOMATIC TRANSMISSION
STRUCTURE AND OPERATION ......................................................... 23-2
TROUBLESHOOTING .......................................................................... 23-6
23-1
Control Mechanisms
Control system
Multi-plate clutches
Torque converter Overdrive input Multi-plate brakes
(lock-up piston) shaft One-way clutches Output shaft
Planetary gears
Oil pump
Vehicle speed
sensor
Control valves Valve body
Shift solenoid Shift solenoid Throttle Lock-up Timing ATF

pressure temperature
1 2 solenoid solenoid solenoid sensor
Accelerator *1 Automatic transmission

sensor electronic control unit
A B
Engine electronic Engine speed
control unit sensor
A : Accelerator position PWM signal : Power transmission

B : Engine speed signal : Hydraulic control circuit
*1: Except FE640
: Electrical signal
41414
23-2
23
*3
Shift control
(incl. O/D
Accelerator shift control)
position *1 Shift
PWM signal
solenoid 1
*3
Accelerator *1 Throttle
sensor *3 pressure
*3 control
Shift
*1 solenoid 2
Inhibitor
switch
Shift pattern
selector
Engine *2 control Throttle
speed pressure
sensor solenoid
Overdrive
Lock-up
OFF switch Lock-up
control
*3 solenoid
ATF
temperature
sensor *3 2-3 shift
*1 Timing
timing
ATF solenoid
control
temperature
switch
4WD LOW
Exhaust Exhaust
switch
brake brake cut-
*2
control off relay
Brake
switch
*3 Fail-safe
Exhaust brake control
activation
switch *1
Vehicle speed *1 : FE640
sensor 2
(mounted on *2 : FG939
A/T) Diagnosis *3 : Except FE640
memory
Vehicle speed
sensor 1
(mounted on A/T) MUT
(for pulse divider)
*1 Self-
diagnosis
Diagnosis function
Warning
switch lamp
41415
23-3
Chart of control items, inputs and outputs
Control item Shift
Shift
control Throttle Exhaust Self-
pattern Lock-up 2-3 shift Fail-safe
(incl. pressure brake diagnosis
selector control control control
overdrive control control control
Item control
control)
Vehicle speed Mounted on transmis-
sensor 2 sion (output shaft ro- Note 1
tation sensor)
Vehicle speed Mounted on transmis-
sensor 1 *1 Note 3 Note 3 Note 3 Note 3 Note 3
sion
*3
Throttle position PWM signal *1 *1 *1 *1 *1 *1 *3
Note 1 *1
Engine speed sensor Note 1
Accelerator sensor *3 Note 1
Input Overdrive OFF switch
Inhibitor switch Note 1
Automatic transmission fluid tempera-
ture switch
Automatic transmission fluid tempera-

ture sensor
4WD LOW switch
Brake switch
Exhaust brake activation signal Note 1
Diagnosis switch Note 2
Shift solenoid 1 Note 1
Timing solenoid Note 1
Out-
Lock-up solenoid Note 1
put
Throttle pressure solenoid Note 1
Exhaust brake cut-off relay Note 1
Warning lamp
Note 1 : The automatic transmission electronic control unit activates fail-safe functions when there is an abnormality in the in-
put/output signals.
Note 2 : The self-diagnosis function actiates.
Note 3 : Backup for vehicle speed sensor 2 (mounted on transmission)
*1 : FE640
*2 : FG639
*3 : Except FE640
23-4
23
P Self-diagnosis function <FE640>
The warning lamp lights when an abnormality occurs during vehicle operation.
The warning lamp does not light if the abnormality causes minimum effect to vehicle operation.
The warning lamp lights when the following parts are malfunctioning to indicate the abnormal condition since these
malfunctions significantly reduce vehicle performance.
Vehicle speed sensor 1
Vehicle speed sensors 1 and 2
Shift solenoid 1
Shift solenoid 2
Accelerator sensor
Timing solenoid
Inhibitor switch
Throttle pressure solenoid
CAUTION k
The warning lamp lights only when the malfunction prevents proper vehicle operation.
The indicator lamp provides self-diagnosis information.

To facilitate the discovery of malfunctions that may not reproduce themselves frequently, the automatic transmission
electronic control unit stores in the memory information of malfunctions that occur during vehicle operation.
An input of a self-diagnosis start signal produces the output of the data from the memory, and causes the automatic
transmission warning lamp to flash according to the data.
CAUTION k
The automatic transmission electronic control unit stores information of all malfunctions that occur after the
previous self-diagnosis operation.
P Vehicle speed sensor <FE640>

The vehicle speed monitoring system is composed of two sensor circuits; vehicle speed sensor 2 (output shaft rotation
sensor) and vehicle speed sensor 1. Accordingly, the normal driving mode is not disabled even when one of the vehicle
speed sensor circuits is faulty.
23-5
TROUBLESHOOTING
P Diagnosis Code Chart
Diagnosis
Problem location Judgement criterion Fail-safe measure
code
1 Normal
11 Power supply voltage Power supply voltage remains below 7.5 V for
1 second or longer with range selector in a
position other than P or N range.
12 Vehicle speed sensor 1 Vehicle speed sensor 1 indicates sudden Maintains the gear selected immediately be-
speed decrease. fore malfunction detection.
Turns off shift solenoids 1, 2 when engine
speed sensor detects a value or less than
1000 rpm.
13 Oil temperature sensor When oil temperature of more than 135C Maximum oil temperature
{275F} or lower than 50C {58F} is detec-
ted. Note that MUT display is fixed at 40C
{104F} after fail-safe judgement result.
15 Engine speed sensor Engine speed sensor detects a value of less Prohibits 2-3 shift timing control.
than 300 rpm when range selector is in a posi-
tion other than P or N range and when output
shaft rotating speed is 1000 rpm or higher.
24 Accelerator sensor When accelerator sensor signal input to en- Shift-point in set at 0% throttle opening.
gine ECU is faulty. Prohibits 2-3 shift timing control.
Executes controls assuming that throttle
pressure is at maximum.
Prohibits lock-up control (lock-up solenoid
OFF) except during diving at high speeds.
25 Vehicle speed sensor 2 Vehicle speed sensor 2 indicates sudden Maintain the gear selected immediately be-
speed decrease. fore malfunction detection.
Turns off shift solenoids 1, 2 when engine
speed sensor detects a value or less than
1000 rpm.
31 Shift solenoid 1 When solenoid output short-circuit occurs Turns off malfunctioning shift solenoid.
while solenoid is receiving current. Turns off lock-up solenoid and timing sole-
When solenoid output disconnection occurs noid.
while solenoid is not receiving current. Refer to the chart on P23-54 for gear selec-
tion.
while solenoid is receiving current. Turns off lock-up solenoid and timing sole-
When solenoid output disconnection occurs noid.
while solenoid is not receiving current. Refer to the chart on P23-54 for gear selec-
tion.
34 Line pressure solenoid When wire breakage or short-circuit occurs. Turns off line pressure solenoid.
35 Lock-up solenoid When solenoid output short-circuit occurs Turns off lock-up solenoid.
while solenoid is receiving current.
When solenoid output disconnection occurs
while solenoid is not receiving current.
43 Inhibitor switch No signal Operates as D range and prohibits shifting to
4th gear.
Two or more signals Control function activates based on priority
order of L > R > 2 > D > N (P).
Refer to pages 23 through 54 for actual vehi-
cle operation conditions.
23-6
23
P Diagnosis Code Chart
Diagnosis
code
50 PTO solenoid When solenoid output short-circuit occurs Turns off PTO solenoid.
51 Timing solenoid When solenoid output short-circuit occurs Truns off timing solenoid.
54 Exhaust brake cut-off Exhaust brake activates when exhaust brake Prohibits exhaust brake cut-off control
signal cut-off signal is generated. Allows lock-up only at high cruising speed.
23-7
TROUBLESHOOTING
P Inspection using MUT-II <FE640>
1 The MUT-II indicates diagnosis codes that provide information of malfunctioning items (devices that require inspec-
tion).
2 The MUT-II indicates sensor signal conditions with numerical values (service data). Comparison of the service data
with judgement criteria allows evaluation of the transmission operation. Diagnosis codes and service data codes can
be effectively used for troubleshooting.
1 2
Indicated by MUT-II Indicated by MUT-II Inspection procedure
Mulfunctioning item
Diagnosis Service Service
(devices that Signal name Inspection condition Judgement criterion
code data code data
require inspection)
11 POWER VOLTAGE
With vehicle standstill 0 MPH
lll.l
12 VEH SPD SNSR 1 12 VEH SPEED 1 MPH To be synchronized
During driving
with speedometer
To show same
In cold engine
temperature as ambient
To show gradually
13 OIL TEMP SNSR 13 A/T OIL TEMP lll.F During warming up engine
increasing temperature
With engine stopped after To show gradually
warming up decreasing temperature
llll. During idling with engine warmed
15 ENG SPD SNSR 15 ENGINE SPEED 650 25 rpm
rpm up
Selector lever in P range ON
19 P POS. SW ON/OFF
Selector lever not in P range OFF
Selector lever in R range ON
20 R POS. SW ON/OFF
Selector lever not in R range OFF
Selector lever in N range ON
21 N POS. SW ON/OFF
Selector lever not in N range OFF
Selector lever in D range ON
22 D POS. SW ON/OFF
Selector lever not in D range OFF
Accelerator pedal released 0%
While depressing pedal slowly Voltage to be increased

24 ACCEL SNSR 24 ACCEL PERCENT lll.% gradually
With accelerator pedal fully
100%
depressed
With vehicle standstill 0 MPH
lll.l
25 VEH SPD SNSR 2 25 VEH SPEED 2 To be synchronized
MPH During driving
with speedometer
Selector lever in 2 range ON
26 2 POS. SW ON/OFF
Selector lever not in 2 range OFF
Selector lever in L range ON
27 L POS. SW ON/OFF
Selector lever not in L range OFF
With O/D ON ON
28 OD-OFF SW ON/OFF
With O/D OFF OFF
POWER mode selected ON
29 POWER S/W ON/OFF
ECO mode selected OFF
23-8
23
1 2
Mulfunctioning item
code data code data
require inspection)
During driving in 1st or 2nd speed ON
31 SHIFT VALVE 1 31 SHIFT VALVE 1 ON/OFF
During driving in 3rd or 4th speed OFF
During driving in 2nd or
ON
32 SHIFT VALVE 2 32 SHIFT VALVE 2 ON/OFF 3rd speed
During driving in 1st or 4th speed OFF
lll.l While depressing accelerator Pressure to be
34 LINE PRESS. V 34 LINE PRESS
lbf/in2 pedal slowly increased gradually
To be turned ON when
During driving with accelerator
lock-up vehicle speed
opening kept constant
35 LOCKUP VALVE 35 LOCKUP VALVE ON/OFF is reached Gr. 23
Vehicle stopped with selector lev-
OFF
er in D range
Oil temperature raised above limit
ON
(Warning lamp ON)
36 OIL TEMP SW ON/OFF Oil temperature normal (Warning
OFF
lamp OFF)
With brake pedal depressed ON
37 BRAKE SW ON/OFF
With brake pedal released OFF
Exhaust brake in operation during
driving ON
38 EXH. BRAKE SIG ON/OFF
Exhaust brake not in operation OFF
ABS in operation ON
47 ABS SW ON/OFF
ABS not in operation OFF
With data link connector removed OPEN
OPEN/
48 M CLEAR SW With data link connector con-
CLOSE CLOSE
nected
With data link connector removed OPEN
OPEN/
49 DIAGNOSIS SW CLOSE With data link connector con-
nected CLOSE
Power take-off in operation (with

accelerator pedal released and
ON
selector lever in P range or N
50 PTO VALVE 50 PTO VALVE ON/OFF
range)
Power take-off not in operation OFF
When 2-3 upshifting is made by
ON
51 TIMING VALVE 51 TIMING VALVE ON/OFF releasing acceleration pedal
When vehicle is stationary OFF
System failure (warning lamp ON) ON
53 DIAG LAMP ON/OFF System in order (warning lamp
OFF) OFF
Exhaust brake in operation OFF

54 EXB CUT SIG. 54 EXB CUT SIG. ON/OFF When vehicle is stopped through
ON OFF
operation of exhaust brake
23-9
TROUBLESHOOTING
1 2
Mulfunctioning item
code data code data
require inspection)
Indication to be
Selector lever moved from P to L changed in the order of
55 SELECTOR POS. l RANGE
range sequentially PRND2
L.
1ST During driving with accelerator See Lock-up Vehicle
2ND opening kept constant. While ac- Speeds table for road
3RD celerating vehicle gradually from test. (1st 2nd 3rd
56 GEAR POS. 4TH 0 mph 4th) Gr. 23
N N range N
REV
R range REV
Power take-off switch ON (P
ON
59 PTO SW ON/OFF range, N range)
Power take-off switch OFF OFF
23-10
7 8 9 h
d e f g
1
6
r 25 26 27
1 Starter switch (key inter lock solenoid installed
inside)
2
3 Meter cluster
10 4 Fuse box
5 Puls divider
3 a b c 4 6 Engine control unit
7 Exhaust brake cut relay <ABS>
5 8 Exhaust brake cut relay <A/T>
9 Relay box
10 Backup lamp relay
11 Diode
12 MUT-II connector
13 Automatic transmission fluid cooler fan relay
14 Neutral start relay
19 15 Stop lamp switch
16 Automatic transmission electronic control unit
21 17 Diagnosis switch
11 24 18 Memory clear relay
19 Key interlock electronic control unit
20 Accelerator sensor
21 Overdrive switch
k 22 Shift lock actuator
t s
34 33 32 31 30 29 28
23 Automatic transmission reverse buzzer
24 P-range switch
12 23 25 Exhaust brake 3-way magnetic valve
26 Automatic transmission fluid thermo switch
17, 18 16 15 14 13 h 27 Back buzzer
28 High current fuse box
22 33 31 29 35 26
29 Vehicle speed sensor
30 Battery
31 Terminal to solenoid and temperature sensor
16 q
32 Automatic transmission fluid cooler fan motor
33 Inhibitor switch
u 34 Automatic transmission fluid cooler fan thermo
m switch
n *: Wiper motor
20
ABS: Anti-lock brake system
A/T: Automatic transmission
p
*
<Left side of transmission> <Right side of transmission>
41274 41274
23-11 23-11
23-13 23-13
GROUP 24 TRANSFER <FG>
STRUCTURE AND OPERATION ......................................................... 24-2
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY .......... 24-4
FRONT DRIVE ...................................................................................... 24-8
IDLER GEAR AND REAR DRIVE ........................................................ 24-14
24-1
Transfer Body
1 2 1 Transmission main shaft
2 Drive shaft gear
3 Transfer idler gear
4 Transfer idler shaft
3 5 Output shaft
6 Output shaft LOW gear
7 Output shaft HIGH gear
8 Front drive hub and sleeve
9 Front drive shaft
4 10 Transfer drive shaft
10
9 8 7 6 5
41094
1 2 The transfer functions as both the distributer for four-wheel

10 drive and as the sub-transmission with a reduction device.
This transfer is a three-shaft constant-mesh type.
3 HIGH/LOW changeover and front drive ON/OFF are controlled
7 4 by a transfer control lever in the cab.
8
6
9
5
To front axle To rear axle
ON OFF
HIGH LOW
Front drive HIGH/LOW switching 41095
24-2
24
MEMO
24-3
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY
2
4
8 6
9 7
10
11
1
13 3
15
5
*
12
14
41139
1 Bolt 10 Bearing
2 Air breather 11 Transfer drive shaft
3 Needle bearing 12 Transfer assembly
4 Transfer input rear cover 13 Bolt
5 Lock nut 14 Oil seal
6 O-ring 15 Transfer front case
7 Drive shaft gear
8 Bolt A: Positioning pin
9 Spacer *: Transmission Assembly
: Non-reusable parts
NOTE
For removal from vehicle, see B Gr 10.
Check backlash of drive shaft gear 7 before disassembly.
Do not remove needle bearing 3 from transfer input rear cover 4 unless it is faulty.
P Assembly sequence
NOTE
Check backlash when assembling parts.
24-4
24
Service standards Unit: mm {in.}

7, 12 Drive shaft gear and transfer idler gear backlash 0.08 to 0.22 0.50
{0.0031 to 0.0087} {0.020}

1 Bolt (Transfer input rear cover mounting) 44 {33, 4.5}
5 Lock nut tightening torque 49049 {36036, 505}
8 Bolt (Transfer assembly mounting) 44 {33, 4.5}
13 Bolt (Transfer front case mounting) 44 {33, 4.5}
Lubricant and/or sealant

* Mounting surface of transfer front case THREEBOND 1215 As required

transmission assembly
1 Thread area of piece bolt THREEBOND 1104J As required
4 Mounting surface of transfer assembly THREEBOND 1215 As required
transfer input rear cover
14 Lip area of oil seal and transfer assembly Wheel bearing grease As required
[NLG1 No.2 (Li soap)]
15 Mounting surface of transfer assembly transfer THREEBOND 1215 As required
front case
0 Special tools Unit: mm {in.}
25 {0.98}
32.5
{1.28}
3 Needle roller MH061929 Installation of input rear cover needle
bearing installer bearing
50
{1.97} 4 {0.16}
06396
50
{1.97}
5 Socket wrench 44490-44101 Removal and installation of transmission

main shaft lock nut
00069
24-5
R Service procedure
3 Installation of needle bearing
0
0 : Needle roller bearing installer
3 4
06399
5 Removal and installation of lock nut

0 : Socket wrench
7
5 0
06400
24-6
24
MEMO
24-7
FRONT DRIVE
3

4 W 13
40
H
33
V
31
30
28 2
27
26 36

35
20 8
E
14 *
9 38 1
22 37
* 39
7 34
6 29
5 19
16 17 20
21
15 24
18
F

41142
1 Bolt 14 Interlock ball 29 Synchronizer sleeve
2 Shift rail cover 15 Lock nut 30 Front drive shift fork
3 Bolt 16 O-ring 31 Snap ring
4 Transfer case side cover 17 Companion flange 32 Front drive shift rail
5 Screw plug 18 Bolt 33 Shift rail stopper
6 Poppet spring 19 Front drive shaft 34 Snap ring
7 Steel ball 20 Snap ring 35 Front drive hub
8 Transfer LOW switch B Gr 54 21 Bearing 36 Snap ring
9 Transfer four-wheel drive switch 22 Dust cap 37 Bolt
B Gr 54 23 Oil seal 38 Front drive case
10 Screw plug 24 Front drive case cover 39 Oil seal
11 Set bolt 25 Set bolt 40 Transfer assembly
12 HIGH/LOW shift rail 26 Snap ring
13 HIGH/LOW shift fork 27 Retainer *: Dowel pin
28 Spring : Non-reusable parts
24-8
24
NOTE
HIGH and LOW shift rail 12 cannot be disassembled unless front drive shift rail 32 is set to front drive ON.
P Assembly sequence
4039383736353433
25
323130282726
29 181716151410
131211
242322212019 987654321
Standard value
Location Maintenance item Limit Remedy
(Basic diameter in [ ])
6 Poppet spring free length 24.85 {0.98} 24.00 {0.94} Replace
12 Deflection of HIGH/LOW shift rail 0.02 {0.00079} or less 0.03 Correct
{0.0012} or replace
12, 40 Clearance between HIGH/LOW shift rail and transfer [16 {0.63}] 0.05 to 0.09 0.2 Replace
assembly rail hole {0.0020 to 0.0035} {0.0079} faulty parts
13 Tilt of claw against HIGH/LOW shift fork hole 0.1 {0.0039} or less 0.2 {0.0079} Replace
13, 29 Clearance between HIGH/LOW shift fork and synchronizer sleeve 0.3 to 0.5 1.0 {0.039} Replace
{0.012 to 0.020} faulty parts
29, 30 Clearance between front drive shift fork and synchronizer sleeve 0.3 to 0.5 1.0 {0.039} Replace
{0.012 to 0.020} faulty parts
30 Tilt of claw against front drive shift fork hole 0.1 {0.0039} or less 0.2 {0.0079} Replace
faulty parts
32 Front drive shift rail deflection 0.02 {0.00079} or less 0.03 {0.0012} Correct
or replace
32, 40 Clearance between front drive shift rail and transfer [16 {0.63}] 0.05 to 0.09 0.2 {0.0079} Replace
assembly rail hole {0.0020 to 0.0035} faulty parts

1 Bolt (Shift rail cover mounting) 44 {33, 4.5}
3 Bolt (Transfer case side cover mounting) 24 {17, 2.4}
5 Screw plug tightening 39 {29, 4}
8 Transfer LOW switch tightening 344.9 {253.6, 3.50.5}
9 Transfer four-wheel drive switch tightening 344.9 {253.6, 3.50.5}
11 Set bolt (Shift fork mounting) 29 {22, 3} Caulk at three
points after
tightening
15 Lock nut tightening 29549 {21536, 305}
18 Bolt (Front drive case cover mounting) 44 {33, 4.5}
37 Bolt (Front drive case mounting) 44 {33, 4.5}
24-9
FRONT DRIVE
4 Mounting surface of transfer assembly transfer case side THREEBOND 1215 As required
cover
5 Thread area of screw plug THREEBOND 1215 As required
18 Thread area of pierce bolt THREEBOND 1104J As required
23 Pack between lips of oil seal Wheel bearing grease (NLGI No. 2 (Li soap) As required
24 Mounting surface of front drive case front drive case cover THREEBOND 1215 As required
38 Mounting surface of transfer assembly front drive case THREEBOND 1215 As required
39 Lip area of oil seal Wheel bearing grease (NLGI No. 2 (Li soap) As required
20, 26, 34 Snap ring expander MH061268 Removal and installation of snap ring
01137
42
Bearing installer {1.65} MB999104
52
{2.05} 05661
23 Installation of front drive case cover oil seal
50 {1.97}
Differential bearing inner MB999105

race installer adapter 88
{3.46}
05667
15.5 {0.61}
39 Oil seal installer MH061923 Installation of shift rail oil seal
35
{1.38} 19 {0.75} 06404
24-10
24
R Service procedure
W H Removal and installation of set bolt
Tighten shift fork mounting set bolt 11, 25 at specified torque, and stake
the thread area at three points using at punch.
06405
E V Inspection of shift rail

If the measured value is higher than the limit, correct or replace shift rails
12, 32.
12, 32
NOTE
To measure the deflection of shift rails 12, 32, turn them one full
revolution and read the dial gauge indicator. The deflection is
one half of the indicated value.
01127
EV\ Clearance between shift rail and transfer assembly rail

hole
Measure the outer diameter of shift rail 12, 32 and the inner diameter of
40 transfer assembly hole 40. If the clearance is higher than the limit, re-
12, 32
place faulty parts.
06406
RZX Clearance between shift fork and synchronizer sleeve

If the measured value is higher than the limit, replace faulty parts.
29
13, 30
06407
24-11
FRONT DRIVE
F Installation of oil seal
a Apply grease to lip area A of oil seal 23, and press-fit it.
a : Bearing installer
b : Differential bearing inner race installer adapter
b 23
A
06409
] Installation of oil seal

40 Apply grease to lip area A of oil seal 39 and press-fit it into transfer as-
A sembly 40.
0 : Oil seal installer
39
0
06410
24-12
24
MEMO
24-13
IDLER GEAR AND REAR DRIVE
27
28
32
29
31 30 25
34
32 29
26
9 7
11
10 1
12 6

13 2
F T
G 4
3 5
21
Y
D 33

33

A
19
O
17 8
16
27278
1 Bolt 19 Rear drive shaft HIGH gear
2 Spring pin 20 Needle bearing
3 Speedometer gear 21 Synchronizer sleeve
4 O-ring 22 Needle bearing
5 Oil seal 23 Rear drive shaft LOW gear
6 Speedometer gear bushing 24 Needle bearing
7 Bolt 25 Bolt
8 Oil seal 26 Plate
9 Output rear cover 27 Idler rear cover
10 Speedometer worm 28 Shim
11 Key 29 O-ring
12 Snap ring 30 Transfer idler shaft
13 Bearing 31 Transfer idler gear
14 Thrust washer 32 Bearing
15 Rear drive shaft 33 Drain plug, inspection plug
16 Snap ring 34 Transfer case
17 Bearing
18 Thrust washer : Non-reusable parts
24-14
24
NOTE
Check backlash and end play of gears before disassembly.
Do not remove needle bearing 22 from rear drive shaft 15 unless it is faulty.
P Assembly sequence
3132
3433 28272625
3029 1716111022
15212423141312201918 7
65432
1
98
NOTE
Check backlash and end play when assembling parts.
Check friction and rotation movements when assembling rotating parts.

Starting torque of transfer idler gear 0 to 2 {0 to 1.45, 0 to 0.2} Adjust shim
3, 6 Clearance between speedometer gear and [12] 0.04 to 0.09 0.15 Replace
speedometer gear bushing {[0.47] 0.0016 to 0.0035} {0.0059}
15, 19, 20 Play of rear drive shaft HIGH gear in diameter 0.02 to 0.06 0.12 Replace
direction after assembly {0.00079 to 0.0024} {0.0047} faulty parts
15, 23, 24 Play of rear drive shaft LOW gear in diameter 0.02 to 0.06 0.12 Replace
19 End play of rear drive shaft HIGH gear 0.25 to 0.40 0.60 Replace
{0.0098 to 0.0016} {0.024} thrust washer
or gear
19, 31 Backlash between rear drive shaft HIGH gear and 0.08 to 0.22 0.50 Replace
transfer idler gear {0.0031 to 0.0087} {0.030}
21 Clearance between synchronizer sleeve groove and 0.3 to 0.5 1.0 Replace
HIGH/LOW shift fork {0.012 to 0.020} {0.039} faulty parts
23 End play of rear drive shaft LOW gear 0.25 to 0.40 0.60 Replace
{0.0098 to 0.016} {0.024} thrust washer
or gear
23, 31 Backlash between rear drive shaft LOW gear and 0.08 to 0.24 0.50 Replace
transfer idler gear {0.0031 to 0.0094} {0.020}

1 Bolt (Speedometer gear bushing mounting) 24 {17, 2.4}
7 Bolt (Output rear cover mounting) 44 {33, 4.5}
25 Bolt (Plate and idler rear cover mounting) 44 {33, 4.5}
33 Drain plug and inspection plug tightening 6915 {5111, 7.01.5}
24-15
3 Friction surfaces between speedometer gear and Molybdenum disulfide grease As required
speedometer gear bushing
5 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
7 Thread area of bolt THREEBOND 1104J As required
8 Pack between lips of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
9 Mounting surface of transfer case output rear cover THREEBOND 1215 As required
27 Mounting surface of transfer case idler rear cover THREEBOND 1215 As required
33 Thread area of drain plug and inspection plug THREEBOND 1105D As required

16.5
{0.65}
8 Oil seal installer MH062691 Installation of output rear cover oil seal
06252
12 Snap ring expander MH061268 Removal and installation of snap rings
01137
40 {1.57}
13
22 Needle roller bearing {0.51} MH061927 Installation of rear drive shaft needle
installer bearing
18.5 28 {1.10}
{0.73} 15 {0.59} 06413
24-16
24
R Service procedure
Inspection before service
P Starting torque of transfer idler gear
28 31
A Disassemble parts, and measure the torque with push gauge A leav-
ing only transfer idler gear 31 in transfer case.
If the value deviates from the standard value, adjust it using shim
28.
On assembly, also check that starting torque is within the standard
value range using the same method.
Shim 28 is available in four thickness: 0.01 mm {0.00039 in.},
0.02 mm {0.00079 in.}, 0.03 mm {0.0012 in.}, 0.06 mm {0.0024 in.}.
07633
2 2 Driving-in spring pin

Drive spring pin 2 into speedometer gear bushing 6 with the opening in
the opposite direction to speedometer gear 3.
3
6
2 03576
3 6 Clearance between speedometer gear and speedometer gear

bushing
3 If the clearance is higher than the limit, replace the faulty parts.
03577
5 Installation of oil seal

B Apply grease to lip area A of the inner rim of the oil seal, and press-fit oil
seal evenly into speedometer gear bushing 6 in the direction as illustrated
using bar B (approximately 15 mm {0.59 in.}).
A 5
6
03578
24-17
6 Installation of speedometer gear bushing
Due to its eccentric center arrangement, speedometer gear bushing 6
allows replacement of speedometer gear 3 with gears having a different
6
number of teeth by changing only the installation direction, the worm gear
does not have to be changed.
M When installing the bushing, align the stamped number, identical to the
number of speedometer gear teeth, with alignment mark M of output rear
cover 9.
The number of speedometer gear teeth can be identified by the identifica-
tion marks stamped on N or P.
Identification mark and number of speedometer gear teeth

3 P N Identification
A B C D L E F G H I J K
mark
Number of teeth 15 16 17 18 19 20 21 22 23 24 25 26
Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.2
06416

Apply grease to lip area A of oil seal 8 and press-fit into output rear cover
9.
0 8
A
06419
TO Installation of thrust washer

Install thrust washer 14, 18 with oil groove A facing gear side.
14, 18
A
06418
24-18
24
YOAFG Play of rear drive shaft gear in diameter direction
after assembly
NOTE
When replacing needle bearing 20, 24, use bearings from the same
color package.
01149
D Installation of needle bearing

0
22
06420
24-19
GROUP 54 ELECTRICAL
1 POWER, CHARGE AND GROUND 210 ENGINE STARTING CIRCUIT

<4D3 Manual Transmission> ............... B 4
SPECIFICATIONS ........................................... B 4 <4D3 Automatic Transmission> .......... B 4
<4M5 Automatic Transmission> ...... 54-28
STRUCTURE AND OPERATION .................... B 4
220 ENGINE PREHEATING CIRCUIT ......... B 1
TROUBLESHOOTING ..................................... B 1
225 ENGINE WARMING UP CIRCUIT
100 INSPECTION AND ADJUSTMENT <4D3> .................................................... B 3
MOUNTED IN VEHICLE <4M5> ................................................. 54-32
Inspection of Alternator ................... B 2
Inspection of Regulator ................... B 2
101 BATTERY ............................................. 54-4 3 LIGHTING

104 FUSE .................................................... 54-7
SPECIFICATIONS ........................................... B 1
106 ALTERNATOR ....................................... B 4
110 POWER CIRCUIT ................................. 54-8
115 RESERVE POWER CIRCUIT ................ B 1
300 INSPECTION AND ADJUSTMENT
125 BATTERY CHARGING CIRCUIT ....... 54-10 MOUNTED IN VEHICLE
Headlamp Aiming ................................ B 1
130 GROUND ............................................ 54-12
310 HEADLAMP CIRCUIT ........................... B 1
313 DAYTIME RUNNING LIGHT CIRCUIT .. B 4

2 STARTING, PREHEATING, AND
STOPPING ENGINE 320 TAIL LAMP, CLEARANCE LAMP AND
LICENSE PLATE LAMP CIRCUITS ..... B 1
SPECIFICATIONS 325 STOP LAMP CIRCUIT .......................... B 1
<4D3> .................................................... B 1
<4M5> ................................................. 54-13 330 TURN SIGNAL LAMP AND HAZARD
LAMP CIRCUITS ................................... B 1
<4D3> .................................................... B 1 340 BACKUP LAMP CIRCUIT
<4M5> ................................................. 54-14 <Manual Transmission> ...................... B 1
<Automatic Transmission> ................. B 3
345 CAB LAMP CIRCUIT ............................ B 1
MOUNTED IN VEHICLE 348 ILLUMINATION LAMP CIRCUIT .......... B 1
Inspection of Engine Preheating 349 MARKER LAMP AND IDENTIFICATION
System ............................................... B 1 LAMP CIRCUITS ................................... B 1
201 STARTER 352 VAN BODY DOME LIGHT CIRCUIT ..... B 1
<4D3> .................................................... B 1
<4M5> ................................................. 54-15
54-2
4 METER 614 WIPER AND WASHER CIRCUIT .......... B 1
616 HORN CIRCUIT ..................................... B 1

SPECIFICATIONS ........................................... B 1
618 HEATER CIRCUIT ................................. B 1
622 POWER WINDOW AND AUTO DOOR
401 METER CLUSTER ................................ B 4
LOCK CIRCUIT ..................................... B 4
410 TACHOMETER CIRCUIT
629 MIRROR HEATER CIRCUIT .......... B 54-38
<4D3> .................................................... B 1
<4M5> ................................................. 54-34
420 FUEL GAUGE CIRCUIT ........................ B 1 7 CHASSIS ELECTRICS

425 WATER TEMPERATURE
GAUGE CIRCUIT .................................. B 1 701 MAGNETIC VALVE ................................ B 1
710 EXHAUST BRAKE CIRCUIT

<4D3 Manual Transmission> ............... B 4
5 INDICATOR AND WARNING <4D3 Automatic Transmission> .......... B 4
<4M5 Automatic Transmission> ...... 54-40

MOUNTED IN VEHICLE 8 ENGINE AND TRANSMISSION
Inspection of Brake Fluid ELECTRICS
Level Switch ...................................... B 1
801 ENGINE ELECTRICS
510 PARKING BRAKE INDICATOR <4D3> .................................................... B 1
CIRCUIT ................................................ B 1
BRAKE
<4M5> ................................................. 54-42
515 BRAKE WARNING CIRCUIT ................ B 1 LOW
VACUUM BRAKE
802 TRANSMISSION ELECTRICS .............. B 1
535 ENGINE OIL LEVEL AND 810 FOUR-WHEEL DRIVE CIRCUIT<FG> 54-46
OIL PRESSURE CIRCUIT ....................
l i B1
537 OVERHEATING WARNING CIRCUIT ... B 1

9 OTHERS
540 BRAKE PAD WARNING
CIRCUIT ................................................ B 1
DISK
BRAKE
550 CAB TILT WARNING CIRCUIT .............
6 B1 910 MULTIPURPOSE TIMING CONTROL
UNIT CIRCUIT
<4D3> .................................................... B 1
6 CAB SIDE ELECTRICAL <4M5> ................................................. 54-48
SPECIFICATIONS ........................................... B 1 B 1: 96 Model Gr 54 (Pub No. TWSE9501-54)

B 2: 98 Model Gr 54 (Pub No. TWSE9501-254)
B 3: 99 Model Gr 54 (Pub No. TWSE5901-3)
601 SWITCH ................................................. B 1 B 4: 00 Model Gr 54 (Pub No. TWSE9501-4)
604 RELAY AND CONTROL UNIT ........... 54-36
606 WARNING BUZZER .............................. B 1
610 CIGARETTE LIGHTER CIRCUIT .......... B 1
612 AUDIO CIRCUI ...................................... B 1
54-3
101 BATTERY
P Removal sequence
1 Battery cover
1 2 Battery cable @
3 Harness
3 4 Battery cable !
5 Battery cable
5 6 Angle frame
4 7 Battery
8 Battery box
2
7
6
41390
DANGER k
Because flammable hydrogen gas is generated from battery 7, be sure to obey the following.
Never attempt to short-circuit the positive and negative terminals of battery 7, and generate sparks, or smoke
a cigarette near it.
Do not wear metal objects on your arms or do not lean over battery 7.
Sulfuric acid of the electrolyte is very corrosive. Whenever handling battery 7, wear safety goggles and rubber
gloves to protect your eyes and hands.
Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
WARNING k
When you disconnect battery cables 2 to 4, disconnect battery cable @ 2 first.
CAUTION k
Make sure that all electrical switches of the vehicle are off before connecting battery cables 2 and 4.
Be sure to connect battery cable ! 4 first before you connect battery cable @ 2.
To prevent a short-circuit, take care that disconnected battery cables 2 and 4 may not accidentally touch the
battery terminals.
Service standards
Location Inspection item Standard value Limit Remedy
7 Specific gravity of battery electrolyte (20C {68F}) 1.220 to 1.290 Charge or replace
54-4
54
A R Service procedure
7 Inspection of battery
A (1) Visual inspection
brush.
If cracks or defects are found on battery 7, replace it because the
CAUTION k
41386
Be sure to apply grease to the ! side of terminal A because it is
easily corroded.
C
If the air bleed hole C of vent plug B is clogged, clean the hole.
B
41387
(2) Inspection of fluid level

Confirm that the level of battery electrolyte is between UPPER and
B LOWER LEVEL lines.
If the level is below LOWER LEVEL line, remove vent plug B and
replenish the distilled water or battery fluid to the UPPER LEVEL.
41388
(3) Specific gravity measurement

Blue :Good
White :Charge or replace
41389
54-5
101 BATTERY
(4) Charging
Battery 7 must be, as a rule, charged in the off-vehicle condition. If
it is charged on vehicle, however, be sure to remove the grounding
cable before starting the procedure.
The battery must be charged with its all of vent plugs removed.
For the recommended charge time and current, see the following
table to avoid overcharging.
Upper limit of
Good
Charge current Charge time
fluid temperature
Specific gravity of
battery electrolyte
1.280 (A) (H)

(C {F})
1.240
1.220 {*Amount of
1.200
Charge discharge
needed
1.160 Normal Value of 5-hour 45
(Ah)/Charge
1.120 charge rating capacity/10 {113}
current (A)}
1.080
1.2 (to 1.5)
0 10 20 30 40 50 60 70 80 90 100
Quick Value of 5-hour 55
Amount of discharge (%) 0.5
charge rating capacity/1.5 {131}
07789
* Amount of discharge (Ah) = 5-hour rating capacity (Ah) [Amount of

discharge (%)] / 100
Use the graph shown left to calculate the amount of discharge (%).
For the battery electrolyte, use diluted sulfuric acid, made up of sul-
furic acid and refined or distilled water.
The specific gravity of fully-charged battery electrolyte is 1.280 at
the liquid temperature of 20C {68F}.
DANGER k
Do not let the battery electrolyte level rise and overflow while charg-
ing the battery.
Keep open flame away from the battery while charging it or it might
explode.
Be careful not to generate sparks while charging the battery be-
cause it is dangerous.
After charging the battery, tighten the vent plugs, wash away sul-
furic acid from the battery using water, and dry the surface.
Be sure to check the electrolyte level before charging the battery.
Charging with the electrolyte level below the lower limit (LOWER
LEVEL) can cause premature deterioration, heat generation and
explosion of the battery.
8 Inspection of battery box

If battery box 8 is corroded, scrub off the corrosion from it using a wire
brush and apply acid resistant coating.
If the battery box 8 is corroded excessively, deformed or cracked, re-
place it with new one.
54-6
104 FUSE 54
Fuse
Main load Capacity
No.
FH5 Starter switch (Terminal B) 50A
FH7 Alternator 100A
FH8 Alternator 100A
Fuse box
Fuse Fuse
Main load Capacity Main load Capacity
No. No.
F1 Headlamp, LH 15A F18 Transmission neutral relay 10A
F2 Headlamp, RH 15A <Manual transmission>
Inhibitor switch
F3 Stop lamp, horn 15A <Automatic transmission>
F4 Turn signal lamp 15A F19 Backup lamp 10A
F5 !Engine control ECU !20A F20 Meter cluster, DRL 10A
F6 Cab lamp 10A F21 Wiper 10A
F7 Reserve power (BATT) 10A F22 Reserve power (MAIN) 10A
F8 Power window 25A F23 Automatic transmission control unit !10A
F9 F24 !Automatic transmission control unit !10A
F10 !Automatic transmission fluid cooler 15A F25 Engine control (ACT) 10A
fan relay
F26
F11 !Automatic transmission fluid cooler !20A
fan relay F27 Exhaust brake 10A
F12 F28 Engine control ECU 10A
F13 Cigarette lighter 15A F29 ABS 10A
F14 Radio 10A F30 !Mirror heater relay !10A
F15 Reserve power (ACC) 10A F31
F16 F32 *Condenser fan 15A
F17 !Mirror heater relay !10A F33 Blower fan 25A
F34 Tail lamp 20A
* : Fuses are provided for these pieces of equipment only
where they are installed.
( marks indicate changed parts or added parts.

DRL : Daytime Running Lights
54-7
110 POWER CIRCUIT
41164
54-8
54
MEMO
54-9
125 BATTERY CHARGING CIRCUIT
41165
54-10
54
1 a b 2
6
8 7
41173
1 Meter cluster B 4 401 5 Alternator B 4 106

2 Diode unit 6 High-current fuse box 104
3 Fuse box 104 7 Battery B 1 101
4 Starter switch B 1 210 8 High-current fuse box 104
B 1 : 96 Model Gr54 (Pub No. TWSE 9501-54)

B 4 : 00 Model Gr54 (Pub No. TWSE 9501-4)
54-11
130 GROUND
41166
54-12
SPECIFICATIONS <4M5> 54
Item Specifications
Starter Manufacturer MITSUBISHI ELECTRIC
Model M8T55371
Output V-kw 12-3
Reduction gear mechanism Planetary gears
Magnetic switch operating voltage V 8 or less
Starter relay Model U1T11672
Excitation current V-A 12-4
Closing voltage V 8 or less
Operating voltage V 3.5 or less
Allowable cutoff current A 200
Glow relay Model U1T11473
Excitation current V-A 12-4
Closing voltage V 8 or less
Opening voltage V 3.5 or less
Glow plug Model Sheathed type
Voltage - Current V-A 11-8.5
54-13
STRUCTURE AND OPERATION <4M5>
SW
6
5
B 8
3 4
M
S 10
2
11
1
22
12
17
21 20 19 18 16 15 14 13
41153
1 Rear bracket 10 Spring 19 Rubber packing

2 Brush holder 11 Pinion stopper 20 York assembly
3 Brush 12 Pinion 21 Armature assembly
4 Brush spring 13 Front bearing 22 Rear bearing
5 Magnetic switch 14 Overrunning clutch
6 Ball 15 E-ring B: Terminal B
7 Lever 16 Gear shaft assembly M: Terminal M
8 Starter relay 17 Internal gear assembly S: Terminal S
9 Front bracket 18 Planetary gear SW: Terminal switch
This starter uses planetary gears 18 as its reduction gearing mechanism.
54-14
201 STARTER <4M5> 54
P Removal sequence
1 Chassis harness
A
2 Starter cable
4 3 Nut (connected to terminal B)
5 1
4 Fuse
6 5 Glow cable
6 Glow relay
8 7 Starter
9
8 Starter relay
1
7
41154
WARNING k
Before removing the starter 7 and/or starter relay 8, disconnect the battery @ terminal and insulate it with tape.
It is dangerous to leave the battery @ terminal connected since the battery voltage is always pressent at each
terminal B.
54-15
201 STARTER <4M5>
30 25
31 26
32 35
J 22
Z
23
34
28
B 27
=
38
24
9
39 6
7 W
8 E
U
20 Q
2 T
1 R
17
21 18
4 15
3 19 41046
1 Stopper ring 15 York 28 E-ring
2 Pinion stopper 16 Armature assembly 29 Gear shaft and internal gear
3 Pinion 17 Rear bearing assembly
4 Spring 18 Washer 30 Gear shaft assembly
5 Magnetic switch 19 Armature assembly 31 Washer
6 Shim 20 Ball 32 Internal gear
7 Rear bracket 21 Front bracket assembly 33 Overrunning clutch
8 York and brush holder 22 Cover 34 Pin
assembly 23 Rubber packing 35 Holder
9 Rubber packing 24 Planetary gear 36 Lever
10 Brush spring 25 Rubber packing 37 Front bearing
11 Brush @ 26 Plate 38 Oil seal
12 Brush holder assembly 27 Gear shaft and overrunning 39 Front bracket
13 York assembly clutch assembly
14 Brush ! Non-reusable parts
54-16
54
CAUTION k
When removing yoke and brush holder assembly 8, make sure you first pull out brushes 11, 14 from brush
holder assembly 12 to avoid damaging the commutator of armature 19.
Do not remove bearings 17, 37 unless they are faulty.
Make sure you do not drop armature assembly 16 when you remove yoke and brush holder assembly 8 from
front bracket assembly 21.
Be careful not to lose ball 20, since it might come out together with armature assembly 16 when you remove it.
NOTE
You do not have to remove pinion 3 when you disassemble or inspect only the motor assembly, for example:
when inspection of the brush assembly is required.
Except for the above, make sure you remove pinion 3 before disassembling any parts.
P Assembly sequence
NOTE
Whenever magnetic switch 5 has been replaced, be sure to adjust the pinion gap.
P Inspection after assembly

P54-18
Service standards Unit : mm {in}

Pinion gap 0.5 to 2.0 {0.02 to 0.079} Adjust
No-load characteristic Current 180 A or less Inspect
(11 V when current flowing) 3800 rpm or more
Revolutions
per minute
10 Pressure of brush spring 29 to 39 N {6.6 to 8.8 lbf, 2 to 4 kgf} 13.7 N Replace
{3.1 lbf, 1.4 kgf}
11, 14 Length of brush 18 {0.71} 11 {0.43} Replace
16 Armature Outer diameter of commutator 32 {1.26} 31.4 {0.24} Replace
assembly
Deflection of commutator periphery 0.05 {0.002} Replace
or more
Insulator depth between segments 0.2 {0.0079} Correct or
or less replace
Lubricant
Location Points of application Kinds Quantity
5 Contact surface between lever and magnetic switch Multipurpose grease [NLGI No.2 Li soap] As required
16 Teeth of armature assembly gear MOLYKOTE AG650 As required
20 Ball MOLYKOTE AG 650 As required
24, 32 Teeth of planetary gear and internal gear MOLYKOTE AG650 As required
30, 33 Friction surfaces of gear shaft and overrunning clutch Multipurpose grease [NLGI No.2 Li soap] As required
31 Washer MOLYKOTE AG650 As required
33 Splin of overrunning clutch Multipurpose grease [NLGI No.2 Li soap] As required
36 Friction surfaces of lever and overrunning clutch Multipurpose grease [NLGI No.2 Li soap] As required
38 Oil seal Multipurpose grease [NLGI No.2 Li soap] As required
54-17
201 STARTER <4M5>
R Service procedure
5
Inspection after assembly the starter should be carried out with current
fed to the starter.
3 WARNING k
Do not touch pinion 3 because it jumps out and turns when cur-
rent is fed to the starter.
Take care not to burn your hand, magnetic switch 5 might be hot
after inspection.
41048
CAUTION k
The current feeding time to the starter should be within 10 sec-
onds at pull-in coil P side and within 30 seconds at holding coil H
side. If the current feeding time exceeds these limits the coil might
burn due to overheating.
When current is flowing into the starter, a current of over 100 am-
peres is fed. When inspecting, use thick cable, such as a booster
cable, and make secure connections.
14257
(1) Performance test

B
Connect the starter as illustrated.
3 A: Ammeter D: DC power supply (12 volts)
B: Terminal B of starter S: Terminal S of starter
S
C: Switch V: Voltmeter
Set the voltage to 11 volts DC.
CAUTION k
Up to12 volts can be loaded.
41049
A V D The following work should be done with current fed to the starter. You
must complete the full procedure of measuring the intensity of the cur-
rent and the number of revolutions within 30 seconds.
C Turn switch C ON and feed current into the starter. In this state,
pinion 3 jumps out and rotates.
CAUTION k
When switch C is turned ON, current is fed both to pull-in coil P
and holding coil H. When a large amount of current is fed into
terminal M from DC power supply D, via terminal B of the starter,
the current stops flowing into the pull-in coil but continues to flow
into the holding coil.
14258
To avoid burning the holding coil, be sure to carry out the perfor-
mance test within 30 seconds.
Measure the intensity of the current and the number of revolutions

of the starter. Train a strobe light on pinion 3 to measure the revolu-
tions.
Turn switch C OFF to stop current to the starter.
If the measured value deviates from the standard value, disassemble
the starter again and inspect it.
54-18
54
(2) Pinion gap
F [Inspection]
3
S C: Switch F: Cable
M D: 12 volts DC M: Terminal M of starter
E: Switch S: Terminal S of starter
The following work should be done with current fed to the starter. You
41050 must complete the full procedure for measuring the pinion gap within
D 30 seconds.
Turn switches C and E ON and feed current to the starter. In this
state, pinion 3 jumps out and rotates.
C
14259
D Within five seconds of pinion 3 rotating, turn switch E OFF to stop

rotation of the pinion.
C
CAUTION k
E When switches C and E are turned ON, current is fed both to pull-
in coil P and holding coil H. The circuit is wired in such a way that
the voltage is not applied to terminal B of the starter, so the cur-
rent continues to flow into the pull-in coil while pinion 3 rotates.
To avoid burning the pull-in coil, be sure to turn switch E OFF
14260
within five seconds of the pinion rotating.
Push the tip of overrunning clutch 33 lightly and measure pinion gap
G in the axial direction.
Turn switch C OFF to stop current to the starter.
G
If the measured value deviates from the standard value, replace the
lever 36.
3
34689
54-19
201 STARTER <4M5>
5 39 36 3 Pinion
3
1 [Removal]
Feed current to the starter and protrude pinion 3 to remove the pinion.
WARNING k
Do not touch pinion 3 because it jumps out and turns when cur-
rent is fed to the starter.
The care not to burn your hand, magnetic switch 5 might be hot
41051 after inspection.
CAUTION k
The current feeding time to the starter should be within 10 sec-
onds at pull-in coil P side and within 30 seconds at holding coil H
side. If the current feeding time exceeds these limits, the coil
might burn due to overheating.
Before making pinion 3 jump out, be sure to feed current to the
starter to obtain the correct state. If current is not fed to the starter
and lever 36 is pulled to protrude the pinion, front bracket 39 or
the lever might be damaged due to the shock produced on re-
moval of stopper ring 1.
14257 The current, when fed to the starter, is over 100 amperes. When
inspecting, use thick cable, such as a booster cable, and make
secure connections.

D A: Switch M: Terminal M of starter
3 C: Switch S: Terminal S of starter
D: Cable
S
M The following work should be done while current is flowing into the
starter. You must complete the full procedure for removing pinion 3
within 30 seconds.
Turn switches A and C ON and feed current to the starter. In this
41050 state, pinion 3 jumps out and rotates.
DC12V
14259
54-20
54
DC12V Within 5 seconds of pinion 3 rotating, turn switch C OFF to stop rota-
tion of the pinion.
A CAUTION k
When switches A and C are turned ON, current is fed both to pull-
C in coil P and holding coil H. The circuit is wired in such a way that
the voltage is not applied to terminal B of the starter, so the cur-
rent continues to flow into pull-in the coil while pinion 3 rotates.
To avoid burning the pull-in coil, be sure to turn switch C OFF
within five seconds after the pinion rotates.
14260
Apply pipe-shaped tool E onto pinion stopper 2.

3 2 1 Hit tool E lightly using a mallet to remove stopper ring 1 from ring groove
F of pinion stopper 2.
Remove stopper ring 1 and pinion 3.
Turn switch A OFF to stop current to the starter.
F
NOTE
E When the current to the starter is stopped, stopper ring 1 might
fall back into ring groove F of pinion stopper 2 because pinion 3
is pushed inside.
If this occurs, feed current to the starter again and carry out the
E
34692 work.
[Installation]
33 When installing pinion 3, it is not necessary to feed current to the starter.
3 Install pinion stopper 2 and pinion 3 onto overrunning clutch 33 in the
1 2
direction as illustrated.
Fit stopper ring 1 into ring groove G of overrunning clutch 33.
34693
Pull pinion 3 firmly and set stopper ring 1 on groove F of pinion stopper
1 2 3 2.
34694
54-21
201 STARTER <4M5>
5 Magnetic switch
5
S [Installation]
Install magnetic switch 5 to lever 36, with terminal S facing the direction
as illustrated.
36
34695
[Inspection]
(1) Testing for coil discontinuity
Make sure that there is continuity between terminal S and M.
If there is no continuity, replace magnetic switch 5.
M 10773
Make sure that there is continuity between terminal M and body A of

A magnetic switch 5.
M
10774
B (2) Inspection of welded connections

Make sure that there is no continuity between terminals B and M.
If there is continuity, replace magnetic switch 5.
M 10775
(3) Inspection of connections

B Push the tip of magnetic switch 5 to close the internal connection.
Make sure that there is continuity between terminals B and M.
M
10776
54-22
54
8 A 10 11, 14 8 Removal and installation of yoke and brush holder assembly
Use the following method to remove the yoke and brush holder assembly
8 in order to prevent the commutator A of the armature assembly 16 from
being damaged by the brushes 11 and 14.
Lift the brushes 11 and 14 away from the commutator A and hold them
lifted by applying the brush springs 10 against the sides of the brush
springs.
16 16083
11, 14 Pull part A of each brush spring 10 and pull up the brushes 11 and 14.
A
Hold the brushes 11 and 14 in position with the brush springs 10 as
illustrated.
10 Remove the yoke and brush holder assembly 8.
14
8 11
34696
Q Inspection of brush springs

Using new brushes 11 and 14, measure the load required to separate
each brush spring 10 from its brush.
If either measurement is lower than the specified limit, replace the brush
springs 10.
10
11, 14 14833
W T Inspection of brush
(1) Length of brush
If the measured value is lower than the limit, replace brushes 11 and
A 14.
A: Length of brush
NOTE
To replace brush @ 11, replace entire brush holder assembly 12.
(2) Contact surface with commutator
35342
If the surface where the brushes contact the commutator is rough or is
worn unevenly, polish the surface with emery paper (300 to 500 grit).
E Inspection of brush holder assembly
12 Make sure that there is no continuity between the ! side of the brush
holder and the @ side of the holder plate.
If there is continuity, they are grounded. Replace brush holder assem-
bly 12.
A B 35343
54-23
201 STARTER <4M5>
14 R Inspection of yoke assembly
(1) Testing for coil disconnection
Make sure that there is continuity between cable A and brush ! 14.
13
If there is no continuity, they are disconnected. Replace brush ! 14
A or yoke assembly 13.
02477
(2) Testing for coil grounding

14
Make sure that there is no continuity between yoke assembly 13
and brush ! 14.
13
If there is continuity, they are short-circuited. Inspect the insulated
point. If it is hard to repair, replace brush ! 14 or yoke assembly
13.
CAUTION k
The coil may be grounded to the yoke assembly 13 due to the
02478 accumulation of worn-off metal particles from the brushes and/or
armature.
A B 16
U Inspection of armature assembly
(1) Testing for coil short-circuit
Place iron rob B parallel to armature assembly 16.
A: Armature tester
Rotate armature assembly 16 slowly.
If iron rob B is pulled or shakes, it indicates that armature assembly
16 is short-circuited, so replace it.
02471
(2) Testing for coil grounding

Make sure that there is no continuity between commutator C and
core D (or shaft E).
If there is continuity between them, they are short-circuited. Re-
place armature assembly 16.
C D E
13329
(3) Deflection of commutator

If the measured value is higher than the limit, adjust the outer diameter
16 of commutator C within the limit.
(4) Rough commutator surface

If the surface is rough or has stepped wear, polish the surface with
emery paper (300 to 500 grit).
After polishing, check deflection of comutator C.
C 13330
54-24
54
(5) Outer diameter of commutator
If the measured value is higher than the limit, replace armature assem-
bly 16.
02474
F (6) Insulator depth between segments

If the measured value is lower than the limit, correct of replace ar-
mature assembly 16.
F: Insulator depth
02475
If the insulator is worn as illustrated, replace armature assembly 16.

p : Good
: Faulty
02476
Z Removal of gear shaft and internal gear assembly

29 Remove the E-rings 28 and then the gear shaft and internal gear assem-
bly 29 from the overrunning clutch 33.
Proceed as follows if the assembly 29 cannot be removed due to interfer-
33 ence of the splined section A of gear shaft 30 with internal parts of the
overrunning clutch 33.
Press the gear shaft 30 against the overrunning clutch 33.
Turn the gear shaft 30 approx. 1/8 of a turn to change the position of
28 splined section A.
16917
33 29
30
A
16915
54-25
201 STARTER <4M5>
B Installation of overrunning clutch
Carry out the following inspection. If any fault is found, replace overrun-
ning clutch 33.
Make sure that shaft A turns smoothly when turned in direction B.
Make sure that shaft A locks when turned in direction C.
C A
13328
- Installation of lever
Install lever 36 onto overrunning clutch 33 in the direction as illustrated.
36
33
34697
= Installation of front bearing

A Install oil seal 38 before press-fitting front bearing 37.
39 Press-fit front bearing 37 into front bracket 39 using pipe-shaped tool
A.
37
38
34698
A Re-caulk front bracket 39.
B 39 NOTE
Do not re-caulk previously caulked points B.
37 A : Caulking points (4 points)
34699
54-26
54
MEMO
54-27
210 ENGINE STARTING CIRCUIT <4M5 AUTOMATIC TRANSMISSION>
41167
54-28
54
5 4 3
6 7
a
10 9
8
41174
1 Starter switch B 1 201 6 Inhibitor switch B Gr23

2 Multipurpose timing control unit B 1 910 7 Starter relay
3 Fuse box 104 8 Starter 201
4 Safty relay B 3 604 9 High current fuse box 104
5 Neutral start relay B 3 604 10 Battery B 1 101
B 1: 96 Model Gr54 (Pub No. TWSE9501-54)

54-29
210 ENGINE STARTING CIRCUIT <4M5 AUTOMATIC TRANSMISSION>
R Service procedure
7 Inspection of starter relay
1 2 Follow the table below to inspect continuity:
3 4 1 2
3 No current
Current +
: There is continuity between terminals p and p.

4 + : Indicates that 12 volts DC is applied to the line between the
41157
terminals.
If any fault is found, replace relay 7.
54-30
54
MEMO
54-31
225 ENGINE WARMING UP CIRCUIT <4M5>
41168
54-32
54
c 4 5 6
d e 3
1 2 a b
f
7
g 9 8
41176
1 Cold start switch B 1 601 6 Relay box 604

2 Meter cluster B 4 401 7 Fuse box 104
3 Engine control unit B Gr13 8 Exhaust brake 3-way magnetic valve B 1 701
4 Exhaust brake relay B 3 604 9 Engine water temperature sensor B Gr13
5 Exhaust brake cut relay B 1 604
B 1 : 96 Model Gr54 (Pub No. TWSE9501-54)

54-33
410 TACHOMETER CIRCUIT <4M5>
41169
54-34
54
1 a b 2 3
e f
41177
1 Meter cluster B 4 401

2 Fuse box 104
3 Engine control unit B Gr13
4 Engine speed sensor 801
54-35
604 RELAY AND CONTROL UNIT
1 2 3 4 5 6 7
( (
U O
(
15 17 ((
P, A
(
S
22
14 13 12 11 10 9 8
<4M5>
23 24, 25 26
<4D3>
25, 27
32 31 30 29 28 41155
1 Wiper relay (LOW) (19 Electronic control unit main relay <4M5>
2 Transmission neutral relay <M/T> (20 Transfer low relay <FG>
Exhaust brake cut relay <A/T> (21 Mirror heater relay
3 Wiper relay (HIGH) 22 Turn signal relay
4 Overheating relay 23 Safety relay
5 Engine oil level relay 24 Electronic governor control unit <4D3> B Gr13
6 Pre-stroke cut relay 25 ABS control unit B Gr35
7 Flasher unit 26 Puls divider
8 Multipurpose timing control unit (27 Engine control unit <4M5> B Gr13
9 Lighting and alarm control unit 28 Daytime running light control unit
10 Backup lamp relay <A/T> 29 Van body dome light relay
11 Exhaust brake relay 30 Automatic transmission fluid cooler fan relay <A/T>
12 Tail lamp relay 31 Neutral relay
13 Head lamp relay (HIGH) 32 Automatic transmission control unit B G23
14 Head lamp relay (LOW)
15 Blower fan relay M/T: Manual transmission
(16 Exhaust brake cut relay <ABS> A/T: Automatic transmission
(17 Drive unit <4M5> B Gr13 ABS: Anti-lock brake system
(18 Drive unit relay
( marks indicate changed parts.

Regarding the inspection procedures for parts for which instructions are not given in this manual, refer to the 99 Model,
Gr54 manual (Pub. No. TWSE9501-3).
54-36
54
R Service procedure
U Inspection of relay (Close type 4-pin)
2
Follow the table below to inspect continuity:
1 2 3 4
No current
Current
1 +
4
3 : There is continuity between terminals p and p.
terminals.
: Indicates that the continuity between the terminals is lost.
If any fault is found, replace the relay.
O Inspection of relay (Open type 5-pin)

3 2 1 Follow the table below to inspect continuity
1 2 3 4 6
No current
Current
+
6
4 02233 + : Indicates that 12 volts DC is applied to the line between the
terminals.
P A S Inspection of relay (Open type 4-pin)

2 1 2 3 4
No current
Current
+
4 1 : There is continuity between terminals p and p.

07142 terminals.
54-37
629 MIRROR HEATER CIRCUIT
41170
54-38
54
1 2 3
c a
b
d, e
This illustrations shows the drivers seat

side door, the assistant drivers side door
is symmetrical.
41124
1 Mirror heater switch

2 Fuse box 104
3 Mirror heater relay 604
54-39
710 EXHAUST BRAKE CIRCUIT <4M5 AUTOMATIC TRANSMISSION>
41109
54-40
54
3 4 5
c d e
2
1 a b
f 7 6
g 9 8
10
j
41183
1 Meter cluster B 4 401 6 Inhibitor switch B Gr23

2 Engine control unit B Gr13 7 Exhaust brake 3-way magnetic valve B 1 701
3 Exhaust brake cut relay <ABS> 604 8 Fuse box 104
4 Exhaust brake cut relay <A/T> 604 9 Automatic transmission control unit B Gr23
5 Relay box 604 10 Accelerator pedal sensor B Gr13

A/T: Automatic transmission
54-41
801 ENGINE ELECTRICS <4M5>
Installation position
2
7 8 9 3
4
5
W 10
6
12
R 14
15
16
41180
54-42
54
1 Top dead center speed sensor B Gr13 9 Water temperature sensor (Connects to engine control
2 Glow plug B 1 220 unit) B Gr13
3 Boost pressure sensor B Gr13 10 Alternator B 4 106
4 Glow relay 11 Engine oil level sensor
5 Starter relay 210 12 Fuel temperature sensor B Gr13
6 Starter 201 13 Engine speed sensor B Gr13
7 Engine oil pressure switch B 1 14 Spil valve B Gr13
8 Water temperature sensor (Connects to 15 Fuel injection rate adjustment read only memory
water temperature gauge and multipur- B Gr13
pose timing control unit) B 1 425 16 Timer control valve B Gr13

Service standard
13 Resistance of engine 12 230 25 Replace
speed sensor
41181
R Service procedure
4 Inspection of glow relay
5 (1) Inspection of fuse
1+
If any fault is found, replace fuse A (127 amperes).
4 (2) Inspection of body

4 2 3 1 5
No current
2
3 Current +
A
+ : Indicates that 12 volts DC is applied to the line between the
terminals.
A: Fuse (127 amperes)
If any fault is found, replace glow relay 4.

AAIA
5 4 3 2 1
33889
W Inspection of engine oil level sensor

45.62 mm 1 2
{1.80.079 in.} ON
ON OFF
Level : There is continuity between terminals p and p.

A If any fault is found, replace engine oil level sensor 11. B Gr12
OFF A: Float
07193
54-43
801 ENGINE ELECTRICS <4M5>
R Inspection of engine speed sensor
2 1 Measure the resistance between terminals 1 and 2.
If the measured value deviates from the standard value, replace en-
gine speed sensor 13. B Gr13.
36798
54-44
54
MEMO
54-45
810 FOUR-WHEEL DRIVE CIRCUIT <FG>
41171
54-46
54
1 a 2
c 5
d
6
7
e
41179
1 Meter cluster B 4 401 5 Automatic transmission control unit B Gr23

2 Fuse box 104 6 Transfer four wheel drive switch B 2 803
3 Electronic governor control unit B Gr13 7 Transfer low switch B 2 803
4 Transfer low relay 604
B 2: 98 Model Gr54 (Pub No. TWSE 9501-254)

B 4: 00 Model Gr54 (Pub No. TWSE 9501-4)
54-47
910 MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT <4M5> 54
41107
54-48 54-49
Table of Contents
BACK /
Model Year Changes
HOME
Pub. No. TWSE9501-4

/
SERVICE MANUAL
FOREWORD
GROUP INDEX
ods for personnel involved in the maintenance and repair of 2000 MODEL CHANGES
2000 model Mitsubishi Fuso Truck FE.FG series.
Read this manual carefully as an aid to providing correct,
GENERAL ........................................ 00
If you have any question, or encounter a problem, please do
FRONT AXLE < FG > ...................... 26B
not hesitate to contact your nearest Mitsubishi Fuso dealer
or distributor. CAB ................................................. 42
Mitsubishi Motors Corporation, May 1999
ELECTRICAL .................................. 54
2000 MODEL CHANGES
2000 MODEL CHANGES
Item 00 Model 99 Model
Gr 00 General Gr 00
Engine output of FE639 series has been
increased to 145 HP/2900 rpm and 275
lbf.ft/1600 rpm (SAE, gross).
Maximum GVW of FE6394 series has
been increased to 12,000 lb.
The vehicle identification number has
changed.
Gr 01 Maintenance Schedule Time of inspection and maintenance

Error in working procedures in Maintenance
Inspection interval
Schedule table has been corrected.

(Applicable to 96 and later models)
Inspection and
Every 250000 km/

Working procedures Remarks
Every 10000 km/
Every 90000 km/

Every 30000 km/
Every 50000 km/

Every 20000 km/
Every 40000 km/

maintenance
150000 miles
54000 miles
18000 miles
30000 miles
12000 miles
24000 miles
6000 miles
2500 miles
POWER TRAIN (Correct)
16 Clutch pedal and clutch disc wear Check pedal for free play. ^ Gr 21
17 Propeller shaft flange torque and Check flange yoke bolts for ^ Gr 25
universal joint looseness looseness and universal joint
for play.
POWER TRAIN (Incorrect)
16 Clutch pedal and clutch disc wear Check pedal for free play. ^ Gr 21
Check clutch disc wear
through inspection hole.
17 Propeller shaft flange torque and Check flange yoke bolts for ^ Gr 25
universal joint looseness looseness and universal joint
for play.
Carry out the first inspection
for new vehicles at 10000 km
or 6000 miles.
-2-
Gr 13 Fuel and engine control < 00 Model >

Components of throttle position sensor
Removal sequence
assembly has been changed.
1 Return spring
6 2 Shaft cover
3 Spring
4 Accelerator control arm
5 Bushing
9 6 Throttle position sensor
7 - 7 Accelerator control extension
8 Bushing
8
9 Bracket
1
4
Installation sequence
1 Follow the removal sequence in reverse.
-5
-5
3 2
P 37123
- Lubricant
5, 8 Slide-contacting surfaces of bushing and support assembly Chassis grease [NLGI No.1 (Ca soap)] As required
< Model >

Removal sequence
6 1 Return spring
3 Bushing
4 Bushing
5 Accelerator control extension
7 6 Throttle position sensor
5 7 Bracket
4-
4-
1
1
-3
3-
P 31483
- Lubricant
Part No. and type of ROM pack are differ- MK 344606 (MRT-E6) MK 327927 (MRT-E4)
ent.
-3-
2000 MODEL CHANGES
Gr 22 Manual Transmission < 00 Model >

Material of transmission case and clutch
housing has been changed from iron to Bolt
Screw plug
37.3 Nm {27 lbf.ft, 3.8 kgfm}
aluminum. (Front bearing retainer mounting) Bolt
44.5 Nm {33 lbf.ft, 4.54 kgfm} (Bearing retainer mounting)
Tightening torque has been changed for 44.5 Nm {33 lbf.ft, 4.54 kgfm}
some bolts.
Reverse idler gear cover gasket is no
longer used, and sealant is used instead.
Oil quantity and mass have been changed.
Transmission case
Apply sealant (Loctite 5999).
Bolt (Reverse idler gear cover mounting)

44.5 Nm {33 lbf.ft, 4.54 kgfm}
Clutch housing
Bolt (Transmission case mounting) Reverse idler
54 Nm {40 lbf.ft, 5.5 kgfm} gear cover
36552
Item Specifications
Oil Quantity L {qts} Approximately 3.7 {3.9} < FE >, Approximately 3.7 {3.9} < FG >
Weight kg {lb} Approximately 83 {183}
< 99 Model >

Screw plug
Bolt 39 Nm {29 lbf.ft, 4 kgfm}
(Bearing retainer mounting)
Bolt
40 Nm {30 lbf.ft, 4.1 kgfm}
(Front bearing retainer mounting)
Reverse idler gear
Gasket
Transmission case
Bolt (Reverse idler gear cover mounting)
Clutch housing
Bolt (Transmission case mounting)

44 Nm {33 lbf.ft, 4.5 kgfm} cover 36553
Item Specifications
Oil Quantity L {qts} Approximately 3.1 {3.3} < FE >, Approximately 3.4 {3.6} < FG >
Weight kg {lb} Approximately 100 {220}
-4-
Gr 23 Automatic Transmission Without power mode switch With power mode switch
Power mode switch is no longer provided.
Power mode switch
Without power mode

switch: 00 models
With power mode

switch: 99 models
99 model
36130
00 model
36131
Gr 26B Front Axle < FG > Gr 26B Front Axle < FG >
Hubs are free-wheel hubs.
(Applicable to 98 models)
Gr 31 Wheel and Tire Item Air pressure kPa {Psi, kgf/cm2}

Tire size Application wheel
Tire size for FE6394 series has been Model Front Rear
changed. 00 model 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50} 166K-127-9
(Wheel with 5 studs)
99 model 215/85R16(D) 450 {65, 4.50} 450 {65, 4.50} 166K-127-9
(Wheel with 5 studs)
Gr 35 Brake System Model

00 model
Disc brakes are installed on all wheels in Item
FE6396 series. Front Brake type Disc brake (Full floating type)
Cylinder inner diameter of caliper mm {in.} 51.1 {2.01}
Disc rotor outer diameterThickness mm {in.} 29340 {11.51.57}
Brake pad thickness mm {in.} 14 {0.55}
Rear Brake type Disc brake (Full floating type)
Model
99 model
Item
Front Brake type Disc brake (Full floating type)
Rear Brake type Drum brake (Dual 2-leading type)
Inner diameter of wheel cylinder mm {in.} 28.57 {1.12}
Inner diameter of brake drum mm {in.} 320 {12.6}
Brake lining widthThickness mm {in.} 759.3 {2.950.37}
-5-
2000 MODEL CHANGES
Gr 35 Brake System Without load sensing valve and bypass With load sensing valve and bypass
Load sensing valve and bypass valve are valve valve
no longer installed due to addition of anti-
lock brake system (ABS).
Procedures for bleeding brake system are [Procedure for bleeding hydraulic unit]
added because of anti-lock brake system Ordinary bleeding procedure is used for the primary side (non ABS-hydraulic
(ABS). system). However, when the solenoid valve of the hydraulic unit operates (ABS
operation) with air mixed in the primary side, air enters the secondary side
(hydraulic system). Therefore, be sure to bleed air from the secondary side using
the MUT-II by following the procedures described below.
Regarding the use of the MUT-II, refer to ^ Gr 35A.
< Bleeding front brakes >

Bleed the primary side of the front brake system. (Ordinary bleeding procedure)
Depress the brake pedal, and select the actuator drive mode, FL ABS MV ON,
on the MUT-II to force-drive the brake.
Open bleeder, bleed air from the wheel cylinder of the front left wheel brake
system.
Repeat the above two steps until air is completely removed.
Depress the brake pedal, and select the actuator drive mode, FR ABS MV
ON, on the MUT-II to force-drive the brake.
Bleed air from the secondary side of the front right wheel brake system.
< Bleeding rear brakes >

Bleed the primary side of the rear brake system. (Ordinary bleeding procedure)
Depress the brake pedal, and select the actuator drive mode, RL ABS MV
Bleed air from the secondary side of the rear left wheel brake system.
Depress the brake pedal, and select the actuator drive mode, RR ABS MV
Bleed air from the secondary side of the rear right wheel brake system.
Gr 35A Anti-lock Brake System ^ Gr 35A Anti-lock brake system (ABS)

Anti-lock brake system (ABS) is added. 00 Minor Change
(Pub. No. TWSE9501-435A)
Gr 42 Cab Gr 42 Cab
Power window system is equipped with
central door lock switch.
-6-
Gr 54 Electrical
1 POWER, CHARGE AND GROUND
High current fuse box (FH3 and FH4) for FH3 (40A ABS hydraulic unit) P54-4
ABS hydraulic unit is added. FH4 (30A ABS hydraulic unit) P54-4
Capacities of fuses listed on the right and F8 Power window 25A F8

main load specifications have changed. F20 Meter cluster, DRL 10A F20 Meter cluster 10A
F29 ABS 10A F29
F34 Tail lamp 20A F34 Tail lamp 15A
Alternator capacity has been increased. 100-A alternator 80-A alternator

106 ALTERNATOR P54-6
Chassis grounding position has been

changed.
< 00 Model >

Chassis ground
< 99 Model >

Chassis ground
(Relocated to vehicle
front section)
36546
Chassis ground (New)
Circuit No. Wire diameter - wire color

EA01 3-B
EA02 3-B
FEE1 B
GEE1 8-B
-7-
2000 MODEL CHANGES
2 STARTING, PREHEATING AND 210 ENGINE STARTING CIRCUIT P54-14

STOPPING ENGINE
Overrun prevention circuit has been added
to engine starting circuit.A
3 LIGHTING 313 DAYTIME RUNNING LIGHT CIRCUIT P54-18

Daytime running light system is added.
4 METER 401 METER CLUSTER P54-22

Meter cluster has been changed, including
addition of indicator.
6 CAB SIDE ELECTRICAL 622 POWER WINDOW AND AUTO DOOR LOCK CIRCUIT P54-24
Power window and auto door lock circuit is
added.
7 CHASSIS SIDE ELECTRICS 710 EXHAUST BRAKE CIRCUIT P54-28

Exhaust brake circuitry has been changed
due to addition of anti-lock brake system
(ABS).
9 OTHERS 210 ENGINE STARTING CIRCUIT P54-14

Circuitry of multipurpose timing control unit
has been changed due to addition of starter
overrun prevention circuit.
-8-
00
GROUP 00 GENERAL
POWER TRAIN TABLE ................................................................... 00-2
VEHICLE IDENTIFICATION NUMBER ........................................... 00-2
00-1
POWER TRAIN TABLE/VEHICLE IDENTIFICATION NUMBER
POWER TRAIN TABLE
Final reduc-
Engine Clutch Transmission Propeller Rear axle tion and
Model
model model model shaft model gear ratio
FE639C, E, F 4D34T3 C4W30 M035S5 P3 R033T D033H

G.V.W. 145 HP/2900 rpm 5.380/0.722 5.714
5445 kg 275 lbf.ft/1600 rpm
{12000 lb} (SAE, Gross)
Torque M035A4
FE639C, E, F C4W30 M035S5

G.V.W. 5.380/0.722
6125 kg
{13500 lb}
Torque M035A4
FG639C, E 4D34T3 C4W30 M035S5+TF3 P2 D1H modified

G.V.W. 135 HP/2900 rpm 5.380/0.722 (Front) 5.714
5445 kg 253 lbf.ft/1600 rpm P3 (Front)
{12000 lb} (SAE, Gross) (Rear) D033H
5.714
(Rear)
FE649C, E, F 4D34T3 C4W30 M035S5 P3 D033H

G.V.W. 145 HP/2900 rpm 5.380/0.722 5.714
6575 kg 275 lbf.ft/1600 rpm
Torque M035A4
J W6 A AC1 H Y L
1 2 345 678 9 FG H
1 Country J: Japan
5 Line A: FE639
B: FE649
G: FG639
6 Series (Wheelbase) C: 2.6 to 2.89 m {8.53 to 9.48 ft.}
E: 3.2 to 3.49 m {10.49 to 11.44 ft}
F: 3.5 to 3.79 m {11.48 to 12.43 ft}
8 Engine H: 3.907l CID Diesel turbocharged and charge air cooled
9 Check digit
F Model year Y: 2000
G Plant K: Kawasaki-1
L: Kawasaki-2
M: Kawasaki-3
N: Nakatsu
H Plant sequential number
00-2
26B
GROUP 26B FRONT AXLE < FG >
STRUCTURE AND OPERATION ..................................................26B- 2
ON-VEHICLE INSPECTION AND ADJUSTMENT

Adjustment of Wheel Alignment ............................................................ 26B- 4
WHEEL HUB AND BRAKE DRUM ...............................................26B- 8
26B-1
Wheel Hub and Brake Drum
1 Lock washer
1 2 3 2 Lock nut
25 26 3 Outer bearing
4
4 Brake drum
24 5 Brake shoe assembly
5
23 6 Wheel hub
7 Oil seal
8 Inner bearing
22 9 Snap ring
6
21 10 Snap ring
11 Center ring plate
*
20 12 Thrust washer
19 13 Hub bolt
14 Driven gear
18
15 Housing
7
16 Gasket
17
17 Cover
16 18 O-ring
15 14 8 19 Knob
13 12 20 Drive gear
11 10
9 21 Snap ring
05601 22 Snap ring
23 Retainer
24 Shift spring
25 Retainer washer
26 Return spring
* : Drive shaft
26B-2
26B
Free-wheel Hub
14 *
A
19
20
24 26
AA A
05602
In the case of a four-wheel drive vehicle, even when it is running in rear-wheel drive only, the drive shaft *, differential,
propeller shaft, and driving parts of the transfer front drive shaft continue to run due to transmission of rotation from the
wheels. This subjects the vehicle drive to a load, and it causes loss of driving power.
Now, with a free-wheel hub, transmission of rotation from the front wheels to the drive shaft * is cut, reducing driving
loss when running in rear-wheel drive only. This improves fuel efficiency and reduces vibration and noise.
With a free-wheel hub, FREE (cutting of driving power) LOCK (transmission of driving power) is made easily by
manual operation.
Operating mechanism
20 From FREE to LOCK

19 When knob 19 is turned to LOCK, retainer 23 shifts to the inside along
with the shape of the knob, pressing return spring 26. At this instance,
driven gear 14, being pressed by shift spring 24, engages with drive
23 gear 20 at the spline, and transmits the driving power.
24
14 26 05603
From LOCK to FREE

When knob 19 is turned to FREE, the action is the reverse of FREE to
20 LOCK, and the driving power is disengaged.
19
23
24
14 26 05604
26B-3
Adjustment of Wheel Alignment
Service standards Unit : mm {in.}

Wheel Toe-in (with tires on the ground) 0 to 6 {0 to 0.24}
alignment Camber 100'30'
Caster 030'100'
Kingpin inclination angle 930' 930'30'
Tightening torque Unit : Nm {lbf.ft, kgfm}

1 Clamp bolt (Tie rod end clamp fastening) 255 {183.6, 2.50.5}
Special tools 0 Unit : mm {in.}

75.2
{2.96}
Alignment gauge adapter MH061994 Measurement of camber and caster angles,

and kingpin inclination angle: with free-
95 wheel hub only
{3.74}
M101.25
05608
NOTE
Measure the wheel alignment when the vehicle is empty and
level.
Be sure that each part of the front axle has been serviced per-
fectly before adjusting the wheel alignment.
Before adjusting the wheel alignment, check for the following faults :
Play in front wheel hub
Play or looseness in kingpin
Play or looseness in the joint between the tie rod and the knuckle arm
Looseness of any fasteners
Fatigued or damaged leaf springs
Incorrect tire pressure
Incorrect steering gear backlash
(1) Measurement and adjustment of toe-in

Point the front wheels exactly forward.
A Put mark A on the left and right front tires at the height of front
wheel axis and in the middle of the tire width.
00887
26B-4
26B
Align the two points of toe-in gauge B to the respective marks A on
the front tires. Measure the distance C between the marks at the
A A front of the vehicle.
C
B 00888
Rotate the tires 180 and measure the distance D between the
E marks at the rear of the vehicle with the tires on the ground.
C Check if the difference between distances C and D is within the
standard value.
E : Front of the vehicle
D
02897
If the measured value deviates from the standard value, with the
2
tires pointed forward, loosen left and right clamp bolts 1 and adjust
the toe-in to the standard value by turning tie rod 2 with a pipe
wrench.
1
05609
Move the vehicle forward and turn tie rod 2 towards the front, with the
4
tires pointed forward (F as illustated). Make sure when adjusting toe-in
1 to the standard value, that both left and right tie rod ends 3 are in
contact with ball stud 4 (G as illustrated) at the same time.
G After adjustment, tighten clamp bolt 1 to secure the tie rod.
In order to keep the end of clamp bolts 1 away from the vehicle, mount
2 tie rod 2 so that clamp center H is placed in the range as illustrated.
3
F
06712
Approxi-
mately 180
H
Approxi-
mately 35 2
63.5
mm 1
{2.5 in.}
06713
26B-5
(2) Measurement of camber
5 Point the front wheels exactly forward.
0
Remove cover assembly 5 and attach 0 alignment gauge adapter.
Then, attach camber/caster kingpin gauge J.
J
05610
While keeping the bubble in level K centered, measure the camber

angle by reading the scale mark at the center of the bubble on
camber scale L. Follow this procedure to measure the camber
angles on the left and right sides.
L K
J
05611
(3) Measurement of caster and kingpin inclination angle

Align turning radius gauges M. Prepare a platform N having the
same height as the turning radius gauges and place the platform
under the rear wheels so that the vehicle is kept level.
Keep turning radius gauges M locked.
Jack up the vehicle and set the left and right front wheels so that the
ground contact area of both front tires and the turntables of turning
radius gauges M meet at their respective centers.
P
N WARNING
M 05612
After jacking up the vehicle, chock the rear wheels securely
with chocks P.
Do not remove chocks P until the entire operation is com-
pleted.
26B-6
26B
Unlock turning radius gauges M, and set the scale at 0.
As in measuring camber explained previously, attach camber/caster
kingpin gauge J tightly to the front wheel hub and keep the bubble
centered.
Apply the brake to the front wheels and turn the steering wheel
slowly from the 0 point on the scale of turning radius gauges M,
Q until direction changes 20 to the left for the left front wheel and 20
R to the right for the right front wheel.
J M NOTE
05613 It is not possible to obtain an exact reading of camber unless
the brake is applied to the front wheels because the tires might
rotate slightly.
At the 20 point, align the bubbles in caster scale Q and kingpin

scale R to 0 by turning the adjuster.
NOTE
Kingpin scale R has scales for left and right; use the left scale
when adjusting the left wheel, and the right scale when adjust-
ing the right wheel.
Turn the steering wheel slowly until the left front wheel changes its
direction 20 to the right, or until the right front wheel changes its
direction 20 to the left, past the 0 point of turning radius gauge M
scale. At this point read the scale marks at the center of the bubbles
on caster scale Q and kingpin scale R. The scale marks indicate the
caster and kingpin inclination angles.
26B-7
WHEEL HUB AND BRAKE DRUM

1
- 38
-
-
40 37

13 39
14 26
15 -
16
- 17 11
- 18
- 10
24 27 3
- 23
- 22
- 21
20
4
- 19
5 25
6 8 -
-
-7 9
-
- 37125
Disassembly sequence
1 Clip 17 Drive gear 32 Inner bearing race
2 Brake hose 18 Return spring 33 Inner bearing
3 Screw 19 Snap ring 34 Outer bearing
4 Cover assembly 20 Retainer 35 Nut
5 Gasket 21 Shift spring 36 Hub bolt
6 Snap ring 22 Driven gear 37 Wheel hub
7 O-ring 23 Retainer washer 38 Brake drum
8 Knob 24 Housing 39 Bolt
9 Cover 25 Free-wheel hub assembly 40 Brake assembly ^ Gr 35
10 Snap ring 26 Bolt
11 Bolt 27 Lock washer * : Knuckle and drive shaft
12 Housing assembly 28 Lock nut ^ Gr 26B
13 Snap ring 29 Outer bearing race : Non-reusable parts
14 Snap ring 30 Wheel hub and brake drum
15 Center ring plate assembly
16 Thrust washer 31 Oil seal
CAUTION
Be sure to protect brake hose 2 from dust by fitting plugs after removal.
NOTE
Do not disassemble wheel hub 37 and brake drum 38 except for replacement.
26B-8
26B
Assembly sequence
*403930292827261211104321
4 : 98765
12 : 242322212019181716151413 25 : Free-wheel hub assembly
30 : 3837363534333231
WARNING
You must bleed air from the brake system after installing the brake hose, failure to do so would cause the
brake to malfunction. ^ Gr 35
CAUTION
Be careful not to damage oil seal 31, press-fitted into the top of wheel hub 37, when installing wheel hub and
brake drum assembly 30 into the knuckle and drive shaft.
Service standards
29, 32, Starting torque of wheel hub bearing 31 Nm Tangential
33, 34 {2.20.7 lbf.ft, 0.30.1 kgfm} force at hub
bolt 18 to
34 N {4.0 to
7.7 lbf., 1.8
to 3.5 kgf}

2 Brake hose tightening 13 to 17 {9.4 to 12, 1.3 to 1.7}
3 Screw (Cover assembly mounting) 51 {3.60.7, 0.50.1}
11 Bolt (Housing assembly mounting) 68.64.9 {513.6, 70.5}
26 Bolt (Lock washer mounting) 92 {6.51.4, 0.90.2}
28 Lock nut (Wheel hub bearing Primary tightening 11315 {8311, 11.51.5}
mounting : wheel hub After primary tighten- 255 {183.6, 2.50.5}
bearing pre-pressure ing, carry-out
adjusting) secondary tightening
35 Nut (Wheel hub and brake drum mounting) 34339 {25329, 354}
39 Bolt (Brake assembly mounting) 1235 {903.6, 12.50.5}
26B-9
- Lubricant and/or sealant
6 Contact surfaces of snap ring and knob Wheel bearing grease [NLGI No.2 (Li soap)] As required
7 O-ring Wheel bearing grease [NLGI No.2 (Li soap)] As required
8 Contact surfaces of knob and retainer Wheel bearing grease [NLGI No.2 (Li soap)] As required
9 Contact surfaces of knob and cover Wheel bearing grease [NLGI No.2 (Li soap)] As required
15 Drive gear joint surface of center ring plate Wheel bearing grease [NLGI No.2 (Li soap)] 3 to 5 g
{0.11 to 0.18 oz}
17, 22 Contact surfaces of drive gear and driven gear Wheel bearing grease [NLGI No.2 (Li soap)] As required
20 Retainer Wheel bearing grease [NLGI No.2 (Li soap)] As required
23 Retainer washer Wheel bearing grease [NLGI No.2 (Li soap)] As required
24 Inner surface of housing Wheel bearing grease [NLGI No.2 (Li soap)] As required
25 Contact surfaces of free-wheel hub assembly and wheel hub THREEBOND 1104 As required
29 Thread area of lock nut Wheel bearing grease [NLGI No.2 (Li soap)] As required
29, 32 Pack the space between rollers of outer and inner bearing inner races Wheel bearing grease [NLGI No.2 (Li soap)] As required
37 Pack interior space of wheel hub Wheel bearing grease [NLGI No.2 (Li soap)] 6510 g
{2.30.3oz}
0 Special tools Unit : mm {in.}

12.7
{0.50}
5 Lock nut adjustment tool MB999151 Removal and installation of lock nut
70
{2.76}
05617
A B C
Hub puller MB999070
7 A : Hub puller body A : MB999071 Removal of wheel hub and brake drum
B : Attachment 50 B : MB999072 assembly
C : Bolt {1.97} C : MB999073
165 {6.50} 05618
70 {2.76} Press-fitting of oil seal (Use in combination
with *1)
8, 10, Bearing installer MB999097 Press-fitting of inner bearing outer race
11 (T90ST30) (Use in combination with *2)
84 Press-fitting of outer bearing outer race
{3.31} 05619 (Use in combination with *3)
84 {3.31}
8 *1 Oil seal installer MB999153 Press-fitting of oil seal (Use in combination)

105
{4.13}
71 {2.80}
05620
26B-10
26B
Unit : mm {in.}
60 {2.36} 92.5
{3.64}
10 *2 Bearing installer MB999069 Press-fitting of inner bearing outer race

(Use in combination)
94.5
{3.72}
05621
71
51 {2.01} {2.80}
11 *3 Bearing installer MB999099 Press-fitting of outer bearing outer race

(T90ST26) (Use in combination)
88.5
{3.48}
05621
Service procedure
Starting torque of wheel hub bearing
30 [Adjustment]
28 34 32 Tighten lock nut 28 at specified torque (primary tightening) while
29 33 turning wheel hub and brake drum assembly 30, then slacken off.
Turn wheel hub and brake drum assembly 30 several times to smooth
operation of outer bearings 29, 34, and inner bearings 32, 33 and
retighten lock nut 28 at specified torque (secondary tightening).
After adjustment, make sure that there is no play in the axial direction.
0 0 : Lock nut adjustment tool
05622
B Insert lock washer 27 so that flat area A fits onto notch B of the
knuckle spindle. Mount two bolts 26 (diagonally opposite each other)
to lock nut 28, and tighten them at specified torque.
27 If lock nut 28 and the hole of lock washer 27 do not align, slacken off
the lock nut slightly.
A 26
05623
[Measurement]
Fasten spring balance C to hub bolt 36 and measure the tangential
force.
If the measured tangential force is the standard value, the starting
torque conforms to the standard value.
If the measured value deviates from the standard value, adjust the
starting torque of the wheel hub bearing according to the procedure
described above.
36 C If any fault is found after adjustment, replace outer bearings 29, 34, or
05624 inner bearings 32, 33.
NOTE
Make sure that there is no drag in the brake lining and brake
drum 38 before you measure the tangential force.
Make sure that you install oil seal 31.
Do not install free-wheel hub assembly 25.
26B-11
2 Removal and installation of brake hose
First remove brake hose 2 from bracket A (on the frame), then remove
A the brake hose from wheel brake B. For installation, follow this procedure
in reverse.
CAUTION
2 Make sure that brake hose 2 is not twisted when you install it.
B
12
05625
L Removal of housing assembly
Remove snap ring 10, and insert bolts 11 (to the same depth) into two
A tapped holes A provided for disassembly. Then, remove housing assem-
11 bly 12.
10
05626
\ Removal and installation of lock nut
When mounting lock nut 28 see P26B-11 : adjustment procedure for
starting torque of the wheel hub bearing.
0 : Lock nut adjustment tool
Y\
28 05627
Packing grease in outer bearing race and inner

29, 32 bearing race
B
A A : Grease pump nozzle
B : Between roller
Z
01000
30 Wheel hub and brake drum assembly

[Removal]
0 : Hub puller
0
05628
26B-12
26B
B If wheel hub and brake drum assembly 30 cannot be removed be-
cause of stepped wear A in brake drum 38, remove the backing plate
C cover. Turn adjuster B in the opposite direction to the arrow on the
backing plate to increase the clearance between the brake drum and
38
brake shoe assembly C. Then, remove the wheel hub and brake drum
assembly.
Correct brake drum 38 if any fault is found. ^ Gr 35
[Installation]
After installing wheel hub and brake drum assembly 30, adjust the
A 08265 clearance between brake drum 38 and brake shoe assembly C.
[
^ Gr 35

Apply grease to lip area A of oil seal 31 and press-fit it.
1 1 : Bearing installer
A 2 : Oil seal installer
2
]
05629
Inner bearing outer race

[Removal]
A Drive out inner bearing race 33 evenly from three indented parts B in
37 wheel hub 37.
33 A : Pin-punch
B
05630
[Press-fitting]
1 : Bearing installer
1
33 2
^
37
05631
Outer bearing race

[Removal]
Drive out outer bearing race 34 evenly from three indented parts B in
A wheel hub 37.
A : Pin-punch
34
B
37 05632
26B-13
[Press-fitting]
37
34
2
05633
36 _` Installation of nut and hub bolt

Hub bolt 36 is marked with L (left) or R (right) to indicate the side
L, R it is to be mounted on. Check this symbol before mounting the bolt.
36
Screw nut 35 onto hub bolt 36 and tighten at specified torque. Then,
stake the hub nut to keep it from turning.
35
05634
26B-14
42
GROUP 42 CAB
STRUCTURE AND OPERATION .................................................. 42 - 2
TROUBLESHOOTING ................................................................... 42 - 4
DOOR ............................................................................................ 42 - 6
42-1
Door Locking System
1 Door lock knob
2 Door lock rod
1
2 3 Door opening rod
3 4 Inside handle
5 Door lock actuator
4 6 Door lock cylinder
7 Door lock cylinder rod
8 Outside handle
10 Door lock latch
5
6
7
05831
Auto Door Lock Electric Circuit

1 Fuse box
2 Driver's side power window switch
1 3 Auto door lock switch
4 Door lock relay
5 Passengers side door lock actuator
6 Drivers side door lock actuator
6
A : Actuator
2
4 3
: Lock signal
5 : Unlock signal
From the drivers side, the doors can be locked

and unlocked by auto door lock switch 3 as
36554
well as by door lock actuator 6.
42-2
42
Door Glass Opening System
1 Door glass
2 Carrier plate
3 Glass holder
4 Cable
5 Regulator
6 Power window motor
7 Rail
3 A : Carrier plate moving range

1 2
Both ends of cable 4 are secured to car-
4
rier plate 2, and regulator 5 is installed to
the wire at a midpoint.
5 Regulator 5 rotates, thus winding cable 4
and moving carrier plate 2 in a vertical
direction to raise or lower door glass 1.
A-
4 6
7
05833
Power Window Electric Circuit

1 Fuse box
2 Drivers side power window motor
3 Drivers side power window switch
assembly
4 Relay
6 Power window lock switch
(for opening and closing assistant
drivers side door glass)
8 Power window relay
9 Passenger's side power window switch
10 Passenger's side power window motor
M : Motor
: UP signal
: DOWN signal
09941
Power window switch assembly 3 on the drivers side is integrated with power window switches 5, 7 and power window
lock switch 6.
When power window lock switch 6 is set to the LOCK position, the door glass on the passenger's side cannot be
operated by power window switches 7, 9.
42-3
TROUBLESHOOTING
Door Lock
Symptoms
Inside door handle does not return properly to original position

Door does not open when outside door handle is operated
Door does not open when inside door handle is operated

Door latch does not engage, and door does not close
Door does not lock when door lock knob is pressed
There is interference between door and cab

Door does not lock when key is turned
Remote door lock does not operate
Remarks
Possible causes
Door installation faulty
Striker installation faulty
Faulty door locking mechanism of door latch
Door latch rod deformed
Door latch rod disconnected
Door latch rod interference
Door lock cylinder deformed
Faulty auto door lock switch in power window & door lock switch
Door lock actuator faulty
Gr 54
Fuse or high-current fuse blown
Open circuit or faulty connection of wire
Left-side outside door handle faulty
Inside door handle installation faulty
Spring fatigue in inside door handle
42-4
Possible causes
Power Window
Power window switch faulty

Power window regulator faulty
Wiring broken or connection faulty

Fuse and high-current fuse burnt-out
Power window regulator mounting faulty
Power window glass and door belt line molding rattling

Symptoms

Door window glass drops on its own while cruising

Abnormal noise from power window regulator while cruising

Power window does not operate

Power window does not stop

Abnormal noise while power window operating
After the starter switch has been turned OFF the window does not operate
within 30 seconds of the power window switch being operated
After the starter switch has been turned OFF and although the doors have

been opened within 30 seconds, the window does not operate within 30
seconds of the power window switch being operated
Gr 54
42
Remarks
42-5
DOOR
Door Assembly
14 13
11
3
32 12
6
7
27
5
33 23
- 22
20
25
-
21
-
30
29 -
17 18 28 24 16 31
- - -
36555
42-6
42
1 Cover 13 Outer weather strip 24 Nut
2 Door lock knob 14 Inner weather strip 25 Glass holder
3 Guard bar 15 Waterproof cover 26 Door glass
4 Pull handle cover 16 Speaker 27 Run channel
5 Ashtray 17 Inside handle 28 Bolt
6 Inside handle cover 18 Clip 29 Regulator & rail assembly
7 Power window switch Gr 54 19 Door lock cylinder 30 Power window motor Gr 54
8 Door trim 20 Screw 31 Door panel
9 Front garnish 21 Door lock actuator Gr 54 32 Weather strip
10 Rear garnish 22 Outside handle 33 Weather strip
11 Outer garnish 23 Lower sash
12 Side combination lamp Gr 54
Reassembly sequence

20 Screw (Door lock actuator mounting) 4 to 6 {2.9 to 4.3, 0.4 to 0.6}
28 Bolt (Regulator & rail assembly mounting) 6.9 to 10.8 {5.1 to 8.0, 0.7 to 1.1}

17 Rotating surface of inside handle Multipurpose grease [NGLI No.2 (Li soap)] As required
21 Sliding surface of door lock actuator Multipurpose grease [NGLI No.2 (Li soap)] As required
22 Sliding surface of outside handle Multipurpose grease [NGLI No.2 (Li soap)] As required
24 Threads of nut Loctite (Japan) Drylock No. 203 As required
25 Threads of glass holder bolt Loctite (Japan) Drylock No. 203 As required
29 Sliding surfaces of regulator & rail assembly Dynamic GB As required
31 Waterproof cover installation surface of door panel Butyl tape As required
42-7
DOOR
1
2
Service procedure
Installation of door lock knob
Install door lock knob 2 to door lock rod A of door lock actuator 21, and
turn the knob fully in clockwise direction.
Back off door lock knob 2 by turning it 1 or 2 turns in counterclockwise
2 direction.
Position cover 1 to prevent door lock knob 2 from turning.
8
05701
Installation of door trim

On the front pillar section, install door trim 8 by pressing it to lip section
A of run channel 27.
27
A On the belt line section, install door trim 8 by pressing it to lip section B
8
of inner weatherstrip 14.
B 8
9F
36556
Installation of front and rear garnishes

A 9
Install clips A to door panel 31 prior to the installation of the garnishes.
Install front garnish 9 and rear garnish 10 to clips A.
31
10 A
31
K
36557
Installation of waterproof cover

A Apply butyl tape A to door panel 31, as indicated in the illustration.
Install waterproof cover 15 by pasting onto butyl tape A.
O
15
31 36558
Installation of door lock cylinder

A Install door lock cylinder 19 to clip 18 in the direction indicated in the
illustration.
A : Vehicle front side
18
19
05705
42-8
42
V Removal and installation of door glass
Remove all parts supporting door glass 26, then remove the door glass
through the open space in the door.
Pull door glass 26 all the way to the top.
26 Remove bolt B through hole A in door panel 31, and remove lower
sash 23.
C Note that the lower sash is inserted in upper sash C.
23 A
23
B
31
36559
Lower door glass 26 until nut 24 becomes visible through hole D in

door panel 31.
Support door glass 26 by hand, then remove glass holder 25.
Remove door glass 26 through the open space in the door.
26 To install door glass 26, follow the removal procedure in reverse.
D D
25
26 31
25
24
36560
42-9
MEMO
42-10
GROUP 54 ELECTRICAL
1 POWER, CHARGE AND GROUND 3 LIGHTING
SPECIFICATIONS ................................................... 54-3 SPECIFICATIONS .................................................... ^ 1
STRUCTURE AND OPERATION ............................ 54-3 STRUCTURE AND OPERATION ............................ ^ 1
TROUBLESHOOTING ..............................................^ 1 TROUBLESHOOTING .............................................. ^ 1

10 0 INSPECTION AND ADJUSTMENT 300 INSPECTION AND ADJUSTMENT
MOUNTED IN VEHICLE MOUNTED IN VEHICLE
Inspection of Alternator .......................... ^ 2 Headlamp Aiming ......................................... ^ 1
Inspection of Regulator ........................... ^ 2
310 HEADLAMP CIRCUIT .................................. ^ 1
101 BATTERY ...................................................... ^ 1
313 DAYTIME RUNNING LIGHT CIRCUIT ...... 54-18
10 4 FUSE ............................................................. 54-4
320 TAIL LAMP, CLEARANCE LAMP AND
10 6 ALTERNATOR ............................................. 54-6 LICENSE PLATE LAMP CIRCUITS ............. ^ 1
110 POWER CIRCUIT ....................................... 54-12 325 STOP LAMP CIRCUIT .................................. ^ 1
115 RESERVE POWER CIRCUIT ....................... ^ 1 330 TURN SIGNAL LAMP AND HAZARD
LAMP CIRCUITS ........................................... ^ 1
125 BATTERY CHARGING CIRCUIT ................. ^ 3
340 BACKUP LAMP CIRCUIT
130 GROUND .......................................................^ 1 < Manual Transmission > ........................... ^ 1
< Automatic Transmission > ...................... ^ 3
345 CAB LAMP CIRCUIT .................................... ^ 1
2 STARTING, PREHEATING, AND 348 ILLUMINATION LAMP CIRCUIT .................. ^ 1

STOPPING ENGINE MARKER LAMP AND
349
IDENTIFICATION LAMP CIRCUITS ............ ^ 1
SPECIFICATIONS ....................................................^ 1
352 VAN BODY DOME LIGHT CIRCUIT ............ ^ 1
STRUCTURE AND OPERATION ............................ ^ 1
TROUBLESHOOTING .............................................. ^ 1
200 INSPECTION AND ADJUSTMENT 4 METER

MOUNTED IN VEHICLE
Inspection of Engine Preheating
System ..........................................................^ 1 SPECIFICATIONS .................................................... ^ 1
201 STARTER ...................................................... ^ 1 TROUBLESHOOTING .............................................. ^ 1
210 ENGINE STARTING CIRCUIT 401 METER CLUSTER ...................................... 54-22

< Manual Transmission > ......................... 54-14
410 TACHOMETER CIRCUIT ............................. ^ 1
< Automatic Transmission > .................... 54-16
420 FUEL GAUGE CIRCUIT ............................... ^ 1
220 ENGINE PREHEATING CIRCUIT ................ ^ 1
225 425 WATER TEMPERATURE
ENGINE WARMING UP CIRCUIT ................ ^ 3
GAUGE CIRCUIT .......................................... ^ 1
54-1
54
5 INDICATOR AND WARNING 7 CHASSIS ELECTRICS
TROUBLESHOOTING .............................................. ^ 1 701 MAGNETIC VALVE ....................................... ^ 1

500 INSPECTION AND ADJUSTMENT 710 EXHAUST BRAKE CIRCUIT
MOUNTED IN VEHICLE < Manual Transmission > ........................ 54-28
Inspection of Brake Fluid < Automatic Transmission > ................... 54-30
Level Switch .............................................. ^ 1
510 PARKING BRAKE INDICATOR
8 ENGINE AND TRANSMISSION
CIRCUIT BRAKE ............................................... ^ 1 ELECTRICS
LOW
515 BRAKE WARNING CIRCUIT VACUUM BRAKE ...... ^ 1
801 ENGINE ELECTRICS ................................... ^ 1
535 ENGINE OIL LEVEL AND
OIL PRESSURE CIRCUIT D B .......... ^ 1 802 TRANSMISSION ELECTRICS ..................... ^ 1
537 OVERHEATING WARNING CIRCUIT .......... ^ 1 810 FOUR-WHEEL DRIVE CIRCUIT ................... ^ 2

CIRCUIT DISK
BRAKE ............................................... ^ 1
550 CAB TILT WARNING CIRCUIT T ........... ^ 1 9 OTHERS
910 MULTIPURPOSE TIMING CONTROL

UNIT CIRCUIT ...............................................^ 1
6 CAB SIDE ELECTRICAL
SPECIFICATIONS ....................................................^ 1
601 SWITCH .........................................................^ 1

604 RELAY AND CONTROL UNIT .................... ^ 3
606 WARNING BUZZER ...................................... ^ 1
610 CIGARETTE LIGHTER CIRCUIT ................. ^ 1
612 AUDIO CIRCUIT ............................................ ^ 1
614 WIPER AND WASHER CIRCUIT ................. ^ 1
616 HORN CIRCUIT ............................................. ^ 1
618 HEATER CIRCUIT ......................................... ^ 1
622 POWER WINDOW AND AUTO
DOOR LOCK CIRCUIT ............................... 54-24
^ 1 : 96 Model Gr 54 (Pub No. TWSE9501-54)

54-2
SPECIFICATIONS/STRUCTURE AND OPERATION 54
This chapter contains information on the alternator. Items not covered in this chapter are the same as those of 99 model.
SPECIFICATIONS
Item Specifications
Alternator Manufacturer MITSUBISHI ELECTRIC
Type Alternator with built-in regulator (without brush external fan)
Model A4TU0488
Output V-A 12-100

Alternator
1 Rectifier
L 2 Rotor assembly
B 3 Stator assembly
4 Fan
5 Pulley
R
6 Front bearing
7 Front bracket
8 Field coil
9 Rear bracket
10 Regulator
11 Rear bearing
E B: Terminal B
E: Terminal E
L: Terminal L
1 2 3 4 R: Terminal R
1
5
A
10
A 11
1 10 6
8
9 7
View A P 36348
54-3
10 4 FUSE
Fuse Main load Capacity

No.
FH1 Fuse box (F1 to F4) 50 A
FH3 ABS hydraulic unit 40 A
FH4 ABS hydraulic unit 30 A
FH5 Starter switch (Terminal B) 50 A
FH7 Alternator 100 A
Fuse box
Fuse Main load Capacity Fuse Main load Capacity
No. No.
F1 Headlamp, LH 15 A F18 Transmission neutral relay 10 A
F2 Headlamp, RH 15 A < Manual transmission >
Inhibitor switch
F3 Stop lamp, horn 15 A
< Automatic transmission >
F4 Turn signal lamp, pre-stroke control unit 15 A
F19 Backup lamp 10 A
(Memory clear switch)
F20 Meter cluster, DRL 10 A
F5
F21 Wiper 10 A
F6 Cab lamp 10 A
F22 Reserve power (MAIN) 10 A
F7 Reserve power (BATT) 10 A
F23 Automatic transmission control unit 15 A
F8 Power window 25 A
F24
F9
F25 Engine control (ACT) 10 A
(Memory clear switch) F26
F11 F27 Exhaust brake 10 A
F12 F28 Engine control ECU 10 A
F13 Cigarette lighter 15 A F29 ABS 10 A
F14 Radio 10 A F30
F15 Reserve power (ACC) 10 A F31
F16 F32 * Condenser fan 15 A
F17 F33 Blower fan 25 A
F34 Tail lamp 20 A
* : Fuses are provided for these pieces of equipment only where they
are installed.
marks indicate changed parts or added parts.

DRL : Daytime Running Lights
54-4
54
MEMO
54-5
10 6 ALTERNATOR
Removal sequence
1 Ground cable
2 Chassis harness
B
2 3 Adjusting bolt
4 V-belts
5 Alternator P54-8
6 Adjusting plate
6
*a: Timing gear case and front plate
1 ^ Gr 11
*b: Power steering oil pump
A : To terminals L and R
A
B : To terminal B
C : Connected to crankcase
E : To terminal E
4 WARNING
*b 3 Terminal B is always loaded with voltage
*a from the battery, supplied via chassis
harness 5. Therefore when you remove
the harness from terminal B, make sure
P 36356
that tools do not touch any adjacent parts
because this would cause a short-circuit.
Make sure that you disconnect terminal
of the battery before removing the har-
ness and insulate the terminal with tape.
Adjustment after installation
Adjustment of V-belt 4 tension ^ Gr 14
Service standards
5 Output current (* When engine is hot At 1500 rpm 53 A or more Inspect
and 13.5 V is loaded ) At 2500 rpm 84 A or more
At 5000 rpm 102 A or more
Adjustment voltage of regulator (At 5000 rpm, 14.70.3 V Replace
5 A is loaded)
* : The value of the ambient temperature is measured after running the alternator drive motor at maximum power
(5000 rpm) for 30 minutes.
54-6
54
A V 12 volts DC
5 Inspection of alternator
(1) Inspection of alternator performance (bench test)

Connect each unit to alternators 5 as illustrated.
CAUTION
Use sufficiently thick wires for the wiring and make
sure all connecting parts are securely connected.
C
D A : Ammeter
5 B : Terminal B on alternator
C : Switch
B
D : Switch
F E : Terminal E on alternator
F : Load resistance (variable resistance)
G : Alternator drive motor
G
L : Terminal L on alternator
R : Terminal R on alternator
E V : Voltmeter
Maximize load resistance F (load current hardly flows).
L
Turn switches C, D ON.
R With the alternator 5 rotating at 5000 rpm, adjust load
P 36357 resistance F to the current specified in the Service Stand-
ards table. Then, operate the alternator for 30 minutes.
Specified output of the alternator : Approx. 100 A
Increase the rotation of alternator 5 gradually and meas-
ure current at specified rpm.
If the measured value deviates from the standard value,
disassemble and inspect alternator 5. P54-8
(2) Inspection of regulator (bench test)

A V 12 volts DC
Connect each unit to the alternators as illustrated.
A : Ammeter
B : Terminal B on alternator
C : Switch
E : Terminal E on alternator
C G : Alternator drive motor
V : Voltmeter
Turn switch C ON.
5 Run alternator 5 at low speed.
Measure the voltage (adjustment voltage) when alterna-
B
tor 5 has reached a speed of 5000 rpm. Make sure at
such time that the value of the current is five amperes or
G
less.
E If the measured value deviates from the standard value,
perform either of the following.
If the measured value is higher than the standard
L value : Replace the regulator
If the measured value is lower than the standard value
R : Before replacing the regulator check the alternator
P 36358 area.
54-7
10 6 ALTERNATOR
Alternator
13
7 6
8
9
10
5
4
3
2 12
13
11 12
18
16
P 36345
1 Rotor and front bracket assembly 10 Front bracket
2 Nut 11 Stator and rear bracket assembly
3 Pulley 12 Screw
4 Fan 13 Screw
5 Spacer 14 Field coil
6 Rear bearing 15 Stator assembly
7 Rotor assembly 16 Regulator
8 Cover 17 Rectifier
9 Front bearing 18 Rear bracket
CAUTION
When removing field coil 15, support the field coil by hand or with a stand to prevent it from falling due to its
own weight.
NOTE
Do not remove parts 6, 9, 14 unless they are faulty.
Assembly sequence
54-8
54
Service standards
15 Field coil resistance (20C {68F}) 2.0 to 2.4 Replace

2 Nut (Pulley mounting) 132 to 162 {98 to 120, 13.5 to 16.5}
14
A
10
1
Service procedure
Rotor and front bracket assembly
[Removal]
Insert screwdriver A between front bracket 10 and stator assembly 14.
Use screwdriver A to pry rotor and front bracket assembly 3 away
from stator and rear bracket assembly 11.
CAUTION
Be careful not to insert the screwdriver too deep or it will damage
coil B of stator assembly 14 and might cause a short-circuit.
11 1
P 36359
B [Disassembly]
CAUTION
Make sure, when you hold rotor assembly 7 in a vise, to grip root
C of the core claws. Gripping claws D can damage them.
7
C P 02319
54-9
10 6 ALTERNATOR
K Inspection of stator
Measure the resistance between the terminals of stator 15.
If the measured value deviates from the standard value, replace stator
14 15.
J
P 16636
Field coil assembly

B
17 [Removal and installation]
Disconnect lead A of field coil assembly 14 from rectifier 17. The lead
is soldered to diode B of rectifier 17 at eight points. (Each of the two
rectifiers has 4 soldered sections.)
CAUTION
Make sure that you desolder within five seconds because the
B
A diode is heat sensitive.
14
P 36360
To install, follow the removal sequence in reverse.
[Inspection]
(1) Continuity of each lead wire
Check electrical conductivity between individual lead wires of the four
wires soldered to each rectifier.
If there is no continuity, the lead wire is broken. Replace field coil
assembly 14.
P 02336
(2) Continuity between lead wires and the core

Make sure that there is no continuity between all lead wires and the
core.
If there is continuity, replace field coil assembly 14, since it might be
short-circuited.
P 02337
54-10
54
E
M Inspection of rectifier
Inspect whether the diode inside rectifier 17 functions properly, and if
A any fault is found, replace the rectifier.
B Infinite resistance in both.....................Open circuit
C F Near-zero resistance in both............Short circuit
D A, B, C, D : Lead connecting area of stator coil
E, G : Heat sink area
F : Regulator connecting area
G
Inspect the rectifier twice, before and after the side and side of
P 15270 the tester have been changed over.
A B G C D
CAUTION
When inspecting using a tester, the current becomes weaker
than the usual current flowing through rectifier 17. Therefore, an
incomplete resistance value might be indicated.
Also, this tendency increases as the range of the tester gets
smaller. Therefore, use as large range as possible.
F E
P 36361
54-11
110 POWER CIRCUIT
starter
36771
54-12
54
MEMO
54-13
210 ENGINE STARTING CIRCUIT < Manual Transmission >
36407
54-14
54
2 3 4
8 7 6 5
a 9 10
13 12 11
36408
1 Starter switch ^ 1 210 8 Neutral start relay ^ 1 604

2 Transmission neutral relay ^ 1 604 9 Transmission neutral switch ^ 1 802
3 Relay box ^ 3 604 10 Starter relay ^ 1 210
4 Multipurpose timing control unit ^ 1 910 11 Starter ^ 1 210
5 Diode 12 High-current fuse box 104
6 Fuse box 104 13 Battery ^ 1 101
7 Safety relay ^ 3 604

54-15
210 ENGINE STARTING CIRCUIT < Automatic Transmission >
36409
54-16
54
5 4 3
6 7
a
10 9 8
36410
1 Starter switch ^ 1 210 6 Inhibitor switch ^ Gr 23

2 Multipurpose timing control unit ^ 1 910 7 Starter relay ^ 1 210
3 Fuse box ^ 1 104 8 Starter ^ 1 201
4 Safety relay ^ 3 604 9 High-current fuse box 104
5 Neutral start relay ^ 3 604 10 Battery ^ 1 101

54-17
313 DAYTIME RUNNING LIGHT CIRCUIT
LOW/HIGH
54-18
54
Alternator
Alternator
Switch turns ON
when fluid level
drops
HIGH/LOW
36411
54-19
313 DAYTIME RUNNING LIGHT CIRCUIT
5
3 4
6 7 8
2 b c
1
d
12 11 10
13
14
15
16
e f
17
18
36412
54-20
54
1 Brake fluid level switch ^ 1 515
2 Meter cluster 401
3 Starter switch ^ 1 210
4 Combination switch ^ 1 601
5 Relay box ^ 3 604
6 Headlamp relay, LOW ^ 3 604
7 Headlamp relay, HIGH ^ 3 604
8 Tail lamp relay ^ 3 604
9 Daytime running light control unit
10 Diode
11 Fuse box 104
12 Parking brake switch ^ 1 510
13 Headlamp, RH
14 Headlamp, LH
15 Rear combination lamp, RH
16 License plate lamp
17 Rear combination lamp, LH ^ 1 : 96 Model Gr 54 (Pub No. TWSE9501-54)
18 Alternator 106 ^ 3 : 99 Model Gr 54 (Pub No. TWSE9501-3)
ON (H)
3 Starter switch OFF (L)
H
18 Alternator L
OFF (H)
12 Parking brake switch ON (L)
DIMMER SWITCH
HIGH LOW
OFF (H)
4 Lighting switch ON (L)
OFF (H)
2 DRL indicator ON (L)
OFF (H)
DRL output signal ON (L)
LIGHT
13, 14 Headlamp (LOW) NO LIT
LIGHT
13, 14 Headlamp (HIGH) NO LIT
P 36413
[Outline]
The daytime running light system (DRL) turns on head lamps 13, 14 in low beam as soon as the engine starts even if the
light switch is in the OFF position.
Headlamps 13, 14 repeat On/Off operations at 120 Hz according to the above timing chart. Because of the cyclic On/Off
operations, the headlamps are dimmer than when the headlamp switch is ON.
Explanation of timing chart
After the engine starts, when alternator 18 begins generating electricity with starter switch 3 in the ON position,
headlamps 13, 14 light.
When parking brake switch 12 is ON, the DRL turns off to switch off the headlamps.
54-21
401 METER CLUSTER
Meter Cluster Internal Circuit
36414
54-22
54
AU13A AU10A AU10A AL2A
AU16A
07417
Terminal Terminal Terminal

AU10A AU13A AU16A
No. No. No.
1 Turn, LH 11 Fuel gauge 24 Tachograph < optional >
2 Beam 12 25 Illumination
3 Beam 13 Tachometer 26
4 Exhaust brake 14 Charge 27 Illumination
5 Turn, RH 15 Disc brake 28 Ground
6 Glow 16 Engine oil 29 Water temperature gauge
7 Glow 17 Engine oil 30 Cab tilt
8 Vacuum 18 Engine oil 31 DRL
9 19 32
10 Brake 20 Pre-stroke control 33
21 Tachometer 34 A/T fluid temperature
22 35 4WD
23 Electronic control governor 36 Starter switch terminal M
37 A/T warning
ABS : Anti-lock Brake System 38 ABS
DRL : Daytime Running Light
Terminal 39
AU10A marks indicate added parts.
No.
40
41 A/T shift
42 A/T shift (P)
43 A/T shift (R)
44 A/T shift (N)
45 A/T shift (D)
46 A/T shift (2)
47 A/T shift (L)
48 A/T overdrive OFF
49 A/T overdrive OFF
Terminal AL2A
No.
1 Buzzer
2 Buzzer
A/T : Automatic transmission
54-23
622 POWER WINDOW AND AUTO DOOR LOCK CIRCUIT
(Ps)
(Ps)
(Ps)
(Ps)
Ps : Passenger's seat side
36415
54-24
54
2
< Dr > 1
b
1 Fuse box 104

2 Power window switch & controller (Dr)
3 Power window motor (Dr)
4 Door lock actuator (Dr)
5 Power window switch & controller (Ps)
6 Door lock actuator (Ps)
7 Power window motor (Ps)
Ps : Passenger's seat side
4 3
Dr : Driver's seat side
5
< As >
7 6
36416
54-25
622 POWER WINDOW AND AUTO DOOR LOCK CIRCUIT
25
Service procedure
Inspection of power window switch & controller
Since the units alone cannot be readily checked in the off-vehicle
state, check the harness, switch and other related parts in each
system.
If any fault is not found in the related parts, and the problem still
37
remains in the system, replace the control unit or other units.
Inspection of power window motors

Follow the table below to check for operation.
1 2
UP (Close)
Down (Open)
: Indicates the terminals where 12 volts DC is to be applied.
P 36417
If any fault is found, replace power window motors 3, 7. Gr42
4 Inspection of door lock actuator (drivers seat side)

Follow the table below to check for continuity and operation.
1 2 3 4 5
LOCK
UNLOCK
: There is continuity between terminals.
19533 : Indicates the terminals where 12 volts DC is to be applied
If any fault is found, replace door lock actuator (drivers seat side) 4.
Gr42
6 Inspection of door lock actuator (passenger's seat side)

Follow the table below to check for operation.
1 2
1 2 LOCK
UNLOCK
: Indicates the terminals where 12 volts DC is to be applied.
15514
If any fault is found, replace door lock actuator (passenger's seat side)
6. ^ Gr42
54-26
54
MEMO
54-27
710 EXHAUST BRAKE CIRCUIT < Manual Transmission >
Throttle position
sensor
36542
54-28
54

1 13 3 4
2 c d e
f g
5
6 a b
2
j
h 10 9 8
12
36543
1 Combination switch ^ 1 601 7 Diode

2 Electronic governor control unit ^ Gr 13 8 Transmission neutral switch ^ 1 802
3 Transmission neutral relay ^ 1 604 9 Exhaust brake 3-way magnetic valve ^ 1 701
4 Relay box ^ 3 604 10 Fuse box 104
5 Exhaust brake relay 604 11 Clutch switch ^ 3 710
6 Meter cluster 401 12 Throttle position sensor ^ Gr 13
13 Exhaust brake cut relay (ABS) ^ 3 604

marks indicate added parts.
54-29
710 EXHAUST BRAKE CIRCUIT < Automatic Transmission >
Throttle position
sensor
36544
54-30
54
11
2 c d e 3 4
f g 5
1 a b
2 2
h 7 6
j 9 8
10
m
36545
1 Meter cluster 401 6 Inhibitor switch ^ Gr 23

2 Electronic governor unit ^ Gr 13 7 Exhaust brake 3-way magnetic valve ^ 1 701
3 Exhaust brake cut relay ^ 3 604 8 Fuse box 104
4 Relay box ^ 3 604 9 Automatic transmission control unit ^ Gr 23
5 Exhaust brake relay 604 10 Throttle position sensor ^ Gr 13
11 Exhaust brake cut relay (ABS) ^ 3 604

marks indicate added parts.
54-31
Table of Contents
BACK
Model Changes
HOME
Pub. No. TWSE9501-3

SERVICE MANUAL
FOREWORD
ods for personnel involved in the maintenance and repair of
1999 model Mitsubishi Fuso Truck FE.FG series.
Read this manual carefully as an aid to providing correct,
If you have any question, or encounter a problem, please do
not hesitate to contact your nearest Mitsubishi Fuso dealer GROUP INDEX
or distributor.
1999 MODEL CHANGES
Mitsubishi Motors Corporation, March 1998
GENERAL ........................................ 00
STEERING ....................................... 37
ELECTRICAL .................................. 54
1999 MODEL CHANGES
1999 MODEL CHANGES
Gr 00 General Gr 00
Automatic transmission has changed.
Maximum GVW has changed.
The vehicle identification number has
changed.
Connectors are added.
Gr 11 Engine
Configuration of pistons combustion cham- Combustion chamber
ber is different. Combustion chamber
30330 30331
Gr 13 Fuel and engine control Electronic governor and pre-stroke Mechanical governor and pre-stroke
Injection pump system has changed to elec- control injection pump system control injection pump system
tronic control system.
^ Gr 13 Fuel and engine control

99 Minor change
(Pub. No. TWSE9501-313)
Governor has changed from Electronic governor Mechanical governor

mechanical type to electronic type.
31496 31497
Governor type RED-III RLD-J all-speed mechanical governor
Electronic with boost compensator
control
governor

99 Minor change
(Pub. No. TWSE9501-313)
Fuel injection timing is different. 30.5BTDC 70.5BTDC
-1-
Engine control system changed due to the < 99 Model >

use of electronic governor.
99 Minor change
(Pub. No. TWSE9501-313) Starter switch
Engine stop cable
Emergency
engine stop cable
Accelerator
position Accelerator
sensor pedal assembly
31498
< 98 Model >

Idle control knob
Idle control cable
Starter switch
Accelerator
arm assembly
Accelerator
Accelerator pedal control cable
assembly
Accelerator Engine stop cable

control cable Engine stop cable
Fuel cut-off motor

31499
-2-
1999 MODEL CHANGES
Gr 14 Cooling
Shapes of thermostat cover and thermo- 1
stat case are different. 1
4
2
3
4
5
5
6 6
11 7
12
* 11
8 *
8
7
10 13
9 10
13
12
9
30332 10846
1 Pressure cap 11 Water temperature sensor
2 Water filter (Water temperature gauge and multipurpose timing
3 O-ring control unit) ^ Gr 54
4 Thermostat cover 12 Overheating switch ^ Gr 54
5 Thermostat cover gasket 13 Water temperature sensor (Pre-stroke control type
6 Thermostat injection pump) ^ Gr 54
7 Thermostat case
8 Thermostat case gasket * : Cylinder head
9 Bypass pipe : Non-reusable parts
10 O-ring
Assembly sequence
CAUTION
Be sure to apply soapy water to O-ring 3, 10 for easier fitting. Never use engine oil because it will cause the
O-ring to swell.
Gr 15 Intake and Exhaust

Boost compensator hose was replaced by
boost pressure sensor hose due to the 0
installation of boost pressure sensor.
Boost pressure
0 sensor hose
Boost
compensator
hose
30333 11383
-3-
Gr 23 Automatic Transmission
Transmission model M035A4 M030A4
Automatic transmission changed from
Manufacturer AISIN JATCO
M030A4 to M035A4. Torque converter Type Symmetrical 3-element, 1-stage, 2-phase type
Stall torque ratio 1.82 2.0
Lock-up mechanism Equipped Equipped
Automatic transmission Type Planetary gear type, 4 forward speeds, 1 reverse speed
Gear ratio FE639 FE649
1st 3.018 3.028 2.784
2nd 1.548 1.570 1.544
3rd 1.000 1.000 1.000
4th 0.703 0.724 0.694
Reverse 2.678 2.625 2.275
Control system Electronic control hydraulic system
^ Gr 23 Automatic transmission
99 Minor change
(Pub. No. TWSE9501-323)
Gr 37 Steering
Steering wheel is different. Steering wheel assembly Steering wheel assembly
400 mm {15.7 in.} 400 mm {15.7 in.}
30368
Steering system is different. Gr 37 Steering
Gr 42 Cab
Side door beams are added.
Side door beam
30546
-4-
1999 MODEL CHANGES
Gr 54 Electrical
Diode layout and mounting position
changed as shown on the right.
< M/T > 30860
< M/T > < A/T >
< A/T >
< A/T >
M/T : Manual transmission

30823
1 POWER, CHARGING AND GROUND

Battery has changed. 115E41R 95E41R
Battery box shape is different. < '98 Model >

1
6
4
9 7
8
10908
Removal sequence
1 Battery cover 6 Battery cable (+)
2 Ground cable 7 Battery side cover
3 Battery cable () 8 Battery
4 Starter cable 9 Battery box
5 Chassis harness
-5-
< '99 Model > 1
Battery box shape is different.
4
2
5
9
6
8
7
7
10
30310
Removal sequence
1 Battery cover 6 Rubber
2 Battery cable () 7 Angle frame
3 Harness (Main high-current fuse) 8 Set bolt
4 Starter cable 9 Battery
5 Battery cable (+) 10 Battery box
Capacities of high-current fuses are dif- FH7 (80A Alternator) 80A FH7 (80A Alternator) 100A
ferent. FH7 (100A Alternator) 100A FH7 (100A Alternator) 100A
High-current fuse box (FH8) for alterna- FH8 (80A Alternator) 80A
tor is added. FH8 (100A Alternator) 100A
125 BATTERY CHARGING CIRCUIT P54-4
Capacities of fuses listed on the right and F4 Turn signal lamps 15A F4 Turn signal lamps,
main load specifications have changed. pre-stroke control unit 15A
Discontinued F5 Fuel cut-off motor 10A
Discontinued F17 Fuel cut-off relay 10A
F18 Transmission neutral relay F18 Transmission neutral switch
< Manual transmission > 10A < Manual transmission > 10A
Inhibitor switch Inhibitor switch
< Automatic transmission > 10A < Automatic transmission > 10A
F23 Automatic transmission F23 Automatic transmission
control unit 15A control unit 10A
F25 Pre-stroke cut-off relay 10A F25 Pre-stroke cut-off relay 15A
F28 Electronic governor
control unit 5A
2 ENGINE STARTING, PREHEATING AND

STOPPING
215 Engine stopping circuit was discon- Electronic control engine stopping Electric and wire-operated engine
tinued due to the use of electronic gover- device stopping device
nor. (Fuel cut-off relay and fuel cut-off Gr 13 Fuel and engine control 215 Engine stopping circuit
motor were also discontinued.)
Circuit indicated on the right changed due 210 ENGINE STARTING CIRCUIT P54-6, 8
to the use of neutral start relay.
-6-
1999 MODEL CHANGES
212 Sub-starter circuit was discontinued.
Circuit indicated on the right changed due 225 ENGINE WARMING UP CIRCUIT P54-10
to the use of electronic governor.
3 LIGHTING
Circuit indicated on the right changed due 340 BACKUP LAMP CIRCUIT <AUTOMATIC TRANSMISSION > P54-12
to the use of backup lamp relay.
4 METER
Warning indicator lamp is added due to (Orange) Electronic governor warning lamp
the use of electronic governor.
(Red) Pre-stroke warning lamp
< Internal circuit of meter cluster >

Meter cluster
(ORANGE) (RED)
< Back side of meter cluster >
AU16C
30849
Connector No. Terminal No.

AU13A 20 Electronic governor control unit
23 Electronic governor control unit
AU16C 36 Starter switch terminal (M)
Relays listed on the right are added. Transmission neutral relay < Manual transmission >
Refer to P54-14 for service procedure. Exhaust brake cut relay < Automatic transmission >
Backup lamp relay < Automatic transmission >
Exhaust brake relay
Neutral start relay
7 CHASSIS SIDE ELECTRICAL

Circuit indicated on the right changed due 710 EXHAUST BRAKE CIRCUIT P54-16, 20
to the use of electronic governor.
-7-
00
GROUP 00 GENERAL
POWER TRAIN TABLE ................................................................... 00-2
VEHICLE IDENTIFICATION NUMBER ........................................... 00-2
CONNECTOR CONFIGURATION CHART ..................................... 00-3
00-1
POWER TRAIN TABLE
Final reduc-
Model

G.V.W. 135 HP/2900 rpm 5.380/0.722 5.714
5262 kg 253 lbf.ft/1600 rpm
Torque M035A4
FE639C, E, F C4W30 M035S5

G.V.W. 5.380/0.722
6123 kg
{13500 lb}
Torque M035A4
FG639C, E C4W30 M035S5+TF3 P2 D1H modified

G.V.W. 5.380/0.722 (Front) 5.714
5443 kg P3 (Front)
{12000 lb} (Rear) D033H
5.714
(Rear)
FE649C, E, F 4D34T3 C4W30 M035S5 P3 D033H

G.V.W. 145 HP/2900 rpm 5.380/0.722 5.714
6575 kg 275 lbf.ft/1600 rpm
Torque M035A4
JW6 A AC1 H L
1 2 345 678 9 FG H
1 Country J: Japan
5 Line A: FE639
B: FE649
FG639
6 Series (Wheelbase) C: 2.6 to 2.89 m {108.3 to 109.4 in}
E: 3.2 to 3.49 m {131.9 to 133.1 in}
F: 3.5 to 3.79 m {148.0 in}
8 Engine H: 238 CID Diesel turbocharged and charge air cooled
9 Check digit
F Model year X: 1999
G Plant K: Kawasaki-1
L: Kawasaki-2
M: Kawasaki-3
N: Nakatsu
00-2
CONNECTOR CONFIGURATION CHART 00
Connector is added due to the use of electronic governor.

Type (numeral indicates
number of terminal)
Female-Male
AQ AQ5A
1 2 3 4 5
BN BN14
BZ BZ12A
BZ16A
BZ76A
BZ22A (BZ26A)
(BZ16A)
(BZ12A)
BZ26A (BZ22A)
CB CB16A
CH CH3A
CM CM28A
CM30A
CM35A
00-3
37
GROUP 37 STEERING
STEERING SYSTEM ....................................................................... 37- 2
37-1
STEERING SYSTEM

10 6
2
11
9
4
13 15
- 12 14 19
3
1

< FE > 30
16

33 20
*
24
33
34 23
22
21
29
28
< FG >
30

33
31
34
33
30369
37-2
37
Removal sequence
1 Column cover outer lower 15 Combination switch ^ Gr 54 28 Pressure tube ^ Gr 37
2 Column cover outer upper 16 Bracket 29 Return tube ^ Gr 37
3 Column cover inner lower 17 Head cutting bolt 30 Drag link ^ Gr 37
4 Column cover inner upper 18 Starter switch ^ Gr 54 31 Nut
5 Horn pad 19 Spring 32 Power steering booster
6 Nut 20 Band ^ Gr 37
7 Telescopic lever 21 Nut 33 Nut
8 Nut 22 Dust cover 34 Tie rod assembly ^ Gr 37
9 Steering wheel assembly 23 Dust cover
10 Horn spring 24 Dust cover * : Front axle assembly
11 Contact plate 25 Bolt < FE > ^ Gr 26
12 Cover assembly 26 Bolt < FG > ^ Gr 26B
13 Steering wheel 27 Steering column subassembly
14 Screw ^ Gr 37 : Non-reusable parts
CAUTION
When disconnecting pressure tube 28 and return tube 29, cover the ports to keep them free from dust and
other foreign particles.

6 Nut (Telescopic lever mounting) 8.8 to 9.8 {6.5 to 7.2, 0.9 to 1.0}
8 Nut (Steering wheel assembly mounting) 39 to 49 {29 to 36, 4 to 5}
14 Screw (Combination switch mounting) 2.50.5 {1.80.4, 0.250.05}
17 Head cutting bolt (Starter switch mounting) 14.21.5 {101.1, 1.450.15}
21 Nut (Steering column subassembly and power 53 to 65 {39 to 48, 5.4 to 6.6}
steering booster mounting)
25 Bolt (Steering column at floor side mounting) 17 to 26 {12 to 19, 1.7 to 2.6}
26 Bolt (Steering column subassembly to instrument 17 to 26 {12 to 19, 1.7 to 2.6}
panel side mounting)
28 Pressure tube 29 to 39 {22 to 29, 3 to 4}
29 Return tube 39 to 49 {29 to 36, 4 to 5}
31 Nut (Power steering booster mounting) 83.5 to 108 {61 to 80, 8.5 to 11.0}
33 Nut (Tie rod assembly mounting) 9325 {6918, 9.52.5}
- Lubricant
12 Contact area between combination switch of cover Wheel bearing grease As required
assembly and horn contact [NLGI No.2 (Li soap)]
37-3
STEERING SYSTEM
5
5
Service procedure
Removal of horn pad
Insert a flat-tip screwdriver into the space between steering wheel
assembly 9 and shoulder sections A, B of horn pad 5, and disengage
9 the latch by prying open the horn pad with the screwdriver until a
B clicking sound is produced.
A
Insert fingers into the space behind lifted horn pad 5 and remove the
horn pad.
7
24551
Telescopic lever
A
B
[Removal]
18mm Secure screw A (M50.8 mm) in tapped hole in telescopic lever 7 and
{0.71 in.} remove telescopic lever from telescopic shaft B.
or more
M50.8 mm
7
24477
9 [Installation]
Make adjustment so that telescopic lever 7 positioned at the designated
location applies the specified torque on telescopic shaft B.
7
CAUTION
Free Be careful not to damage the threads on the tip of telescopic
9 B 6
Locked shaft B.
7 C : Telescopic shaft assembly

8 C 24478
37-4
37
Start procedure Install steering wheel assembly 9. Using a long socket wrench, tighten
>
nut 8 at specified torque 39 to 49 Nm {29 to 36 lbf.ft, 4 to 5 kgfm}
<
Looseness found No looseness
Rotate telescopic shaft B counterclockwise with your fingers and check
for looseness
<
<
Using a flat-blade screwdriver turn telescopic shaft B > Set telescopic lever 7 to specified lock po-
sition (within 10 before the position at
clockwise and drive it in until it hits lightly with a which telescopic lever contacts steering
clunk, but do not turn it any further wheel assembly 9).
>
CAUTION
<
Be careful not to over tighten or you will crush
Tighten nut 6 at specified torque 8.8 to
the end of the telescopic shaft, requiring re-
9.8 Nm {6.5 to 7.2 lbf.ft, 0.9 to 1.0 kgfm}
placement of telescopic shaft assembly C
<
<
Install telescopic lever 7 at a location that allows easy

tightening, then tighten nut 6 until the telescopic lever
will not slip
Lock
<
position 30
Tighten telescopic shaft B at operating torque 6.9 to
7.8 Nm {5.1 to 5.8 lbf.ft, 0.7 to 0.8 kgfm}. (Tighten Range 10
06709
telescopic bar 7 at torque 69 to 78 N {15 to 18 lbf, 7 to
8 kgf} at 100 mm {3.94 in.} from the center of steering When telescopic lever 7 is released, and tel-
wheel assembly 9) escopic shaft B is retightened at operating
torque 6.9 to 7.8 Nm {5.1 to 5.8 lbf.ft, 0.7 to
<
0.8 kgfm}, the telescopic lever should lock in

To maintain lock, hold telescopic lever 7 clockwise, <
the 10 range this side of specified lock posi-
then loosen and remove lock nut 6
tion 30
Out of the Within the
<
range range
Remove telescopic lever 7
NOTE
Remove telescopic lever 7 following the descrip-
<
tion under [Removal], taking care not to loosen Jiggle steering wheel assembly 9 up and
telescopic shaft B. down and check for looseness

<
<
Procedure is
Remove telescopic lever 7 < Remove nut 6
completed
CAUTION
Be sure not to operate telescopic shaft B while steering wheel assembly 9 is removed.
NOTE
Be sure to assemble telescopic lever 7 only after steering wheel assembly 9 has been installed.
37-5
STEERING SYSTEM
17
MN
[Removal]
Head cutting bolt, starter switch
After removing bracket 16, drill a 5.5 to 6.0 mm {0.22 to 0.24 in.} hole
10 to 15 mm {0.39 to 0.59 in.} deep on cutting face A of head cutting
bolt 17 for mounting starter switch 18.
A Screw in screw extractor B counterclockwise, then pull out head
cutting bolt 17.
16
18
B 07241
[Installation]
With new head cutting bolt 17, tighten starter switch 18 at specified
18 torque to cut the head off the bolt.
After installing bracket 16, verify operation of the steering lock function
of starter switch 18.
17 17
16
25
07242
26 UV Installation of bolt
Bolts 25 and 26, differ in shape. Do not mix them up when installing.
NOTE
Thread area A of bolt 25 is elliptical to facilitate grounding of the
horn circuit.
27 A
07243
W\ Removal and installation of steering column

subassembly and power steering booster
Before removing steering column subassembly 27, power streering
booster 32, be sure to make alignment mark A.
32
08374
W Steering column subassembly

When the spline of steering column subassembly 27 is disconnected,
align the yokes to the same direction A.
A
27
A
07254
37-6
MEMO
54-1
GROUP 54 ELECTRICAL
1 POWER, CHARGE AND GROUND 3 LIGHTING
SPECIFICATIONS ....................................................^ 1 SPECIFICATIONS ....................................................^ 1
STRUCTURE AND OPERATION ............................ ^ 1 STRUCTURE AND OPERATION ............................ ^ 1
TROUBLESHOOTING .............................................. ^ 1 TROUBLESHOOTING ..............................................^ 1

10 0 INSPECTION AND ADJUSTMENT 300 INSPECTION AND ADJUSTMENT
MOUNTED IN VEHICLE MOUNTED IN VEHICLE
Inspection of Alternator .......................... ^ 2 Headlamp Aiming .........................................^ 1
Inspection of Regulator ........................... ^ 2
310 HEADLAMP CIRCUIT .................................. ^ 1
101 BATTERY ...................................................... ^ 1
320 TAIL LAMP, CLEARANCE LAMP AND
10 4 FUSE ..............................................................^ 1 LICENSE PLATE LAMP CIRCUITS ............. ^ 1
10 6 ALTERNATOR .............................................. ^ 2 325 STOP LAMP CIRCUIT .................................. ^ 1
110 POWER CIRCUIT .......................................... ^ 1 330 TURN SIGNAL LAMP AND HAZARD
LAMP CIRCUITS ........................................... ^ 1
115 RESERVE POWER CIRCUIT ....................... ^ 1
340 BACKUP LAMP CIRCUIT
125 BATTERY CHARGING CIRCUIT ................. 54-4 < Manual Transmission > ........................... ^ 1
130 GROUND ....................................................... ^ 1 < Automatic Transmission > .................... 54-12
345 CAB LAMP CIRCUIT .................................... ^ 1
348 ILLUMINATION LAMP CIRCUIT .................. ^ 1
2 STARTING, PREHEATING, AND 349 MARKER LAMP AND

STOPPING ENGINE IDENTIFICATION LAMP CIRCUITS ............ ^ 1
352 VAN BODY DOME LIGHT CIRCUIT ............ ^ 1

SPECIFICATIONS .................................................... ^ 1

4 METER
200 INSPECTION AND ADJUSTMENT SPECIFICATIONS ....................................................^ 1

MOUNTED IN VEHICLE
TROUBLESHOOTING ..............................................^ 1
Inspection of Engine Preheating
System ..........................................................^ 1 401 METER CLUSTER .........................................^ 1
201 STARTER ...................................................... ^ 1 410 TACHOMETER CIRCUIT ............................. ^ 1
210 ENGINE STARTING CIRCUIT 420 FUEL GAUGE CIRCUIT ............................... ^ 1
< Manual Transmission > ........................... 54-6
< Automatic Transmission > ...................... 54-8 425 WATER TEMPERATURE
GAUGE CIRCUIT ..........................................^ 1
220 ENGINE PREHEATING CIRCUIT ................ ^ 1
225 ENGINE WARMING UP CIRCUIT .............. 54-10
54-2
54
5 INDICATOR AND WARNING 7 CHASSIS ELECTRICS
TROUBLESHOOTING ..............................................^ 1 701 MAGNETIC VALVE ....................................... ^ 1

500 INSPECTION AND ADJUSTMENT 710 EXHAUST BRAKE CIRCUIT
MOUNTED IN VEHICLE < Manual Transmission > ........................ 54-16
Inspection of Brake Fluid < Automatic Transmission > ................... 54-20
Level Switch ..............................................^ 1
510 PARKING BRAKE INDICATOR
8 ENGINE AND TRANSMISSION
CIRCUIT BRAKE ............................................... ^ 1 ELECTRICS
LOW
515 BRAKE WARNING CIRCUIT VACUUM BRAKE ...... ^ 1
801 ENGINE ELECTRICS ................................... ^ 1
535 ENGINE OIL LEVEL AND
OIL PRESSURE CIRCUIT D B .......... ^ 1 802 TRANSMISSION ELECTRICS ..................... ^ 1
537 OVERHEATING WARNING CIRCUIT .......... ^ 1 810 FOUR-WHEEL DRIVE CIRCUIT ................... ^ 2

CIRCUIT DISK
BRAKE ............................................... ^ 1
550 CAB TILT WARNING CIRCUIT T ........... ^ 1 9 OTHERS
910 MULTIPURPOSE TIMING CONTROL

UNIT CIRCUIT ...............................................^ 1
6 CAB SIDE ELECTRICAL
SPECIFICATIONS ....................................................^ 1
TROUBLESHOOTING ..............................................^ 1
601 SWITCH .........................................................^ 1

604 RELAY AND CONTROL UNIT .................. 54-14
606 WARNING BUZZER ...................................... ^ 1
610 CIGARETTE LIGHTER CIRCUIT ................. ^ 1
612 AUDIO CIRCUIT ............................................ ^ 1
614 WIPER AND WASHER CIRCUIT ................. ^ 1
616 HORN CIRCUIT ............................................. ^ 1
618 HEATER CIRCUIT .........................................^ 1

54-3
3 6
Alternator Battery
7
High-current
fuse box
5
High-current
fuse box
To backup lamp switch

< Manual transmission>
Chassis
c
Cab
Starter switch
Fuse box
Cab 4
d
Meter
b
a
Meter cluster
2
* : Manual transmission
30824
54-4
54
2 a b
d 4
c 3
FH8
7
6 5
30868
1 Starter switch ^ 1 210 5 High-current fuse box ^ 1 104

2 Meter cluster ^ 1 401 6 Battery ^ 1 101
3 Alternator ^ 2 106 7 High-current fuse box
4 Fuse box ^ 1 104

54-5
210 ENGINE STARTING CIRCUIT < Manual Transmission >
9
Starter
8
Starter relay
11
Battery
To glow relay
High-current Transmission
fuse box neutral switch
7
10
Chassis Chassis ground

a
Cab
To electronic
governor
To exhaust control unit
brake relay Relay box
Gr13 Transmission
neutral relay
3
2
Starter switch
Neutral
1
start relay
Fuse box
5
Diode
4
30651
54-6
54
2 3
6 5 4
a 7 8
11 10 9
30869
1 Starter switch ^ 210 7 Transmission neutral switch ^ 802

2 Transmission neutral relay ^ 604 8 Starter relay ^ 210
3 Relay box 9 Starter ^ 210
4 Diode 10 High-current fuse box ^ 104
5 Fuse box ^ 104 11 Battery ^ 101
6 Neutral start relay ^ 604
^ : 96 Model Gr 54 (Pub No. TWSE9501-54)
54-7
210 ENGINE STARTING CIRCUIT < Automatic Transmission >
6
Starter
5
8 Starter relay
Battery
To glow relay
High-current
fuse box Inhibitor switch
Chassis
ground
Chassis
a
Cab
Starter switch
Fuse box
2
30652
54-8
54
3 2
a 4 5
8 7 6
30870
1 Starter switch ^ 1 210 5 Starter relay ^ 1 210

2 Fuse box ^ 1 104 6 Starter ^ 210
3 Neutral start relay 604 7 High-current fuse box ^ 104
4 Inhibitor switch ^ Gr 23 8 Battery ^ 101
54-9
225 ENGINE WARMING UP CIRCUIT
Fuse box
Cab Meter Meter cluster

h b
7
2
a
Gr23
To A/T electric Warming

control unit up switch 1
Relay box
Exhaust brake
cut relay * To electric governor
<A/T> To sub control rack position
Gr13 sensor
To engine speed sensor
4 e 3
^ Gr13
g
5
Exhaust brake Electronic governor
relay control unit
f
c
d
6
10
Accelerator
pedal sensor
Cab ground
Cab
j
Chassis
Engine water
Exhaust brake temperature
3-way magnetic valve sensor
8 9

* : Idle-up circuit
Chassis ground
30653
54-10
54
c d e 4 5
3
f g
1 2 a b 6
h
j 7 8
10
9
30871
1 Warming up switch ^ 1 601 6 Exhaust brake relay 604

2 Meter cluster ^ 1 401 7 Fuse box ^ 1 104
3 Electronic governor control unit ^ Gr 13 8 Exhaust brake 3-way magnetic valve ^ 1 701
4 Exhaust brake cut relay <A/T> 604 9 Engine water temperature sensor ^ Gr 13
5 Relay box 10 Accelerator pedal sensor ^ Gr 13

54-11
340 BACKUP LAMP CIRCUIT < Automatic Transmission >
Fuse box d Meter cluster

b
Relay box
Backup
lamp relay
Cab Meter a
3 4
Automatic Automatic
transmission transmission
reverse buzzer
Gr23
(To automatic
transmission Cab ground
electric control unit)
Diode 5
Gr13
(To electric
governor
Cab
control unit)
c
Rear combination
Inhibitor switch
lamp LH
10
7
Chassis ground
Chassis
e
Rear chassis
Back buzzer
Rear combination
lamp RH
9
30654
54-12
54
3 4
1 a b 2
c d 7 6 9
8
10 30872
1 Meter cluster ^ 1 401 6 Fuse box ^ 1 104

2 Automatic transmission reverse buzzer ^ 1 606 7 Inhibitor switch ^ Gr 23
3 Relay box 604 8 Back up alarm ^ 1 340
4 Backup lamp relay 9 Rear combination lamp RH
5 Diode 10 Rear combination lamp LH
*: Range selector lever ^ Gr 23
54-13
1 3 4 5 6 7
15
14 13 12 9 8
16
17
21 19 18
30873
1 Wiper relay (LOW) 13 Head lamp relay (HIGH)

2 Transmission neutral relay < M/T > 14 Head lamp relay (LOW)
Exhaust brake cut relay < A/T > 15 Blower fan relay
3 Wiper relay (HIGH) 16 Electronic governor control unit ^ Gr 13
4 Overheating relay 17 Turn signal lamp relay
5 Engine oil level relay 18 Van body dome light relay
6 Pre-stroke cut relay 19 Automatic transmission fluid cooler fan relay <A/T >
7 Flasher unit 20 Neutral start relay
8 Multipurpose timing control unit 21 Automatic transmission control unit ^ Gr 23
9 Lighting and alarm control unit
10 Backup lamp relay < A/T > M/T : Manual transmission
11 Exhaust brake relay A/T : Automatic transmission
12 Tail lamp relay
marks indicate changed parts.

Regarding the inspection procedures for parts for which instructions are not given in this manual, refer to the 96 Model,
Gr 54 manual (Pub. No. TWSE9501-54).
54-14
54
2
Service procedure
Inspection of relay (Close type 4-pin)
1 2 3 4
No current

2 1 3 4 Current -----

07387 : There is continuity between terminals and .

: Indicates that 12 volts DC is applied to the line
between the terminals.
----- : Indicates that the continuity between the terminals is
lost.
FGP Inspection of relay (Open type 4-pin)

1 2 3 4
421 3 No current
Current

: There is continuity between terminals and .

07142 : Indicates that 12 volts DC is applied to the line
54-15
Fuse box
Clutch switch
*
10
AL4A
11
Relay box
Transmission e
neutral relay
3 d
4 ^ Gr 13
Exhaust brake
CC16A
relay Electronic
governor
f control unit 2
5
CM35A
c
BZ12A
g
Meter cluster
a j
Accelerator
pedal sensor
6 12
Meter Cab
b Combination switch
Exhaust brake
switch
Cab ground
1
Diode
Cab
h
Chassis Exhaust brake
Transmission 3-way
neutral switch magnetic valve
8 9
Tightened * Depressed : ON
together Released : OFF
Chassis ground
30655
54-16
54
1 3 4
2 c d e
f g
5
6 a b
2
j
h 10 9 8
12
30874
1 Combination switch ^ 1 601 7 Diode

2 Electronic governor control unit ^ Gr 13 8 Transmission neutral switch ^ 1 802
3 Transmission neutral relay ^ 1 604 9 Exhaust brake 3-way magnetic valve ^ 1 701
4 Relay box 10 Fuse box ^ 1 104
5 Exhaust brake relay 604 11 Clutch switch
6 Meter cluster ^ 1 401 12 Accelerator pedal sensor ^ Gr 13
54-17
G
Service procedure
Inspection of clutch switch
1 2 3 4
41 mm {0.170.04 in.} A
A B B

If any fault is found, replace clutch switch 11.
07121
54-18
54
MEMO
54-19
710 EXHAUST BRAKE CIRCUIT < Automatic Transmission >
Fuse box
m
8
^ Gr 23
Automatic 9
transmission
control unit
Relay box
Exhaust brake
k
relay
n
5
4 c
Exhaust brake d
cut relay ^ Gr 13
Electronic 2
3 governor
control unit
BZ16A
Meter
f
Meter cluster Cab g
a BZ12A
1
Accelerator
pedal sensor
b
j
10
Chassis
ground
Cab
h
Chassis
Inhibitor switch
Exhaust brake 3-way
magnetic valve
7
6
Chassis
ground
30656
54-20
54
2 c d e 3 4
f g 5
1 a b
h 7 6
j 9 8
10
m
30875
1 Meter cluster ^ 1 401 6 Inhibitor switch ^ Gr 23

2 Electronic governor unit ^ Gr 13 7 Exhaust brake 3-way magnetic valve ^ 1 701
3 Exhaust brake cut relay ^ 1 604 8 Fuse box ^ 1 104
4 Relay box 9 Automatic transmission control unit ^ Gr 23
5 Exhaust brake relay 604 10 Accelerator pedal sensor ^ Gr 13
54-21
ELECTRIC CIRCUIT
11 Fuse box 3
1 Meter cluster
1 Starter switch 2
Gr 54 14 Key Gr 54 Power mode Automatic transmission
Stop lamp interlock Gr 54 4 switch
switch Gr 54 solenoid
To cigarette Electronic governor 32 30 25 28
To stop lamp lighter control unit
9 Terminal to solenoid and Automatic Vehicle
Inhibitor switch temperature sensor transmission
speed
Diode fluid thermo
sensor
b c switch
d f e j h g
a
Meter ]
Cab
] m
15
Automatic
transmission
electronic
control unit Cab Chassis
n
]
Chassis Rear
chassis
Back buzzer
q
Sound
unit
Intermitted
circuit 26
Gr 54
To rear combination
t lamp LH
27
High current
fuse box
]
s Battery 29
Cab
k
A/T
Over drive
switch
22 To dual
20 Automatic pressure
trans- switch
mission connector
Shift lock reverse MUT : Multi-use tester
r v
actuator buzzer Gr 54
MUT-II u
connector Diagnosis Memory To starter
switch
21 10 clear
Exhaust
Cab ground relay Magnet clutch Tightened
Key interlock switch Exhaust Backup Automatic Neutral
electronic
16 brake cut brake lamp start ^ Gr 54
connector together
transmission
P-range control unit 17 relay relay 8 relay 7 fluid cooler relay Exhaust Automatic Automatic Chassis
switch Accelerator 5 brake 3-way
tansmission transmission ground
fan relay 13
18 sensor Relay box magnetic valve
fluid cooler fluid cooler
23 12
fan thermo fan motor
19 6 24
switch
31
33 30264
PART INSTALLATION LOCATIONS
5 6 k
4 d e f 1 Starter switch (Key inter lock solenoid installed inside)
1
2 Power mode switch
24 3 Meter cluster
s 25 26 4 Electronic governor control unit
5 Exhaust brake cut relay
6 Relay box
7 Backup lamp relay
g h j 8 7 8 Exhaust brake relay
2 3 a b c 9 Diode
4 10 MUT-II connector
11 Fuse box
12 Automatic transmisson fluid cooler fan relay
14 Stop lamp switch
20 17 Memory clear switch
9 23 18 Key interlock electronic control unit
20 Overdrive switch
m u 33 31 30 29 28 27
32 t 21 Shift lock actuator
22 Automatic transmisson reverse buzzer
10 22 23 P-range switch
24 Exhaust brake 3-way magnetic valve
16, 17 15 14 13 12 11 k
32 30 28 25 25 Automatic transmisson fluid thermo switch
21
26 Back buzzer
15 28 Vehicle speed sensor
r
29 Battery
v 30 Terminal to solenoid and temperature sensor
n
31 Automatic transmisson fluid cooler fan motor
p 32 Inhibitor switch
19
33 Automatic transmisson fluid cooler fan thermo switch
q
* < Left side of transmission > < Right side of transmission > * : Wiper motor
30982
30981
Table of Contents
BACK MODEL CHANGES
HOME
Pub. No. TWSE9501-2

1998 MODEL CHANGES
Gr 00 General See page 10 in this manual

Modified vehicle identification number.
Gr 01 Maintenance Schedule ^ Gr 01 Maintenance Schedule

Added for FG 98 Minor Change
(Pub. No. TWSE9501-201)
Gr 10 Removal and Installation of Engine ^ Gr 10 Removal and Installation

Added for FG of engine
98 Minor Change
(Pub. No. TWSE9501-210)
Mount rubber for FE is changed
Mount rubber
28024
< Liquid type > < Solid type >
28151 28152
-2-
Gr 13 Fuel and engine control

Water separator has been changed from
dual type to single type.
27687 27242
1 Fuel feed hose
3 2 Water separator assembly
3 Air vent plug
4 Drain plug
11 5 O-ring
6 Ring nut
10 7 Case
8 Screen assembly
9 Water level ring
10 O-ring
8
11 Head
9
7 WARNING
2 Fuel ignites easily. Do not get it near
6 flame or heat.
Wipe up any spilled gas oil because it
5 can cause a fire.
1 1
4
Assembly sequence
27170 Follow the disassembly sequence in re-
verse.

3 Air vent plug 8 to 12 {5.8 to 8.7, 0.8 to 1.2}
4 Drain plug 3 to 4 {2.2 to 2.9, 0.3 to 0.4}
6 Ring nut 23 to 27 {17 to 20, 2.3 to 2.8}
-3-
1998 MODEL CHANGES
Gr 15 Intake and exhaust

FG exhaust pipe and muffler have been
added as illustrated. 16

8 7 2
2
6
1
*
17
15
14
6
5
3 4 11
12
13
10
06187
1 Nut 11 Front pipe
2 Tail pipe 12 Exhaust brake unit
3 Nut ^ Gr 35
4 Bolt 13 Front pipe
5 Exhaust pipe bracket 14 Nut
6 Nut 15 Center pipe
7 Bolt 16 Bolt
8 Nut < FG639E > 17 Muffler
9 Front pipe assembly
10 Bolt * : Exhaust manifold
Assembly sequence

1 Nut (Tail pipe mounting) 26 to 33 {20 to 25, 2.7 to 3.4}
6 Nut (Front pipe assembly mounting) 20 to 25 {14 to 18, 2.0 to 2.5}
8 Nut (Center pipe mounting) 26 to 33 {20 to 25, 2.7 to 3.4}
10 Nut (Exhaust brake unit mounting) 27 {20, 2.75}
< with exhaust brake >
14 Nut (Muffer mounting) 26 to 33 {20 to 34, 2.7 to 3.4}
9
A 9
Service procedure
Installation of front pipe assembly
Install front pipe assembly 9 so that the offset tolerance in the vertical
and horizontal sections between the front and back of bellows A con-
forms to the standard value.
CAUTION
Be sure when installing bellows A of front pipe assembly 9 that
the bellows are not forcibly bent and that the bellows do not pull
on themselves. This is because they are designed to reduce the
5 mm or less
07701
external noise of the vehicle and are not designed to absorb
dimensional tolerances in the installation of pipes.
-4-
Gr 22 Manual Transmission SPECIFICATIONS

Oil capacity has been increased as illus- Item Specifications
trated. Mode of control Floor shift remote control
(Applies to 96 model and later) Transmission model M035S5

Gear ratio 1st 5.380
2nd 3.028
3rd 1.700
4th 1.000
5th 0.722
Reverse 5.380
Oil Gear Oil General : API GL-3 SAE 80
Warm region : API GL-3 SAE 90
Tropical region : API GL-4 SAE 90
Engine Oil Long period of high-speed driving : API CC SAE 30 or SAE 40
Quantity L{qts} Approximately 3.1 {3.3} < FE >, Approximately 3.4 {3.6} < FG >
Mass kg {lb} Approximately 100 {220}
Number of interlock pins for FE and FG Disassembly sequence

1 Bolt
differs.
-1 2 Gear shifter upper assembly
3 Backup lamp switch
4 Screw plug
-2 5 Interlock pins (5) < FE >
Interlock pins (7) < FG >
6 6 Screws (2)
- 7 Poppet spring plate
7- 8 Poppet springs (3)
3 8 9 Steel balls (3)
9
* : Transmission body
*
Assembly sequence
-
4
03586
5 Interlock pins (5) < FE > 5 Interlock pins (5)

Interlock pins (7) < FG >
Gr 23 Automatic Transmission < Labyrinth cap type air bleeder > < Vinyl tube type air bleeder >
FE automatic transmission
Air bleeder is changed. Air bleeder
Vinyl tube
27954
-5-
1998 MODEL CHANGES
Gr 24 Transfer ^ Gr 24 Transfer
FG transfer has been added. 98 Minor Change
(New settings) (Pub. No. TWSE9501-224)
Gr 25 Propeller Shaft ^ Gr 25 Propeller Shaft

FG P2 Propeller shaft has been added 98 Minor Change
between the front axle and the transfer. (Pub. No. TWSE9501-225)
(New settings)
Gr 26B Front Axle ^ Gr 26B Front Axle

FG front axle has been added. 98 Minor Change
(New settings.) (Pub. No. TWSE9501-226B)
Gr 27 Rear Axle
Item Specifications
FG limited slip differential gear oil has
been added. Gear oil Grade Limited slip differential oil
API GL-5 SAE90
Quantity L {qts.} 4.5 {4.8}
FG limited slip differential has been added. See page 12 to 19 in this manual.
(New settings : optional)
Gr 31 Wheel and Tire Air pressure kPa {Psi, kgf/cm2}

FG tire size has been added. Tire size Application wheel
Front Rear
7.50R16(E) 550 {80, 5.50} 550 {80, 5.50} 166K-127-9
(wheel with 5 studs)
Gr 33 Front Suspension ^ Gr 33 Front Suspension

(Pub. No. TWSE9501-233)
Gr 34 Rear Suspension ^ Gr 34 Rear Suspension

(Pub. No. TWSE9501-234)
Gr 35 Brake ^ Gr 35 Brake
(Pub. No. TWSE9501-235)
Gr 37 Steering ^ Gr 37 Steering
FE power steering booster has been 98 Minor Change
modified. (Pub. No. TWSE9501-237)
Added for FG.
-6-
Gr 42 Cab
Door window regulator has been modi-
fied.
27014
Door trim has changed. Door ash tray

Door ash tray is eliminated.
27743
-7-
1998 MODEL CHANGES
Cab mounting front rubber and rear

rubber are changed.
Rear
Front 28017
< Front > < Front >
Front rubber Front rubber

assembly 28018 28019
assembly
< Rear > < Rear >
Upper rubber
Rear rubber
Lower rubber
assembly 28020 28021
11 1 Bolt
- 2 Nut
3 Plate
7 4 Anchor hook
5 Spacer
5 6 Nut
8 7 Side rubber
9 8 Cab hold bracket
6 9 Bolt
10 Rear rubber assembly
10
11 Rear mounting post
3
2 * : Frame
1
Assembly sequence
* Follow the disassembly sequence in re-
28023 verse.

1 Bolt (Rear mounting post mounting) 78 to 105 {58 to 80, 8 to 11}
2 Nut (Anchor hook mounting) 83 to 98 {61 to 72, 8.5 to 10.0}
6 Nut (Side rubber mounting) 10 to 15 {7.2 to 11.0, 1.0 to 1.5}
9 Bolt (Rear rubber assembly mounting) 16 to 20 {12 to 14, 1.6 to 2.0}
- Lubricant
4 Upper side of anchor hook Chassis grease [NLGI No. 1 (Ca Soap)]
(contact area between lock handle and stopper)
L
< LH > < RH >
R
4
Service procedure
Installation of anchor hook
Install anchor hook 4 so that open side of the hook comes to left side of
the vehicle while aligning the identification marks L and R.
Also always make sure to apply grease on upper part of the left anchor
hook ( part).

10780
-8-
Gr 54 Electrical
The location of the cab harness diode
has been moved from the right to the
center.
< M/T > 26316
< A/T >

27584
FG alternator high-current fuse is

installed to the side of battery box.
high-current fuse
(100A) 28108
FG alternator has been added. ^ Gr 54 Electrical

98 Minor Change
FG meter cluster has been added. (Pub. No. TWSE9501-254)
FG four-wheel drive circuit has been

added.
Only electrical horn specifications have Rated current Rated current

+0.5
been modified. Service procedure is 3.00.5 A 3.0 1.0 A
same. Sound pressure (at 2 m {6.6 ft.}) Sound pressure (at 2 m {6.6 ft.})
1105 dB 1105 dB
FG brake fluid level switch check is same Warning lamp lighting position for
as FE639. brake fluid level switch
41.03 mm
{1.610.12 in.}
-9-
POWER TRAIN TABLE
Final reduc-
Model
FG639C, E 4D34T3 C4W30 M035S5 P2 R033T D1H modified

G.V.W. 135 HP/3000 rpm 5.380/0.722 (Front) 5.714
5000 kg 253 lbf.ft/1800 rpm P3 (Front)
{11000 lb} (SAE, Gross) (Rear) D033H
5.714
(Rear)
(96 model) 00-3
J W 6 A A C 1 H W L
1 2 345 678 9 FG H
1 Country J: Japan
4 Gross vehicle weight/Brake system A: 4536 to 6350 kg {10001 to 14000 lbs}/Hydraulic
B: 6351 to 7258 kg {14001 to 16000 lbs}/Hydraulic
5 Line A: FE639
B: FE649
FG639
6 Series (Wheelbase) C: 2.6 to 2.9 m {102.4 to 114.2 in.}
E: 3.2 to 3.5 m {126.0 to 137.8 in.}
F: 3.5 to 3.8 m {137.8 to 149.6 in.}
9 Check digit
F Model year W : 1998
G Plant L : Kawasaki-2
H Plant sequential number N : Nakatsu
(96 model) 00-4

- 10 -
00
MEMO
- 11 -
MULTIPLE LIMITED SLIP DIFFERENTIAL ASSEMBLY < D033H >
5 8
3 4
2
1
11 10 9
27600
1 Limited slip differential assembly 7 Spring plate

2 Differential case, LH 8 Thrust washer
3 Side gear 9 Pressure ring
4 Differential case, RH 10 Pinion shaft
5 Friction disc 11 Differential pinion
6 Friction plate
Friction disc 5 and friction plate 6 engage side gear 3 and differential case RH 4, respectively. These parts are pressed
against pressure ring 9 by spring plate 7. The pressure ring mates with the groove in the differential case RH and always
turns at the same speed.
- 12 -
27
Operation mechanism
When the wheel of one side starts spinning, a rotational difference
between side gear 3 and differential cases, LH 2 and RH 4 occurs. Then,
friction disc 5 and friction plate 6 start rotating with a relative difference in
revolution speed. This causes friction torque between the disc and plate.
Operation in straight movement

TG
In the case of straight movement, as the revolution speed of the left
axle shaft and that of the right axle shaft are equal, no friction torque
occurs.
TG : Torque input
TG TG
2 2
06577
Operation when there is a difference in revolution speed

TG between left and right wheel
When a difference in the resistance the wheels receive from the road
TF surface occurs, such as when the wheel of one side encounters mud,
the differential function comes into play, transmitting friction torque
TF. This exertion of friction torque reduces the revolution speed caus-
ing the high-revolution speed axle to reduce its speed and the low-
(TGTF) revolution speed axle to increase its speed.
(TG+TF)
2 2 Therefore, when the wheel of one side starts spinning, when caught in
mud for example, a big difference in revolution speed occurs, causing
a large amount of friction torque to come into action. The differential
functions in such a manner that a smaller ratio of the torque is
transmitted to the axle of the wheel which is spinning while the axle of
the wheel on the other side receives a greater ratio of the torque. This
06578
makes it easier for the vehicle to get out of the mud.
(TGTF)
High rotation side (spin side)
2
(TG+TF)
Low rotation side
2
- 13 -
MULTIPLATE LIMITED SLIP DIFFERENTIAL ASSEMBLY < D033H >
DISASSEMBLY AND ASSEMBLY
4
19
15
14
13
12
11
10
9
8
7
17 18 6
16
5
-
1
-
06769
1 Bolt 7 Spring plate 14 Friction plate
2 Final drive gear 8 Friction plate 15 Pressure ring
3 Multiplate limited slip differential 9 Friction disc 16 Side gear
assembly 10 Friction plate 17 Differential pinion
4 Screw 11 Friction disc 18 Pinion shaft
5 Differential case, LH 12 Friction plate 19 Differential case, RH
6 Thrust washer 13 Friction disc
NOTE
Clean the disassembled parts using washing oil and dry by blowing with compressed air.
Assembly sequence
196789101112131415165 4321

1718
NOTE
Apply the specified type of gear oil to each part before assembly, paying particular attention to contact and
sliding surfaces.
- 14 -
27
3 Rotation torque of multiplate When putting in a 200 to 295 Nm Inspect
limited slip differential new clutch plate {150 to 215 lbf.ft, 20.5 to 30 kgfm} internal parts
assembly and replace
When putting in a 115 to 295 Nm
used clutch plate {87 to 215 lbf.ft, 12 to 30 kgfm} faulty parts
6, Variation of tolerance in vertical direction from Adjust
15 to 18 back face of pressure ring to end face 0 to 0.05 {0 to 0.0020} (Replace the
of thrust washer thrust washer)
Deformed friction disc and friction plate 0.08 {0.0031} Replace
Wear of friction disc and friction plate 0.1 {0.0039} Replace
8 to 14 Difference in thickness between Adjust
0 to 0.05
the left and right combinations Change the
{0 to 0.0020}
of friction disc and friction plate combination)
Side gear clearance in axial direction 0.05 to 0.20 Adjust
{0.0020 to 0.0079} (Replace the
thrust washer)
Differential case clearance in axial direction 0.05 to 0.20 Adjust
{0.0020 to 0.0079} (Replace the
thrust washer)

Location Location tightened Tightening torque Remarks
1 Bolt (Final drive gear and differential case, 165 to 225 {120 to 165, 17 to 23}
LH mounting)

2 Thread area of final drive gear LOCTITE271 As required
3 Components of multiplate slip differential assembly Limited slip differential oil API GL-5 SAE90 As required

A
Side gear holding tool set MB999140
A : Gauge case 20
B A: MB990551 Measurement of multiplate slip
{0.79}
3 B : Side gear holding base B: MB999141 differential assembly clutch
C : Side gear holding tool C: MB999142 plate rotation torque
(outer diameter : 42) (D033H)
D : Side gear holding tool D: MH063422
E : Side gear holding tool C D E 06732 E: MH063423
- 15 -
1
2
Service procedure
Final drive gear
Apply LOCKTITE to thread area A of all the bolt holes of final drive gear
2.
CAUTION
Be sure to let bolts 1 harden for at least an hour, after installation,
A before driving.
Furthermore, be sure to let bolts 1 harden for at least four hours
2
before running at full torque.
3
06770
9, 11, 13 Multiplate limited slip differential assembly

7 [Inspection of contact and sliding surfaces]
Inspect spring plates 7, friction plates 8, 10, 12, 14 and friction discs
9, 11, 13 and replace if the friction surface or sliding surface shows
extreme wear or heat discoloration.
8, 10, 12, 14 15
NOTE
The hardened area on the inner periphery of the friction surfaces
of plates and discs 7 to 14 is due to the force exerted by the
06734 springs and should not be mistaken for abnormal wear.
Replace spring plates, friction discs and friction plates 7 to 14 if

their protruding areas have cracks or are damaged.
If there are nicks or marred areas on the friction and sliding surfaces of
pressure rings 15 and friction plates 14 remove using an oil stone,
then fit and correct on the base using compound.
NOTE
The hardened area on the inner periphery of the friction surfaces
of plates and discs 7 to 14 is due to the force exerted by springs
and should not be mistaken for abnormal wear.
Inspect the contact and sliding parts ( ) of differential case LH 5,

19 5 thrust washer 6, pressure ring 15, side gear 16, differential pinion 17,
pinion shaft 18, and differential case RH 19. If there are nicks or
marred areas remove using an oil stone.
6 15
18
16 17
06735
- 16 -
27
[Inspection for deformation]
A Check friction plates 8, 10, 12, 14 and friction discs 9, 11, 13 for
deformation by mounting dial gauge A on a base and rotating the plate or
disc and measuring its flatness.
8 to 14
06736
[Measurement of thickness]
7 Measure the thickness of the friction surfaces and the protruding parts
9, 11, 13
( ) of spring plates 7, friction plates 8, 10, 12, 14 and friction discs 9, 11,
13. If the measured values deviate from the limit, replace the faulty parts.
NOTE
8, 10, 12, 14 Measure several locations on each part.
[Work before assembly]
In order to adjust the tolerance in the axial direction when the internal
parts of differential cases LH 5 and RH 19 are inserted (clutch plates 7 to
06737 14 friction force) and the tolerance in the axial direction of side gear 16
follow the procedure below.
Put friction plates 8, 10, 12, 14 and friction discs 9, 11, 13 one on top
12 10 of the other as illustrated. Using a micrometer measure thickness A,
13
9 and by selecting the right combination of plates and discs for each set,
11
8 make sure the difference in thickness between the left and right sets
14
conforms to the standard value.
NOTE
When using new parts, keep in mind that friction plates 8, 10, 12,
A 14 come in one size, 2.0 mm {0.0079 in.} and friction discs 9, 11,
13 in three sizes, 1.9 mm {0.075 in.}, 2.0 mm {0.079 in.} and 2.1
06775 mm {0.083 in.}.
Put spring plates 7 one on top of the other as illustrated. Using a

micrometer measure thickness B and by selecting the right combina-
B
tion of plates for each set, make sure the difference in thickness
between the left and right sets is minimal.
7
NOTE
When replacing spring plates 7 with new ones, the plate thick-
ness is 2.0 mm {0.079 in.}.
06739
11 Assemble pressure rings 15, pinion shaft 18, the friction discs, the
15 1312
18 14 10 9 8 friction plates and spring plates 7 to 14 and measure total width C
using a micrometer.
NOTE
7 When measuring, press down both ends of pressure ring 15 to
make sure its V-shaped groove is properly mated with pinion
shaft 18.
C 06777
- 17 -
Calculate dimension D between the surfaces of differential cases LH 5
and RH 19 which come in contact with spring plate 7 when the two
19
5 cases are assembled.
D=E+FG
If the above mentioned total width C and clearance (D C) between
differential cases LH 5 and RH 19 deviate from the standard value,
E adjust by changing friction discs 9, 11, 13.
F
NOTE
When using new friction discs 9, 11, 13, keep in mind that there
G 06778 are three different sizes, 1.9 mm {0.075 in.}, 2.0 mm {0.079 in.}
and 2.1 mm {0.083 in.}.
Install thrust washers 6 as illustrated. Make sure the difference be-
H J
tween dimensions H and J from the back face of pressure ring 15 to
15 the end face of thrust washer on either side conforms to the standard
value.
NOTE
When measuring press down both ends of pressure ring 15 to make
sure its V-shaped groove is in full contact with pinion shaft 18.
6 If the variation of tolerance deviates from the standard value, adjust by

6
06779
changing thrust washers 6.
NOTE
When using new thrust washers 6 keep in mind that there are
three different sizes, 1.50 mm {0.059 in.}, 1.60 mm {0.063 in.} and
1.70 mm {0.067 in.}.
Measure total width K.
K
6 6
06780
Calculate dimension L between the surfaces of differential cases LH 5

19 and RH 19 that come in contact with thrust washers 6 when the two
5 cases are assembled.
L=D+M+N
NOTE
M D N Dimension D is the dimension between the surfaces of differen-
tial cases LH 5 and RH 19 that come in contact with spring plate 7
when the two cases are assembled and was calculated above.
06781
Make sure that side gear 16 clearance in the axial direction (L K)
conforms to the standard value. If the measured value deviates from
the standard value, adjust by replacing thrust washers 6.
NOTE
Select thrust washers 6 so that the difference in dimension be-
tween the left and right sides from the back face of pressure ring 15
to the end face of thrust washers conforms to the standard value.
When using new thrust washers keep in mind that there are three
sizes, 1.50 mm {0.059 in.}, 1.60 mm {0.063 in.} and 1.70 mm {0.067 in.}.
- 18 -
27
[Assembly]
17 18 19 Assemble the different parts in differential case RH 19 in the direction
6 as illustrated.
5 CAUTION
16
Make sure that friction plates 8, 10, 12, 14 and friction discs 9, 11,
13 are installed in the correct order and that spring plate 7 is
assembled in the correct direction.
Apply the specified gear oil to each of the parts before assembly.
Special attention should be given to applying oil to the contact
and sliding surfaces.
7 8 10 12 14 15 14 12 10 8 7
9 11 13 13 11 9
06782
[Tightening of screws]
Align alignment marks P (identical Arabian numerals) on differential
cases LH 5 and RH 19 and gradually tighten screws 4 evenly in diagonal
order.
19
CAUTION
If differential cases LH 5 and RH 19 are not joined firmly even
4
when screws 4 have been tightened, it may be because thrust
washers 6 or spring plates 7 are not properly assembled and they
should be reassembled.
5
P 06746
[Measurement of rotational torque]

1 In order to verify the friction force of clutch plates 7 to 14 after
assembly, use 1 side gear holding tool and 2 side gear holding
base to measure the rotation torque and make sure it conforms to the
standard value.
NOTE
2 When measuring the rotation torque, rotate the gear and meas-
ure after the rotation has reached a sufficiently steady pace.
06747 06748
- 19 -
Table of Contents
BACK MODEL CHANGES

7
HOME
Pub. No. TWSE9501-1

Group 00
General
Table of Contents
BACK
HOME
Pub No. TWSE9501-00

00
GROUP 00 GENERAL
MODEL CODING SYSTEM .................................................................... 2
POWER TRAIN TABLE .......................................................................... 3
CHASSIS NUMBER AND ENGINE NUMBER ....................................... 3
POWER TRAIN LABEL .......................................................................... 4
VEHICLE IDENTIFICATION NUMBER .................................................. 4
PRECAUTIONS FOR MAINTENANCE OPERATION ............................ 6
TABLE OF STANDARD TIGHTENING TORQUES ............................. 18
CONNECTOR CONFIGURATION CHART .......................................... 22
00-1
MODEL CODING SYSTEM
Equipment Model Code
Equipment name Model description Code description
Enigine 4 D 3 4 - 0 A T2
With turbocharger
Stands for automobile These are omitted in the
Service Manual
Remodeling sequence
Version number
Series number
Stands for diesel engine
No. of cylinders (4 : Four cylinders)
Clutch C 4 W 30
Disc outer diameter

Facing material (W : Woven)
Loading capacity of major type (tonnage)
Stands for clutch
Transmission M 035 S 5
No. of forward speeds

Meshing (S : Synchromesh A : Automatic)
Stands for transmission
Propeller shaft P 3

Stands for propeller shaft
Reduction and D 033 H
differential
Teeth shape (H : hypoid gear)
Stands for reduction and differential
00-2
POWER TRAIN TABLE/CHASSIS NUMBER AND ENGINE NUMBER 00
POWER TRAIN TABLE
Final reduc-
Model

G.V.W. 135 HP/3000 rpm 5.380/0.722 5.714
5260 kg 253 lbf.ft/1800 rpm
Torque M030A4
FE639C, E, F C4W30 M035S5

G.V.W. 5.380/0.722
6120 kg
{13500 lb}
Torque M030A4
FE649C, E, F 4D34T3 C4W30 M035S5

G.V.W. 145 HP/2900 rpm 5.380/0.722
6580 kg 275 lbf.ft/1600 rpm
Torque M030A4
CHASSIS NUMBER AND ENGINE NUMBER

The serial numbers for chassis and engines are assigned to the respective vehicles and engines in manufacturing
sequence: every vehicle and engine has its own numbers. These numbers are required for registration and incidental
inspection of the vehicle. Please do not fail to mention these numbers to the dealers when ordering spare parts.
Chassis number
Chassis number 1 is punch-marked on the frame by the left-side front
wheel.
1 Example : FE639C
Vehicle Chassis
model number
02251
Engine number
Engine number 2 is punch-marked on the left of the crankcase.
Example : 4D34
2 Engine
number
Engine
model
02252
00-3
POWER TRAIN LABEL/VEHICLE IDENTIFICATION NUMBER
POWER TRAIN LABEL
Power train label 1 located in the position illustrated indicates the vehicle
model, chassis number and information relevant to the vehicles power
transmission components.
1 02650

The vehicle identification number is punch-marked on the plate, which is
attached in the position as illustrated.
The vehicle identification number consists of a 17-digit set of alphanu-
meric characters. Each digit represents the following specifications.
02253
JW6AAC1HTL
1 2 345 678 9 FG H
1 Country J: Japan
4 Gross vehicle weight/Brake system A: 4536 to 6350 kg {10001 to 14000 lbs}/Hydraulic
B: 6351 to 7258 kg {14001 to 16000 lbs}/Hydraulic
5 Line A: FE639
B: FE649
6 Series (Wheelbase) C: 2.6 to 2.9 m {8.6 to 9.5 ft.}
E: 3.2 to 3.5 m {10.5 to 11.5 ft.}
F: 3.5 to 3.8 m {11.5 to 12.5 ft.}
9 Check digit
F Model year T : 1996
G Plant L : Kawasaki-2
00-4
00
MEMO
00-5
In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the
accumulated mileage, operating condition, what the customers demand is, and other information that may be necessary.
Prepare the steps to be taken and perform efficient and wasteless maintenance procedure.
Determine where the fault exists and check for the cause to see whether
removal or disassembly of the part is necessary. Then follow the proce-
dure specified by this manual.
06473
Perform maintenance work at a level area.

Prepare the following.
To prevent the seats, upholstery, floor and bodywork from being
spoiled or scratched, cover with workshop sheet cover(s).
00008
Prepare general and special tools necessary for the maintenance

work.
WARNING
Do not attempt to use tools other than special tools where use of
special tools is specified in this manual. This will avoid injury or
damage.
00009
When jacking up the vehicle to work under the vehicle, carry out the
following preparatory work:
Chock the wheels on both sides.
Jack up the vehicle using a garage jack.
Support the frame on rigid racks.
WARNING
Chock the wheels securely so the vehicle does not move.
Do not remove the chocks until the entire operation is completed.
Supporting a vehicle on a garage jack only is extremely danger-
14192 ous, so always support the frame on rigid racks.
Leave the garage jack and rigid racks in place until the entire
operation is completed. Never remove them during the operation.
00-6
00
When tilting the cab, be sure to insert the safety pin into the cab stay so
that the cab stay remains locked and is not released when the cab is
tilted.
14193
Pay special attention to safety when removing or installing heavy items

such as engines, transmissions and axles.
When lifting up heavy items using cables, pay special attention to the
following points:
Check the mass of the item to be lifted and use a cable capable of
lifting that mass.
14194
If you do not have the specified lifting hanger, secure the item using
cable taking the point-of-balance of the item into consideration.
14195
You must work in a position where you will not be injured even if the
cable comes undone and the lifted item falls.
14196
00-7
Be particularly careful not to work in shoes that have oily soles and are
slippery. When working as a team of two or more, arrange signals in
advance and keep confirming safety. Be careful not to accidentally bump
switches or levers.
00012
Check for oil leakage before cleaning the area having the fault otherwise
you might miss detecting the leakage.
00013
Prepare replacement part(s) beforehand.
00014
Replace oil seals, packing, O-rings and other rubber parts; gaskets and
split pins with new parts whenever any of them has been removed. Use
only genuine MITSUBISHI replacement parts.
00015
On disassembly, visually inspect all parts for wear and tear, cracks,
damage, deformation, degradation, rust, corrosion, smoothness in rota-
tion, fatigue, clogging and any other possible defect.
00016
00-8
00
Put alignment marks on part combinations before disassembly and ar-
range the disassembled parts neatly. This will help avoid mismating of
the parts later.
Put the alignment marks, punch marks, etc. where performance and
appearance will not be affected.
Cover the area left open after removal of parts to keep it free from dust.
CAUTION
Take care to avoid mixing up numerous parts, similar parts, left
and right, etc.
00017 Keep new parts for replacement and original (removed) parts
separate.
Apply the specified oil or grease to U-packings, oil seals, dust seals and
bearings during assembly.
Use only the specified oil, grease, etc. for lubricant, remove the excess
immediately after application with a piece of waste, etc.
CAUTION
When the specified lubricant, fluid and sealant is not available,
you may use an equivalent.
00018
Wear goggles when using a grinder or welder. Pay full attention to safety
by wearing gloves when necessary. Watch out for sharp edges, etc. that
might injure your hands or fingers.
00019
Before carrying out maintenance work on the electric system, disconnect

the negative terminals of the batteries to prevent them from short-
circuiting and burning-out.
CAUTION
Be sure to turn starter and lighting switches, etc. off before
disconnecting or connecting battery terminals, because the semi-
conductors can be damaged.
14184
00-9
Take care when handling sensors, relays, etc. which are vulnerable to
shock and heat. Do not attempt to remove the cover from, or apply paint
to, the electronic control unit.
00021
Pull the connector, and not the harness lead, to separate connectors. To
separate a lock-type connector, first push toward arrow mark. To recon-
nect a lock-type connector, press the separated parts until they click
together.
00022
When washing the vehicle, cover the electric system parts and instru-
ments with waterproof material beforehand (Cover with vinyl sheet or the
like). Keep water away from harness wire connectors and sensors. If any
of them should get wet, wipe them off immediately.
00023
When using an electric welder, such electronic parts that are directly
connected to the batteries might be damaged due to the flow of current
A from the welder that flows through the negative circuit. Parts that have
switches might be subject to the same danger if the switches are left on.
Therefore, do not fail to observe the following.
B A : Welder
B : Connect the negative terminal of the welder as near as possible
t o
the area that is to be welded.
C C : Disconnect the negative cable at the cab.
08727
^ Gr 54 130
00-10
00
Disconnect the negative terminals of batteries.
Disconnect connections between the cab harness wires and the chas-
sis harness wires.
06863
To apply voltage for testing, check that the positive and negative cables
are connected properly, then increase voltage gradually from
0 volt. Do not apply voltage higher than the specified value.
In particular, pay close attention to the electronic control unit and sen-
sors, since they are not always fed the battery voltage.
14185
When using testers or the like for continuity tests, be careful not to allow
test probes to touch the wrong terminals.
00027
00-11
Measurement procedures using connectors
C
B Test with connectors engaged (continuity through circuit
obtained)
B
< Waterproof connector >
A Prepare a test harness and connectors A, then connect if between the
two parts of harness B that is to be tested. Check the circuit by
Connect the test harness
touching test probe C to the test connector.
B and connector A between Never insert the test probe from the harness side of the waterproof
these parts 02587 connection, or waterproof performance might be diminished causing
corrosion of the connector.
< Non-waterproof connector >

Insert test probe C from the harness side of the connector. Where
control units, etc. have connectors that are too small to accept the test
probe, do not force the test probe into them.
C
02588
Test with connectors disengaged

Using female pins
Insert a test probe into a terminal. However, do not force the probe
into the terminal, or it will cause a poor contact.
02589
Using male pins

Touch the pins directly using test probes.
CAUTION
Be sure that you do not short circuit the connector pins when
you use the test probe because this could damage the internal
circuit of the electronic control unit.
02590
00-12
00
Connector inspection procedures
Visual inspection
Check for loose connection and poor engagement.
02591
Check if harnesses are broken by pulling gently around the terminals.
02592
Check for a decrease in contact pressure between the male and

female terminals.
02593
Check for poor contact caused by connector pins having fallen out,
rusted terminals or foreign particles.
Connector pin fall out inspection

Damaged connector pin stoppers can cause poor engagement of the
terminals (male and female pins) even if the connector body is se-
cured, and might cause some pins to fall out. Check if the pins have
fallen out from the connector by pulling each harness gently.
02594
00-13
Inspection procedures for blown fuses
A
Remove fuse B and measure resistance between the loaded side of
_ the fuse and ground.
+
Turn on all circuit switches (connected to the fuse). If the resistance
value reading is approximately 0 , a short has occurred between the
_ + 0
switch and the loaded point. A value of other than zero may indicate
that the fuse was blown by a temporary short but the short is no longer
present.
B The major causes of a short circuit are as follows:

Harness stuck onto the vehicle body.
Harness sheath damaged by friction or heat.
C Water in connectors or circuits.
E
Mistakes (accidental short circuits)
A : Battery
D B : Fuse
C : Loaded switch
D : Load
E : Short circuit
02596
Precautions for handling alternator

When servicing the alternator, pay attention to the following :
Do not connect the alternator with battery polarities reversed.
If the alternator is connected with reversed polarities, a large cur-
rent flow from the battery to the alternator occurs, and the diode or
regulator might be damaged.
04746
While the engine is running, do not remove the battery terminals. If

the battery terminals are removed at that time, a surge voltage is
generated and the diode or regulator might be weakened.
04747
Do not use a high-voltage tester such as a megger for inspection.

If a high-voltage tester is used, the diode or regulator might be
destroyed.
02371
00-14
00
Do not splash water over the alternator.
If water is directly splashed over the alternator, individual compo-
nents will be short-circuited and might be destroyed.
05165
Do not short-circuit terminal B and terminal L while running the

alternator.
If the terminals are short-circuited while the alternator is running,
the diode trio might be destroyed.
04749
Disconnect the battery terminals before quick-charging the battery.

Quick-charging without disconnecting the battery terminals might
damage the diode or regulator.
05166
00-15
Measures for temporary faults
Temporary faults often occur under certain conditions. So identifying
those conditions helps to find possible causes. To find the conditions
under which temporary faults occurred, you need to reproduce the
faults after interviewing customers in detail about actual driving condi-
tions, weather, frequency of occurence and fault phenomena.
Then determine if the faults were caused by vibration, temperature or
other possible elements depending on the actual conditions identified.
If vibration is suspected as a possible cause, inspect individual con-
02597
nectors as follows to check if the fault will occur:
Shake the connector gently in all four directions of the arrows as

illustrated.
Shake the wiring harness gently in all four directions of the arrows
as illustrated.
Wiggle each sensor or piece of equipment by hand.
Gently shake the wiring harnesses near movable parts such as
suspensions.
02598 The inspection subjects include possible causes related to the diagno-
sis code outputs and faults, as well as the connectors and other parts
in the inspection procedure.
02599
00-16
00
MEMO
00-17
TABLE OF STANDARD TIGHTENING TORQUES
Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise
specified.
Threads and contact seats shall be dry.
Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the
bolt shall apply.
Hex-head Bolt and Stud Bolt Unit : Nm {lbf.ft, kgfm}

Strength
classification 4T 7T 8T
Repre-
sentation
Diameter
symbol (Stud) (Stud) (Stud)
2 to 3 4 to 6 5 to 7
M5 {1.4 to 2.2, 0.2 to 0.3} {2.9 to 4.3, 0.4 to 0.6} {3.6 to 5.1, 0.5 to 0.7}
4 to 6 7 to 11 8 to 12
M6 {2.9 to 4.3, 0.4 to 0.6} {5.1 to 8.0, 0.7 to 1.1} {5.8 to 8.7, 0.8 to 1.2}
9 to 14 17 to 26 20 to 29
M8 {6.5 to 10, 0.9 to 1.4} {12 to 19, 1.7 to 2.6} {14 to 22, 2.0 to 3.0}
19 to 28 18 to 26 36 to 52 33 to 49 45 to 60 41 to 59
M 10 {14 to 20, 1.9 to 2.8} {13 to 20, 1.8 to 2.7} {25 to 40, 3.5 to 5.5} {25 to 36, 3.5 to 5.0} {33 to 43, 4.5 to 6.0} {31 to 50, 4.3 to 6.9}
35 to 50 31 to 46 70 to 95 65 to 85 85 to 110 75 to 100
M 12 {25 to 36, 3.4 to 5.0} {22 to 34, 3.1 to 4.7} {51 to 69, 7.0 to 9.5} {47 to 61, 6.5 to 8.5} {61 to 80, 8.5 to 11} {54 to 72, 7.5 to 10}
60 to 85 55 to 75 120 to 160 110 to 140 130 to 180 120 to 160
M 14 {43 to 61, 6.0 to 8.5} {40 to 54, 5.5 to 7.5} {87 to 115, 12 to 16} {80 to 100, 11 to 14} {94 to 130, 13 to 18} {87 to 120, 12 to 17}
90 to 130 90 to 120 180 to 240 160 to 220 200 to 270 190 to 260
M 16 {69 to 94, 9.5 to 13} {65 to 87, 9.0 to 12} {130 to 175, 18 to 24} {115 to 160, 16 to 22} {145 to 195, 20 to 27} {135 to 190, 19 to 26}
140 to 190 120 to 160 260 to 340 220 to 290 290 to 390 260 to 340
M 18 {100 to 135, 14 to 19} {87 to 115, 12 to 16} {180 to 255, 25 to 35} {160 to 215, 22 to 30} {215 to 290, 30 to 40} {190 to 255, 26 to 35}
190 to 260 170 to 230 350 to 470 320 to 420 410 to 550 370 to 490
260 to 340 230 to 300 470 to 640 430 to 570 550 to 740 490 to 670
340 to 450 290 to 390 630 to 840 540 to 730 730 to 980 630 to 840
Hex-head Flange Bolt Unit : Nm {lbf.ft, kgfm}

Strength
classification 4T 7T 8T
Repre-
sentation
Diameter
symbol
4 to 6 8 to 12 9 to 14
M6 {2.9 to 4.3, 0.4 to 0.6} {5.8 to 8.7, 0.8 to 1.2} {6.5 to 10, 0.9 to 1.4}
10 to 15 19 to 28 22 to 32
M8 {7.0 to 11, 1.0 to 1.5} {14 to 20, 1.9 to 2.8} {16 to 24, 2.2 to 3.3}
21 to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65
M 10 {15 to 22, 2.1 to 3.1} {14 to 21, 1.9 to 2.9} {28 to 43, 3.9 to 6.0} {26 to 39, 3.6 to 5.4} {36 to 47, 5.0 to 6.5} {33 to 47, 4.5 to 6.5}
38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110
M 12 {27 to 40. 3.8 to 5.5} {25 to 38, 3.4 to 5.2} {58 to 80, 8.0 to 11} {51 to 69, 7.0 to 9.5} {65 to 87, 9.0 to 12} {61 to 80, 8.5 to 11}
00-18
00
Hex-head Nut Unit : Nm {lbf.ft, kgfm}
Strength
classification 4T 6T
Repre-
sentation
Diameter
symbol Standard screw Coarse screw Standard screw Coarse screw
2 to 3 4 to 6
M5 {1.4 to 2.2, 0.2 to 0.3} {2.9 to 4.3, 0.4 to 0.6}
4 to 6 7 to 11
M6 {2.9 to 4.3, 0.4 to 0.6} {5.1 to 8.0, 0.7 to 1.1}
9 to 14 17 to 26
M8 {6.5 to 10, 0.9 to 1.4} {12 to 19, 1.7 to 2.6}
19 to 28 18 to 26 36 to 52 33 to 49
M 10 {14 to 20, 1.9 to 2.8} {13 to 20, 1.8 to 2.7} {25 to 40, 3.5 to 5.5} {25 to 36, 3.5 to 5.0}
35 to 50 31 to 46 70 to 95 65 to 85
M 12 {25 to 36, 3.4 to 5.0} {22 to 34, 3.1 to 4.7} {51 to 69, 7.0 to 9.5} {47 to 61, 6.5 to 8.5}
60 to 85 55 to 75 120 to 160 110 to 140
M 14 {43 to 61, 6.0 to 8.5} {40 to 54, 5.5 to 7.5} {87 to 115, 12 to 16} {80 to 100, 11 to 14}
90 to 130 90 to 120 180 to 240 160 to 220
M 16 {69 to 94, 9.5 to 13} {65 to 87, 9.0 to 12} {130 to 175, 18 to 24} {115 to 160, 16 to 22}
140 to 190 120 to 160 260 to 340 220 to 290
M 18 {100 to 135, 14 to 19} {87 to 115, 12 to 16} {180 to 255, 25 to 35} {160 to 215, 22 to 30}
190 to 260 170 to 230 350 to 470 320 to 420
260 to 340 230 to 300 470 to 640 430 to 570
340 to 450 290 to 390 630 to 840 540 to 730
Hex-head Flange Nut Unit : Nm {lbf.ft, kgfm}

Strength
classification
4T
Repre-
sentation Standard screw Coarse screw
4 to 6
M6 {2.9 to 4.3, 0.4 to 0.6}
10 to 15
M8 {7.0 to 11, 1.0 to 1.5}
21 to 30 20 to 28
M 10 {15 to 22, 2.1 to 3.1} {14 to 21, 1.9 to 2.9}
38 to 54 35 to 51
M 12 {27 to 40, 3.8 to 5.5} {25 to 38, 3.4 to 5.2}
00-19
TABLE OF STANDARD TIGHTENING TORQUES
Tightening torque for flair nut for general purpose Unit : Nm {lbf.ft, kgfm}
Pipe diameter 4.76 mm {0.19 in.} 6.35 mm {0.25 in.} 8 mm {0.31 in.} 10 mm {0.39 in.} 12 mm {0.47 in.} 15 mm {0.59 in.}
Tightening torque 17 {12, 1.7} 25 {19, 2.6} 39 {29, 4.0} 59 {43, 6.0} 88 {65, 9.0} 98 {72, 10.0}
Tightening torque for air piping nylon tube for general purpose {DIN type} Unit : Nm {lbf.ft, kgfm}
Standard diameter 61 mm {0.240.039 in.} 101.25 mm {0.390.049 in.} 121.5 mm {0.470.059 in.} 151.5 mm {0.590.059 in.}

Tightening torque +5.9 +4.3 +0.6 +9.8 +7.2 +1.0 +9.8 +7.2 +1.0 +4.9 +7.2 +1.0
20 14 2.0 29 22 3.0 49 36 5.0 54 40 5.5
0 0, 0 0 0, 0 0 0, 0 0 0, 0
Tightening torque for air piping nylon tube for general purpose {SAE type} Unit : Nm {lbf.ft, kgfm}
Standard diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.

Tightening torque +3.9 +2.9 +0.4 +4.9 +3.6 +0.5 +4.9 +3.6 +0.5 +4.9 +3.6 +0.5
13 9.4 1.3 29 22 3.0 49 36 5.0 64 47 6.5
0 0, 0 0 0, 0 0 0, 0 0 0, 0
00-20
00
MEMO
00-21
CONNECTOR CONFIGURATION CHART
Model
(Number shows number Connection
of pins)
AA AA 1 A
AA 2 A
AA 2 B
AA 3 A
AA 3 B
AA 4 A
AA 4 B
AA 6 A
00-22
00
Model
of pins)
AA AA 6 B
AA 8 A
AA10A
AA12A
AB AB 1 A
AB 2 A
AB 3 A
AB 4 A
AB 6 A
00-23
Model
of pins)
AC AC 1 A
AC 2 A
AC 3 A
AC 4 A
AD AD 1 A
AD 2 A
AE AE 2 A
AE 3 A
AE 5 A
00-24
00
Model
of pins)
AE AE 7 A
AE 9 A
AE11A
AE13A
AE15A
AE16A
(White, Gray,
Black)
AE16B
(Green)
AE16C
(Blue)
AE17A
00-25
Model
of pins)
AG AG16A
AG20A
AH AH10A
AH12A
AH18A
00-26
00
Model
of pins)
AH AH18B
AH22A
(AH26A) AH22
AH24A
AH26A
AH26A (AH22)
00-27
Model
of pins)
AJ AJ 2 A
AJ 4 A
AJ 8 A
AJ10A
AJ12A
00-28
00
Model
of pins)
AJ AJ16A
00-29
Model
of pins)
AJ AJ20A
AK AK 2 A
AK 3 A
AK 4 A
AK 6 A
00-30
00
Model
of pins)
AK AK 8 A
AK10A
AK14A
AK18A
AK20A
00-31
Model
of pins)
AK AK20B
AK22A
AK22B
AL AL 1 A
or
or
AL 2 A
or
or
00-32
00
Model
of pins)
AL AL 2 B
AL 3 A
or
or
AL 3 B
AL 3 C
AL 3 D
or
AL 3 E
or
00-33
Model
of pins)
AL AL 4 A
or or
AL 4 B
AL 6 A
or or
AL 6 B
AL 8 A
or or
AL 8 B
00-34
00
Model
of pins)
AM AM 2 A
AM 2 B
AM 2 C
AM 4 A
AM 4 B
AM 6 A
AM 6 B
AM 8 A
AM 8 B
00-35
Model
of pins)
AM AM10A
AN AN 1 A
AN 2 A
AN 3 A
AN 4 A
AN 4 B
AN 6 A
AN 6 B
AN 8 A
00-36
00
Model
of pins)
AN AN 8 B
AP AP 1 A
AP 1 B
AP 2 A
AP 2 B
AP 2 C
AQ AQ 3 A
AQ 3 B
AQ13A
00-37
Model
of pins)
AQ AQ15A
AQ20A
AR AR 2 A
AR 2 B
AR 2 C
AR 2 D
AR 2 E
AR 2 F
00-38
00
Model
of pins)
AR AR 3 A
AS AS 1 A
AS 2 A
AS 2 B
AT AT 4 A
AU AU 6 A
AU 8 A
AU10A
00-39
Model
of pins)
AU AU12A
AU13A
AU16A
AV AV 1 A
AV 2 A
AW AW 1 A
AW 1 B
AW 2 A
AX AX 4 A
00-40
00
Model
of pins)
AY AY 2 A
AZ AZ 2 A
BA BA 3 A
BB BB 2 A
BB 3 A
BC BC 3 A
BD BD 8 A
BE BE 6 A
BF BF12A
00-41
Model
of pins)
BG BG16A
BH BH 4 A
BJ BJ 9 A
BL BL 2 A
BM BM 2 A
BM 2 B
BM 2 C
BN BN 1 A
00-42
Group 01 - Maintenance
Schedule
Group 01 - 1998 Minor

Changes
BACK HOME
Group 01
Maintenance Schedule
' 98 Minor Change

Table of Contents
BACK HOME
Pub No. TWSE9501-201
01
MAINTENANCE SCHEDULE
HOW TO READ THE MAINTENANCE SCHEDULE TABLES........ 01- 2
MAINTENANCE SCHEDULE TABLES ........................................... 01- 3
MAINTENANCE OPERATIONS ...................................................... 01- 5

Replacement of Oil Filter ........................................................................... 01- 5
Replacement of Fuel Filter ......................................................................... 01- 6
Draining of Water Separator Condensation ............................................. 01- 7
Cleaning of Fuel Feed Pump Gauze Filter ................................................ 01- 7
Bleeding of Air from Fuel Line .................................................................. 01- 8
Adjustment of V-Belt Tension ................................................................... 01- 9
Cleaning and Replacement of Air Cleaner Element ................................ 01- 11
Inspection of Clutch Pedal Free Play........................................................ 01- 12
Tire ............................................................................................................... 01- 13
Inspection of Brake Lining Thickness < Drum Brake Only > .................. 01- 18
Battery ......................................................................................................... 01- 18
Fuse ............................................................................................................. 01- 21
LUBRICATION ................................................................................. 01- 24

Engine Oil .................................................................................................... 01- 26
Manual Transmission Gear Oil .................................................................. 01- 28
Automatic Transmission Fluid .................................................................. 01- 30
Transfer Gear Oil < FG Model Only > ........................................................ 01- 32
Front Axle Gear Oil < FG Model Only > and Rear Axle Gear Oil ............ 01- 33
Power Steering Fluid .................................................................................. 01- 34
Brake Fluid .................................................................................................. 01- 36
Greasing Various Areas of Chassis .......................................................... 01- 40
01-1
Example Table : E : Exhaust emission items
N : Noise control items
Time of inspection and maintenance (2)
Inspection interval

Inspection and
Every 250000 km/

Working procedures (3) Remarks (4)
Every 20000 km/

Every 10000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance (1)
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
6000 miles
2500 miles
ENGINE
1 Manifold bolts torque Check inlet and exhaust manifold nuts for looseness ^ Gr 15
2 E Check and adjust valve Check valve clearance with feeler gauge ^ Gr 11
clearance
3 E Oil filter replacement Every 10000 km/6000 miles or 12 months Replace oil filter ^ Gr 12
4 E Injection nozzle Check and clean injection nozzle ^ Gr 13
N
5 E Fuel Injection timing Check fuel injection timing ^ Gr 13
N
6 E Fuel feed pump filter Every 40000 km/24000 miles or 24 months Clean gauze filter inside connector with diesel fuel ^ Gr 13
7. E Fuel filter replacement Every 20000 km/12000 miles or 12 months Replace fuel filter ^ Gr 13

(2) The periods between inspection and service are based on the assumption that the vehicle will be driven approximately
Inspections which must be made are indicated by an or by the appropriate period between servicing.
nance item.
01-2
E : Exhaust emission items
Inspection interval

Inspection and
Every 250000 km/

Every 20000 km/

Every 10000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
6000 miles
2500 miles
ENGINE
1 Manifold bolts and nuts torque Check inlet and exhaust manifold bolts and nuts for ^ Gr 15
looseness
clearance
N
N
6 E Fuel feed pump filter Every 40000 km/24000 miles or 24 months Clean gauze filter inside connector with gas oil
7 E Fuel filter replacement Every 20000 km/12000 miles or 12 months Replace fuel filter ^ Gr 13
8 E Fuel line Every 20000 km/12000 miles or 12 months Inspect fuel tank, cap and lines for damage causing
leakage
9 E V-belts tension and Every 10000 km/6000 miles or 12 months Inspect V-belts for cracks, wear and tension ^ Gr 14
N damage
10 E Cooling system Check radiator and radiator cap for sealing
performance and mounting condition. ^ Gr 14
Inspect hoses for looseness, deterioration, damage
causing leakage.
Remove dust and foreign deposits from radiator and
intercooler front
11 Coolant replacement Every 24 months Replace coolant ^ Gr 14
12 E Turbocharger rotor play Check turbocharger rotor play ^ Gr 15
13 Air cleaner element Every 5000 km/3000 miles Clean air cleaner element by blowing clean compressed ^ Gr 15
air through it
14 E Air cleaner element Replace air cleaner element ^ Gr 15
N replacement
15 E Exhaust system Inspect exhaust system for damage, corrosion and ^ Gr 15
N loose connection causing leakage
POWER TRAIN
16 Clutch pedal and clutch disc Check pedal for free play. ^ Gr 21
wear Check clutch disc wear through inspection hole
17 Propeller shaft flange torque Check flange yoke bolts for looseness and universal joint ^ Gr 25
and universal joint looseness for play.
Carry out the first inspection for new vehicles at
10000 km or 6000 miles
18 Propeller shaft center bearing Check center bearing if traces of grease flowing out are ^ Gr 25
evident.
Check center bearing for wear, damage and play
Check center bearing for traces of grease flow.
01-3
MAINTENANCE SCHEDULE TABLES
Inspection interval

Inspection and
Every 250000 km/

Every 20000 km/

Every 10000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
6000 miles
2500 miles
FRONT AND REAR AXLE

19 Wheel hub bearing Check wheel hub bearing for play ^ Gr 26, 26B,
27
20 Wheel hub bearing hub seals Replace wheel hub bearing hub seals ^ Gr 26, 26B,
replacement 27
21 Wheel and tire Check disc wheel for corrosion, deformation and cracks. ^ Gr 31
Measure inflation pressure with tire gauge.
Check tire tread and side wall for cracks and damage.
Measure tire tread groove depth to make sure it is deep
enough.
Check tire tread for uneven wear, stepped wear and
other abnormal wear.
Rotate tires if there is a difference in the amount of wear
of each tire
22 Retightening wheel nuts Check wheel nuts for looseness. ^ Gr 31
Check at the first 50 to 100 km/30 to 60 miles after
changing a wheel
SUSPENSION SYSTEM
23 Retightening U-bolts Check U-bolt nuts for looseness. ^ Gr 33, 34
Check at the first 1000 km/600 miles after removing
and retightening U-bolt nuts
BRAKING SYSTEM
24 Disc brake pad and disc Check disc brake pad and disc for damage and wear ^ Gr 35
25 Brake lining Check lining for wear through inspection hole ^ Gr 35
26 Brake drum Disassemble and check drum for wear, cracks and ^ Gr 35
damage
27 Looseness, play and damage Inspect brake lines and hoses for looseness, play and ^ Gr 35
of brake system parts damage.
Inspect wheel cylinder and brake master cylinder for
looseness, play and damage
STEERING SYSTEM
28 Steering system Check steering system for looseness, steering wheel ^ Gr 37
play and operating condition.
Inspect for fluid leakage, booster and oil pump function
01-4
MAINTENANCE OPERATIONS 01
This section explains simple maintenance procedures. See the relevant Group in this manual for further details.
Replacement of Oil Filter

- Lubricant
2 Inside oil filter Engine oil Approximately
1 L {1.1 qts}
Gasket area of oil filter with thin application Engine oil As required

102.2
{4.02}
2 Oil filter wrench MH061587 Removal of oil filter
06478
WARNING
Wipe up any engine oil that has been spilled because it can
cause a fire.
Do not touch the engine while it is hot because it will burn you.
CAUTION
Take care not to spill engine oil on the V-belts, because this
would cause them to slip, reducing service life.
[Removal]
06446
[Installation]
Clean the surface of oil cooler body 1 that makes contact with oil filter
2.
1
Apply engine oil thinly and evenly to gasket area A of oil filter 2.
Screw oil filter 2 into oil cooler body 1 until gasket area A sits on the
body. From this position, tighten further by rotating by three quarters
A
of a turn.
After installation, run the engine and check that there is no oil leakage
from gasket area A.
2 Check the oil level and if it is low, top it up.
07382
01-5
Replacement of Fuel Filter
- Lubricant
2 Gasket contact surfaces of fuel filter and fuel filter head Engine oil As required

90.2 {3.55}
2 Filter wrench MH061509 Removal of fuel filter
01882
WARNING
Fuel ignites easily. Do not get it near flame or heat.
Wipe up any diesel fuel that has been spilled because it can
cause a fire.
Do not use an unsuitable filter because it can cause a fire.
[Removal]
06872
[Installation]
1 Install by tightening three quarters to one full turn after contact surface
A of fuel filter head 1 makes contact with gasket B of fuel filter 2. Be
B A B
A sure to tighten by hand.
After installation, run the engine and check for fuel leakage.
06874
01-6
01
Draining of Water Separator Condensation

Visually inspect the water separator before driving.

When level ring 1 reaches red line A, drain the condensation as follows:
Loosen drain plug 2 and drain out the condensation.
When level ring 1 has dropped to the bottom, tighten drain plug 2.
Carefully wipe the water separator and the surrounding area.
Check for fuel leakage.
1 2
27422
Cleaning of Fuel Feed Pump Gauze Filter

2 Eye bolt 25 to 29 {18 to 22, 2.5 to 3}
WARNING
cause a fire.
Remove eye bolt 2 on the inlet side of fuel feed pump 1.

2 3 Remove gauze filter 3 from eye bolt 2.
Clean gauze filter 3 with diesel fuel .
Follow the removal sequence in reverse and reinstall gauze filter 3.
Install eye bolt 2 in the fuel feed pump.
Bleed the air from the fuel line.
Start the engine and check for fuel leakage.
1
14212
01-7
Bleeding of Air from Fuel Line

2 Air vent plug 7.8 to 12 {5.8 to 8.7, 0.8 to 1.2}
WARNING
cause a fire.
Turn the top of priming pump 1 of the injection pump counterclockwise

2 and pull it up so the top protrudes.
Loosen air vent plug 2 of the fuel filter and move the top part of priming
pump 1 up and down.
Move priming pump 1 up and down repeatedly until air bubbles are no
longer present in the fuel drained from air vent plug 2.
When the fuel being drained is free of air bubbles, tighten air vent plug
2.
1 After moving priming pump 1 up and down another five or six times,
push the top down and turn clockwise to drive it in fully.
After bleeding the air, carefully wipe up spilled fuel and start the
02375 engine.
01-8
01
Adjustment of V-Belt Tension
Newly installed V-belts can stretch during their initial running-in period.
To prevent this from becoming a problem, run the engine for several
minutes after installing the V-belt, then readjust. Perform this cycle
several times.
WARNING
You must take special precautions to prevent the engine from
rotating while a V-belt is being inspected or adjusted.
CAUTION
Make sure that you turn off the engine before attempting to
inspect or adjust the V-belts.
Make sure that you fasten all bolts and nuts securely after adjust-
ing the V-belts. Remember that too much tension can damage the
V-belts and bearings.
Do not grease V-belts. This causes them to slip, which reduce
service life.

1, 2 V-belt tension (Each one) Fan 12 to 16 {0.47 to 0.63} Adjust
Air-conditioner 16 to 20 {0.63 to 0.79}
0 Special tools
1, 2 Belt tension gauge MH062345 Measurement of tension of V-belt
03612
[Inspection]
D Measure the extent of flex A when the center of V-belts 1, 2 as illustrated
1
2 is depressed with a force of 98 N {22 lbf, 10 kgf}.
C
B : Alternator pulley
A C : Water pump pulley
D : Cooler compressor pulley (Air-conditioner)
B A E : Tension pulley
E F : Crankshaft pulley
F 11518
01-9
G Use of special tool belt tension gauge
Set upper O-ring G of 0 belt tension gauge to 98 N {22 lbf, 10 kgf}
(push load) on graduation H.
H
Set lower O-ring J of 0 belt tension gauge to graduation K (maximum
0
flex of belt).
K 03613
Place 0 belt tension gauge at the center of V-belts 1, 2 perpendicu-

G larly as illustrated and push top L all the way down until upper O-ring
L
G hits upper edge M.
M
1, 2
03614
Measure the extent of flex A of V-belts 1, 2 at this point, and if the

A measured value deviates from the standard value, adjust as follows:
1, 2
03615
N [Adjustment]
2 (1) Adjustment of tension of V-belt for fan

Loosen alternator mounting bolts N (two points), and adjust the
tension of V-belts 2 by moving adjusting bolt P.
P After adjustment, tighten bolts N, P securely.
CAUTION
Bear in mind that excessive tension of V-belts 2 might damage
the belts and bearings that engage with the V-belts.
N 06370
Be sure to replace V-belts 2 as a set to maintain even tension
between them.
Be careful not to let oil stick to V-belts 2. If oil gets onto the
belts, it causes slipping, resulting in overheating and insuffi-
cient battery charging.
(2) Adjustment of tension of V-belt for air-conditioner

Loosen tension pulley mounting nut Q, and adjust the tension of
V-belt 1 moving adjusting bolt R.
After adjustment, tighten mounting nut Q securely.
CAUTION
Bear in mind that excessive tension of V-belt 1 might damage
the belt and bearings that engage with the V-belt.
Be careful not to let oil stick to V-belt 1. If oil gets onto the belt,
Q R it causes slipping, resulting in poor performance of the air
1 05810 conditioner.
01-10
01
Cleaning and Replacement of Air Cleaner Element
[Removal]
Unfasten clamp 1 and remove air cleaner cap 2.
4 Remove air cleaner element 3.
A 3 [Installation]
Install by aligning alignment marks A of air cleaner cap case 4 and air
cleaner cap 2.
1
2
13152
[Cleaning]
3 Blow compressed air of 685 kPa {100 lbf/in2, 7 kgf/cm2} or less through
air cleaner element 3 from the inside.
When using compressed air, move the blowers nozzle up and down
along the pleats of air cleaner element 3 evenly.
CAUTION
Do not tap or hit air cleaner element 3 to remove dust.
Do not blow compressed air through air cleaner element 3 from
the outside.
13150
[Inspection]
Illuminate the inside of air cleaner element 3.
If parts of the filter paper are torn or thin, or if the packing of the upper
surface of air cleaner element 3 is damaged, replace the air cleaner
3
element.
NOTE
If the dust on air cleaner element 3 is wet due to oil smoke or
soot, replace the air cleaner regardless of the scheduled replace-
13151 ment interval.
01-11
Inspection of Clutch Pedal Free Play

1 Clutch pedal free play 36 to 53 {1.42 to 2.09} Adjust
or replace
[Confirmation]
Push clutch pedal 1 with your hand and measure the amount of move-
ment A (free play) until you meet resistance. If the measured value does
not conform to the standard value, adjust stroke of clutch power cylinder
push rod or replace the clutch disc.
A: 36 to 53 mm
1 {1.42 to 2.09 in.}
03480
[Clutch operation]
Check for unusual noises when clutch pedal 1 is pressed while the
engine is idling, and also for abnormally heavy clutch operation. Also
check to be certain that it is not difficult to shift the vehicle into first and
reverse gears.
Gradually release clutch pedal 1 to set the vehicle in motion.
Check to be sure there is no slippage, and that the clutch engages
smoothly.
01-12
01
Tire

1 Depth of tire tread grooves 1.6 {0.063} Replace

2 Wheel nut 49049 {36036, 505}
Air pressure
Tire air pressure should be checked before the vehicle is driven, while
the tires are still cool.
Item Air pressure kPa {Psi, kgf/cm2}

Tire size
Vehicle model Front Rear
FE639 215/85R16(D) 450 {65, 4.50} 450 {65, 4.50}

(GVWR : 11600 lb, 5260 kg)
00592
FE639 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50}
(GVWR : 13500 lb, 6120 kg)
FE649 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50}
(GVWR : 14500 lb, 6580 kg)
FG639 7.50R16(E) 550 {80, 5.50} 550 {80, 5.50}
(GVWR : 11000 lb, 5000 kg)
GVWR : Gross vehicle weight rating
CAUTION
Make certain that there is no difference in the air pressure be-
tween the inner and outer rear tires.
Make certain you use valve caps on the air valves.
It is not necessary to increase the air pressure for high-speed
driving.
01166
Checking tread depth
Check all around the tire treads to make sure that the depth of the
tread grooves is above the wear limit.
If the tread grooves are not deep enough, slip sign A appears at the
position of the mark, where the tread groove has worn away.
1
02353
WARNING
If the depth of the tread grooves is not adequate, the tires will slip
on wet roads and present a hazard. Such tires are also extremely
dangerous because they are more susceptible to hydroplaning
when the vehicle is running at high speeds in the rain. Such tires
must be replaced with new ones as soon as possible.
1
02354
01-13
Checking for cracks, damage, and objects embedded in the treads
Check the tire treads and walls for cracks and damage.
Check tire treads for uneven wear or other abnormal wear.
Check if metal objects or nails have penetrated the tires.
Check for stones embedded between double tires.
WARNING
Badly damaged or worn tires are extremely dangerous, because
they can be punctured more easily when the vehicle is running,
01170
they must be replaced with new ones as soon as possible.
Removing tires
Jacking up point
For FE front wheels : Point A under the leaf spring in front of the
< FE Front wheel > front axle
For FG front wheels : Point A under the front axle housing
For rear wheels : Point B under the rear axle housing
A
02355
< FG Front wheel >
27423
A
< Rear wheel > WARNING
The jack should be placed on flat, solid ground, and should not
be used to raise the vehicle higher than necessary.
Do not use the jack at vehicle locations other than those illus-
trated.
Keep in mind the danger of a slipping jack. Never crawl under the
vehicle while the jack is in use or rock the vehicle. Also, do not
start the engine while the vehicle is jacked up.
B To increase safety, use rigid racks for the vehicle when it is
02356
necessary to leave it jacked up for long periods.
Chock both the tire to be removed and the tire diagonally oppo-
site to it so that they will not rotate when you are removing the
tire.
01-14
01
2 Loosen wheel nuts 2 slightly. The wheel nuts for right tires C have
right-hand threads R, and the wheel nuts for left tires D have left-
C hand threads L.
WARNING
Make certain that wheel nut wrench E is fully engaged, all the way
to the back of nuts 2. If it is not, it could slip.
D CAUTION
Only loosen wheel nuts 2 slightly. Do not remove them.
E Jack up the vehicle carefully, until the tire is slightly off the ground.
14213
Remove wheel nuts 2, then remove the tire.
When working on the double tires at the rear of the vehicle, first
remove the outside tire, then lower the vehicle and loosen the nuts on
the inside tire. After doing this, jack the vehicle back up and remove
the tire.
J 7 Mounting tires
M G To prevent wheel nuts 2, 4 and hub bolt 6 from becoming loose and to
F
prevent mounted parts (tire assemblies 3, 5 and hub 7) from being
L damaged, remove rust, dust, additional coatings of paint, and foreign
2 3 6 H particles from the following areas:
J 7
M K G
F F: Hub bolt thread area
G: Wheel mounting surface of hub
H H: Wheel alignment area of hub
2 4 L 35 11388 J: Disc wheel mating surface
6
K: Disc wheel nut mounting surface
L: Wheel nut thread area
M: Wheel nut spherical area
Put on the double rear tires as follows:

After mounting inner tire 5 and fully tightening inner wheel nuts 4,
2 jack the vehicle up and mount on outer tire 3, then tighten outer
wheel nuts 2.
Even if only outside tire 3 is to be changed, do not mount it until
4 inner wheel nuts 4 have been fastened at the specified torque.
3 Slide the air valves on the inside and outside tires down when
2 mounting the tires.
4 WARNING
5 If the threads are scored, or the disc wheel is deformed or
cracked, change bolts 6, nuts 2, 4 and disc. Driving the truck
before correcting such problems can cause the tire in question
00626 to come loose, which could be the source of major accidents.
CAUTION
Check hub bolt 6 threads carefully for scratches before putting
the tire on.
Place the tapered end of wheel nuts 2, 4 towards the disc wheel and
fasten temporarily. Center so that there is no eccentricity between
bolts 6 and the disc wheel bolt holes.
Lower the vehicle.
01-15
Tighten the nuts in the order as illustrated, tightening each nut two or
< FE639, FG639 > 4
three times. To finish, tighten each nut at the specified torque.
2 1 WARNING
Always use the specified torque when tightening the wheel nuts.
If the wheel nuts are not tightened properly, the wheels could
come loose while the vehicle is being driven, which could result
in life threatening accidents or the truck being disabled.
5 3
Do not coat the threads with grease when tightening the nuts.
This could result in over-tightening force, which could be dan-
gerous.
< FE649 > 3
1 CAUTION
5
Over-tightening the wheel nuts can damage them.
2 6
4 01246
Checking the wheel nuts for looseness

The wheel nuts should be checked for looseness every 10000 km
(6000 miles). All nuts should be tightened at the specified torque.
Check the double rear tires for looseness as follows:
2
1 1 Loosen outer wheel nuts 2.

2 Tighten inner wheel nuts 4 at specified torque.
3 Tighten outer wheel nuts 2 at specified torque.
2
4 CAUTION
3 If outer wheel nuts 2 are tightened without first being loosened, it
might not be possible to tighten them at the specified torque.
2 14224
01-16
01
Tire rotation
Tires wear differently, according to the location where they are mounted.
To make this wear uniform and prolong the life of your tires, they should
be rotated every 10000 km (6000 miles) in the rotation order shown
below:
When the tread patterns for all tires are identical:
< Front > < Rear >

02358
When the tread patterns are different for the front and rear tires:
< Front > < Rear >

02359
CAUTION
Always adjust air pressure after running-in new tires.
When using tires of different tread patterns, use rib-type patterns
for the front tires and traction type patterns for the rear tires.
Avoid using both radial and biased tires on the same vehicle.
01-17
Inspection of Brake Lining Thickness < Drum Brake Only >

2 Thickness of brake lining 4 {0.16} Replace
(Side shoulder
means wear
limit)
NOTE
Be sure to inspect at two points for each wheel per side.
A
Remove cover 1 from the packing plate.
2 Inspect through check hole A whether brake lining 2 is worn to the
point of side shoulder B of the brake lining (the limit).
If the measured value is lower than the limit, replace brake lining 2 on
2
1 the same axle as a unit.
After inspection, be sure to reinstall cover 1.
B 14361
Battery
DANGER
Since flammable hydrogen gas is generated by the battery, be
sure to obey the following warnings :
Do not short-circuit the and terminals on the battery.
Do not wear metal objects on your arms and lean over the
battery.
Because the battery electrolyte is diluted sulfuric acid and is
corrosive, when handling the battery wear safety glasses and
rubber gloves to protect the eyes and hands.
WARNING
CAUTION
Make sure that you disconnect the battery cable first when you
Make sure that all electrical switches of the vehicle are OFF
before connecting the battery cables.
Make sure that you connect the battery cable before you
connect the battery cable .
01-18
01
Visual inspection
brush.
If cracks or defects are found on the battery, replace it since the
CAUTION
Make sure you grease the side of terminal A because it is easily
corroded.
13973
If bleed hole C of vent plug B is clogged, clean the hole.

C
C
13974

B Make sure that the battery electrolyte level is between UPPER and
LOWER.
If the level is below LOWER, remove vent plug B and fill the battery
with distilled water or battery replenisher to UPPER.
13975
Measurement of specific gravity

D
Blue : Good
13976
01-19
Charging
Although, as a rule, charging of the battery should be done
with the battery removed from the vehicle, if you have to
charge the battery while it is on the vehicle, make sure that
you stop the engine and disconnect the battery cable .
For the recommended charge time and current, see the
following table to avoid overcharging.
Upper limit
of fluid
Charge current (A) Charge time (H) temperature
(C {F})
Specific gravity of battery electrolyte
1.280 Value of 5-hour *Amount of

Good rating capacity discharge (Ah)
Normal
1.240 charge 1.2(to 1.5) 45
1.220 10 Charge {113}
1.200 current (A)
Charge
1.160 needed Value of 5-hour
Quick rating capacity
1.120 charge 0.5 55
1.5 {131}
1.080
Amount of
0 10 20 30 40 50 60 70 80 90 100 discharge (%)
Amount of discharge (%) * Amount of discharge (Ah)=5-hour rating capacity (Ah)
100
07789
Use the graph shown on the left to calculate the amount of
discharge (%).
If electrolyte level is low add distilled water to raise level.
The specific gravity of fully-charged battery electrolyte is
1.280 with the temperature at 20C {68F}.
DANGER
Do not let the battery electrolyte level rise and overflow
while charging the battery.
Keep unprotected lights away from the battery while
charging it or it might explode.
Be careful not to generate sparks while charging the
battery because its dangerous.
After charging the battery, tighten vent plug B, wash
away sulfuric acid from the battery using water, and dry
the surface.
01-20
01
Fuse
F18 to 34
F1 to 17
FH7
FH6
FH5
FH4
FH3
FH2
FH1
2
07998
1 Fuse box
CAUTION
If a fuse blows, make sure you identify and remedy the cause, then replace the fuse.
Make sure that you remove the terminal of the battery cable before removing high-current fuses FH1 to 7.
01-21

No.
FH3
FH4
Fuse box
Fuse Fuse Main load Capacity
Main load Capacity No.
No.
< Manual transmission >
F2 Headlamp, RH 15 A Inhibitor switch
F3 Stop lamp, horn 15 A < Automatic transmission >
F4 Turn signal lamp, pre-stroke control unit 15 A F19 Backup lamp 10 A
(Memory clear switch) F20 Meter cluster 10 A
F5 Fuel-cut motor 10 A F21 Wiper 10 A
F6 Cab lamp 10 A F22 Reserve power (MAIN) 10 A
F7 Reserve power (BATT) 10 A F23 Automatic transmission control unit 10 A
F8 F24 Automatic transmission control unit 10 A
F9 F25 Pre-stroke cut relay 20 A
F10 Automatic transmission control unit 15 A F26
F27 Exhaust brake 10 A
F11
F28
F12
F29
F13 * Cigarette lighter 15 A
F30 * Air-conditioner control 10 A
F14 Radio 10 A
F31 * Air-conditioner compressor 10 A
F15 Reserve power (ACC) 10 A
F32 * Condenser fan 15 A
F16
F33 Blower fan 25 A
F17 Fuel-cut relay 10 A
F34 Tail lamp 15 A
are installed.
NOTE
Fuses F4, F10 are also parts of the electric power circuit used to memorize the diagnostic codes that are
transmitted if the electrical controlling system (Pre-stroke control injection pump, automatic transmission)
malfunctions.
01-22
01
MEMO
01-23
LUBRICATION
Inspection interval

Every 40000 km/

Every 20000 km/
Every 10000 km/
Every 30000 km/
Every 50000 km/

24000 miles
12000 miles
18000 miles
30000 miles
6000 miles
2500 miles
1 E Engine oil replacement Engine oil ^ Gr 12
API classification, CD, CD/SF, CE, CE/SF or CF-4
40 to 5C {104 to 23F} SAE 30
15 to 15C {59 to 5F) SAE 20W-20
2 Manual transmission oil level Gear oil ^ Gr 22
API classification
Manual transmission oil
replacement GL-3 SAE 80 (General)
GL-3 SAE 90 (Warm region)
GL-4 SAE 90 (Tropical region)
Engine oil
Long period of high-speed driving
API classification CC
SAE 30 or SAE 40
3 Automatic transmission fluid level Automatic transmission fluid (DEXRON II type) ^ Gr 23
Automatic transmission fluid
10000 km/6000 miles
replacement
4 Transfer gear oil level Gear oil ^ Gr 24
< FG Model only > API classification
Transfer gear oil replacement GL-3 SAE 80 (General)
< FG Model only > GL-3 SAE 90 (Warm region)
Engine oil
Long period of high-speed driving
API classification CC
SAE 30 or SAE 40
5 Rear axle housing gear oil level Gear oil ^ Gr 27
Rear axle housing gear oil API classification GL-5
replacement Below 40C {104F} SAE 90
Over 40C {104F} SAE 140
Use SAE 140 when operating vehicle at high load, such
as continuous ascent on slopes and when the outside
temperature is 10C {50F} or more
< Limited slip differential only >
Limited slip differential oil
API classification
GL-5 SAE 90
6 Front axle housing gear oil level Gear oil ^ Gr 26B
< FG Model only > API classification GL-5
Front axle housing gear oil Below 40C {104F} SAE 90
replacement < FG Model only > Over 40C {104F} SAE 140
7 Hub bearing grease and oil Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 26, 26B
seal replacement 27
8 Front axle birfield joint grease Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 26B
replacement < FG Model only >
9 Front axle kingpin bearing grease Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 26B
replacement < FG Model only >
01-24
01
Inspection interval

Every 40000 km/

Every 20000 km/
Every 10000 km/
Every 30000 km/
Every 50000 km/

24000 miles
12000 miles
18000 miles
30000 miles
6000 miles
2500 miles
10 Front axle steering knuckle Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 26B
grease replacement
< FG Model only >
11 Brake fluid replacement Brake fluid ^ Gr 35
(SAE J1703f or FMVSS No. 116 DOT3)
12 Power steering fluid level Automatic transmission fluid ^ Gr 37
(DEXRON or DEXRON II type)
Power steering fluid replacement
13 Lubrication of Center bearing Bearing grease [NLGI No.3 (Li soap)] ^ Gr 25
propeller shaft
Universal joint, slip joint Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 25
Double cardin joint
< FG Model only >
14 Lubrication of rear suspension spring pin Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 34
15 Lubrication of kingpins Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 26

16 Lubrication of steering linkage ball joint Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 37
17 Lubrication of door hinge Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 42
01-25
LUBRICATION
Engine Oil

4 Oil pan drain plug 34 to 39 {25 to 29, 3.5 to 4.0}
[Inspection]
There are two methods for inspecting the engine oil level; using oil level
check switch 1, and using dipstick 2. Inspection using the oil level check
switch is a simple inspection method. For a more accurate inspection
use the dipstick.
Inspection using oil level check switch 1 (simple inspection)
Press oil level check switch 1 before starting the engine. Check the
oil level using the illuminated lamp.
B lamp (green) : Correct oil level
D lamp (red) : Low oil level
If the level is low, fill to correct level.
1
14216
Inspection using dipstick 2

3 2 Tilt the cab.
Pull out dipstick 2, wipe off the oil with a cloth.
Reinsert dipstick 2, then pull it out carefully.
Oil level is correct if there is oil sticking to the dipstick between the
two notches.
If the level is low, fill to correct level.
02332
01524
01-26
01
[Replenishment]
Clean the area surrounding oil filler cap 3 and prevent dust from
entering through the filler.
Remove oil filler cap 3 and top up with engine oil.
Wait five minutes before checking the oil level.
Replace filler cap 3.
WARNING
cause a fire.
Do not touch the engine while it is hot as it will burn you.
CAUTION
[Replacement]
-30 -20 -10 0 10 20 30 40 C
-22 -4 -14 32 50 68 86 104 F

Since engine oil greatly influences the performance, the life expectancy,
and the ability to start the engine, use only oil of the specified grade and
SAE 10W30
viscosity.
SAE 20W20 The chart illustrates the relationship between oil viscosity and the ambi-
SAE 30
ent air temperature.
SAE 40
SAE 15W40
02303
3
Remove oil filler cap 3.
Remove oil pan drain plug 4, and drain the oil. At the same time
replace the oil filter.
After reinstalling drain plug 4, slowly add engine oil through the oil
filler.
Using the dipstick, check the oil level after more than five minutes
have passed.
02333 Start the engine and let it idle. When the oil has reached all parts, stop
the engine. Let 30 minutes pass before checking the oil level again.
4 01205
01-27
LUBRICATION
Manual Transmission Gear Oil

1 Inspection plug 6915 {5111, 71.5}
2 Drain plug 6915 {5111, 71.5}
- Sealant
Location Points of application Specified sealant Quantity
1 Thread area of inspection plug THREEBOND 1105D As required
2 Thread area of drain plug THREEBOND 1105D As required
WARNING
The engine is hot immediately after the vehicle has stopped, so
take care not to burn yourself.
[Inspection and replenishment]

Remove inspection plug 1 and check whether the oil level is up to the
edge of the entrance.
If the level is low, add oil through the inspection plug hole until the
level comes up to the edge of the entrance.
1 2 02335 [Replacement]
Drain the oil after removing inspection plug 1 and drain plug 2.
Remove any metal particles sticking to the magnetic part of drain plug
2 before reinstalling the plug.
Add oil through the inspection plug hole until the level comes up to the
Insert inspection plug 1.
02336
01-28
01
MEMO
01-29
LUBRICATION
Automatic Transmission Fluid

3 Drain plug 29 to 39 {22 to 29, 3 to 4}

1 Park the vehicle on level ground, make sure that the parking brake is
fully activated and chock the wheels to keep them from rolling.
2
Start the engine and let it idle. To fill the hydraulic circuit with auto-
matic transmission fluid, slowly shift the range selector lever once
through the P to L ranges and finally shift into the N range.
While the engine is still idling, pull out dipstick 1 and wipe off the fluid
C D sticking to it. Reinsert the dipstick, then pull it out again and check the
fluid level.
A B If the fluid level is inspected right after the engine is started and the
07500 fluid temperature is still low (4015C {10427F}) the level should be
within area C marked COLD on dipstick 1 as illustrated in A.
If the fluid level is inspected after the vehicle has been driven and the
fluid temperature is high (6515C {14927F}) the level should be
within area D marked HOT on dipstick 1 as illustrated in B.
WARNING
Take care during the inspection because the engine will be run-
ning. Take sufficient care to avoid burns or injuries resulting
from contact with moving parts.
CAUTION
Be sure to wipe off the dust from the safety cap and the upper
part of filler tube 2 before you pull out dipstick 1.
NOTE
Make sure the vehicle is parked on level ground when you are
checking the fluid level.
Make sure the range selector lever is in the N range and the
engine is idling when you are checking the fluid level. When the
engine is at standstill, the fluid level appears higher than it
actually is.
To ensure the fluid is correct, reinspect the fluid level after an
actual drive.
If the fluid level is low, top it up to the specified level by supplying

automatic transmission fluid (DEXRON II type) through filler tube 2.
07821
01-30
01
[Replacement]
Place a container under the oil pan, remove drain plug 3 in the front of
the oil pan and drain the fluid.
WARNING
Take care because the automatic transmission fluid temperature
immediately after the engine has stopped is very high. To avoid
scalds, wait until a safe temperature has been reached before
3
draining the fluid.
07820
NOTE
The fluid will drain faster if the engine is first run to raise the fluid
temperature.
The fluid cannot be drained from the hydraulic circuit, the torque
converter or the oil cooler.
Reinstall the gasket, and oil pan drain plug 3.

Add automatic transmission fluid (DEXRON II type) through filler tube
2.
CAUTION
Make sure that dirt and foreign particles do not become mixed in
with the fluid when it is added.
2 Shift the range selector lever into the N range, start the engine and let
it idle for at least two minutes.
07821 After shifting the lever through all ranges once, shift it back into N.
CAUTION
To prevent burning out the interior of the automatic transmission
assembly, make sure that the engine is not allowed to race when
you do the above.
Supply the fluid until the fluid level is at the lower limit of the specified
area on dipstick 1. Next, check the fluid level to make sure it is within
the specified limit.
NOTE
Determining the fluid level immediately after supplying the fluid
might be difficult due to the fluid stuck in the inside of the filler
tube. Therefore, check the fluid level a few times between inter-
vals.
If the fluid is overfilled, it will overflow and can be mistaken for
leakage.
Let the engine idle and, while paying attention to the fluid level,
pour in the fluid slowly.
01-31
LUBRICATION
Transfer Gear Oil < FG Model only >
2 Drain plug 6915 {5111, 71.5}
- Sealant

1 WARNING
The oil temperature is high immediately after the vehicle has
stopped, so take care not to scald yourself.
Remove inspection plug 1, check the oil level and make sure it is up to
the edge of the entrance.
2 If the oil level is low, add oil through the inspection plug hole until the
27425 level comes up to the edge of the entrance.
[Replacement]
Supply oil through the inspection plug hole until the level comes up to
Reinstall inspection plug 1.
27426
01-32
01
Front Axle Gear Oil < FG Model only > and Rear Axle Gear Oil
1 Inspection plug 98 to 115 {72 to 87, 10 to 12}
< FG : Front axle> [Inspection and replenishment]

WARNING
1
2
If the oil level is low, add oil through the inspection plug hole until the
< Rear axle > level comes up to the edge of the entrance.
27424
[Replacement]
1 the edge of the entrance.
2
02339
02340
01-33
LUBRICATION
Power Steering Fluid

- Fluid
Location Points of application Specified fluid Quantity
1 Power steering oil tank Automatic transmission fluid Between
(DEXRON or DEXRON II type) MIN and MAX
on filler cap
dipstick

2
Straighten the front wheels and stop the engine.
Tilt the cab.
3 Remove filler cap 2 of power steering oil tank 1 by turning the filler cap
counterclockwise.
Wipe off the fluid sticking to dipstick 3 on filler cap 2. Replace the filler
cap.
NOTE
1 Check the fluid level without screwing on filler cap 2.
02341
Carefully lift up filler cap 2 and check the fluid sticking to dipstick 3 to
make sure that the fluid is at a point between the MAX and MIN
levels. If the fluid position does not reach the MIN level, add fluid.
After inspection install filler cap 2 by turning it clockwise.
WARNING
Close filler cap 2 firmly; otherwise the fluid may leak and could
catch fire. Also wipe up spilled fluid.
02342
CAUTION
If the fluid level is far below the recommended range, the fluid
may be leaking.
01-34
01
[Replacement]
Drainage
Jack up the front wheels.
Release pressure tube 4 and return tube 5 connected to the power
steering booster.
Turn the steering wheel fully left and right repeatedly, and drain the
fluid from the power steering booster.
After draining the fluid, tighten pressure tube 4 and return tube 5 at
specified torque.
08583
[Fluid supply]
1 2
Pour fluid into power steering oil tank 1 up to the inner port of strainer
6
6.
With the engine stopped, jack up the front wheels and turn the steer-
ing wheel fully left and right repeatedly. When the fluid level has
dropped, add fluid to maintain the fluid level within range A.
A
NOTE
Check the fluid level without screwing on filler cap 2.
07236
Start the engine and letting it idle, turn the steering wheel fully left and
right repeatedly. When the fluid level has dropped, add fluid to main-
tain the fluid level within range A. Repeat these steps until the fluid
level does not drop.
If there is an abnormal noise, air is still in the system. Turn the steering
wheel several times to raise the fluid temperature to approximately
60 to 80C {140 to 176F}, then stop the engine and wait for approxi-
mately five minutes.
Lower the front wheels and turn the steering wheel several times. If
there is no noise, bleeding is completed.
When bleeding is finished, check fluid level of power steering oil tank
1, and pipe and hose connections for fluid leakage.
01-35
LUBRICATION
Brake Fluid

1 Air bleeder Front disc brake < FE > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
Front wheel cylinder < FG > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
Rear wheel cylinder < FE639, FG639 > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
Rear disc brake < FE649 > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
Bypass valve 8.8 to 13 {6.5 to 9.4, 0.9 to 1.3}
- Fluid
Fluid tank Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)
WARNING
The clutch fluid system and the brake fluid system use the fluid
tank in common. Therefore, replacement and air bleeding of the
clutch fluid must be carried out simultaneously with that of the
brake fluid. ^ Gr 21
You must use new brake fluid (SAE J1703f or FMVSS No. 116
DOT3). Do not add different quality fluid or mineral oil (gas oil,
engine oil, gear oil, automatic transmission fluid, etc.) to the
clutch system, because this will cause the rubber parts of the
07623 clutch system and brake system to swell, resulting in faulty
clutch operation, as well as ineffective braking and brake drag-
ging.
Do not allow foreign particles or water to become mixed into the
brake fluid when refilling, because this will result in ineffective
clutch and brake operations.
If you use a container for adding brake fluid, keep it solely for
that purpose.
CAUTION
Be careful not to splash brake fluid on related parts as this could
damage the paintwork.
Be sure to wipe off brake fluid immediately if you splash it on the
paintwork.
NOTE
Supply brake fluid to maintain the MAX level of the fluid tank
always.

Inspect the level of the brake fluid in the fluid tank. It should be between
the MAX and MIN levels. If it is below the MIN level, lift up the lid and
remove the cap from the fluid tank, then add specified brake fluid until the
level reaches the MAX level. Do not fill above the MAX level.
01-36
01
< FE : Front < FG: Front [Replacement]
disc brake > drum brake > Start the engine and let it idle until you complete brake fluid replace-
ment.
Attach vinyl pipe A to the front disc brake < FE >, the front drum brake
< FG >, the rear drum brake < FE639, FG639 >, the rear disc brake
< FE649 > and the bypass valve.
1 Place the free end of vinyl pipe A into container B.
1 A
A
B B
12934 27427
< Rear drum brake > < Rear disc brake >
A 1
B
B
< Bypass valve > 06534
1 A
1 B
12935
Loosen air bleeders 1 and depress the brake pedal several times to
drain brake fluid completely.
Maintaining a supply of new brake fluid up to the MAX level of the
fluid tank, depress the brake pedal repeatedly until the old brake fluid
of the brake system is replaced with new fluid. After you complete the
work, tighten each air bleeder 1 at specified torque.
1 NOTE
You can tell when the brake fluid has been completely replaced
12936 because the fluid coming out will be a different color.
Carry out air bleeding of the brake system.
07623
01-37
LUBRICATION
< Front disc < FG: Front [Air bleeding]
brake > drum brake > Start the engine and let it idle until you complete air bleeding of the
brake system.
Attach vinyl pipe A to the front disc brake < FE >, the front drum brake
< FG >, the rear drum brake < FE639, FG639 >, the rear disc brake
< FE649 > and the bypass valve.
1 Place the free end of vinyl pipe A into container B, then bleed air from
the brake system as follows:
1 A
A < Front brake system >
B B FG639 FE639, FE649
12937 27427 Drum brake, RH Disc brake, RH

< Rear drum barke > < Rear disc brake >
Drum brake, LH Disc brake, LH
1
< Rear brake system >
FE639, FG639 FE649
A 1
Drum brake, RH Disc brake, RH

A
Drum brake, LH Disc brake, LH
B
B < Bypass valve system >
08834 Bypass valve
< Bypass valve >
1 A
1
B
12938
Depress the brake pedal slowly several times, and with the brake
pedal depressed, loosen air bleeder 1 to discharge air together with
the brake fluid. After closing the air bleeder, release the brake pedal.
Repeat the above operation until air bubbles are no longer present in
the brake fluid discharged from air bleeder 1.
When the discharged fluid is free of air bubbles, tighten air bleeder 1
at specified torque.
1 Make sure that the brake fluid level is at the MAX level of the brake
fluid tank, and depress the brake pedal several times to ensure that
12936 the brake fluid does not leak from anywhere. Then, conduct a brake
test.
01-38
01
MEMO
01-39
LUBRICATION
Greasing Various Areas of Chassis
Carefully clean away all dust and dirt from the grease nipples, and use the specified type of grease. The areas to be
greased are shown in the following illustration.
< FE >
02328
02329 01516 01517 02330
02331 01198 01199 01200
1 Steering shaft 5 Rear spring pin rear (left and right, 4 points)
2 Drag link front 6 Kingpin bearing (left and right, 4 points)
3 Drag link rear 7 Propeller shaft universal joints-all
4 Rear spring pin front (left and right, 2 points) 8 Propeller shaft slip joint
01-40
01
< FG >
27428
02329 27429 27430 27431
27432 27433 27434 27435
2 Drag link front 6 Tie rod end
3 Drag link rear 7 Propeller shaft universal joints-all
4 Rear spring pin front (left 8 Double cardin joint, propeller shaft slip joint, propeller
and right, 2 points) shaft universal joint
27436
9 Propeller shaft slip joint
Door hinge
01518
01-41
Group 01
Maintenance Schedule
Table of Contents
BACK
HOME
Pub No. TWSE9501-01

01
MAINTENANCE SCHEDULE
HOW TO READ THE MAINTENANCE SCHEDULE TABLES............... 2
MAINTENANCE SCHEDULE TABLES .................................................. 3
MAINTENANCE OPERATIONS ............................................................. 5

Replacement of Oil Filter ................................................................................... 5
Replacement of Fuel Filter ................................................................................. 6
Draining of Water Separator Condensation ..................................................... 7
Cleaning of Fuel Feed Pump Gauze Filter ........................................................ 7
Bleeding of Air from Fuel Line .......................................................................... 8
Adjustment of V-Belt Tension ........................................................................... 9
Cleaning and Replacement of Air Cleaner Element ...................................... 11
Inspection of Clutch Pedal Free Play .............................................................. 12
Tire ..................................................................................................................... 13
Inspection of Brake Lining Thickness < Rear Drum Brake > ........................ 18
Battery ............................................................................................................... 18
Fuse ................................................................................................................... 21
LUBRICATION ...................................................................................... 24
Engine Oil .......................................................................................................... 25
Manual Transmission Gear Oil ........................................................................ 27
Automatic Transmission Fluid ........................................................................ 28
Rear Axle Gear Oil ............................................................................................ 30
Power Steering Fluid ........................................................................................ 31
Brake Fluid ........................................................................................................ 33
Greasing Various Areas of Chassis ................................................................ 36
01-1
Example Table : E : Exhaust emission items
Time of inspection and maintenance (2)
Inspection interval

Inspection and
Every 250000 km/

Working procedures (3) Remarks (4)
Every 20000 km/

Every 10000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance (1)
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
6000 miles
2500 miles
ENGINE
clearance
N
N
6 E Fuel feed pump filter Every 40000 km/24000 miles or 24 months Clean gauze filter inside connector with diesel fuel ^ Gr 13
7. E Fuel filter replacement Every 20000 km/12000 miles or 12 months Replace fuel filter ^ Gr 13

(2) The periods between inspection and service are based on the assumption that the vehicle will be driven approximately
Inspections which must be made are indicated by an or by the appropriate period between servicing.
nance item.
01-2
Inspection interval

Inspection and
Every 250000 km/

Every 20000 km/

Every 10000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
6000 miles
2500 miles
ENGINE
clearance
N
N
6 E Fuel feed pump filter Every 40000 km/24000 miles or 24 months Clean gauze filter inside connector with gas oil
7 E Fuel filter replacement Every 20000 km/12000 miles or 12 months Replace fuel filter ^ Gr 13
8 E Fuel line Every 20000 km/12000 miles or 12 months Inspect fuel tank, cap and lines for damage causing
leakage
9 E V-belts tension and Every 10000 km/6000 miles or 12 months Inspect V-belts for cracks, wear and tension ^ Gr 14
N damage
10 E Cooling system Check radiator and radiator cap for sealing
performance and mounting condition. ^ Gr 14
Inspect hoses for looseness, deterioration, damage
causing leakage.
Remove dust and foreign deposits from radiator and
intercooler front
11 Coolant replacement Every 24 months Replace coolant ^ Gr 14
12 E Turbocharger rotor play Check turbocharger rotor play ^ Gr 15
13 Air cleaner element Clean air cleaner element by blowing clean compressed ^ Gr 15
air through it
14 E Air cleaner element Replace air cleaner element ^ Gr 15
N replacement
15 E Exhaust system Inspect exhaust system for damage, corrosion and ^ Gr 15
N loose connection causing leakage
POWER TRAIN
16 Clutch pedal and clutch disc Check pedal for free play. ^ Gr 21
wear Check clutch disc wear through inspection hole
17 Propeller shaft flange torque Check flange yoke bolts for looseness and universal joint ^ Gr 25
and universal joint looseness for play.
10000 km or 6000 miles
18 Propeller shaft center bearing Check center bearing if traces of grease flowing out are ^ Gr 25
evident.
Check center bearing for wear, damage and play
Check center bearing for traces of grease flow.
01-3
MAINTENANCE SCHEDULE TABLES
Inspection interval

Inspection and
Every 250000 km/

Every 20000 km/

Every 10000 km/
Every 30000 km/
Every 40000 km/
Every 50000 km/
Every 90000 km/

maintenance
150000 miles
12000 miles
18000 miles
24000 miles
30000 miles
54000 miles
6000 miles
2500 miles
FRONT AND REAR AXLE

19 Wheel hub bearing Check wheel hub bearing for play ^ Gr 26, 27
20 Wheel hub bearing hub seals Replace wheel hub bearing hub seals ^ Gr 26, 27
replacement
21 Wheel and tire Check disc wheel for corrosion, deformation and cracks. ^ Gr 31
Measure inflation pressure with tire gauge.
Check tire tread and side wall for cracks and damage.
Measure tire tread groove depth to make sure it is deep
enough.
Check tire tread for uneven wear, stepped wear and
other abnormal wear.
Rotate tires if there is a difference in the amount of wear
of each tire
22 Retightening wheel nuts Check wheel nuts for looseness. ^ Gr 31
Check at the first 1000 km/600 miles after changing a
wheel
SUSPENSION SYSTEM
23 Retightening U-bolts Check U-bolt nuts for looseness. ^ Gr 33, 34
Check at the first 1000 km/600 miles after removing
and retightening U-bolt nuts
BRAKING SYSTEM
24 Disc brake pad and disc Check disc brake pad and disc for damage and wear ^ Gr 35
25 Brake lining Check lining for wear through inspection hole ^ Gr 35
26 Brake drum Disassemble and check drum for wear, cracks and ^ Gr 35
damage
27 Looseness, play and damage Inspect brake lines and hoses for looseness, play and ^ Gr 35
of brake system parts damage.
Inspect wheel cylinder and brake master cylinder for
looseness, play and damage
STEERING SYSTEM
28 Steering system Check steering system for looseness, steering wheel ^ Gr 37
play and operating condition.
Inspect for fluid leakage, booster and oil pump function
01-4
MAINTENANCE OPERATIONS 01
This section explains simple maintenance procedures. See the relevant Group in this manual for further details.

- Lubricant
2 Inside oil filter Engine oil Approximately
1 L {1.1 qts}
Gasket area of oil filter with thin application Engine oil As required

101.2
{3.98}
06478
WARNING
cause a fire.
CAUTION
[Removal]
06446
[Installation]
2.
1
Apply engine oil thinly and evenly to gasket area A of oil filter 2.
Screw oil filter 2 into oil cooler body 1 until gasket area A sits on the
A
of a turn.
from gasket area A.
2 Check the oil level and if it is low, top it up.
07382
01-5
Replacement of Fuel Filter
- Lubricant

90.2 {3.55}
01882
WARNING
Wipe up any gas oil that has been spilled because it can cause a
fire.
Do not use an unsuitable filter because it can cause a fire.
[Removal]
06872
[Installation]
1 Install by tightening three quarters to one full turn after contact surface
A of fuel filter head 1 makes contact with gasket B of fuel filter 2. Be
B A B
A sure to tighten by hand.
After installation, run the engine and check for fuel leakage.
06874
01-6
01
Draining of Water Separator Condensation

2 Drain plug 2.9 to 3.9 {2.2 to 2.9, 0.3 to 0.4}
Visually inspect the water separator before driving.

When float 1 reaches red line A, drain the condensation as follows:
Loosen drain plug 2 and drain out the condensation.
When float 1 has dropped to the bottom, tighten drain plug 2.
Carefully wipe the water separator and the surrounding area.
A A
1
1
2 2
02348
Cleaning of Fuel Feed Pump Gauze Filter

2 Eye bolt 25 to 29 {18 to 22, 2.5 to 3}
WARNING
fire.
Remove eye bolt 2 on the inlet side of fuel feed pump 1.

2 3 Remove gauze filter 3 from eye bolt 2.
Clean gauze filter 3 with gas oil.
Follow the removal sequence in reverse and reinstall gauze filter 3.
Install eye bolt 2 in the fuel feed pump.
Bleed the air from the fuel line.
Start the engine and check for fuel leakage.
1
14212
01-7
Bleeding of Air from Fuel Line

WARNING
fire.
Turn the top of priming pump 1 of the injection pump counterclockwise

2 and pull it up so the top protrudes.
Loosen air vent plug 2 of the fuel filter and move the top part of priming
pump 1 up and down.
Move priming pump 1 up and down repeatedly until air bubbles are no
longer present in the fuel drained from air vent plug 2.
When the fuel being drained is free of air bubbles, tighten air vent plug
2.
1 After moving priming pump 1 up and down another five or six times,
push the top down and turn clockwise to drive it in fully.
After bleeding the air, carefully wipe up spilled fuel and start the
02375 engine.
01-8
01
Adjustment of V-Belt Tension
Newly installed V-belts can stretch during their initial running-in period.
To prevent this from becoming a problem, run the engine for several
minutes after installing the V-belt, then readjust. Perform this cycle
several times.
WARNING
You must take special precautions to prevent the engine from
rotating while a V-belt is being inspected or adjusted.
CAUTION
Make sure that you turn off the engine before attempting to
inspect or adjust the V-belts.
Make sure that you fasten all bolts and nuts securely after adjust-
ing the V-belts. Remember that too much tension can damage the
V-belts and bearings.
Do not grease V-belts. This causes them to slip, which reduce
service life.

1, 2 V-belt tension (Each one) Fan 12 to 16 {0.47 to 0.63} Adjust
Air-conditioner 16 to 20 {0.63 to 0.79}
0 Special tools
03612
[Inspection]
D Measure the extent of flex A when the center of V-belts 1, 2 as illustrated
1
2 is depressed with a force of 98 Nm {72 lbf.ft, 10 kgfm}.
C
B : Alternator pulley
A C : Water pump pulley
D : Cooler compressor pulley (Air-conditioner)
B A E : Tension pulley
E F : Crankshaft pulley
F 11518
01-9
G Use of special tool belt tension gauge
Set upper O-ring G of 0 belt tension gauge to 98 Nm {72 lbf.ft,
10 kgfm} (push load) on graduation H.
H
Set lower O-ring J of 0 belt tension gauge to graduation K (maximum
0
flex of belt).
K 03613
Place 0 belt tension gauge at the center of V-belts 1, 2 perpendicu-

G larly as illustrated and push top L all the way down until upper O-ring
L
G hits upper edge M.
M
1, 2
03614

A measured value deviates from the standard value, adjust as follows:
1, 2
03615
N [Adjustment]
2 (1) Adjustment of tension of V-belt for fan

Loosen alternator mounting bolts N (two points), and adjust the
P After adjustment, tighten bolts N, P securely.
CAUTION
N 06370
between them.
Be careful not to let oil stick to V-belts 2. If oil gets onto the
belts, it causes slipping, resulting in overheating and insuffi-
cient battery charging.
(2) Adjustment of tension of V-belt for air-conditioner

V-belt 1 moving adjusting bolt R.
After adjustment, tighten mounting nut Q securely.
CAUTION
Bear in mind that excessive tension of V-belt 1 might damage
the belt and bearings that engage with the V-belt.
Be careful not to let oil stick to V-belt 1. If oil gets onto the belt,
Q R it causes slipping, resulting in poor performance of the air
1 05810 conditioner.
01-10
01
Cleaning and Replacement of Air Cleaner Element
[Removal]
Unfasten clamp 1 and remove air cleaner cap 2.
4 Remove air cleaner element 3.
A 3 [Installation]
Install by aligning alignment marks A of air cleaner cap case 4 and air
cleaner cap 2.
1
2
13152
[Cleaning]
3 Blow compressed air of 685 kPa {100 lbf/in2, 7 kgf/cm2} or less through
CAUTION
the outside.
13150
[Inspection]
3
element.
NOTE
13151 ment interval.
01-11
Inspection of Clutch Pedal Free Play

or replace
[Confirmation]
Push clutch pedal 1 with your hand and measure the amount of move-
ment A (free play) until you meet resistance. If the measured value does
not conform to the standard value, adjust by stroke of clutch power
cylinder push rod or replace the clutch disc.
A: 36 to 53 mm
1 {1.42 to 2.09 in.}
03480
[Clutch operation]
Check for unusual noises when clutch pedal 1 is pressed while the
engine is idling, and also for abnormally heavy clutch operation. Also
check to be certain that it is not difficult to shift the vehicle into first and
reverse gears.
Gradually release clutch pedal 1 to set the vehicle in motion.
Check to be sure there is no slippage, and that the clutch engages
smoothly.
01-12
01
Tire

1 Depth of tire tread grooves 1.6 {0.063} Replace

2 Wheel nut 49049 {36036, 505}
Air pressure
Tire air pressure should be checked before the vehicle is driven, while
the tires are still cool.

Tire size
FE639 215/85R16(D) 450 {65, 4.50} 450 {65, 4.50}
(GVWR : 11600 lb, 5260 kg)
00592
FE639 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50}
(GVWR : 13500 lb, 6120 kg)
FE649 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50}
(GVWR : 14500 lb, 6580 kg)
CAUTION
Make certain that there is no difference in the air pressure be-
tween the inner and outer rear tires.
Make certain you use valve caps on the air valves.
It is not necessary to increase the air pressure for high-speed
driving.
01166
Checking tread depth
Check all around the tire treads to make sure that the depth of the
tread grooves is above the wear limit.
If the tread grooves are not deep enough, slip sign A appears at the
position of the mark, where the tread groove has worn away.
1
02353
WARNING
If the depth of the tread grooves is not adequate, the tires will slip
on wet roads and present a hazard. Such tires are also extremely
dangerous because they are more susceptible to hydroplaning
when the vehicle is running at high speeds in the rain. Such tires
must be replaced with new ones as soon as possible.
1
02354
01-13
Checking for cracks, damage, and objects embedded in the treads
Check the tire treads and walls for cracks and damage.
Check tire treads for uneven wear or other abnormal wear.
Check if metal objects or nails have penetrated the tires.
Check for stones embedded between double tires.
WARNING
Badly damaged or worn tires are extremely dangerous, because
they can be punctured more easily when the vehicle is running,
01170
they must be replaced with new ones as soon as possible.
Removing tires
Jacking up point
For front wheels : Point A under the leaf spring in front of the front
< Front wheel >
axle
For rear wheels : Point B under the rear axle housing
A
02355
< Rear wheel >
B 02356
WARNING
The jack should be placed on flat, solid ground, and should not
be used to raise the vehicle higher than necessary.
Do not use the jack at vehicle locations other than those illus-
trated.
Keep in mind the danger of a slipping jack. Never crawl under the
vehicle while the jack is in use or rock the vehicle. Also, do not
start the engine while the vehicle is jacked up.
To increase safety, use supports for the vehicle when it is neces-
sary to leave it jacked up for long periods.
Chock both the tire to be removed and the tire diagonally oppo-
site to it so that they will not rotate when you are removing the
tire.
01-14
01
2 Loosen wheel nuts 2 slightly. The wheel nuts for right tires C have
right-hand threads R, and the wheel nuts for left tires D have left-
C hand threads L.
WARNING
Make certain that wheel nut wrench E is fully engaged, all the way
to the back of nuts 2. If it is not, it could slip.
D CAUTION
Only loosen wheel nuts 2 slightly. Do not remove them.
E Jack up the vehicle carefully, until the tire is slightly off the ground.
14213
Remove wheel nuts 2, then remove the tire.
When working on the double tires at the rear of the vehicle, first
remove the outside tire, then lower the vehicle and loosen the nuts on
the inside tire. After doing this, jack the vehicle back up and remove
the tire.
J 7 Mounting tires
M G To prevent wheel nuts 2, 4 and hub bolt 6 from becoming loose and to
F
prevent mounted parts (tire assemblies 3, 5 and hub 7) from being
L damaged, remove rust, dust, additional coatings of paint, and foreign
2 3 6 H particles from the following areas:
J 7
M K G
F F: Hub bolt thread area
G: Wheel mounting surface of hub
H H: Wheel alignment area of hub
2 4 L 35 11388 J: Disc wheel mating surface
6
K: Disc wheel nut mounting surface
L: Wheel nut thread area
M: Wheel nut spherical area
Put on the double rear tires as follows:

After mounting inner tire 5 and fully tightening inner wheel nuts 4,
2 jack the vehicle up and mount on outer tire 3, then tighten outer
wheel nuts 2.
Even if only outside tire 3 is to be changed, do not mount it until
4 inner wheel nuts 4 have been fastened at the specified torque.
3 Slide the air valves on the inside and outside tires down when
2 mounting the tires.
4 WARNING
5 If the threads are scored, or the disc wheel is deformed or
cracked, change bolts 6, nuts 2, 4 and disc. Driving the truck
before correcting such problems can cause the tire in question to
00626 come loose, which could be the source of major accidents.
CAUTION
Check hub bolt 6 threads carefully for scratches before putting
the tire on.
Place the tapered end of wheel nuts 2, 4 towards the disc wheel and
fasten temporarily. Center so that there is no eccentricity between
bolts 6 and the disc wheel bolt holes.
Lower the vehicle.
01-15
Tighten the nuts in the order as illustrated, tightening each nut two or
< FE639 > 4
three times. To finish, tighten each nut at the specified torque.
2 1 WARNING
Always use the specified torque when tightening the wheel nuts.
If the wheel nuts are not tightened properly, the wheels could
come loose while the vehicle is being driven, which could result
in life threatening accidents or the truck being disabled.
5 3
Do not coat the threads with grease when tightening the nuts.
This could result in over-tightening force, which could be dan-
gerous.
< FE649 > 3
1 CAUTION
5
Over-tightening the wheel nuts can damage them.
2 6
4 01246
Checking the wheel nuts for looseness

The wheel nuts should be checked for looseness every 10000 km
(6000 miles). All nuts should be tightened at the specified torque.
Check the double rear tires for looseness as follows:
2
1 1 Loosen outer wheel nuts 2.

2 Tighten inner wheel nuts 4 at specified torque.
3 Tighten outer wheel nuts 2 at specified torque.
2
4 CAUTION
3 If outer wheel nuts 2 are tightened without first being loosened, it
might not be possible to tighten them at the specified torque.
2 14224
01-16
01
Tire rotation
Tires wear differently, according to the location where they are mounted.
To make this wear uniform and prolong the life of your tires, they should
be rotated every 10000 km (6000 miles) in the rotation order shown
below:
When the tread patterns for all tires are identical:
< Front > < Rear >

02358
When the tread patterns are different for the front and rear tires:
< Front > < Rear >

02359
CAUTION
Always adjust air pressure after running-in new tires.
When using tires of different tread patterns, use rib-type patterns
for the front tires and traction type patterns for the rear tires.
Avoid using both radial and biased tires on the same vehicle.
01-17
Inspection of Brake Lining Thickness < Rear Drum Brake >

2 Thickness of brake lining 4 {0.16} Replace
(Side shoulder
means wear
limit)
NOTE
A
Remove cover 1 from the packing plate.
2 Inspect through check hole A whether brake lining 2 is worn to the
point of side shoulder B of the brake lining (the limit).
2
1 the same axle as a unit.
After inspection, be sure to reinstall cover 1.
B 14361
Battery
DANGER
Since flammable hydrogen gas is generated by the battery, be
sure to obey the following warnings :
Do not wear metal objects on your arms and lean over the
battery.
Because the battery electrolyte is diluted sulfuric acid and is
corrosive, when handling the battery wear safety glasses and
rubber gloves to protect the eyes and hands.
WARNING
CAUTION
Make sure that you disconnect the battery cable first when you
Make sure that all electrical switches of the vehicle are OFF
before connecting the battery cables.
Make sure that you connect the battery cable before you
connect the battery cable .
01-18
01
Visual inspection
brush.
If cracks or defects are found on the battery , replace it since the
CAUTION
corroded.
13973
If bleed hole C of vent plug B is clogged, clean the hole.

C
C
13974

LOWER.
13975
Measurement of specific gravity

D
Blue : Good
13976
01-19
Charging
Although, as a rule, charging of the battery should be done
you stop the engine and disconnect the battery cable .
Upper limit
of fluid
(C {F})

Normal
1.240 charge 1.2(to 1.5) 45
1.220 10 Charge
{113} current (A)
1.200
Charge
1.120 charge 0.5 55
1.5
1.080 {131}
Amount of
0 10 20 30 40 50 60 70 80 90 100 discharge (%)
100
07789
discharge (%).
Use diluted sulfuric acid, made up of sulfuric acid and
refined or distilled water, as the battery electrolyte.
DANGER
Keep naked lights away from the battery while charging
it or it might explode.
the surface.
01-20
01
Fuse
F18 to 34
F1 to 17
FH7
FH6
FH5
FH4
FH3
FH2
FH1
2
07998
1 Fuse box
CAUTION
Make sure that you remove the terminal of the battery cable before removing high-current fuses FH1 to 7.
01-21

No.
FH3
FH4
Fuse box
Fuse Fuse Main load Capacity
Main load Capacity No.
No.
F2 Headlamp, RH 15 A Inhibitor switch
F3 Stop lamp, horn 15 A < Automatic transmission >
F4 Turn signal lamp, pre-stroke control unit 15 A F19 Backup lamp 10 A
(Memory clear switch) F20 Meter cluster 10 A
F5 Fuel-cut motor 10 A F21 Wiper 10 A
F6 Cab lamp 10 A F22 Reserve power (MAIN) 10 A
F7 Reserve power (BATT) 10 A F23 Automatic transmission control unit 10 A
F8 F24 Automatic transmission control unit 10 A
F9 F25 Pre-stroke cut relay 20 A
F10 Automatic transmission control unit 15 A F26
F27 Exhaust brake 10 A
F11
F28
F12
F29
F13 * Cigarette lighter 15 A
F30 * Air-conditioner control 10 A
F14 Radio 10 A
F31 * Air-conditioner compressor 10 A
F15 Reserve power (ACC) 10 A
F32 * Condenser fan 15 A
F16
F33 Blower fan 25 A
F17 Fuel-cut relay 10 A
F34 Tail lamp 15 A
are installed.
NOTE
malfunctions.
01-22
01
MEMO
01-23
LUBRICATION
Inspection interval

Every 40000 km/

Every 20000 km/
Every 10000 km/
Every 30000 km/
Every 50000 km/

24000 miles
12000 miles
18000 miles
30000 miles
6000 miles
2500 miles
1 E Engine oil replacement Engine oil ^ Gr 12
API classification, CD, CD/SF, CE, CE/SF or CF-4
40 to 5C {104 to 23F} SAE 30
15 to 15C {59 to 5F) SAE 20W-20
2 Manual transmission oil level Gear oil ^ Gr 22
API classification
Manual transmission oil
replacement GL-3 SAE 80 (General)
GL-3 SAE 90 (Warm region)
3 Automatic transmission fluid level Automatic transmission fluid (DEXRON II type) ^ Gr 23
10000 km/6000 miles
replacement
4 Rear axle housing gear oil level Gear oil ^ Gr 27
Rear axle housing gear oil API classification GL-5
replacement Below 40C {104F} SAE 90
Over 40C {104F} SAE 140
5 Hub bearing grease and oil Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 26, 27
seal replacement
6 Brake fluid replacement Brake fluid ^ Gr 35
7 Power steering fluid level Automatic transmission fluid ^ Gr 37
(DEXRON or DEXRON II type)
Power steering fluid replacement
8 Lubrication of Center bearing Bearing grease [NLGI No.3 (Li soap)] ^ Gr 25
propeller shaft
Universal joint, slip joint Wheel bearing grease [NLGI No.2 (Li soap)] ^ Gr 25
9 Lubrication of rear suspension spring pin Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 34
10 Lubrication of kingpins Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 26

11 Lubrication of steering linkage ball joint Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 37
12 Lubrication of door hinge Chassis grease [NLGI No.1 (Ca soap)] ^ Gr 42
01-24
01
Engine Oil

[Inspection]
There are two methods for inspecting the engine oil level; using oil level
check switch 1, and using dipstick 2. Inspection using the oil level check
switch is a simple inspection method. For a more accurate inspection
use the dipstick.
Inspection using oil level check switch 1 (simple inspection)
Press oil level check switch 1 before starting the engine. Check the
oil level using the illuminated lamp.
B lamp (green) : Correct oil level
D lamp (red) : Low oil level
If the level is low, top it up.
1
14216
Inspection using dipstick 2

3 2 Tilt the cab.
Pull out dipstick 2, wipe off the oil with a cloth.
Reinsert dipstick 2, then pull it out carefully.
Oil level is correct if there is oil sticking to the dipstick between the
two notches.
If the level is low, top it up.
02332
01524
01-25
LUBRICATION
[Replenishment]
Remove oil filler cap 3 and top up with engine oil.
Wait five minutes before checking the oil level.
Replace filler cap 3.
WARNING
cause a fire.
Do not touch the engine while it is hot as it will burn you.
CAUTION
[Replacement]
-30 -20 -10 0 10 20 30 40 C
-22 -4 -14 32 50 68 86 104 F

Since engine oil greatly influences the performance, the life expectancy,
and the ability to start the engine, use only oil of the specified grade and
SAE 10W30
viscosity.
SAE 20W20 The chart illustrates the relationship between oil viscosity and the ambi-
SAE 30
ent air temperature.
SAE 40
SAE 15W40
02303
3
Remove oil filler cap 2.
Remove oil pan drain plug 4, and drain the oil. At the same time
replace the oil filter.
After reinstalling drain plug 4, slowly add engine oil through the oil
filler.
Using the dipstick, check the oil level after more than five minutes
have passed.
02333 Start the engine and let it idle. When the oil has reached all parts, stop
the engine. Let 30 minutes pass before checking the oil level again.
4 01205
01-26
01
Manual Transmission Gear Oil

2 Drain plug 6915 {5111, 71.5}
- Sealant
WARNING
The engine is hot immediately after the vehicle has stopped, so
take care not to burn yourself.

Remove inspection plug 1 and check whether the oil level is up to the
If the level is low, add oil through the inspection plug hole until the
level comes up to the edge of the entrance.
1 2 02335 [Replacement]
Add oil through the inspection plug hole until the level comes up to the
Insert inspection plug 1
02336
01-27
LUBRICATION
Automatic Transmission Fluid


1 Park the vehicle on level ground, make sure that the parking brake is
fully activated and chock the wheels to keep them from rolling.
2
Start the engine and let it idle. To fill the hydraulic circuit with auto-
matic transmission fluid, slowly shift the range selector lever once
through the P to L ranges and finally shift into the N range.
While the engine is still idling, pull out dipstick 1 and wipe off the fluid
C D sticking to it. Reinsert the dipstick, then pull it out again and check the
fluid level.
07500 fluid temperature is still low (4015C {10427F}) the level should be
within area C marked COLD on dipstick 1 as illustrated in A.
If the fluid level is inspected after the vehicle has been driven and the
fluid temperature is high (6515C {14927F}) the level should be
within area D marked HOT on dipstick 1 as illustrated in B.
WARNING
Take care during the inspection because the engine will be run-
ning. Take sufficient care to avoid burns or injuries resulting
from contact with moving parts.
CAUTION
NOTE
engine is idling when you are checking the fluid level. When the
engine is at standstill, the fluid level appears higher than it
actually is.
actual drive.

07821
01-28
01
[Replacement]
Place a container under the oil pan, remove drain plug 3 in the front of
the oil pan and drain the fluid.
WARNING
Take care because the automatic transmission fluid temperature
immediately after the engine has stopped is very high. To avoid
scalds, wait until a safe temperature has been reached before
3
draining the fluid.
07820
NOTE
The fluid will drain faster if the engine is first run to raise the fluid
temperature.
The fluid cannot be drained from the hydraulic circuit, the torque
converter or the oil cooler.

Add automatic transmission fluid (DEXRON II type) through filler tube
2.
CAUTION
Make sure that dirt and foreign particles do not become mixed in
with the fluid when it is added.
2 Shift the range selector lever into the N range, start the engine and let
it idle for at least two minutes.
07821 After shifting the lever through all ranges once, shift it back into N.
CAUTION
To prevent burning out the interior of the automatic transmission
assembly, make sure that the engine is not allowed to race when
you do the above.
Supply the fluid until the fluid level is at the lower limit of the specified
area on dipstick 1. Next, check the fluid level to make sure it is within
the specified limit.
NOTE
Determining the fluid level immediately after supplying the fluid
might be difficult due to the fluid stuck in the inside of the filler
tube. Therefore, check the fluid level a few times between inter-
vals.
If the fluid is oversupplied, it will overflow and can be mistaken
for leakage.
01-29
LUBRICATION
Rear Axle Gear Oil

WARNING
1 the edge of the entrance.
2 If the oil level is low, add oil through the inspection plug hole until the
02339 level comes up to the edge of the entrance.
[Replacement]
02340
01-30
01
Power Steering Fluid

- Fluid
1 Power steering oil tank Automatic transmission fluid Between
(DEXRON or DEXRON II type) MIN and MAX
on filler cap
dipstick

2
Straighten the front wheels and stop the engine.
Tilt the cab.
3 Remove filler cap 2 of power steering oil tank 1 by turning the filler cap
counterclockwise.
Wipe off the fluid sticking to dipstick 3 on filler cap 2. Replace the filler
cap.
NOTE
1 Check the fluid level without screwing on filler cap 2.
02341
Carefully lift up filler cap 2 and check the fluid sticking to dipstick 3 to
make sure that the fluid is at a point between the MAX and MIN
levels. If the fluid position does not reach the MIN level, add fluid.
After inspection install filler cap 2 by turning it clockwise.
WARNING
Close filler cap 2 firmly; otherwise the fluid will leak and could
catch fire. Also wipe up spilled fluid.
02342
CAUTION
If the fluid level is far below the recommended range, the fluid
may be leaking.
01-31
LUBRICATION
[Replacement]
Drainage
steering booster.
specified torque.
08583
[Fluid supply]
1 2
6
6.
A
NOTE
07236
right repeatedly. When the fluid level has dropped, add fluid to main-
tain the fluid level within range A. Repeat these steps until the fluid
level does not drop.
wheel several times to raise the fluid temperature to approximately
60 to 80C {140 to 176F}, then stop the engine and wait for approxi-
mately five minutes.
1, and pipe and hose connections for fluid leakage.
01-32
01
Brake Fluid

1 Air bleeder Front disc brake 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
Rear wheel cylinder < FE639 > 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
- Fluid
WARNING
07623 clutch system and brake system to swell, resulting in faulty
ging.
If you use a mug for adding brake fluid, keep it solely for that
purpose.
CAUTION
paintwork.
NOTE
Supply brake fluid to maintain the MAX level of the fluid tank
always.

Inspect the level of the brake fluid in the fluid tank. It should be between
the MAX and MIN levels. If it is below the MIN level, lift up the lid and
remove the cap from the fluid tank, then add specified brake fluid until the
level reaches the MAX level. Do not fill above the MAX level.
01-33
LUBRICATION
[Replacement]
< Front disc
brake > Start the engine and let it idle until you complete brake fluid replace-
ment.
Attach vinyl pipe A to the front disc brake, the rear drum brake
< FE639 >, the rear disc brake < FE649 > and the bypass valve.
Place the free end of vinyl pipe A into container B.
1
A
B 12934
< Rear drum brake > < Rear disc brake >
A 1
B
B
< Bypass valve > 06534
1 A
1 B
12935
of the brake system is replaced with new fluid. After you complete the
work, tighten each air bleeder 1 at specified torque.
1 NOTE
You can tell when the brake fluid has been completely replaced
12936 because the fluid coming out will be a different color.
Carry out air bleeding of the brake system.
07623
01-34
01
[Air bleeding]
< Front disc Start the engine and let it idle until you complete air bleeding of the
brake > brake system.
Attach vinyl pipe A to the front disc brake, the rear drum brake
< FE639 >, the rear disc brake < FE649 > and the bypass valve.
Place the free end of vinyl pipe A into container B, then bleed air from
1 the brake system as follows:
A 12937
B < Front brake system >
< Rear drum barke > < Rear disc brake > Disc brake, RH
0
Disc brake, LH
A 1
A FE639 FE649

B
B Drum brake, LH Disc brake, RH
08834
< Bypass valve >
< Bypass valve system >
1 A Bypass valve
A
1
B
12938
1 Make sure that the brake fluid level is at the MAX level of the brake
fluid tank, and depress the brake pedal several times to ensure that
12936 the brake fluid does not leak from anywhere. Then, conduct a brake
test.
01-35
LUBRICATION
Greasing Various Areas of Chassis
Carefully clean away all dust and dirt from the grease nipples, and use the specified type of grease. The areas to be
greased are shown in the following illustration.
02328
02329 01516 01517 02330
02331 01198 01199 01200
2 Drag link front 6 Kingpin bearing (left and right, 4 points)
3 Drag link rear 7 Propeller shaft universal joint
4 Rear spring pin front (left and right, 2 points) 8 Propeller shaft slip joint
01-36
01
Door hinge
01518
01-37
Group 10 - Engine
Removal & Installation
Group 10 - 1998 Minor

Changes
BACK HOME
Group 10
Removal and Installation
of Engine
' 98 Minor Change
Table of Contents
BACK HOME
10
GROUP 10 REMOVAL AND INSTALLATION

OF ENGINE
REMOVAL AND INSTALLATION OF ENGINE

Charge and Discharge of Engine Coolant,
Removal and Installation of Hoses .......................................................... 10- 2
Removal and Installation of Transmission Related Parts...................... 10- 4
Removal and Installation of Engine Related Parts ................................. 10- 6
Removal and Installation of Engine
< FE > .......................................................................................................... 10- 8
< FG >.......................................................................................................... 10-10
10-1
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses
10
9 8 11
7 12
13396 13397
2
1
4
13398
13
20
19
18 14
17
5
16
6
15
13399 07352
10-2
10
Work before removal and after installation
P10-3
Removal sequence
1 Battery cable
2 Pressure cap
3 Radiator drain plug ^ Gr 14
4 Crankcase drain plug ^ Gr 14
5 Power steering hose
7 Fuel return hose
8 Fuel feed hose
9 Harness (Chassis harness)
10 Hose (Intake silencer)
11 Hose (Solenoid valve)
12 Harness (Solenoid valve)
13 Reservoir tank
14 Mudguard ^ Gr 42
15 Air box
16 Air duct
17 Hose (3-way magnetic valve)
18 Harness (3-way magnetic valve)
20 Cab bridge
A : Wheel chock
WARNING
You must insert plugs into fuel return hose 7 and fuel feed hose 8 after you remove them and secure them at a
higher level than the fuel tank to prevent fuel from flowing out of them. Otherwise a fire might be caused.
You must make sure that the engine coolant is cold before draining it so as not to scald yourself.
It is dangerous to open pressure cap 2, when the coolant temperature is high, without taking due care because
the hot water could spray out. Be sure to cover the pressure cap with a cloth and loosen slowly to bleed the
pressure before opening fully.
Service procedure
Discharge, charge, and air bleeding of engine coolant ^ Gr 14
Discharge, charge, and air bleeding of oil ^ Gr 37
Air bleeding of fuel system ^ Gr 13
10-3
Removal and Installation of Transmission Related Parts
< FG >
4
12
14 15
27344
13 27333 13446
3
5
2 6
1
11
10
9
13400
NOTE
After removing propeller shaft 8 tie it to the frame temporarily at the height of the installation assembly using a
piece of rope.
When removing power cylinder 11 do not remove the clutch hose otherwise air might become mixed with the
fluid in the clutch system, preventing smooth operation.
After removing power cylinder 11 tie it to the frame temporarily using a piece of rope.
Removal sequence
1 Harness (Ground) 8 Propeller shaft ^ Gr 25
2 Harness (Chassis harness) 9 Brake drum ^ Gr 36
3 Selector rod ^ Gr 22 10 Speedometer cable ^ Gr 22
4 Front pipe ^ Gr 15 11 Power cylinder ^ Gr 21
5 Shift rod ^ Gr 22 12 Transfer LOW switch < FG > ^ Gr 24
6 Shift cross shaft ^ Gr 22 13 Transfer four-wheel drive switch < FG > ^ Gr 24
7 Parking brake cable ^ Gr 36 14 HIGH/LOW control cable < FG > ^ Gr 24
15 2H/4H control cable < FG > ^ Gr 24
10-4
10
1
2
13446
4
5
7 6
13401
NOTE
After removing oil cooler hose 1 tie it up temporarily at a level higher than the upper surface of the oil cooler.
After removing oil cooler hose 1 insert a plug into it, both on the oil cooler and transmission sides, to prevent
the automatic transmission fluid from flowing out.
piece of rope.
Removal sequence
1 Oil cooler hose ^ Gr 23
2 Selector cable ^ Gr 23
3 Front pipe ^ Gr 15
4 Parking brake cable ^ Gr 36
5 Propeller shaft ^ Gr 25
6 Brake drum ^ Gr 36
7 Speedometer cable ^ Gr 23
9 Harness (Ground)
10-5
Removal and Installation of Engine Related Parts
1
2 11 10
8
12
5 13
9 4
6
13402
14
18
17
16
15
13403
10-6
10
Removal sequence
1 Air hose ^ Gr 14
2 Outlet hose ^ Gr 15
3 Heater hose ^ Gr 55B
4 Air intake hose ^ Gr 15
6 Inlet hose ^ Gr 14
8 Intercooler ^ Gr 15
9 Radiator ^ Gr 14
10 Accelerator control cable ^ Gr 13
11 Engine stop cable ^ Gr 13
12 Harness (Starter)
14 Cooler compressor ^ Gr 55A
16 Vacuum hose
NOTE
For vehicles fitted with an air-conditioner do not disconnect the hose that goes to the air-conditioner from
cooler compressor 14 when you remove it otherwise you will have to recharge the air-conditioner with
refrigerant.
After removing cooler compressor 14 tie it to the frame temporarily.
10-7
Removal and Installation of Engine < FE >
< Manual transmission > < Automatic transmission >
07344 07345
28113
1
27386
Removal sequence
1 Nut
2 Bolt
3 Engine and transmission assembly
WARNING
When you lift engine and transmission assembly 3 you must use lifting gear that is strong enough to lift the
mass of the engine and transmission assembly (480 to 560 kg {1060 to 1230 lb}).
10-8
10
1 Nut (Front mounting installation) 68 to 88 {50 to 65, 6.9 to 9.0}
2 Bolt (Rear mounting installation) Manual 125 to 175 {94 to 130, 13 to 18}
transmission
Automatic 83 to 105 {61 to 80, 8.5 to 11.0}
transmission
3
Service procedure
Removal of engine and transmission assembly
Hook cable B and chain block C to two hangers A on the engine and
transmission assembly and lift the engine using crane D until the lifting
D
A B gear becomes taut.
C Support the transmission using transmission jack E.
Make sure that wiring and hoses are disconnected.
A
13404
Lower the transmission carefully so that transmission back plate G

G does not hit engine rear support F then move engine and transmission
F
assembly 3 forward.
3
07277
Lift engine and transmission assembly 3 carefully adjusting the lifting

angle. As the transmission appears from the front of the rear body turn
the transmission 90 clockwise and place it down on the right side
carefully so that it does not hit the frame or cab.
3
07278
10-9
Removal and Installation of Engine < FG >
6 4
2
7
27335
8
28114
1
07351
Removal sequence
1 Nut 6 Rear engine support bracket
2 Bolt 7 Bolt
3 Roll stopper 8 Transmission and transfer assembly ^ Gr 22
4 Bolt 9 Engine assembly
5 Nut
WARNING
Take care not to allow engine assembly 9 to hit the cab and rear body when lifting the engine.
Be sure to use lifting gear or an engine hoist that is capable of lifting engine assembly 9 weighing 380 kg
{840 lb}.
10-10
10
1 Nut (Front mounting installation) 68 to 88 {50 to 65, 6.9 to 9.0}
2 Bolt (Roll stopper bracket mounting) 44 to 64 {33 to 47, 4.5 to 6.5}
4 Bolt (Rear mounting installation) 44 to 64 {33 to 47, 4.5 to 6.5}
5 Nut (Rear engine support bracket mounting) 98 to 115 {72 to 87, 10 to 12}
7 Bolt (Transmission and transfer assembly mounting) 47 {35, 4.8} M101.25
82 {61, 8.4} M121.75
9
Service procedure
Preparatory operations for removal
Hook cable B and chain block C to two hangers A on the engine
assembly and lift the engine using crane D until the lifting gear
become taunt.
D Support the transmission using transmission jack E.
Make sure that the wiring and hoses are disconnected.
B
C
A
A
08425
Lift engine assembly 9 carefully and slowly, and turn the engine 90
9
clockwise when the lower part of engine appears above the frame.
07585
10-11
Group 10
of Engine
Table of Contents
BACK HOME
Pub No. TWSE9501-10

10
GROUP 10 REMOVAL AND INSTALLATION

OF ENGINE

Charge and Discharge of Engine Coolant,
Removal and Installation of Hoses ................................................................... 2
Removal and Installation of Transmission Related Parts............................... 4
Removal and Installation of Engine Related Parts .......................................... 6
Removal and Installation of Engine .................................................................. 8
10-1
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses
10
9 8 11
7 12
13396 13397
2
1
4
13398
13
20
19
18 14
17
5
16
6
15
13399
07352
10-2
10
P10-3
Removal sequence
1 Battery cable
2 Pressure cap
3 Radiator drain plug ^ Gr 14
4 Crankcase drain plug ^ Gr 14
7 Fuel return hose
8 Fuel feed hose
10 Hose (Intake silencer)
11 Hose (Solenoid valve)
12 Harness (Solenoid valve)
13 Reservoir tank
14 Mudguard ^ Gr 42
15 Air box
16 Air duct
18 Harness (3-way magnetic valve)
20 Cab bridge
A : Wheel chock
WARNING
You must insert blanking plugs into fuel return hose 7 and fuel feed hose 8 after you remove them and secure
them at a higher level than the fuel tank to prevent fuel from flowing out of them. Otherwise a fire might be
caused.
It is dangerous to open pressure cap 2, when the coolant temperature is high, without taking due care because
the hot water would spray out. Be sure to cover the pressure cap with a cloth and loosen slowly to bleed the
pressure before opening fully.
Service procedure
Discharge, charge, and air bleeding of engine coolant ^ Gr 14
Discharge, charge, and air bleeding of oil ^ Gr 37
Air bleeding of fuel system ^ Gr 13
10-3
Removal and Installation of Transmission Related Parts
13446
3
5
2 6
1
11
10
9
13400
NOTE
piece of rope.
When removing power cylinder 11 do not remove the clutch hose otherwise air might become mixed up with
the fluid in the clutch system, preventing smooth working.
After removing power cylinder 11 tie it to the frame temporarily using a piece of rope.
Removal sequence
1 Harness (Ground)
3 Selector rod ^ Gr 22
5 Shift rod ^ Gr 22
6 Shift cross shaft ^ Gr 22
11 Power cylinder ^ Gr 21
10-4
10
1
2
13446
4
5
7 6
13401
NOTE
After removing oil cooler hose 1 tie it up temporarily at a level higher than the upper surface of the oil cooler.
After removing oil cooler hose 1 insert blanking plugs into it, both on the oil cooler and transmission sides, to
prevent the automatic transmission fluid from flowing out.
piece of rope.
Removal sequence
1 Oil cooler hose ^ Gr 23
2 Selector cable ^ Gr 23
9 Harness (Ground)
10-5
Removal and Installation of Engine Related Parts
1
2 11 10
8
12
5 13
9 4
6
13402
14
18
17
16
15
13403
10-6
10
Removal sequence
1 Air hose ^ Gr 14
2 Inlet hose ^ Gr 15
6 Outlet hose ^ Gr 14
8 Intercooler ^ Gr 15
9 Radiator ^ Gr 14
10 Accelerator control cable ^ Gr 13
11 Engine stop cable ^ Gr 13
12 Harness (Starter)
14 Cooler compressor ^ Gr 55A
16 Vacuum hose
NOTE
For vehicles fitted with an air-conditioner do not disconnect the hose that goes to the air-conditioner from
cooler compressor 14 when you remove it otherwise you will have to recharge the air-conditioner with
refrigerant.
After removing cooler compressor 14 tie it to the frame temporarily.
10-7
Removal and Installation of Engine
07344 07345
07275
1
07351
Removal sequence
1 Nut
2 Bolt
3 Engine and transmission assembly
WARNING
When you lift engine and transmission assembly 3 you must use lifting gear that is strong enough to lift the
mass of the engine and transmission assembly (400 to 480 kg {880 to 1060 lb}).
10-8
10
1 Nut (Front mounting installation) 69 to 78 {51 to 59, 7 to 8}
2 Bolt (Rear mounting installation) Manual 125 to 175 {94 to 130, 13 to 18}
transmission
Automatic 83 to 105 {61 to 80, 8.5 to 11.0}
transmission
3
Service procedure
Removal of engine and transmission assembly
Hook cable B and chain block C to two hangers A on the engine and
transmission assembly and lift the engine using crane D until the lifting
D
A B gear becomes taut.
C Support the transmission using transmission jack E.
Make sure that wiring and hoses are disconnected.
A
13404
Lower the transmission carefully so that transmission back plate G

G does not hit engine rear support F then move engine and transmission
F
assembly 3 forward.
3
07277
Lift engine and transmission assembly 3 carefully adjusting the lifting

angle. As the transmission appears from the front of the rear body turn
the transmission 90 clockwise and place it down on the right side
carefully so that it does not hit the frame or cab.
3
07278
10-9
Group 11 - Engine
Group 11A - Engine

2001 Model Change
<4M50>
BACK HOME
Pub No. TWSE9501-511A
Service Manual
Group 11A
Engine
<4M50T2>
2001 Model Year Change
Table of Contents
BACK HOME
MAY. 2000
GROUP 11A ENGINE
SPECIFICATIONS ................................................................................ 11A- 2
STRUCTURE AND OPERATION ......................................................... 11A- 4
TROUBLESHOOTING .......................................................................... 11A-14
ON-VEHICLE INSPECTION AND ADJUSTMENT ............................... 11A-16
ROCKER COVER, ROCKER ASSEMBLIES AND CAMSHAFTS ....... 11A-20
CYLINDER HEAD AND VALVE MECHANISM ..................................... 11A-34
FRONT CASE ....................................................................................... 11A-48
TIMING GEARS AND BALANCE SHAFTS ......................................... 11A-52
PISTONS, CONNECTING RODS AND CYLINDER LINERS ............... 11A-60
FLYWHEEL ........................................................................................... 11A-72
CRANKSHAFT AND CRANKCASE .................................................... 11A-76
BALANCE SHAFT BUSHINGS ............................................................ 11A-84
11A-1
SPECIFICATIONS
Item Specifications
Engine model 4M50T2
Type 4-cylinder, in-line, water-cooled, 4-cycle diesel
Combustion chamber type Direct injection
Valve mechanism Double overhead camshaft
Max. power output HP/rpm (SAE Gross) 175/2700
Max. torque lbf.ft/rpm (SAE Gross) 347/1800
Cylinder bore x stroke mm {in.} 114 x 120 {4.49 x 4.72}
Total displacement , 4.899
Compression ratio 17.5
11A-2
11A
MEMO
11A-3
Engine-proper
12
13
11
10 14
9 15
8
7
6
5
4
3
16
2
1 17
35
18
34
19
20
33
21
22
23
24
32
25
31 26
27
30
28
29
29712
1 Cylinder head 13 Rocker cover 25 Lower crankcase

2 Head idler gear 14 Short rocker 26 Balance shaft LH
3 Camshaft frame 15 Inlet rocker shaft 27 Injection pump gear
4 Camshaft gear (Exhaust side) 16 Valve spring 28 Balance shaft gear LH
5 Exhaust camshaft 17 Inlet valve 29 Vacuum pump gear
6 Camshaft gear (Inlet side) 18 Piston 30 No. 1 idler gear
7 Inlet camshaft 19 Flywheel 31 Crankshaft gear
8 Exhaust valve 20 Connecting rod 32 Oil pump gear
9 Exhaust rocker shaft 21 Balance shaft RH 33 Balance shaft gear RH
10 Short rocker 22 Rear plate 34 Fan shaft assembly
11 Rocker shaft spring 23 Crankshaft 35 Idler gear assembly
12 Long rocker 24 Upper crankcase
The 4M50T2 engine is of the double overhead camshaft (DOHC) type. The valve mechanism and timing gear arrangement
is illustrated above.
11A-4
11A
Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame
1 Bolt (x 2)
2 Bolt (x 13)
3 Camshaft frame
2 3 4 Camshaft bearing (Upper)
A 5 Exhaust camshaft
1 6 Camshaft bearing (Lower)
7 Inlet camshaft
8 Cylinder head
9 Cylinder head gasket
4 10 Cylinder head bolt
5
6 4 A: Locating pin
7 B: Locating pin
A C: Notched portion
6 *: Front
B
8
10
9
B
29713
The camshafts 5 and 7 have their journals supported by the cylinder head 8, and are held down from above by the
camshaft frame 3.
The camshaft bearings 4 and 6, both upper and lower, are identical parts. When they are reassembled, however, be
sure to reinstall them in their original positions, as they were before disassembly.
The exhaust camshaft 5 and the inlet camshaft 7 have the same gears but use different cams. Use care not to confuse
them at reassembly.
As for the cylinder head gasket 9, select and use one of proper thickness suitable for the projection of piston. The
thickness of gaskets is identifiable by a difference in the shape of the notched portion C.
The bolts 2 (x 13) are threaded into the cylinder head 8, whereas the bolts 1 (x 2) are threaded into the front case*.
11A-5
Valve Mechanism
3 6 7 4
3 2 2 2 2
1 1 1 1 8
5
9
18
10
2 2 2 2
4 1 1 1 1
17 16 15 14 13 12 11
3 19 5 2 1 1 2
11 15 13
29714
1 Short rocker 8 Inlet camshaft 15 Exhaust valve

2 Long rocker 9 Outer valve spring 16 Exhaust valve seat
3 Exhaust rocker shaft 10 Inner valve spring 17 Exhaust valve guide
4 Inlet rocker shaft 11 Cylinder head 18 Valve stem seal
5 Exhaust camshaft 12 Inlet valve guide 19 Rocker shaft spring
6 Valve collet 13 Inlet valve
7 Upper retainer 14 Inlet valve seat
The rockers come in two types; short rockers 1 and long rockers 2, and are mounted in different directions as illustrated.
The valve springs include the outer springs 9 and inner springs 10. A pair of outer and inner springs are used for a valve.
11A-6
11A
Connecting Rods
1 Connecting rod bushing
1 2 Connecting rod
3 Upper connecting rod bearing
4 Connecting rod bolt
5 Lower connecting rod bearing
6 Connecting rod cap
*a: Weight mark stamp

A to G
2
(where A indicates the maximum
connecting rod weight.)
*b: Alignment mark
*c: Alignment mark
4
3
c a
5 b
6
29589
Pistons
a: Part number
b: Weight mark
c: Size mark
b c
A, B
Pistons marked B are larger than
a those marked A in the outside
diameter.
d: Front mark
Indicated by p.
e: Strut
Pistons to be used can be selected by match-

ing the size mark of the piston with that of
d the cylinder liner. P. 11A-11
The piston is made of special aluminum al-
loy. Its total height is relatively low and both
end faces of the piston in the direction of the
piston pin are concaved for weight reduction.
The piston is an autothermic piston reinforced
e with strut e.
29587
11A-7
Timing Gears
1 Camshaft gear RH (32)
2 Head idler gear (54)
1 2 3
R 3 Camshaft gear LH (32)
R
L
L
4 Idler gear (63, 36)
R
5 Injection pump gear (56)
L
6 Balance shaft gear LH (14)
5 5 7 Vacuum pump gear (15)
5 4 2 8 No. 1 idler gear (49)
2 9 Crankshaft gear (28)
2
10 Oil pump gear (41)
4 4 11 Balance shaft gear RH (14)
4 12 Fan shaft (25)
3
12 Number of teeth shown in parentheses
3
11
7
7 Each of the timing gears (except the vacuum
5
7 pump gear) has alignment marks to ensure
6 correct assembly.
10
7
6
9 8
6
6
1
1
29295
Flywheel
1 Flywheel
b 2 Ring gear
3 Pilot bearing
10 20
a: Angle scale
1 b: Cylinder No. (1 4, I IV)
b
a
2
14 10 20
29588
11A-8
11A
Balance Shaft
1 Balance shaft gear RH
2 Balance shaft RH
3 Crankshaft
4 Upper crankcase
5 No. 3 balance shaft bushing
3 7 Balance shaft LH
4 8 No. 1 balance shaft bushing
2
9 Balance shaft gear LH
10 Vacuum pump gear
11 No. 1 idler gear
1 12 Crankshaft gear
5 13 Oil pump gear
7
6
13 7
8
12 9
11 10 A
29914
The balance shafts RH 2 and LH 7 are mounted in the upper crankcase 4 with the crankshaft 3 sandwiched in between,
and serve to reduce the engine vibration caused by rotation of the crankshaft.
Both balance shafts RH 2 and LH 7 are supported by the three balance shaft bushings 5, 6 and 8 mounted in upper
crankcase 4 and driven by the timing gears ( P. 11A-8).
The balance shaft LH 7 is provided with a positioning hole A to ensure correct assembly. P. 11A-59
P Reduction of vertical vibration (Secondary components)

The reciprocating motion of the piston produces inertial force B, the
source of vertical vibration, at the top and bottom dead centers of the
B piston.
The balance shafts RH 2 and LH 7 rotate in such a way that at the top
and bottom dead centers of the piston, the semi-circular weight portion
C will always be placed opposite to the piston head in terms of top or
bottom position.
As a result, at the top and bottom dead centers of the piston, both
balance shafts RH 2 and LH 7 produce equal centrifugal force D to
offset inertial force B of the piston, thereby reducing vertical vibration.
2
In addition, in the medium and high engine speed ranges, the crank-
D D 7
shaft rotation moments (secondary components) are also reduced by
the balance shafts.
29915
11A-9
Crankcase and Main Bearings
1 Upper crankcase
1 2 Upper thrust plate
3 Lower thrust plate
4 Bolt
5 Main cap bolt
10
6 Lower crankcase
7 Lower main bearing
8 Crankshaft
9 Upper main bearing
10 Cylinder liner
9
2
5 4
40996
P Crankcase
The crankcase is composed of two parts; upper crankcase 1 and lower
crankcase 6, which are coupled together with crankshaft 8 in between.
The upper crankcase 1 has four cylinder bores provided into which
cylinder liners 10 are fitted.
10 Water jacket A is provided around the cylinders to cool down the cylin-
der liners 10.
A The bolts 4 used to couple the upper crankcase 1 and the lower crank-
case 6 and the main cap bolts 5 require the specified procedure to be
1 followed when tightened. P. 11A-79
4 8 5 6
40997
11A-10
11A
Size mark 1 or 2 is stamped on the upper crankcase 1 for selective
fitting of pistons in the crankcase.
The size marks for the four cylinders are collectively stamped at a single
location, and indicate the sizes of the respective cylinder liners as illus-
1 or 2 trated. P. 11A-7
29918
P Cylinder liner
10 A, B
Select a cylinder liner 10 which has the same size mark as those
stamped on the upper crankcase *1 the piston.
The size marks on the upper crankcase *1 are arranged in the order of
No. 1, 2, 3 and 4 cylinders starting from the engine front C.
Size marks on Size marks on Size mark on

upper crankcase cylinder liners pistons
1A, 1B
2A, 2B 1A
29535 1 A
1B
*1 1, 2
2A
2 B
2B
29536
11A-11
P Main bearings
The upper main bearing 9 has an oil hole A through which engine oil is
supplied to the journal of the crankshaft 8.
9
A
7 29919
P Thrust plates
The thrust plates include upper thrust plates 2 and lower thrust plates
A 3. They are mounted at both ends of the upper main bearing 9 and the
2
lower main bearing 7 at the rearmost portion of the crankshaft 8.
The thrust plates to be used should have a proper thickness suitable
for the end play of the crankshaft 8.
A Each thrust plate has an oil groove in two places to assure its smooth
sliding on the journal B of the crankshaft 8.
9
A
7
A 3
30151
11A-12
11A
Oil Seals
1 Front oil seal
2 Front case
3 Front oil seal slinger
4 Fan shaft
5 Crankshaft
8
6 Crankcase
7
7 Rear oil seal slinger
6
8 Rear oil seal
4
3
2
1
29920
2 A P Front Oil Seal

The front oil seal 1 is mounted on the front case 2. Its lip A is in contact
3 with the front oil seal slinger 3 for sealing.
1
The front oil seal slinger 3 is fitted on the fan shaft 4.
4
29921
P Rear Oil Seal

The rear oil seal 8 is mounted on the crankcase 6. Its lip A is in contact
A
with the rear oil seal slinger 7 for sealing.
The rear oil seal slinger 7 is press-fitted on the rear end of the crank-
5 shaft 5.
8
7 29922
11A-13
TROUBLESHOOTING
Symptoms Low power Abnormal Remarks
output engine
Possible Causes noise
Cylinder head and Incorrect valve clearance T T
valve mechanism
Defective cylinder head gasket T T
Worn valve and valve seat, and deposited carbon T T
Weakened valve spring T T
Defective rocker shaft and bracket T
Poor lubrication of rocker shaft bracket T
Timing gears Incorrect backlash in timing gears T
Poor lubrication of timing gear peripheries and idler shafts T
Camshaft Excessive end play in camshaft T
Worn camshaft T
Pistons and Worn/damaged piston ring groove(s) T T
connecting rods
Worn/damaged piston ring(s) T T
Worn piston pin and connecting rod small end bushing T
Crankshaft Excessive end play in crankshaft T
Incorrectly fitted fan pulley T
Worn/damaged crankshaft pin and connecting rod bearing T
Worn/damaged crankshaft journal and main bearing T
Fuel Defective bearing in injection pump bearing housing T
Faulty injection nozzle spray condition T T B Gr 13
Incorrect injection timing T T B Gr 13
Air trapped in fuel system T B Gr 13
Cooling Defective cooling system T B Gr 14
Loose/damaged V belt T
Intake and exhaust Clogged air cleaner T T B Gr 15
Clogged muffler T T
Incorrect oil viscosity T
Improper fuel T
Incorrectly fitted piping, hose, etc. T
Defective/incorrectly fitted auxiliaries like injection pump and alternator T
11A-14
11A
MEMO
11A-15
Measuring Compression Pressure
Service standards
Each cylinder (at 200 rpm) 2550kPa 1960 kPa {285 psi 2,
Inspect
Compression {370 psi 2, 26 kgf/cm2} 20 kgf/cm2}
_
pressure Cylinder-to-cylinder pressure 0.4 kPa
Inspect
difference {57 psi 2, 4 kgf/cm2}

7.2
16W x 18 { 0.28}
thread
Compression Gauge
MH063434 Measuring compression pressure
Adapter
58 {2.28} 01942
A drop in compression pressure should be used as a guide in determining a time to overhaul the engine.
Measure the compression pressure at regular intervals, and keep track of its transition which will provide a useful tool for
troubleshooting. On a new vehicle, or for a while after replacement of parts with new ones, the compression pressure will
be somewhat higher, depending on the break-in condition of piston rings, valve seats, etc., but will return to normal as the
parts wear down.
Prior to an inspection, check to ensure that the engine oil, starter and battery are in normal condition.
Place the vehicle in the following condition.
Warm up the engine until the coolant temperature reaches approx. 75 to 85 C {167 to 185 F}.
Turn off the lights and auxiliaries.
Place the transmission in neutral.
Place the steering wheel in the straight-ahead position.
Remove the fuel cut motor fuse 2 from the fuse box 1 in the cab to
make sure that the fuel is not injected when the engine is cranked by
the starter.
2 (F28)
1 36865
Tilt the cab.
29626
11A-16
11A
Remove the rocker cover 3, fuel leak-off pipe 4 and injection pipe 5.
P. 11A-20
5
3
29515
Remove all injection nozzle assemblies 6 and nozzle gaskets 7.

P. 11A-34
6
7
29516
Cover the injection nozzle mounting holes with pieces of waste cloth B.
After cranking the engine by the starter, check to ensure that no for-
B eign substances are deposited on the waste cloth.
A
WARNING k
If there is a crack in any of the cylinders, some of the coolant,
engine oil, fuel, etc. will enter the cylinder through the crack.
If the engine is cranked in such a condition, these substances
heated to high temperatures will blow out from nozzle mounting
29627 holes A and can be very dangerous. When the engine is cranked,
therefore, stay away from the nozzle mounting holes.
Fit the nozzle gasket 7 and the 0 Compression Gauge Adapter onto
0
C the injection nozzle mounting hole A and mount the compression gauge
7
0 C.
Crank the engine and measure the compression pressure.
On all of the cylinders, measure the compression pressure and deter-
A mine the pressure difference between cylinders.
If any compression pressure or cylinder-to-cylinder pressure difference
is out of the limits, pour in a small amount of engine oil from injection
nozzle mounting hole A and check by measuring the compression pres-
29628 sure again.
If the compression pressure increases:
Worn/damaged piston rings and cylinder inner surfaces are sus-
pected.
If the compression pressure remains unchanged:
A seized valve, incorrectly seated valve or defective cylinder head
gasket is suspected.
11A-17
Inspecting and Adjusting Valve Clearances

Inlet 0.4 {0.016} Adjust
Valve clearance (when cold)
Exhaust 0.5 {0.020} Adjust

2 Lock nut (adjusting screw tightening) 11.2 {8.25, 1.14}
Valve clearances should be checked and adjusted as follows while the

engine is cold.
[Inspection]
Tilt the cab.
Remove the rocker cover. P. 11A-20
To place the piston No. 1 or No. 4 at the top dead center on the com-
A I, IV pression stroke, crank the engine until the pointer A in the clutch hous-
ing inspection window is aligned with the mark between I and IV in-
scribed in the flywheel.
I IV
NOTE:
Find the cylinder where the rocker arms for both the inlet and
exhaust valves can be pushed down. The piston of the cylinder is
at the top dead center (TDC) on the compression stroke.
29523
Use a1/2 drive extension bar C (for socket wrench) to crank the en-
gine; insert its end in the groove B located on the outer circumference
of the fan pulley A to turn the crankshaft.
B C
33109
With the piston No. 1 or No. 4 at the top dead center (TDC) on the
compression stroke, measure the valve clearance B at the valves
marked in the following table.
C
B Cylinder No. 1 2 3 4
Valve arrangement IN EXH IN EXH IN EXH IN EXH
Piston No. 1 at TDC on
T T T T
compression stroke
Piston No. 4 at TDC on
T T T T
29629 compression stroke
11A-18
11A
When measuring the clearances, push the pad 2 of the adjusting screw
1 1 with the tip of a plain screwdriver D or something else from opposite
the side where the feeler gauge C is to be inserted to open a gap as
2 illustrated, then insert the feeler gauge in the gap.
D C
30148
If an attempt is made to insert a feeler gauge C without opening a gap,

the pad will be tilted as illustrated, making it impossible to insert the
feeler gauge.
2 C NOTE:
The feeler gauge C must have a slight drag when taking a mea-
surement.
If the feeler gauge moves without any resistance, the measure-
ment is incorrect (too loose).
30149
If the reading is out of specification, adjust by the following procedures.
C [Adjustment]
D To adjust the valve clearance B, loosen the lock nut 1 and rotate the
B adjusting screw 2 to adjust the clearance to the extent that the feeler
2
gauge C is somewhat hard to move.
1
After the adjustment, hold the adjusting screw 2 in position with a screw-
driver D and tighten the lock nut 1 to the specified torque.
Thereafter, re-check the valve clearance B with the feeler gauge C.
29630
11A-19
ROCKER COVER, ROCKER ASSEMBLIES AND CAMSHAFTS
T
2
3
1
4
6
T
19
S
A
T
5 12
X
A 23
T
17 D
T
18 13 T
T
7
8 A
X T
9
15
11 10 X
X
16
14 T G
K
30
Z L
X
J H
CV
A
H
X
A 29347
11A-20
11A
P Pre-disassembly inspection
P. 11A-23
P Pre-disassembly work
Some work is necessary before disassembly. P. 11A-23
1 Oil filler cap 14 Eye bolt 25 Packing
2 Bolt 15 Gasket 26 Inlet camshaft assembly
3 Plate 16 Fuel return pipe 27 Exhaust camshaft assembly
4 Rubber grommet B Group 13A 28 Camshaft bearing (lower)
5 Rocker cover gasket 17 Bolt (x 2) 29 Camshaft gear
6 Rocker cover 18 Bolt (x 13) 30 Key
7 Eye bolt 19 Bolt (x 10) 31 Inlet camshaft
8 Gasket 20 Exhaust rocker shaft assembly 32 Exhaust camshaft
9 Eye bolt P. 11A-30
10 Gasket 21 Inlet rocker shaft assembly *: Cylinder head assembly
11 Fuel leak-off pipe P. 11A-30 P. 11A-34
12 Injection pipe 22 Camshaft frame A: Locating pin
B Group 13A 23 Injection pipe connector : Non-reusable part
13 Injection pipe 24 Camshaft bearing (upper)
B Group 13A
NOTE
Avoid removing the camshaft gear 29 unless something wrong is evident.
The camshaft frame 22 and the cylinder head assembly * have been machined jointly when manufactured. It is
impossible to replace only either of the parts. Be sure not to change the combination.
P Assembly sequence

Between head idler gear
0.09 to 0.12 {0.0035 to 0.0047} 0.3 {0.012}
assembly and camshaft gear
Backlash Between head idler gear Replace
assembly and idler gear 0.11 to 0.14 {0.0043 to 0.0055} 0.3 {0.012}
assembly
Camshaft assembly 0.10 to 0.20 {0.0039 to 0.0079} 0.3 {0.012} Check all
End play
Head idler gear assembly 0.10 to 0.20 {0.0039 to 0.0079} 0.3 {0.012} the parts.
35.5 {1.39}
24, 28 Camshaft bearing free span
or more
Replace
11A-21
Standard value
For long 7.107 Lobe height: 42.157 {1.66}
7.157 {0.281}
rocker {0.297} Base circle diameter: 35 {1.38}
Cam lift
For short 9.152 Lobe height: 44.201 {1.74}
9.202 {0.36}
26 Inlet camshaft
0.03
Bend 0.01 {0.00039} Replace
{0.0012}
0.07 to 0.12 0.16
Journal oil clearance Replace
{0.0028 to 0.0047} {0.0063}
For long 7.167 Lobe height: 42.217 {1.66}
7.217 {0.284}
Cam lift
For short 9.229 Lobe height: 44.279 {1.74}
9.279 {0.365}
Exhaust rocker {0.363} Base circle diameter: 35 {1.38}
27 camshaft 0.03
Bend 0.01 {0.00039} Replace
{0.0012}
0.07 to 0.12 0.16
Journal oil clearance Replace
{0.0028 to 0.0047} {0.0063}
[30 {1.18}]
29, 31, Camshaft gear and camshaft interference 0.007 to 0.041 Replace
32 {0.00028 to 0.00160}
Tightening torques Unit: Nm {ft.lbs, kgfm}

2 Bolt (mounting rocker cover) 2.0 {14.0, 0.2}
7, 9 Eye bolt (mounting fuel leak-off pipe) 20.6 {15.0, 2.1}
12, 13 Injection pipe 29.4 {22.0, 3.0}
14 Eye bolt (mounting fuel return pipe) 20.6 {15.0, 2.1}
17 Bolt (mounting camshaft frame) 23.5 {17.0, 2.4} Wet
18 Bolt (mounting camshaft frame) 27.5 {20.0, 2.8} Wet
19 Bolt (mounting rocker shaft assembly) 27.5 {20.0, 2.8} Wet
Lubricant and sealant

17, 18 Bolt threads and seating surface Engine oil As required
Surface of camshaft frame which makes contact with cylinder
22 head
THREEBOND 1207C or D As required
24, 28 Inside surface of camshaft bearing Engine oil As required

25 Circumference of packing THREEBOND 1207C or D As required
31, 32 Journal and cam portions of camshaft Engine oil As required
11A-22
11A
29 B 29
(1) Backlash between head idler gear B and camshaft gear 29 and
idler gear assembly C
On a pair of gears, measure backlash at more than three positions. If
the reading is more than the limit, replace defective parts.
29436
(2) End play of camshaft

If the reading is more than the limit, replace defective parts.
29438
D P Pre-disassembly work
C B If the rocker B forced up by the camshaft 26 or 27 is pressing the valve
26, 27 spring C down, loosen the adjusting screw D of the rocker to set the
valve spring free.
29348
R Service procedure
5 6 Installation of rocker cover and rocker cover gasket
6
Before installing the rocker cover 6, remove oil and other deposits thor-
oughly from the gasket groove B.
Face the rocker cover gasket 5 as illustrated when it is installed on the
B rocker cover 6.
up
CAUTION k
5 Make sure that the rocker cover gasket 5 is not twisted when in-
stalled.
29349
11A-23
A to D, H Rocker shaft assemblies, camshaft frame and packing
1 2 [Removal]
Loosen the bolts 18 and 19 (1 through F) one after another, a small
5 9 11 7 amount at a time, in the numbered sequence shown in the illustration.
B Then remove the rocker shaft assemblies 20 and 21 and the camshaft
frame 22.
B: Front of engine
13 17 19 15
20
20 22 23 21
21
14 18 16 12
22
6 10 8 4
3
30168
[Installation]
Apply an even bead of sealant ( 2 1 mm { 0.079 0.039}) without
any break to all around the illustrated portion C of the four packings 25.
Apply an even bead of sealant ( 1 mm {0.039}) without any break on
the circumference D of the camshaft frame 22.
After the sealant application, install the camshaft frame 22 and the
packings 25 on the cylinder head assembly* in less than three min-
D 22 utes.
25
C
A
CAUTION k
25 Check to ensure that the sealant application surfaces C and D are
clean and free from any oil or other deposits.
When installing the parts, make sure that the sealant is not forced
out of position.
Do not start the engine in less than an hour after installation.
A: Locating pin
*
25 A
29441
11A-24
11A
The bolts 18 (x 13) and 19 (x 10) must be tightened in the following
sequence. Therefore, secure the rocker shaft assemblies 20 and 21
19 together with the camshaft frame 22.
CAUTION k
When the bolts 18 and 19 were loosened or removed after instal-
20 lation, be sure to re-apply sealant.
21
22
18
29439
Tighten the bolts 18 and 19 (1 through F) to the specified torque in the

23 22 numbered sequence shown in the illustration.
19 15 13 17
11 7 5 9
20
4 2 1 3
21
10 6 8 12
22
18 14 16 20
21
30169
11A-25
G L Installation of camshaft bearings
Be sure to fit the lugs B of the camshaft bearings 24 and 28 in the mating
notches.
B C: Front of engine
24
B
28 B
C
29440
J K Installation of camshaft assemblies
Place the piston of No. 1 cylinder at the top dead center on the com-
pression stroke.
Install the camshaft assemblies 26 and 27 with the alignment marks B
22 B on the camshaft gear 29 and on the camshaft frame 22 in alignment.
NOTE:
27 The alignment marks L and R on the camshaft gear 29 and
29 B
those on the head idler gears need not always be in alignment,
because the alignment mark of the head idler gears, depending
L R 26 on their mounted condition, does not always match that of the
29450 camshaft gear.
Z Camshaft gear
29 [Removal]
B
Remove the camshaft gear 29 by pressing the camshaft end with a press.
31, 32
B: Removal block
CAUTION k
Never strike the camshaft gear 29 with a hammer to remove it. Be
sure to use a press or a similar tool.
29443
[Installation]
29 Heat the camshaft gear 29 to 150 C {302F} by a piston heater or a
R
similar tool and install it with the alignment mark R or L directed as
L
shown.
Install the camshaft gear 29 such that it is held tightly against the cam-
shaft 31 or 32.
31, 32
29444
11A-26
11A
Z C V Camshaft gear and camshaft interference
29 If the reading is out of the standard values, replace defective parts.
31, 32
29446
C V Inspection of camshafts
(1) Cam lift (Difference between lobe height and base circle
diameter)
If the reading is less than the limit, replace the camshafts 31 and 32.
C
B: Measuring position
C: Cam lobe height
B B D D: Base circle diameter
E: Long rocker side cam
22307
F: Short rocker side cam
E NOTE:
The cam dimensions are different between the long rocker side
32 F cams E and the short rocker side cams F.
E
31
29447
(2) Bend
G
Measure the bend of the camshafts 31 and 32 at the journal H with the
journals G supported. If the reading is in excess of the limit, replace
the camshaft.
G NOTE:
The bend of the camshafts 31 and 32 is one half of the reading of
H
the dial indicator taken after turning the camshaft through a rota-
29448
tion.
11A-27
(3) Oil clearance between journals and bearings
Measure the oil clearance. If the reading is in excess of the limit, re-
22
place defective parts.
CAUTION k
If a camshaft bearing 24 or 28 is to be replaced, make sure that
both upper and lower halves are simultaneously replaced as a
* pair.
24
31, 32
28
29449
11A-28
11A
MEMO
11A-29
Rocker Shaft and Rocker Assembly
2 1
5 E
4
6
7
6 8
1
R
9 Q
11
A
29465
PDisassembly sequence
1 Short rocker assembly 6 Rocker shaft spring 11 Long rocker
2 Lock nut 7 Long rocker assembly 12 Exhaust rocker shaft
3 Adjusting screw 8 Lock nut 13 Inlet rocker shaft
4 Rocker bushing 9 Adjusting screw
5 Short rocker 10 Rocker bushing A: Front of engine
PAssembly sequence
CAUTION k
The rockers come in two types; short rocker assembly 1 and long rocker assembly 7. Note the difference in
mounting sequence between the inlet and exhaust rocker shafts.
Standard value
1, 7 Radial play of rocker assembly rollers 0.038 to 0.100 {0.0014 to 0.0039} Replace
4, 10, Clearance between rocker bushing and rocker [22 {0.87}] 0.01 to 0.08 0.12
Replace
12, 13 shaft {0.0039 to 0.0031} {0.0047}
Tightening torque Unit: Nm {ft.lbs, kgfm}

2, 8 Lock nut (securing adjusting screw) 11.2 {8.24, 1.14}
11A-30
11A
Lubricant
4, 10 Inside of rocker bushing Engine oil As required
0 Special tools Unit: mm

22 {0.87} 24.5 {0.96}
4, 10 Rocker Bushing Puller Use Equivalent Installation and removal of rocker bushing
24.5 22
{0.96} {0.87}
P29932
R Service procedure
1, 7 1 7 Inspection of rocker assemblies
If the play C of the roller B of the rocker assembly 1 or 7 are out of the
standard values, replace the assembly.
C: Radial play
B 30251
4 Q E R Rocker bushing and rocker shaft

[Inspection]
If the clearance is in excess of the limit, replace defective parts.
12, 13
4, 10
29466
Rocker bushing
B B [Removal]
0
0 0: Rocker Bushing Puller
5 11
B: Press
4 10
29467
11A-31
[Installation]
Install the rocker bushings 4 and 10 on the rockers 5 and 11 in the illus-
H trated direction.
5 E G 0: Rocker Bushing Puller
0
C: Rocker bushing oil hole
4 D: Rocker bushing oil hole
C D
E: Rocker oil hole
F: Rocker oil hole
C 4 DF G: Rocker bushing clinch (seam)
5 H: Rocker bushing notch (rear side)
H
G 11 0
10
C
D
E
F D 10 C 11
29468
E Installation of exhaust rocker shaft

Install the exhaust rocker shaft 12 in the illustrated direction.
A: Front of engine
B: Camshaft frame locating pin mounting hole
A
29469
R Installation of inlet rocker shaft

Install the inlet rocker shaft 13 in the illustrated direction.
B A: Front of engine
B: Camshaft frame locating pin mounting hole
A 29470
11A-32
11A
MEMO
11A-33
CYLINDER HEAD AND VALVE MECHANISM
T
1
W 12 X 3
T
14
4
13 X
Q T
7
5
T
Y
6
X
U
9
8
T *b
*c
*a
29350
11A-34
11A
P. 11A-36
1 Bolt 10 Head idler gear assembly *a: Idler gear assembly
2 Injection nozzle B Gr 13A 11 Head idler gear bushing P. 11A-52
3 O-ring 12 Head idler gear *b: Upper crankcase
4 Nozzle tip gasket 13 Thrust plate P. 11A-76
5 Nut 14 Cylinder head bolt *c: Front case assembly
6 Connecting plate 15 Cylinder head assembly P. 11A-48
7 Glow plug P. 11A-40
8 Bolt 16 Cylinder head gaskect P: Locating pin
9 Head idler shaft : Non-reusable part
CAUTION k
The cylinder head bolts 13, 14 utilize the torque-turn tightening method. Any cylinder head bolt that has appar-
ently been tightened three times already must be replaced with a new one. P. 11A-37
P Assembly sequence
Standard value
Head idler shaft - to - head idler gear bushing [32 {1.26}] 0.01 to 0.05 0.1
9, 11 clearance {0.00039 to 0.002} {0.0039}
Replace

1 Bolt (injection nozzle installation) 14.7 {11, 1.5}
5 Nut (connection plate installation) 1.0 to 1.5 {0.7 to 1.1, 0.1 to 0.15}
7 Glow plug 22.6 {17, 2.3}
8 Bolt (Head idler shaft installation) 44.1 {33, 4.5} Wet
14 Cylinder head bolt 147 {110, 15} + 90 Wet
Lubricant and/or sealant Unit: mm {in.}

3 O-ring Engine oil As required
8 Thread and bearing surface of bolt Engine oil As required
9 Outer surface of head idler shaft Engine oil As required
Upper surface of joint section between front case assembly
*c and crankcase assembly and cylinder head gasket contacting Threebond 1211 As required
surface
11A-35
46
Removal and installation of idler gear
11 Idler Gear Bushing Puller MH061779
bushing
31
{ 1.22}
22322
R Service procedure
End play of head idler gear assembly
If any measurement exceeds the specified limit, replace the defective
part(s).
29437
10 9 Installing head idler shaft

Install the head idler shaft 9 as illustrated.
B 9
13 B: Depression
C: Oil hole
CAUTION k
Dont forget to install the thrust plate 13.
C 8
40867
9 WHead idler shaft and head idler gear bushing

[Inspection]
9 11
If the clearance exceeds the specified limit, replace the defective part(s).
29291
Head idler gear bushing.

[Removal]
0 B: Press
B
0: Idler Gear Bush Puller
11
29292
11A-36
11A
[Installation]
0
D Fit the idler gear bushing 11 in the head idler gear 12 in the illustrated
B direction so that the oil holes C may be aligned with each other when
11 press-fitted.
C Using the 0 Idler Gear Bush Puller, press the bushing into the head
idler gear 12 until its end face becomes flush with the chamfered end D
of the gear.
5
B: Press
5
12
29293 After press-fitting, measure the clearance again. If the measurement is
below the specified limit, ream the head idler gear bushing 11 to the
standard value.
Y Cylinder head assembly

15 [Removal]
Loosen and remove the cylinder head bolts 14 in the sequence shown (1
to F). Each cylinder head bolt should be loosened a little at a time.
8 16 13 5
4 12 18 9 1
2 10 17 11 3
6 14 15 7
29451
[Fitting]
14 B CAUTION k
Before fitting any cylinder head bolt 14, check the punch marks B
on its head. Do not use bolt if there are more than two punch
marks.
The punch marks indicate the number of times each bolt has been
tightened using the torque-turn tightening method. Any bolt that
already has three punch marks must be replaced.
21229
Select an appropriate cylinder head gasket 16. P. 11A-38

Apply a coat of specified sealant to the upper surface C of the joint
C 16 section between the frontcase assembly *c and the crankcase assem-
bly *b.
Within 3 minutes after the sealant application, install the cylinder head
*c *b assembly to the crankcase assembly *b together with the cylinder head
gasket 16.
CAUTION k
C
30145 Check to ensure that the sealant application surface C is clean
and free of oil and other foreign matter.
During installation of the cylinder head assembly, use care to
ensure that the sealant is kept in place.
Do not start the engine for at least 1 hour after the cylinder head
assembly is installed.
Whenever the cylinder head bolt 14 is loosened or removed after
the cylinder head assembly has been installed, always apply a
fresh coat of specified sealant.
11A-37
Tighten the cylinder head bolts 14 (1 through O) to a torque of 145
Nm {110 lbf.ft, 15 kgfm}(wet) in the sequence shown.
After tightening,give the bolts an additional 90 degree turn in the se-
11 3 6 14
quence of the numbers shown.
15 7 1 10 18
After tightening the cylinder head bolts 14 using the torque-turn tight-
17 9 2 8 16
ening method, make a punch mark on the head of each one to indicate
13 5 4 12 the times of use.
CAUTION k
29452 Since the cylinder head bolts utilize the torque-turn tightening
method, they must not be tightened further after the angular tight-
ening procedure has been performed.
U Cylinder head gasket

[Removal]
CAUTION k
D Be careful not to scratch cylinder head assembly 15, the crank-
case assembly *b and the front case assembly *c when removing
16 cylinder head gasket 16.
[Installation]
Cylinder head gasket 16 installed must be the one which can accommo-
date the piston projection. Select such a gasket as follows:
Measure the piston projection at each cylinder. P. 11A-62
Select a cylinder head gasket 16 appropriate for the piston projection
average value from the following table.
A B C If any of the piston projection measurements is more than 0.05 mm
*c
*b {0.002 in.} larger than the average value, then use the gasket one rank
higher than that rank (A B, B C).
Size classification Unit: mm {in.}
Average value of Cylinder head gasket
piston projection Size classification Thickness when tightening
40868
0.088 to 0.027
A 0.75 0.03 {0.029 0.0012}
{0.0034 to 0.0106}
0.027 to 0.033
B 0.80 0.03 {0.031 0.0012}
{0.0106 to 0.0129}
0.035 to 0.094
C 0.85 0.03 {0.033 0.0012}
{0.0129 to 0.0370}
The classification (size) of the cylinder head gasket 16 can be known

from the shape of the notches D cut in the gasket edge.
Install the cylinder head gasket 16 on the crankcase *b in the direction
as illustrated.
E: Part number
11A-38
11A
MEMO
11A-39
Cylinder Head Assembly
1
2
3
4
X 5
8
9
T
R
E
T
17
16
T
6 7
Q W
O
15
E
E X
29549
1 Valve collets 10 Exhaust valve seat 16 Stud (short)
2 Upper retainer 11 Inlet valve seat 17 Stud (long)
3 Outer valve spring 12 Sealing cup plug 18 Cylinder head
4 Inner valve spring (22 mm { 0.87 in.})
5 Valve stem seal 13 Sealing cup plug : Non-reusable part
6 Exhaust valve (30 mm { 1.18 in.})
7 Inlet valve 14 Sealing cup plug
8 Exhaust valve guide (40 mm { 1.57 in.})
9 Inlet valve guide 15 Taper plug
P Assembly sequence
CAUTION k
Any valve stem seal 5 removed from an exhaust valve 6 or inlet valve 7 must be replaced.
11A-40
11A
Standard value
Free length 87.8 {3.45} Replace
Outer valve Installed load
3 spring (at 57 {2.24} installed length)
360N {36.7 kgf} Replace
Squareness 2.5 {0.098} Replace

Free length 78.8 {3.10} Replace
Inner valve Installed load
4 spring (at 52.3 {2.05} installed length)
168N {17.1 kgf} Replace
Squareness 2.5 {0.098} Replace
Stem outside diameter f 8

8 0.060 {
{f 00.31
.31 0.0024}}
Replace
f 8 0.075 {f 0.31 0.0029}
Sinkage from cylinder head
0.2 0.25 {0.0079 0.00098} Inspect
6 Exhaust valve bottom surface
Reface or
Valve margin 1.5 {0.059}
replace
Seat angle 45 Correct
[8 {0.31}]0.07 to 0.10 0.2
6, 8 Exhaust valve stem-to-valve guide clearance
{0.0028 to 0.0039} {0.0079}
Replace
f 8 0.025 {f 0.31 0.00098}

Stem outside diameter 8 { 0.31 } Replace
f 8 0.040 {f 0.31 0.00160}
Sinkage from cylinder head
0.2 0.25 {0.0079 0.00098} Inspect
7 Inlet valve bottom surface
Reface or
Valve margin 1.5 {0.059}
replace
Seat angle 45 Correct
[8 {0.31}] 0.03 to 0.06 0.2
7, 9 Inlet valve stem-to-valve guide clearance
{0.0012 to 0.0024} {0.0079}
Replace
Correct or
10 Exhaust valve seat width 2.5 0.2 {0.098 0.0079} 3.5 {0.13}
replace
Correct or
11 Inlet valve seat width 2 0.2 {0.079 0.0079} 2.8 {0.11}
replace
0.2 Correct or
Bottom surface distortion 0.05 {0.0020} or less
{0.0079} replace
18 Cylinder head
Height from top to bottom 106.5
107 0.5 {4.21 0.02} Replace
surface {4.19}

15 Taper plug 14 {10, 1.4}
16, 17 Stud 20 {14, 2.0}

5 Lip of valve stem seal Engine oil As required
6,7 Valve stem Engine oil As required
11A-41
A: Valve Lifter
B: Valve Lifter Seat Obtain Locally
38 {1.49} 21239
1 Removing and installing valve cotters
Valve Lifter Hook Use Equivalent
21240
14.7 {0.57}
Valve Stem Seal
5 26.5 8 Use Equivalent Installing valve stem seals
Installer
{1.04} {0.31}
P29931
Lapping inlet and exhaust valves and valve

6, 7 Valve Lapper Obtain Locally
seats
01958
12
{0.47}
Valve Guide Remover Obtain Locally Removing valve guides
8
{0.31}
01959
8, 9
25.5
{1.0}
Valve Guide Installer MH063604 Installing valve guides
13
{0.51} 29
{1.14}
01960
A: Caulking Tool Body

10, 11 B: Caulking Ring 8 Use Equivalent Installing inlet and exhaust valve seats
{0.31} 38
{1.49} B A
01961
11A-42
11A
R Service procedures
1 Valve cotter
a [Removal]
To remove the valve collets 1, use the a Valve Lifter, b Valve Lifter
1
Hook and c Valve Lifter Seat to evenly compress the valve springs 3, 4.
c
[Installation]
b To install valve collets, follow the removal instructions in reverse.
29550
5 Installing valve stem seals

0 Apply engine oil to the lip A of the valve stem seal 5.
Install the valve stem seal 5 using the 0 Valve Stem Seal Installer.
6, 7 Strike the 0 Valve Stem Installer until it sits snugly on the cylinder
head 18.
A
5
CAUTION k
After installing the valve stem seal 5, check that its spring area is
neither deformed nor damaged.
29552
6 7 Inlet and exhaust valves

[Inspection]
(1) Valve stem outside diameter
Replace the valve 6, 7 if its stems outside diameter is below specifica-
tion or severely worn.
6, 7
CAUTION k
Whenever a valve 6, 7 is replaced, be sure to lap the valve and
01965 valve seat 10, 11. P. 11A-45.
(2) Valve seat angle and valve margin

Reface or replace the valve 6, 7 if the valve seat angle or valve margin
exceeds the specified limits.
6, 7
A: Valve seat angle
B: Valve margin
A
B
02264
11A-43
[Rectification]
NOTE:
Keep grinding to a minimum.
If the valve margin is below specification after grinding, replace
the valve 6, 7.
After grinding, be sure to lap the valve 6, 7 and valve seat 10, 11.
P. 11A-45
01966
6 to 9 Valve and valve guides

[Inspection]
If any clearance exceeds the specified limit, replace the defective part(s).
6, 7
29553
Valve guides
[Removal]
0
0: Valve Guide Puller
8, 9
[Installation]
29554
Using the 0 Valve Guide Installer, install the valve guide 8, 9 until the tool
sits snugly on the cylinder head 18.
0 CAUTION k
18 The valve guides 8, 9 must be pressed in to the specified depth.Be
sure to use the 0 Valve Guide Installer for this operation.
Exhaust valve guides 8 are longer than inlet valve guides 9.Be
sure to install the correct type of guide in each location.
8, 9
29555 6 7 Q W Valves and valve seats

[Inspection]
Apply an even coat of prussian blue to the valve seat 10, 11 surface A
A 0 that makes contact with the valve 6, 7.
6, 7 Strike the valve 6, 7 against the valve seat 10, 11 once. Do not rotate
the valve during this operation.
0: Valve Lapper
NOTE:
Carry out these inspections after inspecting the valves 6, 7 and
29556
valve guides 10, 11.
11A-44
11A
If the prussian blue deposited on the valve 6, 7 indicates a poor con-
tact pattern, rectify the contact pattern as follows:
Contact Corrective action
Minor defect Lapping
Serious defect Reface or replace valve and valve seat
01969
[Refacing]
6, 7
Lap the valve in accordance with the following procedure:
Apply a thin, even coat of lapping compound to the surface B of the
C valve 6, 7 that makes contact with valve seat 10, 11.
CAUTION k
B
Ensure that no compound adheres to the stem C of the valve 6, 7.
01970
NOTE:
Start with intermediate-mesh compound (120 to 150 mesh) and
finish with fine-mesh compound (200 mesh or more).
The addition of a small amount of engine oil makes lapping com-
pound easier to apply.
Strike the valve 6, 7 against the valve seat 10, 11 while turning it little
by little.
0
0: Valve Lapper
6, 7 Wash away the compound with cleaning fluid.
Apply engine oil to the contact surfaces of the valve seat 10, 11 and
10, 11
rub it in so that the contact surfaces are lubricated and mate together
snugly.
Inspect the contact pattern of the valve 6, 7 and valve seat 10, 11 once
more.
29557
If the contact pattern is still defective, replace the valve seat 10, 11.
Q W Valve seats
[Inspection]
6, 7
(1) Valve seat width
10, 11
If the measurement exceeds the specified limit, rectify or replace the
A valve seat 10, 11.
A: Valve seat width
NOTE:
01975
Whenever a valve seat 10, 11 is rectified or replaced, be sure to
lap the valve seat and valve 6, 7. P. 11A-45
11A-45
(2) Valve sinkage from cylinder head bottom surface
6, 7 If any measurement exceeds the specified limit, rectify or replace the
defective part(s).
10, 11
B: Valve sinkage
B 02265
[Rectification]
B C
Grind the valve seat 10, 11 using a valve seat cutter or valve seat
grinder.
Use a 15 or 75 cutter to achieve the specified valve seat width A of
A the valve 6, 7.
10, 11 After grinding, put some sandpaper of around #400 grade between the
6, 7 cutter and valve seat and grind the valve seat lightly.
C: Valve seat angle
29558
CAUTION k
Ensure that grinding does not cause the sinkage B of the valve 6,
7 to exceed the specified limit.
After rectification, lap the valve 6, 7 and valve seat 10, 11.
P. 11A-45
[Removal]
10, 11
Valve seats 10, 11 are installed by expansion fitting. To remove a valve
seat, grind the inside surface to reduce its thickness, then remove the
valve seat at room temperature.
D: Material to be ground
D 0.5 to 1.0 mm
{0.02 to 0.039}
01973
[Installation]
Check that the valve seat hole diameter E in the cylinder head 18 con-
forms with the value shown below.
Unit: mm {in.}
1A
1 A
1B
2A
38 {1.49 }
2 B
2B
E
29559
11A-46
11A
Cool the valve seat 10, 11 by immersing it in liquid nitrogen.
Install the valve seat 10, 11 in the cylinder head 18 using the a Caulk-
ing Tool Body and the b Caulking Ring.
G H
a CAUTION k
For installation, the chamfered side F of the b Caulking Ring
F must be against the valve seat 10, 11.
b
G: Configuration for installation
Invert the b Caulking Ring such that its chamfered side F is against
the a Caulking Tool Body, then caulk the valve seat 10, 11.
F H: Configuration for caulking
After installing the valve seat 10, 11, lap the valve seat and valve 6, 7.
P. 11A-45
10, 11
29560
E to T Installing sealing cup plugs

12 Drive the sealing cups 12 to 14 in the cylinder head 18 until the specified
13
depth is reached.
12
14
13 2 mm 12
12 {0.079 in}
12, 14
12
12
29561
O Inspecting cylinder head

Measure the extent of distortion in the cylinder head 18 bottom surface.
If the degree of distortion exceeds the specified limit, rectify the distortion
with a surface grinder.
CAUTION k
Ensure that grinding does not cause the cylinder head 18 top sur-
face-to-bottom surface distance to fall below the specified limit.
29562
11A-47
FRONT CASE
15
14
13 *a
12 24
J
11
*b
10 *c
F H
9
8
16
6 19 22
17
18 S
4
3 20
2
1
5
29296
1 Bolt 13 Washer 22 O-ring
2 Washer 14 Rubber 23 Front oil seal
3 Spacer 15 Breather cover 24 Bolt
4 Insulator 16 Engine speed sensor 25 Front case
5 Front case cover B ELECTRICAL 26 Front oil seal slinger
6 Spacer 17 Bolt
7 Front case rubber insulation 18 Power steering oil pump *a: Fan shaft assembly
8 Nut assembly P. 11A-52
9 Fan pulley B Group 37 *b: Upper crankcase
10 Bolt 19 O-ring P. 11A-76
11 Water pump assembly 20 Bolt *c: Balance shaft assembly LH
B Group 14 21 Vacuum pump assembly P. 11A-52
12 Bolt B Group 35 : Non-reusable part
CAUTION k
When the vacuum pump assembly 21 is removed, be sure to follow the specified procedure. Blind removal will
result in failure of the assembly being positioned with the balance shaft assembly LH *c.
Do not remove the front oil seal 23 unless something wrong is evident.
P Assembly sequence
11A-48
11A

1 Bolt (mounting front case cover) 2.9 to 3.9 {2.2 to 2.9, 0.3 to 0.4}
8 Nut (mounting fan pulley) 196.1 {145, 20.0}
10 Bolt (mounting water pump assembly) 23.5 {17, 2.4}
12 Bolt (mounting breather cover) 2.9 {2.2, 0.3}
16 Engine speed sensor 29.4 {22, 3.0}
17 Bolt (mounting power steering oil pump assembly) 23.5 {17, 2.4}
20 Bolt (mounting vacuum pump assembly) 23.5 {17, 2.4}
24 Bolt (mounting front case) 23.5 {17, 2.4}

16 Threaded portion of engine speed sensor THREEBOND 1104J As required
19, 22 All around O-ring Engine oil As required
23 Lip of front oil seal Engine oil As required
25 Front case mounting surface THREEBOND 1207C or D As required
R Service procedure
S Installation of vacuum pump assembly
The vacuum pump assembly 21 serves also to position the balance shaft
assembly LH *c. For this reason, before the assembly is installed, the
balance shaft assembly must be kept in the right position by the following
procedure.
Place the piston of cylinder No. 1 at the top dead center on the com-
pression stroke.
Remove plug A from the upper crankcase *b.
Insert a screwdriver into the hole from which the plug A was removed
until it slightly touches the balance shaft assembly LH *c.
*b
CAUTION k
Be sure not to force the screwdriver in, as there is danger of dam-
A age to the No. 1 journal of the balance shaft assembly LH *c.
*c Slowly rotate the balance shaft assembly LH *c to align the tip of the
21 screwdriver with the shaft support hole B in the No. 1 journal of the
balance shaft.
B
Supporting the balance shaft by inserting the screwdriver in the hole,
29297 install the vacuum pump assembly 21.
After the installation, remove the screwdriver.
11A-49
FRONT CASE
25
F Installation of front oil seal
23 Install the front oil seal 23 on the front case 25 in the illustrated direction
after applying engine oil to the lip A.
B: Front of vehicle
B
29298
H Installation of front case

Apply sealant A evenly without any break to the mounting surface of
the front case 25 as shown. (Approx. 1 mm { 0.0393})
After application of sealant A, install the front case 25 in less than
three minutes.
25 CAUTION k
A Check to ensure that the sealant application surface is clean and
free from any oil and other deposits.
29363
When installing the parts, make sure that the sealant is not forced
out of position.
Do not start the engine less than an hour after installation.
If the mounting bolts were loosened or removed after installation
of the front case 25, be sure to re-apply sealant A.
J Installation of front oil seal slinger

Install the front oil seal slinger 26 on the fan shaft assembly *a in the
illustrated direction.
*a
26
29364
11A-50
11A
MEMO
11A-51
TIMING GEARS AND BALANCE SHAFTS
5
*b
6
4 3
*c
23
D
2 *d
1
A 9
11
41
Q 21 *a
40
T
A 13
E
16
7 15
8 42
A
43
19 I
O
24
31
39
30
29
28
27
26
B 37
38
36
35
34
32
40869
11A-52
11A
P. 11A-55
1 Bolt 20 No. 1 idler shaft 38 Thrust plate
2 Thrust plate 21 Bolt 39 Balance shaft LH
3 Idler gear assembly 22 Oil pump assembly 40 Bolt
4 Idler gear bushing B Group 12 41 Injection pump bearing
5 Idler gear 23 O-ring housing assembly
6 Idler shaft 24 Bolt 42 Bearing
7 Bolt 25 Balance shaft assembly RH 43 Injection pump bearing
8 Fan shaft case assembly 26 Nut housing
9 Thrust plate 27 Balance shaft gear RH
10 Fan shaft case bushing 28 Thrust spacer *a: Crankshaft gear P. 11A-76
11 Fan shaft case 29 Key *b: Upper crankcase
12 Fan shaft assembly 30 Thrust plate P. 11A-76
13 Bolt 31 Balance shaft RH *c: Injection pump gear
14 Fan gear shaft 32 Bolt B Group 13
15 Bolt 33 Balance shaft assembly LH *d: Lower crankcase
16 Thrust plate 34 Nut P. 11A-76
17 No. 1 idler gear assembly 35 Balance shaft gear LH
18 No. 1 idler gear bushing 36 Thrust spacer A: Locating pin
19 No. 1 idler gear 37 Key : Non-reusable part
CAUTION k
For details on the balance shaft removal and installation procedures, refer to P. 11A-84.
P Assembly sequence
11A-53
Standard value
Idler gear assembly and fan
0.09 to 0.13 {0.0035 to 0.0051} 0.3 {0.012}
shaft assembly
Fan shaft assembly and No. 1
0.06 to 0.10 {0.0024 to 0.0039} 0.3 {0.012}
idler gear assembly
No. 1 idler gear assembly and
0.11 to 0.13 {0.0043 to 0.0051} 0.3 {0.012}
Backlash crankshaft gear
Replace
between gears No. 1 idler gear assembly and
0.09 to 0.12 {0.0035 to 0.0047} 0.3 {0.012}
injection pump gear
Crankshaft gear and oil pump
0.12 to 0.15 {0.0047 to 0.0059} 0.3 {0.012}
gear
Balance shaft gear RH and oil
0.19 to 0.22 {0.0075 to 0.0087} 0.3 {0.012}
pump gear
Idler gear assembly 0.10 to 0.20 {0.0039 to 0.0079} 0.3 {0.012}
Fan shaft assembly 0.07 to 0.19 {0.0028 to 0.0075} 0.3 {0.012}
End play of
each gear and No. 1 idler gear assembly 0.15 to 0.25 {0.0059 to 0.0098} 0.3 {0.012} Replace
shaft
Balance shaft RH 0.1 to 0.2 {0.0039 to 0.0079] 0.3 {0.012}
Balance shaft LH 0.1 to 0.2 {0.0039 to 0.0079} 0.3 {0.012}
Clearance between idler gear bushing and idler [51 {2.0}] 0.02 to 0.06 0.1
4, 6 shaft {0.00079 to 0.0024} {0.0039}
Replace
Clearance between fan shaft case bushing and fan [41 {1.61}] 0.03 to 0.07 0.1
10, 12 shaft assembly {0.0012 to 0.0028} {0.0039}
Replace
Clearance between fan shaft assembly and fan [36 {1.41}] 0.01 to 0.05 0.1
12, 14 gear shaft [36] 0.01 to 0.05 {0.00039 to 0.0020} {0.0039}
Replace
Clearance between No. 1 idler gear bushing and [59 {2.32}] 0.03 to 0.07 0.1
18, 20 No. 1 idler shaft {0.0012 to 0.0028} {0.0039}
Replace
0.05
25 Bend of balance shaft assembly RH 0.025 {0.00098}
{0.002}
Replace
0.05
33 Bend of balance shaft assembly LH 0.025 {0.00098}
{0.002}
Replace

1 Bolt (mounting idler shaft) 23.5 {17, 2.4}
7 Bolt (mounting fan shaft case assembly) 23.5 {17, 2.4}
13 Bolt (mounting fan gear shaft) 23.5 {17, 2.4}
15 Bolt (mounting No. 1 idler shaft) 44.1 {33, 4.5}
21 Bolt (mounting oil pump assembly) 27.4 {20, 2.8}
24 Bolt (mounting balance shaft assembly RH) 23.5 {17, 2.4}
26 Nut (mounting balance shaft gear RH) 96.1 {71, 9.8} Wet
32 Bolt (mounting balance shaft assembly LH) 23.5 {17, 2.4}
34 Nut (mounting balance shaft gear LH) 96.1 {71, 9.8} Wet
Bolt (mounting injection pump bearing housing
40 assembly)
27.4 {20, 2.8}
11A-54
11A
Lubricant
3, 17 Inside surface of bushing of each gear Engine oil As required
6, 12, Outside circumference of each shaft Engine oil As required
14, 20
23 All around O-ring Engine oil As required
25, 33 Journal portions of balance shaft Engine oil As required
26, 34 Threaded portion of nut Engine oil As required
50
{1.97}
Installation and removal of idler gear
4 Idler Gear Bushing Puller Use Equivalent
bushing
46.5
{1.83} P29270
40
{1.57}
Installation and removal of fan shaft case

10 Idler Gear Bushing Puller Use Equivalent
bushing
37
{1.45}
P29270
58
{2.28}
Installation and removal of No. 1 idler gear

18 Idler Gear Bushing Puller MH062541
bushing
54.5
{2.14} P29270
R Service procedure
(1) Backlash between gears
On a pair of gears, measure backlash at more than three positions. If
the reading is more than the limit, replace defective parts.
29273
11A-55
(2) End play of each gear and shaft
29274
3 E I D Installation of timing gears

Install the timing gears in the following sequence.
Place the piston of No. 1 cylinder at the top dead center to position the
crankshaft gear *a.
Install the gear of the oil pump assembly 22 while aligning the align-
12 ment marks 6 and 7 with those on the crankshaft gear *a and bal-
2
2 ance shaft gear RH 27, respectively.
3 2
Install No. 1 idler gear assembly 17 while aligning the alignment marks
4 4
4 1 and 3 with those on the crankshaft gear *a and injection pump
3
27 gear *c, respectively.

3
7
7
Install the fan shaft assembly 12 while aligning the alignment mark 2
7 with that of No. 1 idler gear assembly 17.
*c
22 Install the idler gear assembly 3 while aligning the alignment mark 4
17 with that of the fan shaft assembly 12.
6
*a
6
6
1
1
29275
4 6 Idler gear bushing and idler shaft

[Inspection]
4 6
29276
Idler gear bushing

B
[Removal]
0 B: Press
0: Idler Gear Bushing Puller
4
29277
11A-56
11A
[Installation]
0
B Face the idler gear 5 in the illustrated direction. Using 0 Idler Gear
C Bushing Puller, press-fit the idler gear bushing 4 into the idler gear up
to the chamfered portion C.
B: Press
4
After press-fitting the bushing, re-measure the clearance. If the read-
5 ing is less than the standard limits, ream the idler gear bushing 4 until
the clearance falls within the standard limits.
29278
9 Installation of thrust plate

9 Install the thrust plate 9 with that side which does not have oil grooves B
toward the fan shaft case 11.
11
B
29279
Q E Fan shaft case bushing and fan shaft assembly

10 12 [Inspection]
If the clearance is more than the limit, replace defective parts.
29280
Fan shaft case bushing

B
[Removal]
0 B: Press
10
29281
0 [Installation]
B Face the fan shaft case in the illustrated direction. Using 0 Idler Gear
Bushing Puller, press-fit the fan shaft case bushing up to the cham-
C
fered portion C of the fan shaft case.
10 B: Press
After press-fitting the bushing, re-measure the clearance. If the read-
ing is less than the standard limits, ream the fan shaft case bushing 10
until the clearance falls within the standard limits.
11 29282
11A-57
E T Fan shaft assembly and fan gear shaft
[Inspection]
T Installation of fan gear shaft

12
Install the fan gear shaft 14 with its oil hole upward.
14
29283
O A No. 1 idler gear bushing and No. 1 idler shaft

18 20 [Inspection]
29284
Idler gear bushing

B
[Removal]
0 B: Press
18 29285
[Installation]
B Face the No. 1 idler gear 19 in the illustrated direction. Using 0 Idler
0 Gear Bushing Puller, press-fit the idler gear bushing up to the cham-
C fered portion C of the No. 1 idler gear.
18
B: Press
19 After press-fitting the bushing, re-measure the clearance. If the read-
ing is less than the standard limits, ream the No. 1 idler gear bushing
2
18 until the clearance falls within the standard limits.

2
29286
11A-58
11A
H B Balance shaft assembly
[Inspection]
B C Check the balance shaft assemblies RH 25 and LH 33 for bend.
Measure the balance shaft bend at No. 2 journal D while supporting
the shaft at No. 1 journal B and No. 3 journal C.
D
NOTE
The bend of the balance shaft assemblies RH 25 and LH 33 is one
29287 half of the reading of the dial indicator taken after turning the bal-
ance shaft assembly through a rotation.
If the reading exceeds the limit, disassemble the balance shaft assem-
bly RH 25, LH 33, and replace the balance shaft RH 31, LH 39.
31 [Disassembly]
30 The nut 26 of the balance shaft RH 31 and the nut 34 of the balance
29
28 shaft LH 39 are different in the thread cutting direction.
27 Remove the nut 26 by turning counter-clockwise. Remove the nut 34
26
by turning clockwise.
39
38
37
35 36
34 29288
[Assembly]
31 Of the balance shaft RH 31 and LH 39, one with a shaft support hole D
30 39
29 ( 5 mm { 0.2 in.}) in No. 1 journal is the balance shaft LH 39.
28
E Install the thrust plates 30 and 38 in the illustrated direction.
26 27
35 E: Oil groove
34 D
Install the balance shaft gears RH 27 and LH 35 in the illustrated direc-
38 tion.
37
7
36 Install the nut 26 by turning clockwise. Install the nut 34 by turning

8
8
counter-clockwise.
29289
[Installation]
The installation position of the balance shaft assembly RH 25 is deter-
mined by the gears to put in mesh when oil pump assembly 22 is in-
stalled. P. 11A-49
The balance shaft assembly LH 33 is not brought in mesh with any
gear until when the vacuum pump assembly is installed with the front
*b case attached. Therefore, the following steps must be performed be-
fore installation.
B 33 Remove the plug G from the upper crankcase *b.
Insert a screwdriver from the hole from which the plug G was re-
moved into the shaft support hole E ( 5 mm { 0.2 in.}) provided in
the No. 1 journal B of the balance shaft assembly LH 33 to support
G E the balance shaft assembly.
29290 Align the alignment marks of all the timing gears. P. 11A-56
By so doing, the balance shaft assembly LH 33 can be positioned.
Keep it in position until the vacuum pump assembly is installed
( P. 11A-49).
11A-59
PISTONS, CONNECTING RODS AND CYLINDER LINERS
5 P. 11A-61
P Removal sequence
4 1 Bolt
*b
5 Piston and connecting rod assembly
P. 11A-65
6 Cylinder liner
*a
6
*a: Crankshaft assembly P. 11A-76
*c
*b: Upper crankcase P. 11A-76
*c: Lower crankcase P. 11A-76
*d: Oil pan B Group 12
T1
2 *e: Oil strainer B Group 12
3
*e NOTE:
Since the bolts 1 (for installing connect-
ing rod cap 3) utilize the torque-turn tight-
ening method, they must not be removed
*d unless it is absolutely necessary.
29524 P Installation sequence

Standard value
Inspect
Piston protrusion 0.09 to 0.09 {0.0035 to 0.0035} each
location
Connecting rod end play 0.15 to 0.45 {0.0039 to 0.018} 0.6 {0.024} Replace
[65 {2.56}] 0.04 to 0.09 0.2
Oil clearance Replace
Connecting {0.0016 to 0.0035} {0.0079}
2,4 rod bearing Less than
Span when free
69.5 {2.73}
Piston and connecting rod assembly-to-cylinder [114 {4.49}] 0.135 to 0.155
5,6 Liner clearance {0.0053 to 0.0061}
Replace
Flange projection 0.01 to 0.07 {0.00039 to 0.0028} Replace

114 to 114.02 114.25
Inside diameter Replace
Cylinder { 4.4881 to 4.4889} { 4.498}
6 liner Cylindricity 0.03 {0.0012} or less Replace
Difference in cylinder liner flange
0.04 {0.0016} or less Replace
projection from adjacent cylinders

1 Bolt (connecting rod cap installation) 29 {22, 3} +90 Wet
11A-60
11A
Lubricant
1 Bolt threads Engine oil As required
2, 4 Connecting rod bearing inside surface Engine oil As required
6 Portions of cylinder liner held by upper crankcase Engine oil As required
A
A: Piston Guide Clamp A: MH063432 Installing piston and connecting rod
5 B: Piston Guide Lever
B
B: MH061658 assembly
01981
Cylinder Liner Extractor MH062537 Removing cylinder liners
30008
6 Cylinder Liner Installer MH063606 Installing cylinder liners
113.5
{ 4.46} 30010
B M14 x 2
A: Adapter 40 C A: MH063433 Measuring cylinder liner flange projection
B: Bolt {1.57} B: MF130625 amount and their difference from adjacent
C: Washer A C: MH005012 cylinders.
30009
R Service procedure
CAUTION k
A The cylinder liners 6 may be forced out if the upper crankcase *b
6 is turned over or if the crankshaft assembly *a is rotated with the
pistons inserted. Before beginning with inspection procedures,
*b
be sure to hold each cylinder liner at its flange section using a
washer A or a similar tool.
29525
11A-61
(1) Piston protrusion from crankcase top surface
*b
NOTE:
B The piston protrusion affects engine performance and must there-
fore be checked.
Set the piston at top dead center.

A
Make standard points A (five points) on upper crankcase assembly *b
the 0 (zero) point and measure any protrusion relative to this point.
Measure at four points on each piston at the nearest standard point
29323
from the zero point and produce the average value.
B: Measurement point (16 points)
If the average value is out of specification, check the clearances be-
tween all relevant parts.
(2) Connecting rod end play

Measure the end play every connecting rod.
part (s).
29526
(3) Cylinder liner flange protrusion amount and its difference

between adjacent cylinders.
c
A Install the a Adapter on the upper crankcase in such a way that it
b
a may not ride on the flange A of the cylinder liner 6 and secure it by
tightening the b Washer and c Bolt to a torque of 49 Nm {36 lbf.ft,
6 *b 5 kgfm}.
29527
Measure the protrusion amount B of flange of the cylinder liners 6.

6 If the measurement is out of specification, replace the defective part(s).
Calculate the differences of the protrusion amounts between adjacent
B cylinders. If any difference is out of specification, check the mounting
condition of the liners and replace the defective part(s).
CAUTION k
If the cylinder liner 6 flange protrusion is insufficient, bearing pres-
sure on the cylinder head gasket will be too low in the region of
29528 the bore, possibly causing gas to leak.
11A-62
11A
2 4 A 2 4 Connecting rod bearings
A [Installation]
Fit the lower connecting rod bearing 2 into the connecting rod cap 3, and
3 fit the upper connecting rod bearing 4 into the piston and connecting rod
B
assembly 5. Make sure the lugs A on the bearings are fitted into their
respective grooves.
CAUTION k
5
29529 The upper connecting rod bearing 4 has an oil hole B. The lower
connecting rod bearing 2 has no oil hole. Take care not to confuse
the upper and lower parts.
[Inspection]
CAUTION k
Do not attempt to manually expand a connecting rod bearing 2, 4
if its span is insufficient.
Upper and lower connecting rod bearing 2,4 must be replaced as
a set.
(1) Span when free

If the span is less than the specified requirement, replace the upper
and lower connecting rod bearings 2, 4 as a set.
2, 4
01995
(2) Connecting rod bearing-to-crankshaft pin clearance

(oil clearance)
5 Fit the lower connecting rod bearing 2 into the connecting rod cap 3,
and fit the upper connecting rod bearing 4 into the piston and connect-
4 ing rod assembly 5. Then, tighten the bolts 1 to the specified torque.
Measure the inside diameter of the connecting rod bearings 2, 4 and
2 the outside diameter of the crankshaft *a pin A. If the clearance ex-
3 ceeds the specified limit, replace the defective part(s).
1 If the connecting rod bearing 2, 4 have to be changed to undersized
ones, adjust crankshaft *a pin outer diameter A in accordance with the
29530
specified procedure to fit the undersized dimensions. P. 11A-82
*a
A
03627
11A-63
6
5 Installing piston and connecting rod assembly
B
Ensure the gaps of the piston rings A remain in their correct positions.
A P. 11A-70
Check that the size marks B on the piston and cylinder liner are the
5 same. P. 11A-65
Use care to prevent the connecting rod C from damaging the cylinder
C liner 6 and crankshaft pin.
29531
With the pistons front mark p facing the front of the engine D, care-
p
a fully insert the piston and connecting rod assembly into the cylinder
liner.
Using the bolt E of the b Piston Guide Lever, adjust the inside diam-
eter of the a Piston Guide Clamp such that it matches the pistons
b outside diameter.
After adjustment, remove it from the piston and smear engine oil over
the following items:
E
Outside of piston
Inside of the a Piston Guide Clamp
29327 Inside of the cylinder liner
b a
29532
With the piston installed, align the mating marks F on the connecting
3 rod and connecting rod cap 3 and tighten the bolts 1 to the specifica-
tion.
Tighten bolts 1 alternately in the following manner.
First tighten to a torque of 29 Nm {22 ft.lbs, 3 kgfm}.
Then tighten further 90 5.
F
1 NOTE:
After installation of connecting rod cap 3, inspect the following points:
29533 End play of the connecting rod: P. 11A-62
Piston Protrusion: P. 11A-62
11A-64
11A
5 6 Piston-and-connecting rod assembly and cylinder liners
[Inspection]
58.6 mm Take measurements to determine the clearance between the piston
and cylinder liner 6.
A: Outside diameter measurement position
B: Direction of crankshaft axis
C: Perpendicular to crankshaft axis
If the clearance is out of specification, replace the defective part(s).

185 mm 03375
75 mm
20 mm
C B
02003
Cylinder liners
[Removal]
0
0: Cylinder Liner Extractor
29534
[Installation]
10 A, B Select a cylinder liner 6 which has the same size mark as those stamped
on the upper crankcase *b and the piston.
The size marks on the upper crankcase *b are arranged in the order of
No. 1, 2, 3 and 4 cylinders starting from the engine front C.

1A, 1B 1A
2A, 2B 29535 1 A
1B
*1 1, 2
C 2A
2 B
2B
29536
11A-65
Apply engine oil to the indicated parts of the cylinder liner 6.
22028
0 Using the 0 Cylinder Liner Installer, gently tap down the cylinder liner
6 until it is snugly seated on the upper crankcase *b.
6
*b
CAUTION k
The cylinder liner 6 is thin in wall thickness.
Use utmost care when handling it.
30011
11A-66
11A
Piston and Connecting Rod Assembly
1 Snap ring
5 2 Piston pin
6 3 Connecting rod bushing
4 Connecting rod
7 5 1st compression ring
6 2nd compression ring
7 Oil ring
2 8 Piston
8
1 P Assembly sequence
3
4
29537

Piston pin-to-connecting small end bushing [36 {1.42}] 0.03 to 0.04 0.1
2, 3 clearance {0.0012 to 0.0016} {0.0039}
Replace
[36 {1.42}] 0.007 to 0.021 0.05

2, 8 Piston pin-to-piston clearance
{0.00028 to 0.00083} {0.002}
Replace
0.05
Connecting rod bend Replace
{0.002}
4
0.1
Connecting rod twist Replace
{0.0039}}
1st compression ring 0.3 to 0.45 {0.012 to 0.018} 1.5 {0.059}
Piston ring end
5 to 7 gap
2nd compression ring 0.4 to 0.55 {0.016 to 0.022] 1.5 {0.059} Replace
Oil ring 0.3 to 0.5 {0.012 to 0.02} 1.5 {0.059}
0.2
1st compression ring 0.02 to 0.10 {0.00079 to 0.0039}
Piston ring-to- {0.0079}
piston ring 0.15
5 to 8 groove
2nd compression ring 0.07 to 0.10 {0.0028 to 0.0039}
{0.0059}
Replace
clearance 0.15
Oil ring 0.03 to 0.06 {0.0012 to 0.0024}
{0.0059}
Lubricant
2 Piston pin outer surface Engine oil As required
3 Connecting rod bushing outer surface Engine oil As required
4 Bushing installation surface of connecting rod Engine oil As required
11A-67
Use Locally
Connecting Rod Bushing Removing and installing connecting rod
3 Puller Kit
Manufactured
bushings
Equivalent
02015
60 to 120
{ 2.36 to 4.72}
5 to 7 Piton Ring Tool Obtain Locally Removing and installing rings
02013
R Service procedure
2 3 Piston pin and connecting rod
[Inspection]
If the clearance exceeds the specified limit, replace the defective part(s).
2
03634
Connecting rod bushing

0 Replace the connecting rod bushing 3 using the 0 Connecting Rod Bush-
ing Puller Kit.
(Components of the 0 Connecting Rod Bushing Puller Kit)
A: Collar
B: Collar
C: Puller
D: Base
E: Bracket
02019 F: Plate
C H G: Nut
[Removal]
A Remove the upper bearing (if fitted) from the big end of the connecting
3 rod 4.
E 4
F
Mount the connecting rod 4 on the base D and lock it in position with
the bracket E and place F.
Fit the Collar A over the Puller C in the direction shown. Then, slowly
apply pressure of approximately 49 kN (11020 lbf, 5,000 kgf) H until
D the connecting rod bushing 3 is pressed out.
02020
11A-68
11A
[Installation]
Apply engine oil to the small end of the connecting rod 4 and to the
4 outer surface of the connecting rod bushing 3.
Fit the Collar B over the Puller C, position the connecting rod bushing
3 and the Collar A, and lock this arrangement together with the Nut G.
Align the oil holes J in the connecting rod bushing 3 and in the small
3 J end of the connecting rod 4. Then, use a press to slowly apply pres-
H sure of approximately 49 kN (11020 lbf, 5,000 kgf) H until the bushing
is pressed into place.
C
B After press-fitting the connecting rod bushing 3, ream it to achieve the
specified normal clearance between the bushing and piston pin 2.
3
NOTE:
A After reaming the connecting rod bushing 3, insert the piston pin
2 and check that it turns smoothly and without play.
29538
2 4 8 Piston Pin, connecting rod, and piston.

[Removal]
8
1 2 Removal the snap ring 1 and tap out the piston pin 2 using a rod A and
A
hammer.
If the piston pin 2 is difficult to remove, heat the piston 8 in hot water or
using a piston heater.
29539
[Installation]
Apply engine oil to the piston pin 2. With the connecting rod 4 and
A piston 8 and aligned as illustrated, insert the piston pin to hold these
components together.
p A: Weight mark
B: Weight mark (A through G: A stands for the largest weight)
C: Alignment mark for connecting rod cap
p: Front mark
If the piston pin 2 is difficult to insert, heat the piston pin 8 in hot water
2
or using a piston heater.
1 8
CAUTION k
Make sure that all pistons have the same weight mark.
4 The connecting rods must all have the same weight mark.
After inserting the pin 2, check that it turns smoothly and without
C play.
B
29540
11A-69
2 8 Piston pin-to-piston clearance
8 If the clearance exceeds the specified limit, replace the defective part(s).
02016
A 4 Connecting rod bend and twist

Fit the connecting rod bushing 3 and piston pin 2 in their respective
C positions of the connecting rod 4.
100 mm
{3.94 in.} Measure the extent of bending A and twisting B in the connecting rod
4. If either measurement exceeds the specified limit, replace the con-
2 necting rod.
C: Connecting rod aligner (Measurement device)
NOTE:
02039
Before mounting the connecting rod 4 on the connecting rod
aligner C, install the upper and lower connecting rod bearings in
their respective positions. P. 11A-64
Measurements must be made with the connecting rod cap mount-
B
ing bolts tightened to the specification. P. 11A-64
100 mm
{3.94 in.}
2
C
02040
5 to 8 Piston rings and piston

0 Piston rings
[Removal]
0: Piston Ring Tool
29334
[Installation]
B D Fit the oil ring 7 onto the piston 8 with its gap A and the expander
spring end joint B in the position illustrated.
p Fit the piston ring 5, 6 onto the piston 8 such that the manufacturers
marks C near the gaps face upward.
Align the gaps D, E of the piston ring 5, 6 as illustrated.
E A D: 1st compression ring gap
C E: 2nd compression ring gap
8 5, 6
p: Front mark
29335
11A-70
11A
[Inspection]
F (1) Piston ring end gap
Using the crown of a piston 8, push the piston ring 5, 6 or 7 horizontally
8 into a cylinder liner F in the upper crankcase for measurement.
Taking care not to remove the piston ring 5, 6 or 7, measure the end
G gap using a thickness gauge G. Replace all the rings of piston if any
gap exceeds the specified limit.
5 to 7
29336
NOTE:
To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them
into the cylinder liner F using a piston 8.
Push the piston ring 5, 6 or 7 down to the bottom of cylinder liner
F; the bottom should be less worn than the top.
Piston rings 5, 6 or 7 must be replaced as a set. Never replace
piston rings individually.
(2) Piston ring-to-piston ring groove clearance

8
5 to 7 part(s).
Measure the 1st compression ring 5 clearance with a thickness gauge
G while pressing the ring against the piston 8 with a straight edge H.
NOTE:
Remove any carbon deposits from the ring groove of the piston 8
and measure the clearance around the pistons entire periphery.
Piston ring 5, 6, 7 must be replaced as a set. Never replace piston
29713
G rings individually.
8
5
02026
11A-71
FLYWHEEL
1
2, 3
4
A
6
5
41233
1 Bolt 4 Flywheel assembly *: Crankshaft assembly
2 Plate 5 Ring gear P. 11A-76
3 Pilot bearing 6 Flywheel A: Locating pin
P Assembly sequence
CAUTION k
Make sure that the mounting surface of the flywheel assembly 4 is free from any foreign substances, oil and
detrimental flaws.
After installing flywheel assembly 4, check for runout.
NOTE
Do not remove the pilot bearing 3 or ring gear 5 unless an abnormality is evident.

1 Blot (flywheel assembly installation) 39.0 {29.0, 4.0} +40 Wet
11A-72
11A
Lubricant
1 Blot threads Engine oil As required
Socket Wrench Obtain Locally
Width across
flats: 22 {0.87} P01984
4 Installation of flywheel
Magnet Base Obtain Locally
00471
11A-73
FLYWHEEL
R Service procedure
[Installation]
a
D Tighten the bolts 1 to the specified torque (39.0 Nm {29 ft.lbs, 4.0
kgfm}. After that, turn the bolts further in accordance with the follow-
C ing procedure.
E Turn the holder C of the a Socket Wrench counterclockwise to the
F
tension the built-in spring.
D: Socket
E: Rod
F: Rod (extension)
01991
Fit the b Magnet Base on the flywheel at a position where it can

come in contact with the Rod F (for extension) as shown in the illustra-
H 10
tion.
Set the rod F (for extension) such that it may be pressed against the
G b Magnet Base by the spring force.
a Align any inscribed line G on the holder C with any inscribed line H on
the socket D. (Use this point as reference 0 position.)
From the above reference position, turn the socket D clockwise by 40
to tighten the bolt further.
b F 41234
11A-74
11A
5 Ring gear
[Inspection]
Inspect ring gear 5 for damage and abnormal wear. If any defect is evi-
dent, the ring gear must be replaced.
[Removal]
Heat the ring gear 5 evenly with an acetylene torch or the like.
5 WARNING k
41238
Remove the ring gear 5 from the flywheel by tapping around its entire
periphery.
[Installation]
B
Using an acetylene torch or the like, heat the ring gear 5 to approximately
5 6 100 C {212 F} for 3 minutes.
WARNING k
Fit the ring gear 5 with the non-chamfered side of its teeth toward the
flywheel 6.
41235
B: Chamfered side of ring gear 5.
11A-75
CRANKSHAFT AND CRANKCASE
A A A T
3T
A 4
1
16
2
A
P
C Y
X TO 11
I Q
T6 5T
8
A
R
T 9
E 29412
P. 11A-78
1 Bolt 9 Lower crankcase 17 Upper main bearing
2 Rear plate 10 Lower thrust plate * 18 Check valve
3 Bolt 11 Crankshaft assembly 19 Oil jet
4 Rear oil seal * 12 Crankshaft gear 20 Upper crankcase
5 Bolt * 13 Rear oil seal slinger
6 Main cap bolt 14 Crankshaft A: Locating pin
7 Lower crankcase assembly 15 Upper thrust plate : Non-reusable part
8 Lower main bearing 16 Upper crankcase assembly
NOTE:
Do not remove parts marked * unless defects are evident.
The lower crankcase 9 and upper crankcase 20 have been machined in a pair. Therefore, replacing either one of
the pair is not allowed.
11A-76
11A
P Assembly sequence
CAUTION k
If the main cap bolt shows evidence of having been tightened three times, replace it. P. 11A-79
Do not overtighten the check valve 18. If the tightening torque exceeds the specified one, the check valve may
malfunction, resulting in seizure of the engine.
Standard value
Replace
Crankshaft end play 0.10 to 0.28 {0.0039 to 0.0110} 0.4 {0.016}
thrust plate
[86 {3.385}] 0.04 to 0.11
No. 1, 2, 4, 5
{0.0016 to 0.0043} 0.15
Oil clearance Replace
[86 {3.385}] 0.06 to 0.13 {0.0059}
8, 17 Main bearing No. 3
{0.0024 to 0.0051}
Less than
Span when free (See pg.11A-80) Replace
91.5 {3.60}
0.05 Correct or
Bend 0.02 {0.00079} or less
{0.002} replace
0.03 Correct or
14 Crankshaft Roundness 0.01 {0.00039} or less
{0.0012} replace
Pin and journal
Correct or
Cylindricity 0.06 {0.00024} or less
replace
0.2
20 Distortion of upper crankcase top surface 0.07 {0.0028} or less
{0.0079}
Replace

1 Bolt (rear plate installation) 63,7 {47, 6.5}
3 Bolt (rear oil seal installation) 9.8 {7.2, 1.0}
5 Bolt (lower crankcase installation) 23.5 {17, 2.4} Wet
Wet
6 Main cap bolt (lower crankcase installation) 49 {36, 5.0} + 90
Reusable 3 times
18 Check valve 29.4 {22, 3.0} Wet

Location Points of application Specified lubricant/sealant Quantity
Rear oil seal lip Engine oil As required
4 Upper and lower crankcase contracting surface of rear oil
Threebond 1207 As required
seal
5, 6 Bolt threads and seating surface Engine oil As required
8, 17 Main bearing inside surfaces Engine oil As required
16 Lower crankcase attaching surface of upper crankcase Threebond 1207 As required
18 Check valve threads Engine oil As required
11A-77
12 Gear Puller Obtain Locally Removing crankshaft gear
P02065
100
{ 3.94}
Rear Oil Seal Slinger

13 Installer
MH061470A Installing rear oil seal slinger
103 15
{ 4.06} {0.59}
P02051
R Service procedure
11 Crankshaft end play
Before removing the lower crankcase assembly 7, measure the extent
7 of crankshaft end play.
If the measurement exceeds the specified limit, replace the thrust plates
with oversize ones. P. 11A-87
29413
4 Mounting of rear oil seal

1.5 mm { 0.059 in.}
Apply engine oil to lips B of rear oil seal 4.
Apply sealant D along black line C stamped on the rear oil seal 4 evenly
without break. ( 1.5 mm { 0.059 in.})
After applying sealant D, install the rear oil seal 4 between the lower
crankcase assembly 7 and upper crankcase assembly 16 within three
minutes.
4
CAUTION k
C Make sure that the sealant application surfaces are clean and free
30144 from grease and oil.
Use care not to let the applied sealant slip out of place during
installation.
After fitting rear oil seal, wait at least an hour before starting the
B engine.
16 Apply a new bead of sealant D whenever mounting bolts 3 of rear
4 oil seal have been loosened.
3
7
29419
11A-78
11A
7 Lower crankcase assembly
1 U : Bolt 5
4 8 12 16 13 9 5 1 I J : Main cap bolt 6
20 24 26 21 17
[Removal]
Gradually loosen the bolts 5 in the sequence of numbers 1 U shown
18 22 25 23 19
in the illustration.
2 6 10 14 15 11 7 3
Then, gradually loosen the main cap bolts 6 in the sequence of num-
bers I J shown, and remove.
29415
[Installation]
6 B CAUTION k
Before installing the lower crankcase assembly check the head of
the main cap bolt 6 for punch marks B.
The number of punch marks corresponds to the number of times
the bolt has been tightened using torque-turn method (bolts with
two or less punch marks are reusable). If there are three, replace
the main cap bolt.
21229
Apply 2 mm { 0.079 in.} thick bead of specified sealant C to the
fitting surface of the upper crankcase assembly 16 as shown.
After applying sealant C, install the lower crankcase assembly 7 to the
16 C
upper crankcase assembly 16 within three minutes and secure with
the main cap bolts 6 and the bolts 5 as follows:
CAUTION k
Make sure that the sealant application surfaces are clean and free
from grease and oil.
Use care not to let the applied sealant C slip out of place during
29416
installation.
Apply a thin coat of engine oil to the threaded part and seating surface
16 of each main cap bolt 6, then tighten the bolts to a torque of 49 Nm {36
lbf.ft, 5.0 kgfm} in the sequence of the numbers shown (I J)
11 After tightening, give the bolts an additional 90 turn.
13 9 5 1 4 8 12 16
Following the main cap bolts 6, tighten the bolts 5 to the specified torque
in the sequence of the numbers shown (1 U).
23 19 17 22 26
25 21 18 20 24
CAUTION k
15 11 7 3 2 6 10 14 After installation, wait at least an hour before starting the engine.
29417 Apply a new bead of sealant C whenever the bolts 5 or the main
cap bolts 6 have been loosened.
After tightening the main cap bolts 6 using the torque-turn tightening
method, make a punch mark on the head of each one to indicate the
time of use.
NOTE:
Since bolts 1 utilize the torque-turn tightening method, they must
not be tightened further after this procedure.
11A-79
After installing the lower crankcase assembly, check the following:
Smooth rotation of crankshaft assembly 11
End play of the crankshaft assembly 11 P. 11A-78
8 I Main bearings
17
[Installation]
C Install the main bearings 8, 17 such that their lugs B fit into the corre-
sponding grooves.
B
CAUTION k
The upper main bearing 17 has an oil hole C. The lower main bear-
8 ing 8 has no oil hole. Take care not to confuse the upper and
29418 lower parts.
[Inspection]
CAUTION k
Do not attempt to manually expand either bearing 8, 17 if its span
is insufficient.
Upper and lower bearings 8, 17 must be replaced as a set.
(1) Span when free

8, 17
If either bearings span when free exceeds the specified limit, the bear-
ings 8, 17 must be replaced.
01995
(2) Main bearing-to-crankshaft clearance

17 20
Fit the upper main bearing 17 into the upper crankcase 20 and the
lower main bearing 8 into the lower crankcase 9. Then, tighten the
main cap bolts 6 to their specified torque (49 Nm {36 lbf.ft, 5.0 kgfm}).
Measure the internal diameters of the main bearings 8, 17 and the
journal outside diameter D of the crankshaft 14. If the clearance ex-
ceeds the specified limit, replace the defective part(s).
8 9 6
29419
14
D
29420
11A-80
11A
Q Y Thrust plate
15 15
Install the thrust plates 10, 15 to the crankshaft assembly 11 at No. 5
journal only. Install all halves of the thrust plates with the oil groove B
B oriented outward.
NOTE:
If any oversize thrust plates are to be used, be sure to use an
11 B upper thrust plate 15 and lower thrust plate 10 of the same size at
10 10 one side. However, using the same size upper (or lower) thrust
29421
bearings on both sides is not necessary.
Available oversize: 0.15, 0.30, 0.45 mm {0.0059, 0.012, 0.018 in.}
12
E Crankshaft gear
0 [Removal]
0: Gear Puller
CAUTION k
Do not tap off the crankshaft gear 12 since this could damage it.
29422
[Installation]
12 B A Using a piston heater or the like, heat the crankshaft gear 12 to a tem-
perature of approximately 150 C {302 F}.
WARNING k
14 Align the location pin A on the crankshaft 14 with the notch B in the
crankshaft gear 12. Then, drive the gear into position by striking its end
29423
face with a plastic mallet.
13 R Rear oil seal slinger

[Removal]
Taking care not to damage the crankshaft 14, split the oil seal slinger
using a chisel or the like.
[Installation]
0 With the rear oil seal slinger 13 directed as illustrated, drive it onto the
14 B A crankshaft using the 0 Rear Oil Slinger Installer until the tools end face A
40870 is pressed firmly against the guide B.
11A-81
14 T Crankshaft
C [Inspection]
B
(1) Roundness and cylindricity of crankshaft journal and pin
If either measurement exceeds the specified limit, grind it to undersize
or replace the crankshaft 14.
B: Roundness
C: Cylindricity
29420
(2) Bend
D 14 F E Support the crankshaft 14 at its No. 1 journal D and No. 7 journal E.
Measure the extent of bending in the crankshaft at the center of the No.
4 journal F.
If the measurement exceeds the specified limit, replace the crankshaft
14.
NOTE:
Turn the crankshaft 14 through one revolution. One-half of the
29425
dial indicator reading represents the extent of bending.
[Rectification]
NOTE:
If the crankshaft 14 is rectified by grinding, the main bearings 8,
17 must be replaced with undersized ones.
Available undersizes: 0.25 mm, 0.50 mm 0.75 mm, 1.00 mm
K L {0.0098, 0.02, 0.03, 0.039 in.}
M H
G Grind such that the center-to-center distance J between the journal G
M and pin H never be changed.
J: 60 0.05 mm {2.36 0.002 in.}
J
Grind such that the journal width K and pin width L do not change.
K: 33.5 mm {1.32 in.} (No. 1 journal)
35 mm {1.38 in.} (No. 2 to No. 4 journals)
35+0.039
0
mm {1.38+0.0015
0
in.} (No. 5 journal)
L: 41 0 mm {1.61+0.0079
+0.2
0
in.}
Finish the corner fillet smoothly and to the specified radius M.
M: 5 mm {0.2 in.}
Carry out a magnetic inspection to check for cracks caused by grind-
29426 ing. Also, check that the Shore hardness of the surface has not dropped
below Hs 75.
11A-82
11A
Crankshaft undersize dimensions Unit: mm {in.}
Degree of undersize
0.25 {0.0098} 0.50 {0.020} 0.75 {0.030} 1.00 {0.039}
85.68 to 85.70 85.43 to 85.45 85.18 to 85.20 84.93 to 84.95
No. 1, 2, 4, 5
Finished journal {3.373 to 3.374} {3.363 to 3.364} {3.353 to 3.354} {3.343 to 3.344}
diameter 85.66 to 85.68 85.41 to 85.43 85.16 to 85.18 84.91 to 84.93
No. 3
{3.372 to 3.373} {3.362 to 3.363} {3.352 to 3.353} {3.342 to 3.343}
64.69 to 64.71 64.44 to 64.46 64.19 to 64.21 63.94 to 63.96
Finished pin diameter
{2.546 to 2.547} {2.537 to 2.5378} {2.527 to 2.528} {2.517 to 2.518}
Roundness 0.01 {0.00039} or less
Cylindricity 0.006 {0.00024} or less
When grinding N, turn the crankshaft 14 counter-clockwise as viewed

N R from its front end. The grinder P should rotate in the same direction.
When finishing R the crankshaft 14 with whetstone or sandpaper Q,
rotate the crankshaft clockwise.
Q
14
P
14 02108
18 O P Installation of check valve and oil jet

CAUTION k
Do not overtighten the check valve 18. If the tightening torque
exceeds the specified one, the check valve may malfunction, re-
sulting in seizure of the engine.
19
21872
A Inspecting upper crankshaft

B Measure the upper surface distortion of the upper crankcase 20.
If distortion exceeds the specified limit, correct it with a surface grinder.
B: Measurement positions
CAUTION k
When grinding the crankcase 20, take care that the piston protru-
sions stay within specification.
29427
11A-83
BALANCE SHAFT BUSHINGS
*a: Upper crankcase P. 11A-76

*b: Balance shaft P. 11A-52
CAUTION k
Do not remove the balance shaft bush-
ings 1 through 3 unless something wrong
is evident.
*a 3
P Assembly sequence
2
3 Follow the disassembly sequence in reverse.
1
2
1
*b
30172
Standard value
[51.5 {2.027}] 0.055 to 0.099
No. 1 journal
{0.0021 to 0.0039}
Clearance between
*b, balance shaft and No. 2 journal
[51 {2.0}] 0.075 to 0.119 0.15
Replace
1 to 3 balance shaft bushing
{0.0029 to 0.0046} {0.0059}
[50.5 {1.98}] 0.055 to 0.099
No. 3 journal
{0.0021 to 0.0039}
Lubricant
1 to 3 Inside surface of balance shaft bushing Engine oil As required

Balance shaft bushing
installer and extractor
Dimensions Dimension C
A and C B B
55.25 51.5 Installation and removal of balance shaft
1 to 3 No. 1
{ 2.175} { 2.027}
MH062782
bushing
No. 2 55 51
{ 2.165} { 2.007}
A
No. 3 55.75 50.5
{ 2.155} { 1.988}
02083
11A-84
11A
R Service procedure
*b 1 to 3 Balance shaft and balance shaft bushing
*a [Inspection]
*b If the clearance is more than the limit, replace defective parts.
1 to 3
NOTE:
Measure the inner diameter of the balance shaft bushings 1
through 3 with the bushings installed on the upper crankcase *a.
30170

B
C Use the 0 Balance Shaft Bushing Installer & Extractor to replace the
balance shaft bushings 1 through 3.
D (Components of 0 Balance Shaft Bushing Installer & Extractor)
A: Rod
B: Adapter
C: Guide piece
D: Nut
A 30173
5, 6, 7, 8,
[Removal]
Drive out the balance shaft bushings 1 to 3 using the 0 Balance Shaft
Bushing Installer & Extractor consisting of the adapter B appropriate to
each bushing secured on rod A with nut D.
Balance shaft bushing Identification mark of adapter B
A Left 5
No. 1
Right 6
B No. 2 7
D 30174
No. 3 8
Remove the No. 1 balance shaft bushing 1 from the front side of the
upper crankcase *a.
0: Balance Shaft Bushing Installer & Extractor
*a
0 0 *a
30175
11A-85
Remove the No. 2 balance shaft bushing 2 from the upper crankcase
*a by inserting the 0 Balance Shaft Bushing Installer & Extractor
through the hole E from which the No. 1 balance shaft bushing was
removed.
*a
*a
0 E 0 2
30176
Remove the No. 3 balance shaft bushing 3 from the rear side of the
upper crankcase *a.
*a 0
*a 0
30177
LH1, 1, 2, 3
[Installation]
Identify balance shaft bushings 1 through 3 by the marks 1, 2, 3 or
LH1 stamped on each bushing.
If the mark on a bushing is unclear, identify the bushing by measuring
F the outside diameter F of the bushing.
Balance shaft bushing Outside diameter
Mark
(from front of engine) (mm {in.})
Left (two oil holes) LH1
1 to 3 No. 1 55.25 { 2.175}
06224 Right (one oil hole) 1
No. 2 2 55 { 2.165}
No. 3 3 54.75 { 2.155}
Drive the balance shaft bushings 1 through 3 in position by hammering

5, 6, 7, 8
on the 0 Balance Shaft Bushing Installer & Extractor consisting of the
A adapter B and guide piece C appropriate to each bushing secured on
the rod A with nut D.
B
C Identification mark of Identification mark of
D adapter B guide piece C
Left 5
No. 1 5
Right 6
5, 7, 8 30178 No. 2 7 7
No. 3 8 8
11A-86
11A
Install the No. 3 balance shaft bushing 3 from the rear side of the upper
crankcase *a.
In this case, make sure that the oil hole G in the bushing matches the
*a oil passage H in the crankcase.
0
*a
3 0
H
3 H
G 3G
30179
Install the No. 2 balance shaft 2 by inserting the 0 Balance Shaft Bush-
ing Installer & Extractor through the No. 1 balance shaft bushing mount-
ing hole E of the upper crankcase *a.
In this case, make sure that the oil hole J in the bushing matches the
oil passage K in the crankcase.
*a
*a
0E
0 2
K
2 K
J 2J
30180
11A-87
Install the No. 1 balance shaft bushing 1 from the front side of the
upper crankcase *a.
In this case, make sure that the oil hole L in the bushing matches the
oil passage M in the crankcase.
*a
CAUTION k
*a The No. 1 balance bushings 1 include the right and left ones which
are different from each other. Use care to prevent confusion when
0 0
1 installing them.
The left one has two oil holes, whereas the right one has one oil
hole.
Before installing No. 1 balance bushing 1, check to ensure that
No. 2 balance shaft bushing 2 has been installed.
M
L 1 M
1 L
L
30181
11A-88
Group 11
Engine
Table of Contents
BACK
HOME
Pub No. TWSE9501-11

11
GROUP 11 ENGINE
SPECIFICATIONS .................................................................................. 2
STRUCTURE AND OPERATION ........................................................... 3
TROUBLESHOOTING ........................................................................... 6
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

Inspection of Engine Compression ................................................................. 7
Inspection and Adjustment of Valve Clearance .............................................. 9
CYLINDER HEAD AND VALVE MECHANISM ................................... 12
TIMING GEAR ..................................................................................... 26
CAMSHAFT .......................................................................................... 30
PISTON, CONNECTING ROD AND CYLINDER SLEEVE .................. 36
FLYWHEEL .......................................................................................... 50
CRANKSHAFT AND CRANKCASE .................................................... 54
11-1
SPECIFICATIONS
Item Specifications
Vehicle model FE639 FE649
Engine model 4D34T3
Type 4-cylinder in-line, water-cooled 4-cycle diesel
Combustion chamber type Direct injection type
Valve mechanism Overhead valve (OHV) type
Maximum output HP/rpm 135/3000 145/2900
(SAE Gross)
Maximum torque lbf.ft/rpm 253/1800 275/1600
(SAE Gross)
Borestroke mm {in.} 104115 {4.094.53}
Total displacement cm3 {cu. in.} 3907 {240}
Compression ratio 17.5
11-2
STRUCTURE AND OPERATION 11
Engine Body
3 4 5 6
2
14
13
12
11
7
A
10 9 8
11999
1 Rocker arm 9 Piston

2 Valve spring 10 Connecting rod
3 Camshaft 11 Timing gear
4 Cylinder sleeve 12 Tappet
5 Cylinder head 13 Inlet valve
6 Flywheel 14 Push rod
7 Crankshaft
8 Exhaust valve A : Direction of rotation
11-3
Connecting Rod
1
2 Connecting rod
4 Connecting rod bolt
2
A : Alignment mark
4 B : Mass mark
5 (A, B, C, D, E, F, G)
A B
6
3
03141
Piston
A A : Stamped mass
B B : Stamped T
C : Part number
C D : Free space for piston cooling
: Front mark

14204
11-4
11
Timing Gear
1 Camshaft gear
2 Injection pump gear
3 Crankshaft gear
5 A 4 Oil pump gear
5 Idler gear
1 6 6 Idler shaft
9 7 Idler bushing
7 8 Bolt
10 9 Thrust plate
8
10 Power steering oil pump gear
A : Oil hole
2
Alignment marks 1, 2, 3 are punch-marked
on each timing gear to ensure proper engage-
ment of the gears at installation.
4 3
11998
11-5
TROUBLESHOOTING
Symptoms
Remarks
Engine noise abnormal

Decrease of power
Possible causes
Oil viscosity unsuitable ^ Gr 12
Fuel incorrect or unsuitable
Valve clearance faulty
Head gasket faulty
Valve and valve seat worn, and carbon deposits
Valve spring fatigued
Piston ring worn or damaged
Piston ring grooves worn or damaged
Injection timing faulty ^ Gr 13
Injection pump malfunctioning ^ Gr 13
Cooling system malfunctioning ^ Gr 14
Injection nozzle malfunctioning ^ Gr 13
Fuel system sucking air ^ Gr 13
Air cleaner mesh clogged ^ Gr 15
Muffler clogged ^ Gr 15
Pipe and hose installation faulty
Ancillary equipment (injection pump, alternator, etc.) or installation faulty ^ Gr 13

^ Gr 54
V-belt loose or damaged ^ Gr 14
Crankshaft pulley mounted incorrectly
Air cleaner or muffler malfunctioning ^ Gr 15
Rocker shaft and bracket faulty
Rocker shaft bracket lubrication faulty
Timing gear backlash faulty
Timing gear system and idler shaft lubrication faulty
Connecting rod small end bushing worn and piston pin worn
Crankshaft pin and big end bearing of connecting rod worn or damaged
Crankshaft journal and main bearing worn or damaged
Crankshaft and camshaft end play excessive
Tappet and camshaft worn
11-6
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 11
Inspection of Engine Compression
Service standards
2 2
Engine Each cylinder (200 rpm) 2550 kPa {370 lbf/in , 26 kgf/cm } 1960 kPa Inspect
Compression {285 lbf/in2,
20 kg/cm2}

Pressure difference between each within Inspect
cylinder 390 kPa
{57 lbf/in2,
4 kgf/cm2}

Compression gauge MH061460 Measurement of engine compression

adapter
M141.5
06197
The decrease of engine compression is a signal that it is time to overhaul

the engine. It is strongly recommended that this item is inspected periodi-
cally and that you record the history of deterioration in engine perform-
ance as this will help you to diagnose causes of future irregularities.
When the vehicle is still new or immediately after installation of new
parts, there may be a slight increase in engine compression, but normal
performance will be restored soon.
Before inspection make sure that engine oil, starter and battery are in
normal condition.
Before inspecting the vehicle do the following:
Run the engine to bring the temperature of the coolant up to
approximately 75 to 85C {167 to 185F}.
Turn all the lights and accessory equipment OFF.
Put transmission in neutral. (P range for automatic transmission)
Set the steering wheel at center and straight position.
11-7
Remove fuse 2 for the fuel-cut motor from fuse box 1 inside the cab to
prevent the fuel from being injected when the engine is cranked by the
starter.
1 2 12000
Remove all the injection nozzles. ^ Gr 13

Check that no foreign particles are sticking to waste cloth B covering
B injection nozzle mounting hole A after cranking the engine.
A WARNING
You must stay clear of injection nozzle mounting hole A when
you crank the engine during this inspection. Assume that all
cylinders have cracked, and that coolant, engine oil, fuel, etc.
have seeped into the cylinder chambers. If this is the state when
the engine is cranked, there is an extreme danger of these sub-
06200 stances being injected out of the injection nozzle mounting hole
at high temperature.
Mount gasket 3 and 0 compression gauge adaptor in injection

0 nozzle mounting hole A and fasten them with nozzle bridge 4, then
C
mount compression gauge C.
3 Measure engine compression while cranking the engine.
Measure engine compression of cylinders and calculate the difference
A
among the cylinders.
If the engine compression and pressure difference between each
4 cylinder deviate from the limit, reinspect by pouring a small amount of
engine oil into injection nozzle mounting hole A.
06201 When pressure is high : It is likely that either wear or damage of the
slide-contact area of both the piston ring and the cylinder inner
surface has taken place.
When pressure is low : It is likely that burning of the valve, faulty
contact of valve surfaces and/or faults in the cylinder head gasket
have developed.
11-8
11
Inspection and Adjustment of Valve Clearance

Valve clearance (When engine is cold) 0.4 {0.016} Adjust

Cranking handle MH061289 Cranking of engine
36 {1.42}
05999
Flat-blade screwdriver MH060008 Valve clearance adjustment

(Used for an installed engine)
06000
2 Inspect and adjust the valve clearance while the engine is cold in the
following way.
[Inspection]
Crank the engine to move No.1 or No.4 piston to top dead center. Do
0 this by turning crankshaft pulley 1 clockwise using 0 cranking handle
1 to align stamped mark 0 on the crankshaft pulley with pointer 2.
NOTE
The cylinder whose push rod is not pushing up the inlet/outlet
rocker is the one whose piston is at top dead center.
0 0 There are two pointers 2. Use any one of the two pointers to align
the stamped mark of crankshaft pulley 1 in the position as illus-
trated.
2
06204
11-9
Measure valve clearance A when either No.1 or No.4 piston is at top
dead center in accordance with the following tabulated sequence of
A each valve.
Cylinder No. 1 2 3 4
Valve arrangement In- Ex- In- Ex- In- Ex- In- Ex-
take haust take haust take haust take haust
3
No.1 piston at top dead
center
06205
No.4 piston at top dead

center
NOTE
Be sure when taking measurements using feeler gauge 3 that
some resistance is felt when inserting the gauge. If the gauge
can be inserted freely without any resistance, an accurate meas-
urement cannot be obtained.
If the measured value deviates from the limit, adjust as follows:
[Adjustment]
4 5
6 Adjust valve clearance A so that feeler gauge 3 encounters some
resistance when it is inserted. Do this by loosening lock nut 4 and
turning adjusting screw 5.
After adjusting, tighten adjusting screw 5 using screwdriver 6 and
tighten lock nut 4. Reinspect valve clearance A using feeler gauge 3.
3
A
06206
When turning adjusting screw 5 on an engine that is installed, using

0 flat-blade screwdriver will make the work easier.
0
06207
11-10
11
MEMO
11-11
1 Oil filler cap
2 Spacer
3 Insulator
1
4 Breather cap
2 5 Rocker cover gasket
3 6 Outer rocker cover
4 7 Washer
6 8 Insulator
9 Inner rocker cover gasket
5 10 Inner rocker cover
10
11 Cylinder head bolt
12 Rocker and bracket assembly
7
9 P11-16
8
13 Push rod
12 14 Cylinder head and valve
assembly P11-18
- 11
11 - 15 Cylinder head gasket
16 Tappet
-
* : Crankcase P11-54
A A : Positioning pin
Assembly sequence
Follow the disassembly sequence in
reverse.
A 03319

13 Push rod deflection 0.4 {0.016} Replace
16, * Clearance between tappet and crankcase [28] 0.05 to 0.09 0.2 {0.0079} Replace
tappet hole {[1.10] 0.0020 to 0.0035}

11 Cylinder head bolt 145 {110, 15}+90 Wet
Reuse up to
three times
- Lubricant
11 Thread area of cylinder head bolt Engine oil As required
13 Both ends of push rod Engine oil As required
16 Outer periphery of tappet Engine oil As required
11-12
11
0 Special tools
14 Socket wrench MH061560 Installation of cylinder head and valve

assembly
01984
16 Tappet extractor MH063329 Removal of tappet
03320
I
Service procedure
Push rod deflection
If the measured value is higher than the limit, replace push rod 13.
13
J
01948
C Cylinder head and valve assembly

[Removal]
11 A
Before undoing cylinder head bolts 11, first loosen adjusting screw C
of rocker A that pushes down valve spring B.
14
B
03321
First loosen cylinder head bolts 11 in the numbered order as illus-

trated, then remove them.
4 12 17 11
8 16 15 7 3
2 6 10 14 13 9 5 1
03322
11-13
[Installation]
Center punch the heads of cylinder head bolts 11 before installation.

CAUTION
14 6 1 7 If there are already three center-punch marks, replace the cylin-
10 2 3 11 15
der head bolt with a new one.
16 12 8 4 5 9 13 17
After tightening cylinder head bolts 11 at specified torque in the
numbered order as illustrated, tighten further as follows:
03322 : Tightened simultaneously with rocker and bracket assembly
Turn 0 socket wrench holder D counterclockwise and keep the

E spring in the wrench compressed.
0
E : Socket
D F : Rod
G : Rod (for connection)
F G
01991
Set 0 socket wrench holder D so that the repercussive force of the

spring presses rod G (for connection) against adjacent parts such as,
J 5 rocker shaft bracket or the injection pipe.
Select a scale that is convenient for reading graduation H on holder D.
G
H Tighten further by turning socket E clockwise by 90 (setting is in 5
increments), referring to graduation J on the selected scale.
12758
11-14
11
K Cylinder head gasket
[Removal]
CAUTION
Be careful not to scratch the cylinder head or crankcase * when
UP
you remove cylinder head gasket 15.
15
[Installation]
* Install cylinder head gasket 15 onto crankcase * in the direction as
illustrated.
CAUTION
Be sure to measure the amount of protrusion whenever a piston
or connecting rod is replaced, since replacement changes the
amount of protrusion.
12775
L Removal of tappet
16
08790
L* Clearance between tappet and crankcase tappet hole

If the measured value is higher than the limit, replace the faulty parts.
16
03325
11-15
Rocker and Bracket Assembly
1 Set bolt
5 2 Rocker shaft bracket
3 Rocker assembly
6 4 Rocker bushing
-
7 5 Lock nut
6 Adjusting screw
7 Rocker
8 Rocker shaft spring
9 Rocker shaft
1 Assembly sequence
Follow the disassembly sequence in re-
verse.
8
3
2
03241

Standard value
Location Maintenance item (Basic diameter in [ ]) Limit Remedy
4, 9 Clearance between rocker bushing and rocker shaft [19] 0.06 to 0.11 0.2 {0.0079} Replace
{[0.75] 0.0024 to 0.0043}
- Lubricant
4 Inner surface of rocker bushing Engine oil As required

19
{0.75}
19
4 Rocker bushing puller {0.75} MH061378 Removal and installation of rocker bushing
21
{0.83}
01951
11-16
11
49
Service procedure
[Inspection]
Rocker bushing and rocker shaft
If the clearance is higher than the limit, replace the faulty parts.
9
4 01952
Rocker bushing
[Removal]
0
06009
[Press-fitting]
Align oil hole A of rocker bushing 4 with oil hole B of rocker 7.
Position clinch C and split D of rocker bushing 4 in the direction as
0
illustrated.
Press-fit rocker bushing 4 from chamfered side E of rocker 7.
4
D C
E
A
9
7 B 03242
C Installation of rocker shaft

When installing rocker shaft 9, bring oil passage hole for lubrication A to
front side B.
C C : Fixing hole of the set bolt.
B A 03243
11-17
Cylinder Head and Valve Assembly
1 Valve cap
9
2 Valve cotter
- 10 3 Upper retainer
1 16 4 Outer valve spring
11 5 Inner valve spring
3 12 6 Valve stem seal
15
7 Inlet valve
14
13 8 Exhaust valve
9 Nut
10 Connecting plate
- 11 Glow plug ^ Gr 54
12 Bolt
13 Nozzle bridge
14 Nozzle tip gasket
15 O-ring
16 Injection nozzle ^ Gr 13
17 Inlet valve guide
- 18 Exhaust valve guide
19 Inlet valve seat
20 Exhaust valve seat
22 21 Water director
-
22 Stud
23 Cylinder head
CAUTION
Be careful of the protrusion of glow
plug 11 and injection nozzle 16 from
the bottom surface of cylinder head
03263
23.
Assembly sequence
NOTE
When inlet valve 7 and exhaust valve 8 have been removed, replace valve stem seal 6.
11-18
11

4 Outer valve Without load 66.1 {2.60} 63.0 {2.48} Replace
spring Installed load 2714 N 230 N {52 lbf, Replace
(Installed length 47.25 {1.86}) {623.0 lbf, 27.91.4 kgf} 23.7 kgf}
Tilt 2.5 {0.098} Replace
5 Inner valve Without load 60.0 {2.36} 52.1{2.05} Replace
spring Installed load 1195.9 N 79 N {18 lbf, Replace
(Installed length 40.3 {1.59}) {271.3 lbf, 12.10.6 kgf} 8.1 kgf}
Tilt 2 {0.079} Replace
7 Inlet valve Stem diameter 8.96 to 8.97 {0.3527 to 0.3531} 8.85 {0.348} Replace
Valve recess from the cylinder 0.75 to 1.25 {0.030 to 0.049} 1.5 {0.059} Inspect
head bottom surface each part
Valve margin 1.5 {0.059} 1.2 {0.047} Correct or
replace
Valve seat angle 4515' Correct or
replace
7, 17 Clearance between inlet valve stem and inlet valve [9] 0.04 to 0.06 0.15 Replace
guide {[0.35] 0.0016 to 0.0024} {0.0059}
8 Exhaust valve Outer diameter of stem 8.93 to 8.94 {0.3515 to 0.3519} 8.85 {0.348} Replace
Valve recess from the cylinder 0.95 to 1.45 {0.037 to 0.057} 1.7 {0.067} Inspect
head bottom surface each part
Valve margin 1.5 {0.059} 1.2 {0.047} Correct or
replace
Valve seat angle 4515' Correct or
replace
8, 18 Clearance between exhaust valve [9] 0.07 to 0.1 0.2 Replace
stem and exhaust valve guide {[0.35] 0.0028 to 0.0039} {0.0079}
19 Seat width of inlet valve seat 20.2 {0.0790.0079} 2.8 {0.11} Correct or
replace
20 Seat width of exhaust valve seat 20.2 {0.0790.0079} 2.8 {0.11} Correct or
replace
23 Cylinder head Distortion of bottom 0.05 {0.0020} or less 0.2 {0.0079} Correct or
replace
Height from top to bottom 950.1 {3.740.0039} 94.6 {3.72} Replace

11 Glow plug 15 to 20 {11 to 14, 1.5 to 2.0}
12 Bolt (Nozzle bridge mounting) 25 {18, 2.5}
- Lubricant
1 Slide contact areas of valve cap and rocker Engine oil As required
6 Lip of valve stem seal Engine oil As required
7, 8 Valve stem Engine oil As required
11-19
2 Valve lifter 30091-08500 Removal and installation of valve cotter
47
{1.85}
03265
6 Valve stem seal 28 9 MH061293 Installation of valve stem

{1.10} {0.35}
installer
01957
7, 8 Valve lapper 30091-07500 Fitting of valve and valve guide
01958
13
{0.51}
Valve guide remover MH061066 Removal of valve guide
9 {0.35}
01959
17, 18
28.5
{1.12}
Valve guide installer MH061998 Press-fitting of valve guide
15
{0.59}
18
{0.71}
01960
A : Caulking tool body

B : Caulking ring
A : MH061067
C dimension B : MH061275
19, 20 Inlet 47.6 {1.87} (Inlet) Press-fitting of valve seat
Exhaust 40.6 {1.60} 9 MH061069
{0.35} (Exhaust)
C
B A
01961
11-20
11
0 2
Service procedure
Valve cotter
[Removal]
Remove valve cotter 2 making sure that valve springs 4, 5 are squarely
and evenly pressed down by 0 valve lifter.
3 2 2
4 [Installation]
5
6 Follow the removal procedure in reverse.
CAUTION
03252 Be sure not to press down on valve springs 4, 5 too hard because
this would cause upper retainer 3 to contact valve stem seal 6
and damage it.
45 Installation of outer and inner valve springs

Install outer springs 4 and inner springs 5 in cylinder head 23 in the
A 4
5 A : Closely wound area
6
23 03253
Installation of valve stem seal

0 Apply engine oil to lip A of valve stem seal 6.
Tap down 0 valve stem seal installer until it hits cylinder head 23.
A
6
78
23
01964
Inlet valve and exhaust valve

[Inspection]
(1) Inspection of stems
If the measured value is lower than the limit or in the case of excessive
wear, replace valves 7, 8.
CAUTION
7, 8 Be sure to lap valve seats 19, 20 when valves 7, 8 are replaced
with new ones. P11-23
01965
11-21
(2) Valve seat angle and valve margin
If the measured value is higher than the limit, correct or replace valves
7, 8.
7, 8
A : Valve seat angle
B : Valve margin
A B
02264
[Correction]
NOTE
Be sure to keep the grinding work as light as possible.
Be sure to replace valves 7, 8 after grinding if valve margin
deviates from the limit.
Be sure to lap valve 7, 8 and valve seats 19, 20 after grinding.
P11-23
01966
78MN
[Inspection]
Valve and valve guide
When the clearance is higher than the limit, replace the faulty parts.
7, 8
17, 18
03254
Valve guide
[Removal]
0
17, 18
03255
[Installation]
0 Tap down valve guides 17, 18 with 0 valve guide installer until it hits
cylinder head 23.
23 CAUTION
10 mm {0.39 in.} The length of fit of valve guides 17, 18 is standardized. Be sure to
use 0 valve guide installer.
17, 18 Be sure to distinguish between valve guides 17, 18. Exhaust
valve guide 18 is longer.
03256
11-22
11
78OP
[Inspection]
Valve and valve seat
0 Apply red lead evenly to entire surface A of valve seats 19, 20 that
A contact valves 7, 8.
Fit valves 7, 8 to valve seats 19, 20 and tap once without rotating.
NOTE
Be sure to carry out inspection under the condition that valves 7,
01968 8 and all parts of valve guides 17, 18 are normal.
Check how much red lead has transferred to valves 7, 8 to determine

the contact of the valve and the seat. According to the degree of
abnormality, take proper measures to correct it.
Contact conditions Correction measures

Minor fault Valve lapping
Major fault Repair of valve and seat or replacement of both
01969
[Correction]
7, 8 Valve polishing is done in the following manner:
Apply valve lapping compound thinly to contact surface A of valves
B 7,8 with valve seats 19, 20.
CAUTION
Take care not to smear stems B of valves 7, 8 with the compound.
A
NOTE
01970
Start with medium grit compound (120 to 150 grit) and for finish-
ing up, use finer grit (200 grit or finer).
Mixing with a small amount of engine oil will make the compound
consistent and make even application easier.
Tap valves 7, 8 against valve seats 19, 20 several times while rotating
the valves slightly at each strike.
Clean off the compound with gas oil.
0 Apply engine oil to contact surface A of valve seats 19, 20 and smooth
the surface.
Check the contact of valves 7, 8 and valve seats 19, 20.
If contact does not take place completely around the seat, replace
valve seats 19, 20.
01971
11-23
7, 8
OP
[Inspection]
Valve seat
19, 20 (1) Valve seat width

A If the measured value is higher than the limit, replace valve seats 19,
20.
A : Valve seat width
NOTE
Be sure to lap and fit valves 7, 8 and valve seats 19, 20 after
01975
correction or replacement.
(2) Extent of valve recess from the bottom surface of cylinder

7, 8 head
19, 20 If the measured value is higher than the limit, correct or replace the
faulty parts.
B : Extent of valve recess
B
02265
[Correction]
B C
Grind valve seats 19, 20 using valve seat cutter or valve seat grinder.
After grinding, do another light abrasion using 400 grit emery paper
placed between the cutter and the seat.
A
Adjust the seat width A of valves 7, 8 using 15 or 75 cutter to make
19, 20
seat width conform to the standard value.
7, 8
C : Valve seat angle
CAUTION
Be sure that as a result of grinding, recess B of valves 7, 8 does
01977
not become higher than the limit.
After correction is done, be sure to carry out lapping and fitting on

valves 7, 8 and valve seats 19, 20.
[Removal]
19, 20
Valve seats 19, 20 have been set in by the cooling-off-process, and
have to be thinned by grinding off the inner side for removal under
normal temperature.
D : Part to be ground
0.5 to 1.0 mm
D {0.020 to 0.0039 in.} 01973
11-24
11
[Installation]
Make sure that the diameter of valve seat hole of cylinder head 23
E : Inlet valve seat hole diameter
F : Exhaust valve seat hole diameter
E F
+0.025 +0.025
46 0 mm 39 0 mm
+0.00098 +0.00098
{1.81 0 in.} {1.54 0 in.}
23 03257
Immerse valve seats 19, 20 in liquid nitrogen and cool them substan-
1 tially. Press-fit into the cylinder head using 1 caulking tool body and
2 caulking rings inlet and exhaust.
G 2 CAUTION
Be sure, when press-fitting, to place the chamfered side G of 2
caulking rings inlet and exhaust against valve seats 19, 20.
19, 20
After installation of valve seats 19, 20, work until they contact valves 7,
Q
08400 8 smoothly.
Installation of water director

4 mm 23 With indent A set in the direction as illustrated, press-fit water director
A {0.16 in.} 21 into cylinder head 23 to the specified depth.
21
S
03259
Inspection of cylinder head

Measure the extent of distortion of the bottom of cylinder head 23, and if
the measured value is higher than the standard value, grind using a
surface grinder.
CAUTION
Be sure to keep the amount of grinding within the limit of the
height of cylinder head 23.
23
03262
11-25
TIMING GEAR
*4
18 *3
- 19 21
17 21
8
16
-4
-
6
20
*2 *1 12101
5 *3
-

7-
*2
-
*4

10
*1
2 14
1 *6
3 *5
12100
Inspection before disassembly

P11-28
1 Nut 16 Clamp
2 Crankshaft pulley 17 Rubber hose ^ Gr 37
3 Bolt 18 Nut
4 O-ring 19 Pressure hose ^ Gr 37
5 O-ring 20 O-ring
6 Vacuum pump assembly ^ Gr 35 21 Power steering oil pump ^ Gr 37
7 Front oil seal
8 Bearing *1 : Crankshaft gear P11-54
9 Timing gear case *2 : Oil pump gear ^ Gr 12
10 Bolt *3 : Camshaft gear P11-30
11 Thrust plate *4 : Injection pump gear ^ Gr 13
12 Idler gear assembly *5 : Key P11-54
13 Idler gear bushing *6 : Front oil seal slinger P11-54
14 Idler gear
15 Idler shaft : Non-reusable parts
NOTE
Do not remove front oil seal 7 and bearing 8 unless it is faulty.
11-26
11
Assembly sequence
CAUTION
Be sure to install key *5 when installing crankshaft pulley 2.

Backlash of Idler gear assembly and crankshaft 0.07 to 0.15 {0.0028 to 0.0059} 0.3 {0.012} Replace
gears gear
Idler gear assembly and camshaft 0.07 to 0.17 {0.0028 to 0.0067} 0.3 {0.012}
gear
Idler gear assembly and injection 0.07 to 0.17 {0.0028 to 0.0067} 0.3 {0.012}
pump gear
Crankshaft gear and oil pump gear 0.10 to 0.18 {0.0039 to 0.0071} 0.3 {0.012}
Camshaft gear and power steering 0.08 to 0.16 {0.0031 to 0.0063} 0.3 {0.012}
oil pump gear
End play of idler gear 0.05 to 0.15 {0.0020 to 0.0059} 0.3 {0.012} Inspect
13, 15 Clearance between idler gear bushing and [45] 0.03 to 0.06 0.1 {0.0039} Replace
idler shaft {[1.77] 0.0012 to 0.0024}

1 Nut (Crankshaft pulley mounting) 590 {435, 60}
10 Bolt (Thrust plate mounting) 24 {17, 2.4}
18 Nut (Pressure hose mounting) 29 to 39 {22 to 29, 3 to 4}
- Lubricant and sealant

4, 5, 20 Entire body of O-ring Engine oil As required
7 Front oil seal lip Engine oil As required
9 Mounting surface of timing gear case THREEBOND 1207C As required
10 Thread area of bolt Engine oil As required

49
{1.93}
13 Idler gear bushing puller MH062224 Removal and installation of idler gear
bushing
44.5 {1.75}
03532
11-27
TIMING GEAR
Service procedure
(1) Backlash of each gear
Measure three or more locations on the pairing gears and if the
measurements are higher than the limit, replace the faulty parts.
12103
(2) End play of idler gear

9
12104
Installation of timing gear case

1 to 1.5 mm
{0.039 to 0.059 in.} Apply sealant A to the mounting surface of timing gear case 9 evenly
A without break. After applying sealant, within three minutes, mount to the
front plate.
CAUTION
Be sure to clean and wipe off oily substances from the surface
where sealant A is to be applied.
Make sure that sealant A is not transferred to other areas while
03535
the mounting work is being done.
Be sure to reapply sealant A if the bolts are loosened or removed
by any cause whatsoever after mounting.
Do not start the engine within an hour of mounting.
A
G Installation of thrust plate
A : Chamfered side
11
10 12105
11-28
11
12
*3
H Installation of idler gear assembly
Install idler gear assembly 12 by matching alignment marks 1, 2, 3
*2
on the gears that engage with those on the assembly.
*1 : Crankshaft gear
*2 : Camshaft gear
*3 : Injection pump gear
NOTE
*1 When aligning each gear with its alignment mark, make sure that
IK
12106 pistons No.1, 4 are higher than top dead center.
Idler gear bushing and idler shaft

[Inspection]
03538
A Idler gear bushing

[Removal]
0 A : Press
13 03539
[Press-fitting]
A Press-fit idler gear bushing 13 from chamfered side B of idler gear 14
and align oil holes C of the idler gear and the bushing.
0 After press-fitting, finish the fitting by bringing the clearance between
13 B 14 idler gear bushing 13 and the idler shaft to the standard value.
C
03540
11-29
CAMSHAFT
-
- *
-
-
-
6
1
3
12126
1 Bolt 7 Camshaft 13 No.5 camshaft bushing
2 Camshaft assembly 8 No.1 camshaft bushing
3 Bolt 9 No.2 camshaft bushing * : Crankcase P11-54
4 Camshaft gear 10 No.3 camshaft bushing : Non-reusable parts
5 Thrust plate 11 No.4 camshaft bushing
6 Key 12 Sealing cap
NOTE
Do not remove camshaft gear 4 unless it is faulty.
Assembly sequence

Standard value
End play of camshaft assembly 0.05 to 0.22 {0.0020 to 0.0087} 0.3 {0.012} Inspect
4, 7 Interference of camshaft gear and camshaft [30] 0.03 to 0.07 Reuse up to
{[1.2] 0.0012 to 0.0028} three times
7 Camshaft Difference between Inlet 7.1950.05 {0.280.0020} 6.70 {0.26} Long diameter
47.105 {1.85}
long and short Short diameter
Replace
39.910 {1.57}
diameters Long diameter
46.979 {1.84}
Exhaust 7.3210.05 {0.290.0020} 6.82 {0.27} Short diameter
39.658 {1.56}
Bend 0.02 {0.00079} or less 0.05 {0.0020} Replace

7 to 11, Clearance between camshaft and No.1 to No.4 [54.5] 0.04 to 0.09 0.15 {0.0059} Repair
13 camshaft bushing {[2.15] 0.0016 to 0.0035} or replace
No.5 [53] 0.04 to 0.09 0.15 {0.0059}
Tightening torque {[2.09] 0.0016 to 0.0035} Unit : Nm {lbf.ft, kgfm}
3 Bolt 34 to 39 {25 to 29, 3.5 to 4.0}
11-30
11
- Lubricant
8 to 11, Inner surface of camshaft bushing Engine oil As required
13

Camshaft bushing
installer and extractor
C
A, C B
Dimension Dimension B
8 to 11, No. 1 58.5 {2.30} 54.5 {2.15} MH061276 Removal and press-fitting of camshaft
13 No. 2
58 {2.28} 54.5 {2.15}
bushing
No. 3 A
No. 4 57.5 {2.26} 54 {2.13}
No. 5 57 {2.24} 53 {2.09} 02083
Service procedure
Camshaft end play
12127
2
[Removal]
Camshaft assembly
1
4 Remove camshaft assembly 2 by undoing bolts 1 through the holes in
camshaft gear 4.
CAUTION
Be careful not to damage the camshaft bushings when you
remove camshaft assembly 2.
2
12128
11-31
CAMSHAFT
4 [Installation]
Before installing camshaft assembly 2, measure the end play be-
5 tween thrust plate 5 and camshaft 7.
If the measured value is higher than the limit, replace thrust plate 5.
7 Install the camshaft assembly by matching the alignment mark on
camshaft gear 4 with the alignment mark on the idler gear. P11-29
4
12131
A Camshaft gear
4 [Removal]
A : Press
14915
A [Installation]
Install camshaft gear 4 onto camshaft 7 in the direction as illustrated.
2 A : Press
Be sure when finishing the installation to install key 6.
4
12133
F
5 Installation of thrust plate
Install thrust plate 5 onto camshaft 7 in the direction as illustrated.
5
03550
11-32
11
7 Inspection of camshaft
7 (1) Difference between long diameter and short diameter

If the measured value is lower than the limit, replace camshaft 7.
D
B NOTE
Measure at point A, as illustrated, because the cam is tapered.
6.5 mm 6.5 mm C B : Long diameter

{0.26 in.} {0.26 in.} C : Short diameter
A A D : Front of the engine
02090
(2) Degree of bend

To measure bend, support camshaft 7 at area E of No.1 journal, and
E F area F of No.5 journal. Then, measure the amount of bend at area G
7 of No.3 journal. If the measured values are higher than the limit,
replace the camshaft.
NOTE
G Degree of bend of camshaft 9 is a half of the indicated value of
the gauge after rotating the shaft 360.
03551
7 GI to
[Inspection]
Camshaft and camshaft bushing
If the clearance is greater than the limit, replace the faulty parts.
NOTE
Measure bushings 8 to 11, 13 mounted in the crankcase.
03552
Camshaft bushing
7 to 11,13
[Removal]
0
Remove No. 5 camshaft bushing 13 from the rear of the engine by
striking 0 camshaft bushing installer and extractor.
06223
1,A,2,C,4 [Press-fitting]
Identify, by referring to the table below, No.1 to No.5 camshaft bush-
ings by noting marks 1, A, 2, C, 4 on camshaft bushings 7
to 11, 13. If you cannot identify the mark, measure outer diameter A of
the bushing and refer to the table below.
A
Outer diameter A
Bushing No. (from the front of the engine) Mark
(mm {in.})
No.1 1 58.50 {2.30}
7 to 11,13
No.2 A 58.25 {2.29}
06224
No.3 2 58.06 {2.28}
No.4 C 57.75 {2.27}
No.5 4 57.06 {2.25}
11-33
CAMSHAFT
For press-fitting, mount guide B to 0 camshaft bushing installer and
8 to 11,13 extractor.
Install camshaft bushings 8 to 11 and 13 in descending order, from
No.5 to No.1.
Install No.5 camshaft bushing 13 from the rear end of the engine, and
0 No.4 to No.1 camshaft bushings 8 to 11 from the front end of the
engine.
B
06225
Align oil hole C of No.5 camshaft bushing 13 in the direction as

*
illustrated.
13
C
40
06230
Press in until surface D of No. 5 camshaft bushing 13 is flush with

chamfered part E of crankcase *.
* F : Front of the engine
13
D
F 0
E
06231
Align oil hole G, of No.2 to No.4 camshaft bushings 9 to 11, in the

9 to 11 *
direction as illustrated, and press-fit in the order of No. 4, 3, 2.
G
40
06228
Press in until surface H of No.2 to No.4 camshaft bushings 9 to 11 is

* flush with surface J of crankcase *.
F : Front of the engine
F H
0 J
9 to 11
06229
11-34
11
For press-fitting of No.4 camshaft bushing 11, use tool K as illustrated.
K 0
200 mm {7.37 in.}

50 mm {1.97 in.}
30 mm
{1.18 in.}
17.5 mm
{0.69 in.}
07584
Align oil holes L, M of No.1 camshaft bushing 8 in the direction as

illustrated.
*
8 L : 3 mm {0.11 in.}
L
M : 8 mm {0.31 in.}
15
40
* : Crankcase
M
06226
Align oil hole M of No.1 camshaft bushing 8 with oil hole N of crank-
* case * and press in until camshaft bushing surface P is flush with
P crankcase surface Q.
0 F Q F : Front of the engine
8
8
M
F
* N
H
06227
* Installation of sealing cap

* A
Press-fit sealing cap 12 into crankcase * to the specified depth.
A : Front of the engine
12
2.5 mm
{0.098 in.}
06232
11-35
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
*2
-
*1
-
3
- 1
*3
03373
1 Bolt *1 : Crankshaft P11-54
2 Lower connecting rod bearing *2 : Crankcase P11-54
3 Connecting rod cap *3 : Oil pan ^ Gr 12
5 Piston and connecting rod assembly
P11-44
6 Cylinder sleeve
Assembly sequence
11-36
11

Extent of piston protrusion 0.47 to 0.64 {0.019 to 0.025} Inspect
End play of connecting rod 0.15 to 0.45 {0.0059 to 0.018} 0.6 {0.024} Inspect
2, 4 Connecting rod bearing Oil clearance [60] 0.04 to 0.09 0.2 {0.0079} Replace
{[2.36] 0.0016 to 0.0035}
Expansion Upper :
less than 64.5
{2.54}
Lower :
less than 64.27
{2.53}
5, 6 Clearance between piston and connecting rod [104] 0.07 to 0.11 Adjust or
assembly and cylinder sleeve {[4.094] 0.0028 to 0.0043} replace with
oversizes
6 Cylinder sleeve Inner 104 to 104.03 {4.094 to 4.095} 104.25 {4.10} Adjust or
diameter replace with
Circular 0.01 {0.00039} or less oversizes
accuracy
Cylindrical 0.03 {0.0012} or less
accuracy
6, *2 Interference between cylinder Standard 0.17 to 0.23 {0.0067 to 0.0091} Replace with
sleeve and crankcase oversizes
Oversize 0.19 to 0.21 {0.0075 to 0.0083} Replace

1 Bolt 30 {22, 3}+905 Wet
- Lubricant
2, 4 Inner surface of bearing Engine oil As required
*2 Sleeve hole of crankcase Spindle oil (ISO VG 32) As required
11-37
Socket wrench MH061560
5 01984 Installation of piston and connecting

rod assembly
A
A : Piston guide clamp B A : MH061890
B : Piston guide lever B : MF061658
01981
6 Cylinder sleeve installer MH062228 Installation of cylinder sleeve
103
{4.06} 03377
Service procedure
A (1) Extent of piston protrusion from the upper surface of

crankcase *2
*2 NOTE
Always inspect the extent of piston protrusion because it af-
fects the engine performance greatly.
Measure piston protrusion at two points on the top of the piston, and
03378 produce the average value.
A : Front of the engine
If the average valve deviates from the limit, inspect clearance of the
related parts.
(2) End play of connecting rod

Measure the end play of each connecting rod.
If the measured value is higher than the limit, replace the faulty
parts.
03379
11-38
11
2 4
24 Connecting rod bearing
[Installation]
B A Install connecting rod bearings 2, 4 by matching lugs A to the connecting
A rods.
CAUTION
Be sure to distinguish between upper and lower connecting rod
bearings 2, 4. The upper bearing has oil opening B while the
lower bearing has no oil opening.
03381
[Inspection]
CAUTION
Do not forcibly open or expand connecting rod bearings 2, 4.
When either upper or lower connecting rod bearings 2, 4 needs
replacing, replace as a set.
(1) Expansion at free state

If the measured value is lower than the limit, replace connecting rod
bearings 2, 4.
06358
(2) Clearance between connecting rod bearing and crankshaft

If the clearance between connecting rod bearing 2, 4 and crankshaft
*1 is lower than the limit, replace the faulty parts.
12158
01997
11-39
B 5 Installation of piston and connecting rod assembly
CAUTION
A Be sure to fit piston ring A in the correct position.
P11-48
Be careful not to scratch or damage head B of the piston (a part
C of the combustion chamber).
Make sure that the connecting rod does not hit oil jet C.
03383
Install piston front mark directed towards the front of the engine
using the following procedure.
D : Front of the engine
03384
Match the inner diameter of 1 piston guide clamp to the outer

diameter of the piston skirt by turning adjusting bolt E of 2 piston
1
guide lever.
After adjusting, set 1 piston guide clamp and 2 piston guide lever
at the top of the piston so that the clamp is flush with the top of the
piston.
2
11651
2 1
03386
After the piston is inserted, align alignment marks F on the connecting

1 rod with the alignment marks on connecting rod cap 3 and tighten bolt
1 at specified torque. Then tighten the bolt further as follows:
3
F
12169
11-40
11
Turn 0 socket wrench holder G counterclockwise and keep the
H 0 spring in the wrench compressed.
H : Socket
G J : Rod
K : Rod (for connection)
J K
01991
Set 0 socket wrench holder G so that the repercussive force of the

*1 spring presses rod K (for connection) against crankshaft *1.
Select a scale that is convenient for reading graduation L on holder G
K side.
M 5 Tighten further by turning socket H clockwise by 90 (setting is in 5
increments), referring to graduation M on the selected scale.
NOTE
L After installation of connecting rod cap 3, inspect the following
points :
56
03389
End play of the connecting rod : P11-38
Piston protrusion : P11-38
*2 Piston and connecting rod assembly, and cylinder
6
sleeve
20 mm {0.79 in.}
or more [Inspection]
B If the inner diameter of cylinder sleeve 6 is higher than the limit, bore
A
the cylinder sleeve oversize and use an oversized piston.
A : In the direction of the crankshaft axis
60 mm {2.36 in.}
B : At right angles to the crankshaft axis
or more
If the clearance between piston 5 and cylinder sleeve 6 deviates from
03391
the standard value, even when the inner diameter of the cylinder
sleeve is within the limit, replace the piston.
72.15 mm [Selection of oversized piston]

{2.84 in.}
Extent of oversize : 0.50, 1.00 mm {0.020, 0.039 in.}
Determine the extent of oversize by measuring the inner diameters of
C
all the cylinders and calculating the maximum wear amount of all the
cylinders.
Measure the outer diameter of the oversized piston to be used.
03375 C : Position to measure the outer diameter of the piston
Bore cylinder sleeve 6 and hone it to make the clearance between

piston 5 and the cylinder sleeve conform to the standard value.
NOTE
Even if only one cylinder sleeve 6 requires boring, all the other
cylinder sleeves must be bored to the identical oversize.
Piston rings must be replaced with the corresponding oversized
ones.
11-41
D Cylinder sleeve
[Removal]
Mount a boring machine on crankcase *2 and center. Centering must
be done at the lower part of cylinder sleeve 6 which is less unevenly
E
worn.
Bore until the thickness of cylinder sleeve 6 is approximately 0.5 mm
{0.020 in.}.
Insert tool D (a modified screwdriver) between crankcase *2 and
cylinder sleeve 6, break the sleeve by tapping it gently, then remove.
6 *2 03392
CAUTION
Make sure when inserting tool D that round part E is facing
crankcase *2.
[Installation]
{0.59 in.}
15 mm
Inspect sleeve hole of crankcase *2 before installing cylinder sleeve

*2 6. If there are irregularities, such as defects or insufficient interfer-
ence, correct them by boring.
{3.90 in.}
183 mm {7.20 in.}

99 mm
D1 NOTE
Pull out cylinder sleeve 6 of all cylinders and bore the sleeve
B holes perfectly round when you bore the sleeve holes of crank-
D2 A
case *2.
D3 Apply spindle oil (ISO VG 32) when you push cylinder sleeve 6
03380 into the sleeve hole of crankcase *2.
{0.59 in.}
15 mm
Inspection of interference must be carried out as follows.

6
Measure the inner diameter of the sleeve hole of crankcase *2 and
{3.90 in.}
the outer diameter of cylinder sleeve 6 at the specified positions

183 mm {7.20 in.}
99 mm
D1 illustrated.
Take the average value at the top, middle and bottom (D1, D2, D3)
B
D2 A and across the diameter (A, B). If the interference is lower than the
limit, bore the sleeve hole of crankcase *2 oversize.
D3
05337
11-42
11
< If interference is sufficient >
0 Press-fit cylinder sleeve 6 into crankcase *2 from the chamfered end
using 0 cylinder sleeve installer.
6 NOTE
Align the top of cylinder sleeve 6 with the top of crankcase *2
when press-fitting.
*2
After press-fitting, make the inner diameter of cylinder sleeve 6 con-

form to the standard value by honing the surface.
03346
< If interference is insufficient >

Prepare cylinder sleeve 6 which is 0.5 mm {0.020 in.} oversize in
diameter.
Hone crankcase *2, making the clearance between the outer diam-
eter of cylinder sleeve 6 and the sleeve hole of crankcase *2 conform
to the standard value.
Press-fit cylinder sleeve 6 into crankcase *2 from the chamfered end
using 0 cylinder sleeve installer.
NOTE
Align the upper face of cylinder sleeve 6 with the upper face of
crankcase *2 when press-fitting.
After press-fitting, make the inner diameter of cylinder sleeve 6 con-

form to the standard value by honing the surface.
11-43
Piston and Connecting Rod Assembly
1 Snap ring
2 Piston pin
4 Connecting rod
- 5 1st compression ring
6 2nd compression ring
7 Oil ring
1
8 Piston
Assembly sequence
- Follow the disassembly sequence in re-
- verse.
12170

Standard value
2, 3 Clearance between piston pin and [36] 0.03 to 0.04 0.1 {0.0039} Replace
connecting rod bushing {[1.42] 0.0012 to 0.0016}
2, 8 Clearance between piston and piston pin [36] 0.007 to 0.021 0.05 {0.0020} Replace
{[1.42] 0.00028 to 0.00083}
4 Degree of bend and distortion of connecting rod 0.05 {0.0020} Repair or
replace
5 to 7 Deviation of piston ring 1st compression ring 0.3 to 0.45 {0.012 to 0.018} 1.5 {0.059} Replace
fitted position 2nd compression ring 0.4 to 0.55 {0.016 to 0.022}
Oil ring 0.25 to 0.45 {0.0098 to 0.018}
5 to 8 Clearance between piston 1st compression ring 0.02 to 0.10 {0.00079 to 0.0039} 0.2 {0.0079} Replace
ring and piston ring groove 2nd compression ring 0.05 to 0.08 {0.0020 to 0.0031} 0.15 {0.0059}
Oil ring 0.03 to 0.06 {0.0012 to 0.0024}
- Lubricant
2 Exterior of piston pin Engine oil As required
3 Exterior of connecting rod bushing Engine oil As required
4 Bushing attachment area of connecting rod Engine oil As required
11-44
11
3 Connecting rod bushing puller kit MH062225 Removal and installation of connecting
rod bushing
02015
60 to 120
{2.36 to 4.72}
5 to 7 Piston ring tool MH060014 Removal and installation of piston ring
02013
23
Service procedure
[Inspection]
Piston pin and connecting rod bushing
If the clearances are higher than the limit, replace the faulty parts.
2
12171
Connecting rod bushing

Use 0 connecting rod bushing puller kit to replace connecting rod
bushing 3.
0
(Components of 0 connecting rod bushing puller kit)
A : Base B : Bracket C : Puller D : Collar
E : Plate F : Collar G :
Nut
[Pulling-out]
02019
Remove upper connecting rod bearing from the big end of connecting
rod 4.
C Place connecting rod 4 on base A and fix it to the base at two points,
bracket B and plate E.
Fit collar D in puller C in the direction as illustrated, and pull out
D
3 4 connecting rod bushing 3 with a gradual load of approximately 49 kN
B E {11020 lbf, 5000 kgf}.
A
02020
11-45
[Press-fitting]
Apply engine oil to the exterior peripheral area of connecting rod
4 bushing 3 and the inner area of the bushing fitting ring of connecting
rod 4.
Fit collar F, connecting rod bushing 3 and collar D in puller C in the
arrangement and direction as illustrated and mount them with nut G.
FC Align oiling holes H of connecting rod bushing 3 and connecting rod 4,
3 H and gradually press in the bushing with approximately 49 kN {11023 lbf,
3 5000 kgf} load.
After press-fitting, ream connecting rod bushing 3 to make its clear-
D ance with piston pin 2 conform to the standard value.
NOTE
After press-fitting bushing 3, insert piston pin 2 and make sure
that the rod moves smoothly without any excessive play.
G
12172
8
248 Piston pin and connecting rod and piston
2
[Disassembly]
Drift out piston pin 2 using a rod.
When removal of piston pin 2 is difficult, warm piston 8 using a piston
heater or hot water.
02022
A [Installation]
Apply engine oil to piston pin 2 and assemble connecting rod 5 and
piston 8 in the direction as illustrated.
8 A : Piston mass (Mass of piston is marked)
B : Connecting rod mass mark (Alphabetical: A, B, C, D, E, F, G)
2
4 C : Mounting base of connecting rod cap
: Front mark
C
B 12173 When piston pin 2 insertion is difficult, warm piston 8 using a piston
heater or hot water.
CAUTION
Make sure that the total mass error of all pistons 8 in one engine
is 10 g {0.35 oz.} or less.
Be sure to install connecting rods 4, to be used in one engine,
that have identical mass mark B.
Be sure that after inserting piston pin 2 the connecting rod
operates smoothly without excessive play.
11-46
11
8
28 Clearance between piston pin and piston
4
02016
C Degree of bend or distortion of connecting rod

A
Mount connecting rod bushing 3 and piston pin 2 to connecting rod 4.
100 mm Measure degree of bend A and distortion B of connecting rod 4. If the
{3.94 in.}
measured value is higher than the limit, repair or replace the connect-
ing rod.
2
C : Connecting rod aligner (Measuring instrument)
NOTE
When making measurements by mounting connecting rod 5 to
02039 connecting rod aligner C, make sure that the upper connecting
rod bearing and the lower connecting rod bearing are mounted
on the rod.
B Mount the connecting rod cap by tightening the bolt at specified
torque. P11-36
100 mm
{3.94 in.}
2
C
02040
11-47
0 58 to
Piston ring
Piston ring and piston
[Removal]
02024
[Installation]
E Install oil ring 7 so that split D and the butting joint of expander spring
B E come to the points as illustrated.
Compression rings 5 and 6 have a manufacturers mark A at the split,
and installation should be made with the mark outward.
B : The split of the 1st compression ring
C : The split of the 2nd compression ring
5, 6 A
D : Oil ring slit
C D E : Oil ring expander spring butt joint
02028 : Front mark of piston
[Inspection]
(1) Clearance of piston ring slit
Install piston rings 5 to 7 into the crankcase cylinder sleeve using the
head of piston 8 to level the piston ring.
8 Measure the clearance of the piston ring split while keeping them level
and stationary. If the measured value is higher than the limit, replace
the piston ring.
NOTE
5 to 7 03175 Use piston 8 to ensure that piston rings 5 to 7 are kept level when
inserting them into the crankcase cylinder sleeve.
Insert piston rings 5 to 7 into the lower part of the crankcase
cylinder sleeve, where the area is less worn, when measuring
clearance of piston ring split 5 to 7.
Exchange the whole set of piston rings 5 to 7 as a set if any of the
rings is faulty.
11-48
11
(2) Clearance between piston ring and ring groove
If the measured value is higher than the limit, replace the faulty
parts.
Measure using feeler gauge F, by pressing 1st compression ring 5
against piston 8 with straight edge G.
NOTE
Measurement has to be conducted around the whole periphery
of piston 8 after removing carbon deposits.
F 02025
Be sure to exchange the whole set of piston rings 5 to 7 as a
8 set if any of the rings is faulty.
5
02026
11-49
FLYWHEEL
6
-

1
2
-

< Automatic transmission > 1
2
3
A
*
12175
1 Bolt 5 Ring gear
2 Plate < Manual transmission > 6 Flywheel
Wear plate < Automatic transmission >
3 Bearing < Manual transmission > * : Crankshaft assembly
4 Flywheel assembly P11-54
A : Positioning pin
Assembly sequence
NOTE
Be sure to check wobble of flywheel 6 after installing flywheel assembly 4. P11-51

4 Flywheel Height from bolt mounting surface 24.5 {0.96} 23.5 {0.93} Repair or
assembly to friction surface replace
< Manual
transmission > Distortion of friction surface 0.05 {0.0020} or less 0.2 {0.0079}
Wobble of friction surface 0.2 {0.0079}

1 Bolt (Flywheel mounting) 39 {29, 4}+40 Wet
11-50
11
- Lubricant
0 Special tools
Socket wrench MH061560
4 01984 Installation of flywheel assembly
Magnetic base < Manual transmission > MH062356
00471
4
Service procedure
Flywheel assembly
[Installation]
B 0
After tightening bolt 1 at specified torque, tighten further as follows:
Turn 0 socket wrench holder A counterclockwise and keep the
A spring in the wrench compressed.
C B : Socket
D
C : Rod
D : Rod (for connection)
01991
Set 1 socket wrench holder A so that the repercussive force of its

spring presses rod D (for connection) against 2 magnetic base
1 Select a scale that is convenient for reading graduation E on holder A
F 5 side.
1 Tighten further by turning the socket clockwise by 40 (setting is in 5
increments) referring to graduation F on the selected scale.
E
2 D
14196
[Inspection]
(1) Wobble
If the measured value is higher than the limit, check the fastening of
bolt 1, the attachment surface of crankshaft assembly, and depending
on the condition found, either repair or replace flywheel assembly 4.
4
1
03348
11-51
FLYWHEEL
(2) Height of friction surfaces
If the measured value is lower than the limit, repair or replace flywheel
G G assembly 4.
4
G : Height from bolt mounting surface to friction surface
03349
(3) Distortion of friction surface

If the measured value is lower than the limit, repair or replace flywheel
4 assembly 4.
NOTE
If any fault is found in ring gear 5, replace it first, then begin
the inspection.
5
03350
[Correction]
Make sure when grinding the friction surfaces for correction, that height
G G is not lower than the limit while maintaining the degree of parallel with
G
surface H within 0.1 mm {0.0039 in.}.
5
03351
Ring gear
[Inspection]
Check and see if there is any damage, wear or other fault, and if any fault
is found, replace ring gear 5.
[Removal]
Heat up ring gear 5 evenly using an acetylene torch.
Hammer the outer edge of ring gear 5 evenly until it drops off.
5
03352
5 [Installation]
Heat up ring gear 5 using a piston heater to approximately 100C
A
{212F} for three minutes.
With the side of the chamfered teeth of ring gear 5 facing you, mount it
on flywheel 6.
A : Chamfered ring gear side
6 03353
11-52
11
MEMO
11-53
3
4
1
22
21
24
- 25 23
-
*2
*1
-
17
14
-
- 5
-
5

12176

P11-56
1 Bolt 11 Rear main bearing cap 21 Front plate
2 Rear oil seal 12 Thrust plate 22 Gasket
3 Bolt 13 Side seal 23 Taper plug
4 Rear plate 14 Crankshaft assembly 24 O-ring
5 Bolt 15 Front oil seal slinger 25 Block heater adaptor
6 Lower main bearing 16 Crankshaft gear 26 Crankcase
7 No.1 main bearing cap 17 Key
8 No.2 main bearing cap 18 Rear oil seal slinger *1 : Check valve ^ Gr 12
9 No.3 main bearing cap 19 Crankshaft *2 : Oil jet ^ Gr 12
10 No.4 main bearing cap 20 Upper main bearing : Non-reusable parts
NOTE
Do not remove crankshaft gear 16, check valve *1 and oil jet *2 unless they are faulty.
Assembly sequence
11-54
11

Crankshaft end play 0.10 to 0.26 {0.0039 to 0.010} 0.4 {0.016} Inspect
6, 20 Main bearing Oil clearance No.1, 2, 4, 5 [78] 0.04 to 0.09 0.15 {0.0059} Replace
{[3.07] 0.0016 to 0.0035}
No.3 [78] 0.06 to 0.12
{[3.07] 0.0024 to 0.0047}
Expansion at free state less than 82.5 Replace
{3.25}
19 Crankshaft Degree of bend 0.02 {0.00079} or less 0.05 {0.0020} Replace
Pin and journal Circular 0.01 {0.00039} or less 0.03 {0.0012} Repair or
accuracy replace
Cylindrical 0.006 {0.00024} or less Repair or
accuracy replace
26 Crankcase top surface distortion 0.07 {0.0028} or less 0.2 {0.0079} Repair or
replace

3 Bolt (Rear plate mounting) 64 {47, 6.5}
5 Bolt (Main bearing cap mounting) 59 {43, 6}+90 Wet
Reuse up
to three times

2 Rear oil seal lip Engine oil As required
Rear oil seal mounting surface to crankcase THREEBOND 1207C As required
6, 20 Interior of main bearing Engine oil As required
11 Pack side seal driving groove of rear main bearing THREEBOND 1207C As required
13 Side seal tip and groove THREEBOND 1207C As required
23 Thread area of taper plug THREEBOND 2410 As required
24 O-ring Soapy water As required

7 to 11 Socket wrench MH061560 Installation of main bearing cap
01984
11 Bearing cap extractor MH061083 Removal of rear main bearing cap

M81.25
60 {2.36} 03516
100
{3.94}
15 Rear oil seal slinger installer MH062677 Installation of rear oil seal slinger
103 15 {0.59}
{4.06}
02051
16 Gear puller MH061326 Removal of crankshaft gear
02065
11-55
Service procedure
Crankshaft assembly end play
If the measured value is higher than the limit, replace thrust plates 12
with oversized ones. P11-58
< Available oversize ones >
+0.15, +0.30, +0.45 mm
{+0.0059, +0.012, +0.018 in.}
03518
2 Mounting of rear oil seal

Apply engine oil to lip area A of rear oil seal 2.
A A
1
06152
Apply sealant C along line B on rear oil seal 2 evenly without break.
C After applying sealant C, within three minutes, mount rear oil seal 2.
CAUTION
2 mm
Do not start the engine within an hour of mounting rear oil seal 2.
{0.079 in.} Be sure to reapply sealant C if bolts 1 (for mounting rear oil seal
2) are loosened or removed by any cause whatsoever after mount-
2 ing.
6P
B
03354
Main bearing
B
[Installation]
20 When installing main bearings 6, 20, align lugs A.
6
CAUTION
A A Be sure to distinguish between main bearings 6, 20. The upper
bearing has oil opening B while the lower bearing has no oil
opening.
03519
[Inspection]
CAUTION
Do not forcibly expand main bearings 6, 20.
Be sure to replace both upper and lower main bearings 6, 20 as a
pair when replacement is necessary.
(1) Expansion at free state

01995 If the measured value is lower than the limit, replace main bearings 6,
20.
11-56
11
(2) Clearance between main bearing and crankshaft
If the measured value is lower than the limit, replace faulty parts.
7G
03520
to Main bearing cap

[Removal]
Use 0 bearing cap extractor to remove rear main bearing cap 11
because side seal 13 is installed between crankcase 23 and the rear
0
main bearing.
11
03521
[Installation]
7 8 9 10 11 Install main bearing caps 7 to 11 in the direction as illustrated.
A : Front of engine

R
03522
11-57
Center punch the head of bolt 5 before installation.
C 0 CAUTION
If there are already three center-punch marks, replace the cylin-
B
der head bolt with a new one.
D E
After tightening bolt 5 at specified torque, tighten further as follows:
Turn 0 socket wrench holder B counterclockwise and keep the
spring in the wrench compressed.
01991 C : Socket
D : Rod
E : Rod (for connection)
Set 0 socket wrench holder B so that the repercussive force of the

14
spring presses rod E (for connection) against crankshaft assembly 14.
E Select a scale that is convenient for reading graduation F on holder B.
5 Tighten further by turning socket C clockwise by 90 (setting is in 5
G
increments), referring to graduation G on the selected scale.
After installation, check the following points :
Crankshaft assembly 14 can be rotated easily by hand.
F The end play of crankshaft assembly 14. P11-56
12776
A
11 H Installation of thrust plate
Install thrust plates 12 on both ends of rear main bearing 11 and the rear
B
12 end of crankcase 26 in the direction as illustrated.
12
A : Oil groove
A B : Positioning pin
B CAUTION
When installing oversized thrust plates 12, mount them on the
12
front and rear of rear main bearing cap 11. It is not necessary that
26
A 03523 the thrust plates used are all of the same size, but use the same-
size-combination of thrust plates for mounting on the rear of
crankcase 26 and on the rear of the rear bearing cap.
13 C D
I Installation of side seal
Supply sealant in side seal mounting groove A of rear main bearing
A
cap 11.
B Apply sealant at end B of side seal 13.
Press in side seal 13 between rear main bearing cap 11 and crank-
case 26 in the direction as illustrated.
26 C : Rear main bearing cap side
E
11 D : Crankcase side
03524
After pressing in, apply sealant to side seal mounting E of rear main
bearing cap 11.
11-58
11
0 L Crankshaft gear
[Removal]
Never remove crankshaft gear 16 by striking, hitting or hammering it.
[Installation]
17
16 Before installing heat up crankshaft gear 16 using a piston heater or
similar device to approximately 100C {212F}.
NOTE
03525 Install key 17 to prevent rotation.
18
0
N Installation of rear oil seal slinger
Install rear oil seal slinger 18 using 0 oil seal slinger installer. Strike
installer A until it hits guide B positively.
19 B A
03526
O Crankshaft
[Inspection]
19 (1) Cylindrical and circular accuracy of the journal and the pin
If the measured value is higher than the limit, grind and correct
crankshaft 19 to convert it to the undersize specifications or replace it.
02105
B (2) Degree of bend

A 19
The degree of bend of crankshaft 19 is measured at No.3 journal C by
supporting No.1 journal A and No.2 journal B. If the measured value is
higher than the limit, replace the crankshaft.
NOTE
The degree of bend of crankshaft 19 is half of the indicated
value of the gauge after rotating the shaft 360.
C 03527
11-59
[Correction]
H G
J NOTE
E
D Be sure to replace main bearings 6, 20 with those that meet the
J undersize specifications after crankshaft 19 is corrected by grind-
F ing.
Set F, distance between the center line of the journal D and that of the
pin E, constant.
F : 57.50.05 mm {2.260.0020 in.}
19 02107 Set the width of journal G and pin H so they are constant.
G : 35 mm {1.38 in.} (32 mm {1.26 in.} for No.1 journal)
H : 41 +0.2
0
mm
{1.61 +0.0079
0
in.}
Finish the fillet J smoothly.

J : R40.2 mm {0.0079 in.}
Check and confirm that there has been no cracking caused by grind-
ing using the magnetic particle inspection method (Magnafluxing).
Also make sure the surface hardness has not deteriorated (Shore
hardness to be maintained at not less than Hs 75).
When grinding K, set crankshaft 19 and grinder L so that they both
K N
rotate counterclockwise as viewed from the front of the crankshaft.
To finish grinding M using a grindstone or emery paper N, rotate
crankshaft 19 clockwise.
M
19
L
19
02108
Undersize specifications of crankshaft Unit : mm {in.}

Undersize scales
0.25 {0.0098} 0.50 {0.020} 0.75 {0.030} 1.00 {0.039}
Finish outer diameter No.1, 2, 4, 5 journals 77.68 to 77.70 77.43 to 77.45 77.18 to 77.20 76.93 to 76.95
of journal {3.058 to 3.059} {3.048 to 3.049} {3.038 to 3.039} {3.028 to 3.029}
No.3 journal 77.66 to 77.68 77.41 to 77.43 77.16 to 77.18 76.91 to 76.93
{3.057 to 3.058} {3.047 to 3.048} {3.037 to 3.038} {3.027 to 3.028}
Finish outer diameter of pin 59.695 to 59.715 59.445 to 59.465 59.195 to 59.215 58.945 to 58.965
{2.3501 to 2.3509} {2.340 to 2.341} {2.33 to 2.331} {2.320 to 2.321}
Circular accuracy 0.01 {0.00039} or less
Cylindrical accuracy
0.006 {0.00024} or less
26
02114
11-60
Group 12 - Lubrication
Group 12A - Lubrication
2001 Model Change
<4M50>
BACK HOME
Service Manual
Group 12A
Lubrication
<4M50T2>
Table of Contents
BACK HOME
Mar. 00H
GROUP 12A LUBRICATION
TROUBLESHOOTING .......................................................................... 12A-14

12A-16
Oil Filter Replacement ......................................................................................
Engine Oil Replacement .................................................................................. 12A-17
Oil Pressure Measurement .............................................................................. 12A-18
OIL PAN, OIL STRAINER AND OIL JET ............................................. 12A-20
OIL PUMP ............................................................................................. 12A-22
OIL FILTER ........................................................................................... 12A-26
OIL COOLER ........................................................................................ 12A-28
12A-1
SPECIFICATIONS
Item Specifications
Mode of lubrication Oil pump type
Oil filter type Paper-filter, spin-on type
Oil cooler type Shell and plate type (multi-plate type)
Grade API CD or higher
Engine oil Oil pan Approx.9 L {9.5 qts}
Oil quantity
Oil filter Approx.1 L {1.1 qts}
12A-2
12A
MEMO
12A-3
Lubrication System (Oil Flow)
22
5 13
16 20
2 6 12
11 24
15
14
3 7 8
4 A 17 23
9
18
21
19
25
10
40872
1 Main oil gallery 15 Balancer bushing LH

2 Bypass valve 16 Crankshaft main bearing
3 Bypass valve 17 Connecting rod bearing
4 Relief valve 18 Connecting rod bushing
5 Engine oil pressure switch 19 Piston
6 Oil cooler 20 Balancer bushing RH
7 Full-flow oil filter 21 Oil jet check valve
8 Bypass oil filter 22 Rocker bushing
9 Oil pump 23 Camshaft bushing
10 Oil strainer 24 Rocker roller
11 Turbocharger 25 Oil pan
12 Vacuum pump
13 Idler bushing A: Orifice
14 Timing gear
12A-4
12A
Oil Pump
1 Oil pump gear
2 Crankshaft gear
3 Oil pump
1 A: To oil filter
B: From oil strainer
A
Oil pump 3 is a gear type. It is driven by rotation of the crank-
shaft via crankshaft gear 2 and oil pump gear 1.
B
3
29458
12A-5
Oil Filter
1 Oil filter head
2 Oil filter
3 Bypass filter
4 Full-flow filter
B
5 Bypass valve
6 Regulator valve
C
A: To oil cooler
B: From oil pump
C: To oil pan
6 A 1
The oil filter is a spin-on filter-paper type incorporating a
bypass filter 3 and a full-flow filter 4.
A bypass valve 5 is fitted at the bottom of the filter assem-
B
bly. If the elements become clogged, the bypass valve
C
opens and allows oil to flow to oil cooler without passing
through the elements. This operation prevents seizure of
2
the engine.
When the pressure of oil going to the main oil gallery ex-
ceeds a specified level, regulator valve 6 opens, allowing
some of the engine oil to return to the oil pan. The oil pres-
3 sure is thus constantly regulated.
5
29503
12A-6
12A
Oil Cooler
1 1 Oil cooler
2 Engine oil pressure switch
B 3 Bypass valve
A: Coolant outlet
B: Coolant inlet
C: To main oil gallery
D: From oil filter
C
2
D
3
29460
P Bypass valve
1
When the oils viscosity is high at low temperatures or when oil cooler
1 element is clogged and resists the oils flow, bypass valve 3 opens,
D thus allowing engine oil to flow to main oil gallery without passing through
the cooler.
C
3
29504
1 P Oil pressure switch

If the pressure of oil fed to main oil gallery drops below the specified
level, electric contacts close inside engine oil pressure switch 2. As a
2 result, a warning lamp illuminates in the meter cluster to alert the driver.
C 29459
12A-7
Lubrication of Related Parts
P Main bearing and connecting rod bearing
1 A
A 1 Main oil gallery
2 Main bearing
B 3 Crankshaft
A: Oil jet
B: Connecting rod oil passage
4 2 Oil supplied via the oil passage in the crankshaft

3 flows through oil passage B in the connecting rod to
lubricate the connecting rods small end. The oil then
sprays out from oil jet A at the top of the connecting
rod to cool the piston.
29590
P Timing gear
1 Head idler gear
1 A
2 Idler gear A, B
3 Idler gear No.1
4 Balanceshaft gear LH
5 Crankshaft gear
10 6 Balanceshaft gear RH
2
7 Main oil gallery
A 8 Fan shaft assembly
9 Upper crankcase
3
A 10 Cylinder head
9
A: Oil hole
8
4
A
5 A
6
29716
Engine oil from main oil gallery 7 passes through upper crankcase 9 and cylinder head 10 to lubricate the journals of the
gears. The oil that has lubricated head idler gear 1 sprays out of oil hole in the gear boss and returns to the oil pan through
inside the front case while lubricating the gears.
12A-8
12A
2
1
6
6
1
4
5
3
29591 30015
P Valve mechanism
1 Camshaft frame 5 Camshaft
2 Rocker arm 6 Rocker shaft
3 Upper crankcase
4 Cylinder head A: From main oil gallery
Engine oil from main oil gallery A passes through upper crankcase 3, cylinder head 4 and camshaft frame 1 to rocker
shaft 6. Then, the oil flows through the oil passage of rocker shaft and returns to the oil pan while lubricating rocker arm
2 and camshaft 5.
P Oil jet
1 Piston
1 2 Oil jet
3 Check valve
A
A: Main oil gallery
An oil jet 2 is fitted in the lower part of the main oil gallery A for each
3 2 cylinder. These oil jets cool the pistons 1 by injecting oil into them.
29505
Each oil jet is fitted with check valve 3 that opens and closes at speci-
fied oil pressure levels. At low engine speeds, these check valves close
to maintain the required volume of oil in the lubrication system and
prevent reductions in oil pressure.
12A-9
P Vacuum pump
1 Front case
A 2 Oil pipe
3 Vacuum pump
A: Main oil gallery

C
B: To front case
1 C: To automatic timer
B
3 2 29592
Engine oil delivered from main oil gallery A flows to vacuum pump 3 where it branches into two flows; one is, after
lubricating the vanes, discharged into front case 1 from the air vent hole and returns to the oil pan. The other passes
through oil pipe 2 to lubricate various parts of the automatic timer and then returns to the oil pan.
12A-10
12A
Lubrication System Monitoring Circuit
1 Starter switch
12 2 Meter cluster
3 Oil pressure switch
4 Oil level sensor
5 Relay box
6 Oil level relay
7 Oil level check switch
8 Fuse box
A: Oil level indicator lamp

B: Oil pressure warning lamp
06442
This circuit monitors the lubrication system by detecting the pressure and level of engine oil.
P Oil level normal (oil level sensor ON)

12 When oil level check switch 7 is turned ON
while the engine is not running (oil pres-
sure switch 3 ON), oil level sensor 4 is
grounded and therefore oil level relay 6 is
energized. This allows current to flow
through the route given below and turn on
oil level indicator lamp A.
06443
Fuse box 8 oil level check switch 7 relay box 5

oil level relay 6 oil level sensor 4 ground
meter cluster 2 oil level indicator lamp A
oil pressure switch 3 ground
12A-11
12 P Oil level low (oil level sensor OFF)
Even when oil level check switch 7 is turned
ON while the engine is not running (oil pres-
sure switch 3: ON), oil level relay 6 is not
energized because oil level sensor 4 is off.
This causes the current to flow through the
route given below and turn on oil pressure
warning lamp B.
06444
Fuse box 8 oil level switch 7 Relay box 5 oil level relay 6 meter cluster 2 oil pressure warning lamp B oil
pressure switch 3 ground
P Oil pressure abnormal (oil pressure switch
12
ON)
The oil pressure drops while the engine is
running oil pressure switch 3 turns ON. As
a result, current flows through the route
given below to turn on oil pressure warn-
ing lamp B. When oil pressure is normal,
oil pressure switch 3 remains off and no
current flow.
06445
Starter switch 1 fuse box 8 relay box 5 oil level relay 6 meter cluster 2 oil pressure warning lamp B oil
pressure switch 3 ground
12A-12
12A
MEMO
12A-13
TROUBLESHOOTING
Symptoms
Excessive oil consumption (oil leakage)

Remarks
Engine hard to start
Low oil pressure

Overheating
Possible causes
Oil cooler element installed poorly
Gasket defective
O-ring defective
Oil cooler
Oil cooler element clogged
Oil cooler element damaged
Fatigue in bypass valve spring
Oil pump malfunctioning
Oil pump Interference between oil pump gear and oil pump
case or cover
Oil filter fitted poorly
Oil filter Element clogged
Gasket defective
Fatigue in regulator valve spring
Oil strainer installed poorly, clogged
Front case installed poorly B Group 11A
Fan shaft front oil seal defective B Group 11A
Crankshaft rear oil seal defective B Group 11A
Piston cooling oil jet(s) defective
Oil working its way up into combustion chamber(s)
Oil working its way down into combustion chamber(s)
Oil viscosity too high
Unsuitable of quality
Deterioration in oil
Fuel mixed with oil
12A-14
12A
MEMO
12A-15
Oil Filter Replacement
Lubricant
2 Oil filter Engine oil (API CD or higher) Approx.1 L {1.1 gts}
Oil Filter Element Socket MH061566
08550
Oil filter removal
107 to 120
Oil Filter Wrench MH063200
{4.21 to 4.72}
01503
WARNING k
burns.
2
CAUTION k
1
29367
Loosen oil filter drain plug 1 to drain the engine oil from inside the filter 2.
[Removal]
0: Oil Filter Element Socket or Filter Wrench
0
41054
[Installation]
Clean the surface of oil filter head 3 to which oil filter 2 is fitted.
Apply a thin coat of engine oil to the gasket A of oil filter 2.
3 Screw oil filter 2 into oil filter head 3 by hand until gasket A contacts the
oil filter head. Then, tighten oil filter 2 further by giving it a 3/4 turn.
A
After installing the oil filter, start the engine and check gasket A for oil
leakage.
2 Check to see if the engine oil level is in the specified range.
29368
12A-16
12A
Engine Oil Replacement

2 Oil pan drain plug 34.3 to 43.1 {25 to 32, 3.5 to 4.4}
3 Oil filter drain plug 9.81.96 {7.21.4, 1.00.2}
Lubricant
Oil pan Engine oil (API CD or higher) Approx.9 L {9.5 qts}
Oil filter Engine oil (API CD or higher) Approx.1 L {1.1 qts}
1 WARNING k
Wipe up any spilled engine oil since it can cause a fire.
burns.
CAUTION k
41236
[Draining]
Warm up the engine, then remove oil filler cap 1.
Remove oil pan drain plug 2 and oil filter drain plug 3. Then, drain the
engine oil.
[Filling]
Tighten oil pan drain plug 2 and oil filter drain plug 3 to their specified
torques. Then, add new engine oil to the specified level.
2 07381
3 29717
12A-17
Oil Pressure Measurement
Service standards
Oil pressure (at At no-load minimum speed 145 kPa 49 kPa Check
oil temperature {21 psi2, 1.5kgf/cm2} {7.1 psi2, 0.5 kgf/cm2}
of 158 to 194F, At no-load maximum speed 295 to 490 kPa 195 kPa
70 to 90C) {43 to 71 psi2, 3 to 5 kgf/cm2} {28 psi2, 2 kgf/cm2}

2 Engine oil pressure switch 7.8 to 14.7 {5.8 to 11.0, 0.8 to 1.5} Check with engine
cold
Sealant
Location Point of application Specified sealant Quantity
2 Threaded part of engine oil pressure switch Teflon tape 3 and half turns
Remove engine oil pressure switch 2 from oil cooler 1.

2
1
29371
Fit adapter 3 onto the engine oil pressure switch 2 mounting, then fit
the oil pressure gauge onto the adapter.
Warm up the engine until the oil temperature reaches 158 to 194F (70
to 90C).
Measure the oil pressure at no-load minimum speed and at no-load
maximum speed. If the measured values are below the specified stan-
dard values, overhaul the lubrication system.
After taking measurements, fit oil pressure switch 2 and tighten it to the
PT1/8 3 specified torque.
29372
CAUTION k
Oil pressure switch 2 must be fitted when the engine is cold.
Inspection of oil pressure switch

B ELECTRICAL SYSTEM
12A-18
12A
MEMO
12A-19
OIL PAN, OIL STRAINER AND OIL JET
5 3
1 Gasket
7 2 Oil drain plug
3 Bolt
6 4 Stiffner RH
5 Bolt
6 Stiffner LH
9 7 Rubber spacer
8 4 8 Bolt
9 Oil pan
10 Bolt
11 Bolt
1 12 O-ring
2 13 Oil strainer
14 Bolt
13 14 15 O-ring

10 11 16 Engine oil level sensor B ELECTRICAL
16 SYSTEM
17
12 15 17 Check valve
* 18 18 Oil jet
*: Crankcase B Group 11A

: Non-reusable part
40873
P Assembly sequence
CAUTION k
Do not tighten check valve 17 in excess of the specified torque. Excessive tightness can cause defective opera-
tion, resulting in scorching of the engine.
12A-20
12A

2 Oil drain 34.3 to 43.1 {25 to 32, 3.5 to 4.4}
3 Bolt (spacer stay RH mounting) 23.5 {17.3, 2.4}
5 Bolt (spacer stay LH mounting) 23.5 {17.3, 2.4}
8 Bolt (oil pan mounting) 23.5 {17.3, 2.4}
10 Bolt (oil strainer mounting) 23.5 {17.3, 2.4}
11 Bolt (oil strainer mounting) 23.5 {17.3, 2.4}
14 Bolt (engine oil level sensor mounting) 23.5 {17.3, 2.4}
17 Check valve 29.4 {22, 3.0} Wet

9 Crankcase mounting surface of oil pan Threebond 1207C As required
12, 15 Entire circumference of O-ring Engine oil As required
17 Threads of check valve Engine oil As required
R Service procedure
2.5 mm 9 Fitting oil pan
A
Apply sealant A to the mounting surface of oil pan 9 as illustrated.
9 A Apply the sealant evenly and without breaks.
Within three minutes of applying sealant A, fit oil pan 9 onto the crank-
case*.
CAUTION k
Clean the oil pan mounting surface and ensure it is free of oily
29313 substances before applying sealant.
Carefully mount oil pan exactly in the correct position. Ensure
that sealant A does not spread to other areas.
After fitting oil pan 9, wait at least one hour before starting the
engine.
Reapply sealant A to the oil pan mounting surface whenever the
mounting bolts 8 of oil pan 9 have been loosened.
12A-21
OIL PUMP
1 Bolt
2 O-ring
*d 3 Oil pump assembly
*a 4 Bolt
A
A 5 Oil pump cover
6 Driven gear assembly
3 7 Oil pump case assembly
*a: Crankcase B Group 11A

*b: Crankshaft gear
2 *c: Drive gear
*d: Balanceshaft gear RH
A: Locating pin (Bushing)
*b : Non-reusable part
1

P Assembly sequence
*c Follow the disassembly sequence in re-
verse.
7
6
4

5
29314
Standard value
(Basic diameter in[ ])
Backlash between oil pump gear and crankshaft 0.12 to 0.15 0.3 Replace
gear Gr.11 {0.0047 to 0.0059} {0.012}
Backlash between oil pump gear and balanceshaft 0.19 to 0.22 0.3 Replace
gear Gr.11 {0.0075 to 0.0087} {0.012}
5, 6, 7 Clearance between gear shaft and oil pump case [20 {0.79}] 0.04 to 0.075 0.15 Replace
and cover {0.0016 to 0.0028} {0.0059}
5, *C Clearance between gear shaft and oil pump cover [20 {0.79}] 0.04 to 0.075 0.15 Replace
{0.0016 to 0.0028} {0.0059}
6, 7, *C Difference between height of each gear and depth 0.040 to 0.094 0.15 Replace
of oil pump case {0.0016 to 0.0035} {0.0059}
Clearance between tooth tips of each gear and oil 0.13 to 0.22 0.23 Replace
pump case {0.0051 to 0.0087} {0.0091}

1 Bolt (oil pump assembly mounting) 27.4 {20, 2.8}
4 Bolt (oil pump cover mounting) 8.22.46 {5.81.8, 0.80.25}
12A-22
12A
Sealant
Oil pump gears Engine oil As required
2 Entire circumference of O-ring Engine oil As required
5 Pump Cover Pin Oil pump cover

MH063431
installation
0
7 {0.28} +0.014
{+0.00055} 20 {0.79}
29507
R Service procedure
*d 3 Installation of oil pump assembly
7 With No. 1 cylinder set at its top dead center, position crankshaft gear
7
*b.
7
Install oil pump assembly 3 while meshing its gear with crankshaft gear
*b and balance shaft gear RH *d at the match marks 6 and 7 as
3 shown.
6
*b
6
6
29731
5 6 7 5 to 7 Inspection of oil pump cover, driven gear assembly and oil

pump case assembly
Measure the clearance between each gear shaft and oil pump case as-
sembly 7 or cover 5. Replace the oil pump assembly if any measurement
is out of specification.
29315
12A-23
OIL PUMP
5 7 Installation of oil pump cover and oil pump case assembly
4 Position oil pump cover 5 on oil pump case assembly 7 using two 0
Pump Cover Pins.
0 Fit bolt 4 and tighten it to the specified torque.
Remove 0 Pump Cover Pins, then fit other bolts 4 and tighten them to
5 the specified torque.
0
7 CAUTION k
A Before assembly, apply engine oil to various parts. Pour approxi-
29508
mately 5 cm3 {0.3 Cu.in.} of engine oil into the assembly from the
oil outlet before installing to the engine.
After assembly, turn the oil pump gear A by hand and check that it
rotates smoothly. If the gear does not rotate smoothly, disassemble
and reassemble the components.
7 67 Inspection of driven gear assembly and oil pump case

assembly
6
(1) Differences between gear heights and oil pump case depth
Replace the oil pump assembly if the measurement is out of specifica-
tion.
*C
29316
(2) Clearance between gear teeth tip and oil pump case
Replace the oil pump assembly if the measurement is out of specifica-
6 tion.
*C
7
29317
12A-24
12A
MEMO
12A-25
OIL FILTER
1 Gasket
2 Oil drain plug
3 Oil filter P. 12A-16
4 Bolt
5 Bolt
6 O-ring
* 7 Oil pipe
8 O-ring
9 Bolt
10 Plug
11 Spring
12 Regulator valve
6
7 5 13 Oil filter head
14 Gasket

8 *: Crankcase B Group 11A

4 : Non-reusable part
P Assembly sequence
10
12
14
13
3 5
9

1
2

29318
WARNING k
Do not touch oil when the engine is hot since it can inflict severe burns.
CAUTION k
When pouring oil into the engine, take care not to spill any on the V-ribbed belts. Contact with oil could make the
V-ribbed belts slip, rendering the cooling system less effective.
Fit gasket 14 in right direction. If installed in wrong direction, it blocks oil hole.
Service standards
+100
600 0 kPa Replace
12 Regulator valve opening pressure
{85 +14.2 2 +1 2
0 lbf/in. , 6 0 kgf/cm }
spring
12A-26
12A
T Tightening torques Unit: Nm {ft.lbs, kgfm}

2 Oil drain plug 9.81.96 {7.21.4, 1.00.2}
4 Bolt (Oil pipe mounting) 9.8 {7.2, 1.0}
5 Bolt (Oil pipe mounting) 23.5 {17, 2.4}
9 Bolt (Oil filter head mounting) 44.1 {33, 4.5}
10 Plug (Regulator valve mounting) 60 {43, 6.0}
Lubricant
3 Gasket of oil filter Engine oil As required
Oil Filter Element Socket Obtain Locally
08550
3 Oil filter removal
107 to 120
Filter Wrench Obtain Locally
{4.21 to 4.72}
01503
12A-27
OIL COOLER
3
2
19
10
5
7 11
18 14
17 12 6
15 13
16 4

40874
1 Bolt 10 Coolant temperature sensor (for 18 Bypass valve
2 Oil cooler assembly MUTIC) 19 Oil cooler body
3 Gasket B Electrical
4 Nut 11 Engine oil pressure switch *: Crankcase B Group 11A
5 Nut B Electrical : Non-reusable part
6 Eyebolt 12 O-ring
7 Oil pipe 13 Plug
8 Oil cooler element 14 Water drain valve
9 Coolant temperature sensor (for 15 O-ring
engine control) 16 Plug
B Electrical 17 Spring
12A-28
12A
P Assembly sequence
Service standards
8 Oil cooler element air leakage 0 cm3 {0 Cu.in.} Replace
(air pressure of 980 kPa {140 psi2, 10 kgf/cm2} for 15 seconds)
18 Bypass valve opening pressure 390 kPa Replace
{57 psi2, 4 kgf/cm2} spring

1 Bolt (Oil cooler assembly mounting) 23.5 {17, 2.4}
4 Nut (Oil cooler element mounting) 24.55 {183.6, 2.50.5}
6 Eyebolt (Oil pipe mounting) 21.6 {16, 2.2}
9 Coolant temperature sensor 34.3 {25, 3.5}
10 Coolant temperature sensor 34.3 {25, 3.5}
11 Engine oil pressure switch 7.8 to 14.7 {5.8 to 11.0, 0.8 to 1.5}
13 Plug 34.55 {253.6, 3.50.5}
14 Water drain valve 19.5 to 29.5 {14 to 22, 2.0 to 3.0}
16 Plug 34.34.9 {253.6, 3.50.5}
Lubricant
12A-29
OIL COOLER
R Service procedure
P Cleaning
Check whether carbon deposits or sludge have accumulated in the oil
passage of oil cooler element 8 or in the oil coolers bypass arrange-
ment. Remove any deposits with cleaning solvent.
Clean out any water scale or fur that has accumulated in the oil cooler
element 8 or oil cooler body 19.
8 Inspection of oil cooler element

Plug outlet A of oil cooler element 8 and connect a hose to the oil inlet
B. Then, immerse the oil cooler element in a tank of water.
Apply an air pressure of 980 kPa {140 psi2, 10 kgf/cm2} via the hose
A and check that no air leaks from the oil cooler element 8.
If any air leaks, replace the oil cooler element 8.
8
B 04240
12A-30
Group 12
Lubrication
Table of Contents
BACK
HOME
Pub No. TWSE9501-12

12
GROUP 12 LUBRICATION
SPECIFICATIONS .................................................................................. 2
TROUBLESHOOTING .......................................................................... 12

Replacement of Oil Filter ................................................................................. 13
Replacement of Engine Oil .............................................................................. 14
Measurement of Oil Pressure .......................................................................... 15
OIL PAN, OIL STRAINER AND OIL JET ............................................. 16
OIL PUMP ............................................................................................. 18
OIL COOLER AND OIL FILTER ........................................................... 22
12-1
SPECIFICATIONS
Item Specifications
Mode of lubrication Oil pump type
Oil filter type Spin-on filter paper type
Oil cooler type Shell and plate type (Multiple-plate type)
Engine oil Grade Grade CD or above as per API classification
Quantity of oil Oil pan Approximately 8 {8.5}
L {qts} Oil filter Approximately 1 {1.1}
12-2
Lubrication System (Flow of Oil)
4
14 20
12
15
2 5 6
A 13 16 17 21
7 8
18 22 25
3 10
9
23 26
24
19
27
11
12828
1 Main oil gallery 11 Oil strainer 21 Rocker bushing

2 Bypass valve (Built-in within oil filter) 12 Injection pump 22 Push rod
3 Regulator valve 13 Automatic timer 23 Tappet
4 Engine oil pressure switch 14 Crankshaft main bearing 24 Check valve for oil jet
5 Full-flow filter element 15 Idler bushing 25 Turbocharger
6 Bypass filter element 16 Timing gear 26 Vacuum pump
7 Bypass valve 17 Connecting rod bearing 27 Oil pan
8 Oil cooler 18 Connecting rod bushing
9 Oil pump 19 Piston A : Orifice
10 Relief valve (Built-in within oil pump) 20 Camshaft bushing
12-3
Oil Pump
1 Crankshaft gear
2 2 Oil pump gear
1 3 Oil pump
4 Relief valve
A : To oil cooler
B : From oil strainer
C : To oil pan
A Oil pump 3 is a gear type, driven by rotation of the crankshaft

3 transmitted by crankshaft gear 1 that engages oil pump gear
2. Relief valve 4 is installed on the oil pump and when the oil
pump discharge pressure becomes higher than the standard
C pressure level, part of the engine oil is returned to the oil pan
by relief action of the valve, protecting the lubricating system
from breakdown caused by excessive oil pressure.
B
4
06429
12-4
12
Oil Cooler and Oil Filter
2 Oil cooler
2 3 Regulator valve
B 4 Bypass filter element
1
5 Oil filter
6 Full-flow filter element
7 Bypass valve
A
3 8 Bypass valve
A : Coolant exit port

C B : Coolant entry port
C : To oil cooler
D D : To oil pan
E : To main oil gallery
E
8
4
5
D
6
06430
C Operation of bypass valve

When the viscosity of the engine oil is high at low temperatures, or when
8 oil cooler 2 element is clogged, flow resistance is high, and if this
happens, bypass valve 8 opens to let the engine oil return directly to oil
filter 5 without going through the oil cooler.
06431
Operation of regulator valve

E When the oil pressure in the main oil gallery becomes higher than
3 standard, regulator valve 3 opens to let part of the oil return to oil pan D,
D thereby regulating the oil pressure.
06432
12-5
Oil filter element
E
This oil filter uses a spin-on, filter paper type element, that
integrates full-flow filter element 6 and bypass filter element 4.
When the filter element is clogged, bypass valve 7, installed at
D the base of the filter, opens to let the oil bypass the element
and flow directly to main oil gallery E, preventing engine sei-
zure.
7
06434
Operation of engine oil pressure switch

When pressure for delivering the oil to main oil gallery E becomes lower
E than standard, the built-in electric contact point of engine oil pressure
1 switch 1 closes to light the warning lamp in the meter cluster, warning the
driver that the oil pressure is abnormal.
06433
12-6
12
Lubrication of Related Parts
Main bearing and connecting rod bearing
1 Main oil gallery
1 2 Main bearing
3 Crankshaft
A
A : Connecting rod oil passage
4 2 Engine oil supplied through the oil passage drilled in

3 the crankshaft flows through connecting rod oil pas-
sage A to lubricate the small end of the connecting rod.
10801
Timing gear
1 2 A
3 4
11
9 8 B 7 6
10
06436
1 Thrust plate 9 Idler shaft

2 Camshaft 10 Vacuum pump
3 Idler gear bushing 11 Camshaft gear
4 Automatic timer
5 Oil pipe A : From main oil gallery
6 Timing gear case B : Oil jet (for forced lubrication of automatic timer)
7 Bearing
8 Idler gear
Eengine oil from main oil gallery A flows through the inside of camshaft 2 and idler shaft 9 and lubricates each gear along
the way including vacuum pump 10. Inside timing gear case 6 is oil jet B that constantly provides automatic timer 4 with
forced lubrication.
12-7
6 Valve mechanism
A
5 1 Crankcase
2 Cylinder head
4
3 Rocker shaft
3 4 Rocker shaft bracket
5 Rocker bushing
6 Rocker
2 7 Push rod
8 Tappet
9 Camshaft
7 10 No. 1 camshaft bushing
1
8 A : Rocker oil hole

B : From main oil gallery
C
C : To oil pan
B 10 06437
Oil jet
1 Piston
2 Oil jet
1 3 Check valve
A
A : Main oil gallery
An oil jet 2 is installed, in the lower part of main oil gallery A, for each
2 cylinder and cools piston 1 by injecting engine oil toward the inside of the
3 06438 piston. The oil jet is fitted with check valve 3 which opens and closes at
standard oil pressure levels. This prevents a decrease of oil volume at
low oil pressure as well as a decrease of oil pressure itself.
1 Turbocharger
2
1 Bearing housing
2 Snap ring
A 3 Piston ring
4 Bearing
A : From main oil gallery

B : To oil pan
B Engine oil is delivered from the main oil gallery to bearing housing 1
3 through the oil pipe to lubricate bearing 4. Piston ring 3 installed at both
3 ends of the turbine wheel shaft works as an oil seal.
4 01488
12-8
12
Injection pump
1 1 Governor
2 Injection pump
3 Bearing cover
5 4 Oil pipe
5 Timing gear case
4
Engine oil that has lubricated injection pump 2 and governor 1 returns to
3 the oil pan through the oil passage of bearing cover 3.
2 10796
A Vacuum pump
1 B
1 Timing gear case
2 Vacuum pump
A : Main oil gallery

B : To camshaft
C : To crankshaft
C
Engine oil is delivered from main oil gallery A to vacuum pump 2 through
2
06441 the oil passage of timing gear case 1 to lubricate the vanes. Then, the oil
is discharged to the timing gear case through the air outlet port together
with air to be returned to the oil pan.
12-9
Lubrication System Electric Circuit
1 Starter switch
12 volts DC 1 2 2 Meter cluster
3 4 3 Engine oil level indicator lamp (Green)
4 Engine oil pressure warning lamp (Red)
6 Relay box
7 Engine oil level relay
10 8 Engine oil level sensor
9 Engine oil level check switch
10 Fuse box
9
8 5
7
6 15075
This system detects irregularities of engine oil pressure and engine oil level using a sensor-based system.
When oil level is normal

1 (Engine oil level sensor : ON)
12 volts DC 2
3 4 When the engine is at a standstill (engine oil pres-
sure switch 5 : ON), by turning engine oil level check
switch 9 ON, engine oil level relay 7 is magnetized
through engine oil level sensor 8 making electric
current flow to light engine oil level indicator lamp 3.
10
10 9 7 (coil) 8 Ground
10 7 (contact point) 3 5 Ground
9 5
8
7
6 15076
12-10
12
When oil level is low
1 2 (Engine oil level sensor : OFF)
12 volts DC
3 4 When the engine is at a standstill (engine oil pres-
sure switch 5 : ON), no magnetization of engine oil
level relay 7 takes place when engine oil level switch
9 is turned ON because engine oil level sensor 8 is
OFF, but electric current flows to light engine oil
10 pressure warning lamp (Red) 4.
10 9 7 4 5 Ground
9 8 5
7
6
15077
When oil level is abnormal

12 volts DC 1 2 (Engine oil pressure switch : ON)
3 4 When the oil pressure drops while the engine is
running, engine oil pressure switch 5 is ON, making
electric current flow to light engine oil pressure warn-
ing lamp (Red) 4. Under normal conditions, engine
oil pressure switch 5 remains OFF and therefore no
10
electric current flows.
1 10 7 4 5 Ground
9
8 5
7
6
15078
12-11
TROUBLESHOOTING
Symptoms
Oil consumption excessive (Oil leakage)

Remarks
Oil pressure low

Overheating
Possible causes
Oil cooler element installation faulty
Gasket faulty
O-ring faulty
Oil cooler Oil cooler element clogged
Oil cooler element damaged
Bypass valve spring fatigued
Regulator valve spring fatigued
Malfunctioning
Oil pump Oil pump gear interfering with oil pump case or cover
Relief valve spring fatigued
Installation faulty
Oil filter Element clogged
Gasket faulty
Oil strainer installation faulty or clogged
Crankshaft front oil seal faulty ^ Gr 11
Crankshaft rear oil seal faulty ^ Gr 11
Timing gear case installation faulty ^ Gr 11
Oil jet for piston cooling faulty
Oil working its way up into combustion chamber
Oil working its way down into combustion chamber
Oil viscosity too high
Oil quality unsuitable
Oil deteriorated
Fuel mixed with oil
12-12
101.2
{3.98}
06478
WARNING
cause a fire.
When replacing oil filter 2, take care not to spill oil on the V-belt.
[Removal]
06446
[Installation]
2.
1 Apply engine oil thinly and evenly to gasket area A of oil filter 2.
Screw in oil filter 2 to oil cooler body 1 until gasket area A sits on the
A of a turn.
from gasket area A.
2 07382 Check the oil level and if it is low, fill to correct level.
12-13
Replacement of Engine Oil

- Lubricant
Oil pan Engine oil (Grade CD or above as per Approximately
API Classification) 8 L {8.5 qts}
Oil filter Engine oil (Grade CD or above as per Approximately
API Classification) 1 L {1.1 qts}
WARNING
cause a fire.
When replacing oil, take care not to spill oil on the V-belt.
1 [Draining]
After warming-up the engine, remove oil filler cap 1 and remove drain
plug 2 of the oil pan and drain the engine oil.
[Refilling]
Tighten drain plug 2 of the oil pan at specified torque and fill with the
specified quantity of engine oil.
10799
2 07381
12-14
12
Measurement of Oil Pressure
Service standards
Oil pressure At no-load minimum revolution 145 kPa 49 kPa Inspect
(Oil tempera- {21 lbf/in2, 1.5 kgf/cm2} {7.1 lbf/in2,
ture 70 to 0.5 kgf/cm2}
90C {158 to At no-load maximum revolution 295 to 490 kPa 195 kPa
194F}) {43 to 71 lbf/in2, 3 to 5 kgf/cm2} {28 lbf/in2,
2 kgf/cm2}

2 Engine oil pressure switch 7.8 to 15 {5.8 to 11, 0.8 to 1.5} When engine
is cold
- Sealant
2 Thread area of engine oil pressure switch Teflon tape 31/2 turns
Remove oil pressure switch 2 from oil cooler 1.

Mount the oil pressure gauge after installing adaptor 3 onto oil cooler
1.
2 Warm up the engine until the oil temperature reaches 70 to 90C {158
to 194F}.
Measure oil pressure at no-load minimum revolution and at no-load
1 maximum revolution. If the measured values are lower than the limit,
overhaul the lubricating system.
06447
After measurement, install engine oil pressure switch 2 and tighten at

specified torque.
CAUTION
Make sure you install oil pressure switch 2 when the engine is
cold.
Inspection of engine oil pressure switch

3
PT ^ Gr 54
1/8
06448
12-15
OIL PAN, OIL STRAINER AND OIL JET
1 Drain plug
2 Stiffener
2 3 Rubber spacer
4 Bolt
4 5 Oil pan
6 Oil strainer
3 7 O-ring
8 O-ring
1 9 Engine oil level sensor ^ Gr 54
10 Check valve
- 11 Oil jet
6
9 * : Crankcase
8 : Non-reusable parts
10 -
*
11 Assembly sequence
7
-
verse.

CAUTION
Make sure that you do not tighten check
10740 valve 10 higher than the specified torque.
Overtightening will cause damage to the
check valve, resulting in serious over-
heating damage to the engine.

1 Drain plug 34 to 39 {25 to 29, 3.5 to 4.0}
10 Check valve 29 {22, 3} Wet

5 Oil pan to crankcase connecting surface THREEBOND 1207C As required
7 Body of O-ring Engine oil As required
10 Thread area of check valve Engine oil As required
2 mm {0.079 in.}
5
Service procedure
Installation of oil pan
Apply sealant A to lower connecting surface of oil pan 5 as illustrated
5 A evenly without break.
After applying sealant A, within three minutes, mount oil pan 5 to
crankcase *.
CAUTION
Be sure to clean and wipe off oily substances from the surface
where sealant A is to be applied.
06450
Make sure that sealant A is not transferred to other areas while
the mounting work is being done.
Do not start the engine within an hour of mounting oil pan 5.
Be sure to reapply sealant A if bolts 4 (for mounting oil pan 5) are
loosened or removed by any cause whatsoever after mounting.
12-16
12
MEMO
12-17
OIL PUMP
*1 1 Oil pump assembly
*2 2 Bolt
A 3 Snap ring
4 Relief valve
1 5 Spring
6 Seat
7 Oil pump cover
8 Driven gear assembly
9 Oil pump case assembly
10
10 O-ring
- 2

*1 : Crankcase ^ Gr 11
*2 : Crankshaft gear
*3 : Drive gear
5
4
A : Positioning pin (Bushing)
3
*3 : Non-reusable parts
Assembly sequence
reverse.
06451

Backlash between oil pump gear and crankshaft 0.10 to 0.18 {0.0039 to 0.0071} 0.3 {0.012} Replace
gear ^ Gr 11
4 Relief valve opening pressure 108098 kPa
{15514 lbf/in2, 111.0 kgf/cm2}
5 Relief valve spring load 21511 N {492.4 lbf, 22.11.1 kgf} Replace
(Installed length : 33.4 {1.31})
7, 8, 9 Clearance between gear shaft and oil pump case [20 {0.79}] 0.04 to 0.07 0.15 {0.0059} Replace
and oil pump cover {0.0016 to 0.0028}
7, *3 Clearance between gear shaft and oil pump cover [20 {0.79}] 0.04 to 0.07 0.15 {0.0059} Replace
{0.0016 to 0.0028}
8, 9, *3 Difference between height of each gear and depth 0.01 to 0.07 {0.00039 to 0.0028} 0.18 {0.0071} Replace
of oil pump case
Clearance between tooth tip of each gear and oil 0.10 to 0.19 {0.0039 to 0.0075} 0.2 {0.0079} Replace
pump case

2 Bolt (Oil pump cover mounting) 9.82.0 {7.21.4, 1.00.2}
- Lubricant
12-18
12
6
6
Service procedure
Installation of seat
A : Oil pump cover side
7
10719
7 8 9 79 to Inspection of oil pump cover, driven gear assembly,

and gear and case assembly
Measure the clearance between oil pump cover 7 and driven gear
shaft A, and the clearance between oil pump gear case assembly 9
and the driven gear shaft.
A
Measure the clearance between the oil pump cover and drive gear
shaft B.
B If the measured values are higher than the limit, replace the faulty
04943
parts.
79 Installation of oil pump cover and oil pump case

assembly
Prepare two pins A of 9 mm {0.35 in.} in outer diameter and position oil
pump cover 7 and oil pump case assembly 9 as illustrated.
A
9
8
7 08774
Tighten the illustrated bolts 2 at specified torque.

A
A 08775
12-19
OIL PUMP
Remove pins A, replacing them with bolts 2 and tighten at specified
B torque.
2 NOTE
Confirm smooth movement by rotating oil pump gear B by hand.
If it catches, disassemble and reassemble it.
2
08776
9
*3
893 *3 Inspection of driven gear assembly, and oil pump
case assembly
(1) Difference between height of each gear and depth of oil pump
case
8 06453
(2) Clearance between tooth tip and oil pump case

8 *3
9 06452
12-20
12
MEMO
12-21
OIL COOLER AND OIL FILTER
18
2
7 8
9
- 6 17
10
- 4
1
*
-
16 3 11

13

14 15 12

06454
1 Oil filter P12-13 12 Drain plug
2 Oil cooler assembly 13 Plug
3 Nut 14 O-ring
4 O-ring 15 Spring
5 Oil cooler element 16 Bypass valve
6 Engine oil pressure switch ^ Gr 54 17 Oil cooler body
7 Plug 18 Gasket
8 O-ring
9 Spring *: Crankcase assembly ^ Gr 11
10 Regulator valve : Non-reusable parts
11 Thermostat switch ^ Gr 54
Assembly sequence
12-22
12
Service standards
5 Oil cooler element air leakage (Air pressure 0 cm3 {0 cu. in.} Replace
980 kPa {140 lbf/in2, 10 kgf/cm2}, 15 seconds)
10 Regulator valve opening pressure 59029 kPa Replace
{854.3 lbf/in2, 6.00.3 kgf/cm2}
16 Bypass valve opening pressure 39029 kPa Replace
{574.3 lbf/in2, 4.00.3 kgf/cm2}

6 Engine oil pressure switch 7.8 to 15 {5.8 to 11, 0.8 to 1.5}
7 Plug (Regulator valve spring mounting) 19.55 {143.6, 2.00.5}
11 Thermostat switch 345 {253.6, 3.50.5}
12 Drain plug (Oil cooler) 34 {25, 3.5}
13 Plug (Bypass valve spring mounting) 19.55 {143.6, 2.00.5}

1 Gasket area of oil filter with thin application Engine oil As required
P12-13
6 Thread area of engine oil pressure switch Teflon tape 31/2 turns
Service procedure
Cleaning
Check and see if any carbon deposits or sludge have developed in
the oil passage of oil cooler element 5 or its bypass. Clean any
deposits off thoroughly with cleaning solvent.
Also clean any water scale or fur found in oil cooler element 5 or oil
5
cooler body 17.
Inspection of oil cooler element

Immerse oil cooler element 5 in a water tank after plugging exit port A
and connecting the hose to engine oil entry port B.
Apply air pressure of 980 kPa {140 lbf/in2, 10 kgf/cm2} via the hose and
A see if there is any air leakage from any part of oil cooler element 5.
If you see any leakage, replace oil cooler element 5.
5
B
04240
12-23
BACK HOME
Group 13 - Fuel & Engine Control
Group 13 - Fuel & Engine Control

1999 Minor Changes
Group 13A - Fuel & Engine Control

2001 Model Change <4M50>
Group 13E - Fuel & Engine Control

2001 Model Change <4M50>
Service Manual
Group 13A
Fuel and Engine Control
<4M50T2>
Table of Contents
BACK HOME
Mar. 00H Printed in Japan

GROUP 13A FUEL AND ENGINE CONTROL

1. Fuel System (Fuel flow) ........................................................................ 13A- 3
2. Engine Control ...................................................................................... 13A- 4
3. Fuel Filter ............................................................................................... 13A- 5
ON-VEHICLE INSPECTION AND ADJUSTMENT ............................... 13A- 6

1. Checking Minimum and Maximum
No-Load Speeds ................................................................................... 13A- 6
2. Bleeding Air from Fuel System ........................................................... 13A- 7
3. Replacing Fuel Filter ............................................................................ 13A- 7
ENGINE CONTROL .............................................................................. 13A-10
FUEL TANK .......................................................................................... 13A-13
FUEL FILTER........................................................................................ 13A-14
INJECTION PUMP ................................................................................ 13A-16
INJECTION NOZZLE ............................................................................ 13A-20
For system control of the electronically controlled injection pump, refer to Group 13E Electroni-
cally Controlled Fuel System.
SPECIFICATIONS
Injection Pump Assembly
Item Specification
Manufacturer DENSO
Model V4
Type Distributor type electronically controlled pump
Spill valve solenoid Electronically controlled
Timer Control High-pressure chamber control
Drive Timer controlled valve (TCV)
Feed pump type Vane
Injection Nozzle Assembly

Item Specification
Manufacturer DENSO
Type Hole-type (2-spring)
No. of holes 6
Hole diameter mm {in.} 0.20 {0.0079}
Fuel Filter
Item Specification
Fuel filter type Spin-on type (paper filter)
Water level alarm Provided
Priming pump Provided
13A-2
STRUCTURE AND OPERATION 13A
1. Fuel System (Fuel flow)
37446
1 Injection nozzle 6 Fuel filter

2 Fuel leak-off pipe 7 Fuel suction pipe
3 Injection pipe 8 V4 injection pump
4 Fuel return pipe 9 Overflow valve
5 Fuel tank 10 Fuel hose
Fuel from the fuel tank 5 is drawn up by the feed pump, which is driven by the V4 injection pump 8. Then, the fuel is
delivered into the V4 injection pump through the fuel filter 6.
After filtration, the fuel is fed to the V4 injection pump 8. From there, it is fed under high pressure to the injection nozzles
1. The injection nozzles spray the fuel into the combustion chambers.
Excess fuel from the injection nozzles 1 returns to the fuel tank 5 by way of the fuel leak-off pipe 2.
If the fuel pressure in the V4 injection pump 8 exceeds a preset level, the overflow valve 9 opens to allow excess fuel to
return from the fuel return pipe 4 to the fuel tank 5.
13A-3
2. Engine Control
1 Starter switch
2 Accelerator position sensor & accelera-
tor switch assembly
3 Accelerator pedal
5 C 4 Lever
5 Emergency engine stop switch
D 6 V4 ECU
1 E
7 EDU
6 8 Spill valve
9 V4 injection pump assembly
7
2 A: Idling position
B 3 B: Full-load position
9 8 C: Engine stopping position
A
D: Engine starting position
4 F E: Fuel cut signal
F: Power supply
37447
P Accelerator position sensor & accelerator switch unit

The accelerator position sensor & accelerator switch unit 2 consists of an accelerator position sensor and a built-in
accelerator switch.
The accelerator switch responds to the foot pressure acting upon the accelerator pedal 3.
The accelerator position sensor detects the movement of the accelerator pedal 3 and outputs an electric signal to the
V4 ECU 6. The lever 4 is constantly pulled by the return spring toward the idling position A.
P Emergency engine stop switch

The emergency engine stop switch 5 is used to stop the engine when the starter switch 1 placed in the ACC position fails
to do it due to a system failure or for other reason. If the switch is pulled into the engine stopping position C, a fuel cut
signal F is sent to the V4 ECU 6, which in turn supplies power F to the spill valve 8 of the V4 injection pump assembly 9
to stop the engine.
CAUTION k
When restarting the engine stopped by means of the emergency engine stop switch 5, set the starter switch 1 to
the ACC or LOCK position beforehand to initialize the computer in the V4 ECU 6.
13A-4
13A
3. Fuel Filter
1 Fuel filter head
2 Fuel filter cartridge
C 3 Water level sensor
1 A: To injection pump
B: From fuel tank
A B C: Priming pump
D: Drain port
2 The fuel filter cartridge 2 serves also as a water separator, it separates

water from fuel as well as removes impurities. Separated water is col-
lected in the lower part of the filter. The filter is provided with a water level
sensor 3. When water is collected to a certain level, this sensor turns on
the warning lamp in the meter cluster.
3
Collected water can be drained away through the drain port D by loosen-
D
ing the water level sensor 3. The fuel filter head 1 is equipped with a
priming pump C for bleeding the fuel system.
37448
13A-5
1.Checking Minimum and Maximum No-Load Speeds
Service standards
No-load minimum speed (Idling speed) 650 25 rpm Check
No-load maximum speed 3400 50 rpm Check
P No-load minimum speed

Prepare the vehicle for inspection as follows.
Engine coolant temperature: 176 to 203F {80 to 95C}
Lamps and electrical equipment: Off
A/T: P range
Steering wheel: Neutral position
Connect a tachometer A to the injection nozzle 1 or the injection
pipe.
NOTE:
Before connecting the tachometer A to the injection pipe, undo
A all clamps from the pipe.
Check that the minimum speed meets the standard value when the
accelerator pedal is free of foot pressure.
1 37449 If the reading deviates from the standard value, check the accelera-
tor position sensor & accelerator switch unit 2 for malfunction.
B Gr 13E
If the accelerator position sensor & accelerator switch unit 2 is found
normal, check the fuel system diagnosis code, injection pump and
ECU. B Gr 13E
P No-load maximum speed

Connect a tachometer A to the injection nozzle 1 or the injection
pipe.
NOTE:
Before connecting the tachometer A to the injection pipe, undo
all clamps from the pipe.
Check that the maximum speed meets the standard value when the
2 lever B of the accelerator position sensor & accelerator switch unit 2
is in contact with the full load stopper bolt C.
C If the reading deviates from the standard value, check the accelera-
tor position sensor & accelerator switch unit 2 for malfunction.
B B Gr 13E
If the accelerator position sensor & accelerator switch unit 2 is found
normal, check the fuel system diagnosis code, injection pump and
ECU. B Gr 13E
34530
13A-6
13A
2. Bleeding Air from Fuel System

1 Air vent plug 6 1 {4.3 0.7, 0.6 0.1}
Loosen the fuel filter air vent plug 1.

Operate the priming pump 2 to pump up fuel.
2 Continue to pump fuel until no air bubbles are found in the fuel flowing
out from the air vent plug 1.
After ascertaining that air bubbles have completely disappeared, tighten
the air vent plug 1 securely.
1
Operate the priming pump 2 further until it feels heavy.
37450
WARNING k
of heat.
catch fire.
3. Replacing Fuel Filter

Lubricant
Location Point of application Specified lubricant Quantity
1 Gasket for fuel filter cartridge Engine oil As required
[Removal]
A: Filter Wrench
(Commercially available one: For filter diameter of approx. 90 mm {3.54
A in.})
1
WARNING k
2 of heat.
37451
CAUTION k
The water level sensor 2 may be reused if it properly functions.
13A-7
[Installation]
WARNING k
Use of an unsuitable fuel filter cartridge 1 can lead to fuel leaks
and fires. Be sure to use a genuine filter.
CAUTION k
To prevent injection failures, keep dust and dirt out of the fuel
filter cartridge 1 and the fuel pipe.
To fit the fuel filter cartridge 1, turn it until the gasket C touches seal
surface of the fuel filter head 2. Be sure to turn the filter by hand clock-
2 wise.
Then, tighten the filter by 3/4 turn.
Bleed all air out of the fuel system. P. 13A-7
C
After fitting the filter, start the engine and check that no fuel leakage
occurs.
1
37452
13A-8
13A
MEMO
13A-9
ENGINE CONTROL
17
A
19 18
16
14
* 9
13
15 9
10
7 14
10
14
12 11
3 4
6 1
2
40900
1 Accelerator pedal assembly 8 Accelerator position sensor & 15 Bushing

2 Clevis pin accelerator switch assembly 16 Accelerator control extension
3 Accelerator pedal 9 Return spring 17 Accelerator position sensor &
4 Stopper bolt 10 Bushing accelerator switch unit
5 Nut 11 Shaft cover B Gr 13E
6 Accelerator pedal bracket 12 Spring 18 Bracket
7 Harness connector 13 Accelerator control arm 19 Harness connector
14 Bushing 20 Emergency engine stop switch
B Gr 13E
*: Bracket
P Assembly sequence
13A-10
13A
Service standards
Idling
0.85 0.1 V Replace
position
Accelerator position sensor Full-load
4.15 0.1 V Replace
& accelerator switch output position
voltage Sensor I Accelerator
2-5 switch
17 5 4 3 2 1 Sensor II actuated
37519 2-1 position (no
(Backside of harness 1.0 0.24 V Replace
continuity
connector) between
terminals
3-2)
Lubricant
Location Point of application Specified lubricant Quantity
3 Sliding contact surface between accelerator pedal and bracket Mitsubishi chassis grease As required
R Service procedure
A
1 Accelerator pedal assembly
B [Removal]
Extract the stopper A from the accelerator pedal 3.
3 To do so, pinch the hook B of the stopper with a pair of pliers C and pull it
lightly toward the front of the vehicle while twisting the hook approximately
45 degrees.
C
05900 CAUTION k
Do not pull the stopper A by force. It could be damaged.
[Installation]
D Fit the accelerator pedal assembly 1 to the accelerator position sensor
& accelerator switch assembly 8.
16 Depress the accelerator pedal 3 until the accelerator control extension
16 touches the stopper bolt D of the accelerator position sensor & ac-
celerator switch assembly 8.
Check that the clearance between the stopper bolt 4 and the stopper
8
bolt contacting surface E of the accelerator pedal 3 is within the toler-
3 0 to 2 mm ance shown in the illustration.
{0 to 0.079 in.} If not, adjust the stopper bolt 4 to achieve the specified clearance. Se-
cure the bolt with the nut 5.
E
34502
13A-11
ENGINE CONTROL
7 8 Accelerator position sensor & accelerator switch assembly
8
A [Inspection]
Fit the harness connector 7 to the accelerator position sensor & accel-
B 5 4 3 2 1 erator switch assembly 8.
16
Turn on the starter switch.
Backside of harness
connector Check the output voltage level of the accelerator position sensor &
accelerator switch assembly 8 at the backside of the harness connec-
13 tor 7 in accordance with the table below.
C
37520 Connector terminal Harness connector 7
Accelerator Accelerator
Accelerator
position position
switch
sensor I sensor II
Control lever B position 2 5 2 1 3 2
Idling position D
Accelerator switch actuated
position E
Full-load position F
Continuity established between terminals
D: Accelerator control arm 13 in contact with stopper C
E: Continuity lost between terminals 3 and 2 as accelerator pedal is de-
Accelerator switch pressed
sensor output voltage (V)
ON
F: Accelerator control extension 16 in contact with stopper bolt A
OFF
Accelerator position
4.15 0.1
If the sensor output voltage deviates from the specified value, rectify
the deviation as follows.
1.0 0.24
0.85 0.1
0
DE 80 F
Accelerator pedal opening 31479
[Adjustment]
17 Output voltage in idling position D:
H
Loosen the screw G move the accelerator position sensor & accelera-
G
A tor switch unit 17 as required and retighten the screw.
Output voltage with lever B in full-load position F:
Loosen the nut H, turn the stopper bolt A as required and retighten the
G nut.
34504
A Installation of emergency engine stop switch

Pull the knob A of the emergency engine stop switch 20 into the OFF
20 position. Loosen the nut B to remove from the threaded end C of the
switch.
A B C Set the shaft D in the bracket *.
Position the shaft D properly in the hole of the bracket * and tighten the
nut B.
*
D 37099
13A-12
FUEL TANK 13A
8
1 9
2
10
3
5
7 4
13737
P Work before removal
WARNING k
Keep unprotected lights away because of the risk of explosion.
Wipe up any spilled fuel because it can cause a fire.
NOTE:
Drain fuel before working on the job.
P Removal sequence
1 Suction hose 5 Fuel tank band 9 Fuel gauge unit B Gr 54
2 Return hose 6 Bolt 10 Fuel tank
3 Drain plug 7 Fuel tank bracket *: Chassis harness B Gr 54
4 Nut 8 Screw
Tightening torque Unit: N m {lbf.ft, kgfm}

4 Nut (Fuel tank band mounting) 5.9 to 9.8 {4.3 to 7.2, 0.6 to 1.0}
6 Bolt (Fuel tank bracket mounting) 59 to 78 {43 to 58, 6 to 8}
8 Screw (Fuel gauge unit mounting) 1.0 to 1.5 {0.7 to 1.1, 0.1 to 0.15}
13A-13
FUEL FILTER
7
1 Fuel hose
2 Water level sensor B Gr 54
3 O-ring
1 4 Fuel filter cartridge P. 13A-7
5 Air vent plug
*a
6 Gasket
B
7 Fuel filter head
A: From fuel tank

5 6 B: To injection pump

*a: Bracket
: Non-reusable part
A
1 3
2

40901

2 Water level sensor 2.5 0.5 {1.81 0.36, 0.25 0.05}
5 Air vent plug 6 1 {4.3 0.7, 0.6 0.1}
Lubricant
Location Points of application Specified sealant Qunatity
Fuel filter cartridge gasket (surface in contact with fuel filter
4 Engine oil As required
head)
13A-14
13A
MEMO
13A-15
INJECTION PUMP
6 8
10
9
19
7 18
1 2
17
16
23 4
22
*
20 14
G
13
21 5 15 12
11

40902
1 Harness connector (Engine speed sensor) 14 Injection pump cover

2 Harness connector (Spill valve) 15 Injection pump sound insulation
3 Harness connector (Injection control ROM) 16 Rubber spacer
4 Harness connector (Timer control valve) 17 Bolt
5 Harness connector (Fuel temperature sensor) 18 Bolt
6 Overflow valve 19 Pump bracket
7 Fuel return pipe 20 Bolt
8 Eyebolt 21 O-ring
9 Fuel suction pipe 22 Bolt
10 Injection pipe 23 Sensor plate
11 Bolt 24 Injection pump assembly
12 Spacer *: Front case assembly B Gr 11
13 Insulator : Non-reusable part
P Assembly sequence
CAUTION k
For maintenance of the injection pump assembly 24, please contact a Denso service station.
Dirt particles in the injection pump assembly 24 can seriously detract from engine performance. To prevent
enter of dirt, cover all pipes, hoses and other parts after removal.
13A-16
13A

6 Overflow valve (fuel return pipe mounting) 19.6 to 29.5 {14 to 22 , 2 to 3}
8 Eyebolt (fuel suction pipe mounting) 19.6 to 29.5 {14 to 22 , 2 to 3}
10 Injection pipe (union nut mounting) 29.4 {22, 3}
11 Bolt (injection pump cover mounting) 9.8 {7.2, 1}
17 Bolt (pump bracket mounting) 44.1 {33, 4.5}
18 Bolt (injection pump assembly mounting) 47.0 {35, 4.8}
20 Bolt (injection pump assembly mounting) 23.5 {17, 2.4}
22 Bolt (sensor plate mounting) 4.9 {3.6, 0.5}
Lubricant
R Service procedure
G Installation of injection pump assembly
A "1, 4"
Crank the engine clockwise to bring the cylinder No. 1 piston to the top
1 4
dead center of compression stroke; align the pointer A in the torque

converter housing inspection opening with the inscribed mark between
1 0
1 and 4 on the flywheel.

Check that the rocker arms of both inlet and exhaust valves of the
cylinder No. 1 move.
If the rocker arms still hold the valves down, give the engine another
turn.
29667
NOTE:
There are two kinds of marks inscribed in the flywheel, I and
IV and 1 and 4. Do not confuse.
Align the notch B in the flange plate with the inscribed mark C on the
B
injection pump gear.
37455
13A-17
INJECTION PUMP
Ascertaining the alignment between notch B and inscribed mark C,
B
B push in the injection pump assembly to install in position. At this time,
C the inscribed mark moves in the direction D.
C
37456
13A-18
13A
MEMO
13A-19
INJECTION NOZZLE
2
3
5
4

6
1 18
17
22
16
8
10 21
11
7 20
12
23
13 19
14
15
9
41237
1 Injection pipe 14 Needle valve

2 Eyebolt 15 Nozzle
3 Gasket 16 2nd pressure spring
4 Eyebolt 17 Adjusting shim (for adjustment of 2nd valve opening
5 Leak-off pipe pressure)
6 Bolt 18 Spring seat
7 O-ring 19 Pressure pin
8 Injection nozzle assembly 20 1st pressure spring
9 Retaining nut 21 Adjusting shim (for adjustment of 1st valve opening
10 Spring seat (for adjustment of pre-lift) pressure)
11 Tip packing 22 Nozzle holder
12 Straight pin 23 Nozzle gasket
13 Washer (for adjustment of needle valve lift) *: Cylinder head Gr 11
: Non-reusable part
P Assembly sequence
13A-20
13A
CAUTION k
Take care not to touch the sliding part of the needle valve 14. It could be scratched or corroded in the worst case,
resulting in the loss of airtightness between the valve and the nozzle 15.
Under no circumstances change the needle valve 14 and nozzle 15 combination between cylinders.
Dirt particles can seriously detract from engine performance. To prevent ingress of dirt, cover parts to which the
injection nozzle assemblies 8 were fitted after removal.
NOTE:
Clean off any carbon deposits before disassembling, reassembling or adjusting the injection nozzle assembly
8. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leads. If no
abnormality is apparent, do not commence disassembly.

1st valve 16.18
+0.98
MPa
0
opening
+142 +10
Injection nozzle assembly injection pressure {2346 0 psi2, 165 2
0 kgf/cm }
8 Adjust
pressure (valve opening pressure) 2nd valve 20.10 0.49 MPa
opening
pressure {2915 71 psi2, 205 5 kgf/cm2}
Prelift 0.08 0.01mm {0.0031 0.14in} Adjust
+0.03 +0.0012
Needle valve lift 0.25 - 0.02 {0.0098- 0.00079 } Adjust

1 Union nut (injection pipe mounting) 29.4 {22, 3.0}
2 Eyebolt (leak-off pipe (nozzle side) mounting) 29.4 {22, 3.0}
4 Eyebolt (leak-off pipe (head side) mounting) 20.6 {15, 2.1}
6 Bolt (injection nozzle assembly mounting) 14.7 {11, 1.5}
9 Retaining nut 25 to 34 {18 to 25, 2.5 to 3.5}
0 Special tool
Location Tool name Part No. Application
Nozzle Cleaning Tool !105789-0010 Cleaning injection nozzle assemblies
Disassembly, assembly and adjustment of
Tool Set *95093-00040
injection nozzle
*1 Attachment Measure *95093-10300 Measurement of prelift
*1 Base *95093-10230 Assembly of injection nozzle
Master Spring Seat *95093-10330 Adjustment of 2nd valve opening pressure
!: ZEXEL product number

*: DENSO product number
*1: Component of Tool Set (95093-00040)
13A-21
INJECTION NOZZLE
R Service procedure
P Inspection before disassembly
Fit the injection nozzle assembly 8 onto the nozzle tester A ready for
inspection.
WARNING k
Do not touch the spray that comes out of the nozzle.
NOTE:
Before commencing inspection, operate the lever on the nozzle
tester A two or three times to bleed all air out of the arrangement.
(1) Checking valve opening pressure
A Push down the lever on the nozzle tester A at a rate of 1 to 2 sec-

onds per stroke. The pressure gauge reading will gradually rise, then
B the needle will suddenly deflect. Note the pressure when the needle
starts to deflect.
If the measurement is out of specification, disassemble the nozzle,
clean it and make adjustments by changing the shims 17, 21.
If the measurement is still out of specification after adjustment, re-
place the injection nozzle assembly 8.
29252
Good No Good
(2) Inspecting spray condition
Pump the lever on the nozzle tester A at a rate of about 1 to 2
strokes per second and maintain a continuous spray.
B: Even spray from all five injection orifices (Good)

C: Even and symmetrical spray (Good)
D: Asymmetrical spray (No Good)
E: Branched spray (No Good)
B C D E F G F: Thin spray (No Good)
06931 G: Irregular spray (No Good)
If the spray is unsatisfactory, disassemble and clean the injection

nozzle assembly 8, then inspect the spray again. If the spray is still
unsatisfactory, replace the injection nozzle assembly.
Check that no fuel drips from the nozzle after the spray is complete.
(3) Inspecting for oil-tightness and leaks

Slowly increase the nozzle pressure to the pressure below the speci-
2
fied 1st valve opening pressure by 1.96 MPa {285 lbf/in., 20 kgf/
2
cm }. Maintain this pressure for 10 seconds and check that no fuel
drips from the end of the nozzle.
If the injection nozzle assembly 8 appears defective, disassemble
and clean it, then inspect it again. If the injection nozzle assembly
Good No Good still appears defective, it must be replaced.
05388
13A-22
13A
8 Injection nozzle assembly
[Disassembly]
14 A
CAUTION k
Never touch the sliding part A of the needle valve 14.
Never change the needle valve 14 and nozzle 15 combination on
each cylinder.
06932
[Assembly]
11 Assemble the tip packing 11 and the washer 12 (for adjustment of needle
valve lift) in the illustrated directions.
12
13
24108
B [Cleaning]
Wash the needle valve 14 and nozzle 15 in diesel fuel, then use the 0
Cleaning Tool to remove any carbon deposits in accordance with the fol-
lowing procedure.
14 Remove carbon from the end of the needle valve 14 using the Clean-
ing Bar B of the 0 Cleaning Tool.
CAUTION k
Do not use a wire brush or any hard metallic object for cleaning.
01892
C Remove carbon from the injection orifice of the nozzle 15 using the
Cleaning Needle C of the 0 Cleaning Tool. Insert the Cleaning Needle
and rotate it to remove carbon.
15
Cleaning needle diameter: 0.20 mm {0.0079 in.} or smaller
01893
13A-23
INJECTION NOZZLE
D Clean the seat of the nozzle 15 using the Cleaning Scraper D of the 0
15 Cleaning Tool.
To remove burned and hardened carbon, use FUSO Carbon Remover.
01894
[Inspection]
Wash the needle valve 14 and nozzle 15 in diesel fuel, then fit them
together.
Pull up the needle valve 14 by approximately 1/3 of its entire stroke,
then check that it drops under its own weight. Repeat this test several
times, turning the needle valve each time.
If the needle valve 14 does not drop as required, wash it in diesel fuel
14
and carry out this test again. If the needle valve is still defective, re-
15
place the needle valve and nozzle 15 as a set.
01911 [Adjustment]
During reassembly, make adjustments in the sequence shown below.
CAUTION k
Before making adjustments, wash all parts in diesel fuel and en-
sure that they are free of dirt and other foreign material.
Do not touch the sliding surfaces of the needle valve 14.
Check needle valve full lift
Check prelift
Adjust 2nd valve opening pressure
Adjust 1st valve opening pressure
13A-24
13A
P Checking needle valve full lift
E a
Set the a Attachment Measure to a dial gauge E.
2 mm {0.079 in.}
or more
06937
Mount the nozzle 15 on the b base, with the needle valve 14 and
10 spring seat 10 (for adjustment of pre-lift) fitted to the nozzle in that
14 order.
10
14
15
15
b
24109
E Fit the a Attachment Measure onto the nozzle 15.

Zero the dial gauge E.
10
15
24193
10 Remove the a Attachment Measure. Remove the spring seat 10 (for

adjustment of pre-lift) and refit it to the nozzle upside down.
10
24110
E Fit the a Attachment onto the nozzle 15 again, and read the dial
gauge E. The reading should be the illustrated dimension L1.
15 14
L1
a
14954
13A-25
INJECTION NOZZLE
11 Remove the a Attachment Measure and the needle valve 14. Fit the
tip packing 11 to the nozzle 15 as shown.
a
15
14
24111
Zero the dial gauge E on the b base.
24152
E Fit the a Attachment Measure to the tip packing 11, and read the dial
11 L2 gauge E.
The reading should be the illustrated dimension L2.
11
13
24112
Measure the thickness L3 of the washer 13 (for adjustment of needle

valve lift).
L3
13
24113
14 11 Calculate the maximum lift F of the needle valve 14 from the measure-
ments L1, L2 and L3 as follows.
13 Maximum lift F = L1 + L2 - L3
If the calculated value is out of specification, make the necessary ad-
justment by changing the washer 13 (for adjustment of needle valve
15 F lift).
Washers 13 are available in the following thicknesses (L3):
2.40, 2.425, 2.45, 2.475, 2.50 mm {0.094, 0.095, 0.096, 0.097, 0.098
in.} (5 sizes)
24114
13A-26
13A
P Adjusting pre-lift
11 Measure the thickness L4 of the tip packing 11.
L4 Measure the thickness L5 of the spring seat 10 (for adjustment of pre-
lift).
10
L5
24115
13 14 10 11 Calculate the pre-lift G from the measurements L1, L3, L4 and L5 as

follows.
Pre-lift G = L4 - L5 - L3 + L1
If the calculated value is out of specification, make the necessary ad-
justment by changing the spring seat 10 (for adjustment of pre-lift).
Spring seats 10 are available in the following thicknesses (L5):
15
G 2.59 to 2.80 mm {0.101 to 0.110 in.} (22 sizes at steps of 0.01 mm
{0.00039 in.})
24212
P Adjusting 2nd valve opening pressure

Assemble parts to the nozzle holder 22 as shown. Fit the c Master
22 Spring Seat in the place of the spring seat 10 (for adjustment of pre-
lift).
Tighten the retaining nut 9 to the specified torque.
Fit the nozzle assembly onto the nozzle tester and measure the 2nd
18 valve opening pressure.
17
16 CAUTION k
10
Never touch the spray that comes out of the nozzle.
11 12
If the reading is out of specification, make the necessary adjustment
13 by changing the adjusting shim 17 (for adjustment of 2nd valve open-
15 ing pressure). Adjusting shims 17 are available in the following thick-
14
nesses.
9 0.70 to 2.15 mm {0.028 to 0.085 in.} (30 sizes at steps of 0.05 mm
{0.002 in.})
0.975 to 1.775 mm {0.038 to 0.070 in.} (17 sizes at steps of 0.05
mm {0.002 in.})
29253
A difference of 0.025 mm {0.00098 in.} in the thickness of the adjust-
ment shim 17 changes the 2nd valve opening pressure by 345 kPa {50
psi2, 3.5 kgf/cm2}.
13A-27
INJECTION NOZZLE
P Adjusting 1st valve opening pressure
Assemble parts to the nozzle holder 22 as shown.
21 Tighten the retaining nut 9 to the specified torque.
22
Fit the nozzle assembly onto the nozzle tester and measure the 1st
20 valve opening pressure.
19
18
17 CAUTION k
Never touch the spray that comes out of the nozzle.
16 10
If the reading is out of specification, make the necessary adjustment
11
12 by changing the adjusting shim 21 (for adjustment of 1st valve opening
pressure).
13 Adjusting shims 21 are available in the following thicknesses:
15 0.8 to 2.0, 2.05, 2.075 to 2.2 mm {0.031 to 0.079, 0.080, 0.081 to
14 0.087 in.} (56 sizes at steps of 0.025 mm {0.00098 in.})
9 A difference of 0.025 mm {0.00098 in. } in the thickness of the ad-
justing shim 21 changes the 1st valve opening pressure by 345 kPa
{20 psi2, 3.5 kgf/cm2}.
29254
13A-28
Pub No. TWSE9501-513E
Service Manual
Group 13E
<4M50T2>
Table of Contents
BACK HOME
Pub No. TWSE9501-513E
Mar. 00H Printed in Japan

GROUP 13E V4 SYSTEM <4M5>
SPECIFICATIONS ................................................................................ 13E- 2

1. General .................................................................................................. 13E- 3
2. Electronic Control System ................................................................... 13E- 5
3. Pin Configuration of Engine Control Unit .......................................... 13E- 9
TROUBLESHOOTING
1. Inspection Procedures ......................................................................... 13E-14
2. Connection of Multi-Use Tester II ........................................................ 13E-16
3. Reading and Erasing Diagnostic Trouble Codes ............................... 13E-17
4. Diagnostic Trouble Codes and Check Items ...................................... 13E-19
5. Service Data of Multi-Use Tester II ...................................................... 13E-28
6. Actuator Test by Multi-Use Tester II ..................................................... 13E-30
7. Checks at Connector of Control Unit .................................................. 13E-32
8. Checks on Intermittent Troubles ......................................................... 13E-35
INSPECTION OF ELECTRICAL EQUIPMENT .................................... 13E-36
LOCATIONS OF PARTS ...................................................................... 13E-44

SPECIFICATIONS
Item Specification
Manufacturer DENSO
Model V4
Type Distribution type electronically controlled pump
Spill valve (Solenoid valve) Electronically controlled type
Control scheme High pressure chamber control
Timer
Injection pump Drive method Timer control valve (TCV)
assembly Valve opening pressure
Overflow valve 343 {49.8, 3.5}
kPa (psi 2, kgf/cm2)
Type Vane type
Feed pump Theoretical delivery rate
6.4 {0.39} (per rotation)
cc {cu.in.}
Fuel temperature sensor Provided
Engine speed sensor Provided
Manufacturer DENSO
Engine control unit
Rated voltage V 12
Manufacturer DENSO
Drive unit
Rated voltage V 12
13E-2
STRUCTURE AND OPERATION 13E
1. GENERAL
The V4 system adopts a distribution type injection pump, which features small size and light weight and yet high speed, as
well as an electronic control unit which controls the fuel injection rate, fuel injection timing, etc., thereby operating the
engine in an optimum condition.
Theory of Operation
2 3 4 5
6
7
1
8
21
11
10
9
20
19
18 17 16 15 14 13 12
36592
1 Fuel filter 8 Injection nozzle 15 Inner cam

2 Fuel temperature sensor 9 Fuel chamber 16 Plunger
3 Overflow valve 10 Delivery valve 17 Feed pump
4 Pump chamber 11 Injection rate adjusting read- 18 Injection pump proper
5 Spill valve only memory 19 Fuel tank
6 Drive unit 12 Rotor 20 Drive shaft
7 Engine control unit 13 Timer control valve 21 Engine speed sensor
14 Timer piston
13E-3
The feed pump 17 in the injection pump proper 18 pumps up the fuel from the fuel tank 19, keeping the inside of the
injection pump full of the fuel at all times.
The rotor 12 rotates in the inner cam 15.
The drive unit 6 converts the spill valve 5 drive signal delivered from the engine control unit 7 into a high voltage signal
to enhance the responsiveness of the spill valve 5.
The fuel injection rate is increased or reduced by adjusting the opening time of the spill valve 5.
When the spill valve 5 is opened, the inside of the rotor 12 is filled with the fuel.
After it has been filled, the spill valve 5 closes to confine the fuel in the rotor 12. In this condition, as the drive shaft 20
rotates, the fuel is pressurized by the inner cam 15 and plunger 16 and fed through the delivery valve 16 to the injection
nozzle 8 from which it is injected.
Then the spill valve 5 opens, and a resultant decline in the fuel pressure in the rotor 12 causes the delivery valve 10 to
close, thereby bringing the fuel injection to an end.
The overflow valve 3 returns the fuel to the fuel tank 19 when the fuel pressure in the injection pump exceeds a predeter-
mined value.
The fuel injection timing is controlled by the timer control valve 13 which controls the fuel pressure acting on the timer
piston 14.
The timer control valve 13 is activated by commands from the engine control unit 7.
13E-4
13E
2. ELECTRONIC CONTROL SYSTEM
2.1 System Block Diagram
Input Signal Engine Control Unit Output Signal

Drive
unit 15 Spill valve drive 16
Engine speed signal 1
Fuel Injection Amount
Fuel temperature signal 2 Control
Coolant temperature signal 3
Timer control valve (TCV) 17
Crank angle signal 4
Boost pressure signal 5
Boost air temperature signal 6
Warning lamp
Engine start signal 7
Fuel Injection Timing
Accelerator pedal position signal 8 Control Indicator lamp
Warmup signal 9
Fuel injection amount signal 10
Intake shutter 3-way magnet valve 18
Auxiliary brake signal 11
Vehicle speed signal 12
Diagnostic signal 13 Exhaust brake 3-way magnet valve
Engine emergency stop signal 14 Diagnostic Function

Tachometer
Automatic Transmission Control Unit

Automatic transmission control unit
Exhaust brake cut signal
Engine speed
Idle up inhibit signal
Accelerator opening
Information Signal Part Names Major Function or Operation

1 Engine speed signal Engine speed sensor Detection of engine speed
2 Fuel temperature signal Fuel temperature sensor Detection of fuel temperature
3 Coolant temperature signal Coolant temperature sensor Detection of coolant temperature
4 Crank angle signal TDC sensor Detection of crank angle signal
5 Boost pressure signal Boost pressure sensor Detection of boost pressure
6 Boost air temperature signal Boost air temperature sensor Detection of boost air temperature
Recognition of engine start when starter switch is
7 Engine start signal Starter switch
placed at START position
Detection of amount that accelerator pedal has been
Accelerator position sensor
8 Accelerator depressed signal depressed
Accelerator switch Detection of released/depressed accelerator pedal
Idle control variable resistor
9 Warmup accelerating signal Acceleration of warmup
Cold start switch
Fuel injection amount
10 Injection amount adjusting ROM Adjustment of fuel injection amount
adjustment signal
Exhaust brake switch
11 Auxiliary brake signal Control of auxiliary brake
Exhaust brake cut relay
12 Vehicle speed signal Vehicle speed sensor Detection of vehicle speed
13E-5
Information Signal Part Names Major Function or Operation
Diagnosis switch Transmission of diagnosis signal
13 Diagnostic signal Erasure of diagnostec trouble code
Memory clear switch
Transmission of past diagnostic trouble code
Engine emergency stop
14 Emergency engine stop switch Emergency shutdown of engine
signal
Assurance of high voltage for high speed drive of spill
15 Drive unit
valve
16 Spill valve Control of fuel injection amount and injection rate
Timer control valve operation
17 Timer control valve Operation of timer piston
signal
Intake shutter 3-way magnet
18 Operation of intake shutter 3-way magnet valve
valve
13E-6
13E
2.2 Fuel Injection Rate Control
Engine control unit
Engine speed sensor

TDC sensor
Coolant temperature sensor Various control
Drive unit Spill valve
maps
Fuel temperature sensor
Accelerator position sensor 1
Accelerator position sensor 2
Injection rate adjusting resistor
Injection rate adjusting read-only memory Target injection
rate
Boost pressure sensor
During operation of the engine, the engine control unit (ECU) processes the individual information signals according to
the control maps to select an appropriate injection mode from among the basic, maximum and minimum.
After selection of the injection mode, the ECU calculates the minimum value to ensure that the maximum injection rate
is not exceeded and determines the target injection rate.
Once the target injection rate has been determined, the engine control unit outputs a signal to drive the spill valve.
The signal to drive the spill valve is passed through the drive unit so that its responsiveness for high speed driving will be
enhanced.
The drive unit immediately converts the signal voltage delivered from the engine control unit to a high voltage.
2.3 Fuel Injection Timing Control
Engine control unit

Engine speed sensor
TDC sensor
Coolant temperature
sensor
Atmospheric pressure Various control
sensor maps Target injection Timer control valve (TCV)
Accelerator position timing
sensor 1
Accelerator position
sensor 2
Boost air temperature
sensor
During operation of the engine, the engine control unit (ECU) processes the individual information signals according to
the control maps to calculate the target injection timing, and drives the timer control valve (TCV) in such a way that the
real timing computed on the basis of the engine speed sensor and TDC sensor will match the target timing.
Controls at the time of an engine start are achieved by the start compensation map contained in each control map.
13E-7
2.4 Warmup Accelerating Function
The warmup accelerating function varies the idling speed according to
Engine the engine coolant temperature to accelerate warmup. The function in-
Coolant control cludes the automatic and manual modes. Either of the modes can be
temperature unit selected by pushing/pulling the idle adjusting potentiometer.
sensor
Accelerator
Comparative
Idling
position sensor 1
Accelerator computing
speed
position sensor 2 control
Idle adjusting
potentiometer
Target
injection
timing
13E-8
13E
3. PIN CONFIGURATION OF ENGINE CONTROL UNIT
C: CC12B D: CC22A
6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12
A: CC26A B: CC16A
A
13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
B 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9
C
D
35643
Connector A: CC26A Connector B: CC16A

Pin Pin
Connected to Connected to
No. No.
1 1 Coolant temperature sensor
2 Intake silencer 3-way magnet valve 2 Injection rate adjusting resistor (signal)
3 Injection rate read-only memory 3 Accelerator position sensor 1 (+5V)
4 4 Accelerator position sensor 2 (+5V)
5 5 Sensor power supply (+5V)
6 PMW acceleration OUT (signal) 6 Accelerator position sensor (Ground-1)
7 Vehicle speed sensor (signal) 7
8 Engine control unit main relay 1 8 Accelerator position sensor (Ground-2)
9 Engine control unit main relay 2 9 Boost pressure sensor (signal)
10 Drive unit relay 10 Idle adjusting potentiometer (signal)
11 11 Accelerator position sensor 1 (signal)
12 Timer control valve 12 Fuel temperature sensor (signal)
13 Ground (ANALOG) 13 Accelerator position sensor 2 (signal)
14 14
15 15 Boost air temperature sensor
16 Drive unit (FAIL signal) 16 Sensor ground
17 Injection rate adjusting read-only memory (CLK)
18 Magnet valve surge OUT 1
19 Magnet valve surge OUT 2
20 Drive unit (Spill valve signal)
21 Warning lamp (Red)
22 Warning lamp (A mber)
23
24 Engine control unit POWER-1
25 Exhaust brake
26 Ground (POWER)
13E-9
Connector C: CC12B Connector D: CC22A
Pin Pin
Connected to Connected to
N o. No.
1 1
2 2 Starter switch (S terminal)
3
3 Starter switch (M terminal-1)
4 Engine speed OUT (signal)
4
5 TDC sensor (signal)
5 Multi-Use Tester (DTC)
6 Engine speed sensor (signal)
6
7
7
8 Idle up cancel
9 8
10 Tachometer output (signal) 9 Diagnosis switch

11 TDC sensor (ground) 10 Accelerator switch
12 Engine speed sensor (ground) 11 Ground (POWER)
12 Ground (ANALOG)
13 Multi-Use Tester (K-LINE)
14 Starter switch (M terminal-2)
15 Memory clear switch
16 Emergency engine stop switch
17 Auxiliary brake cut relay (for automatic transmission)
18
19 Cold start switch
20 Cooler switch
21 Exhaust brake switch
22 Engine control unit POWER-2
13E-10
13E
MEMO
13E-11
Starter switch
B ACC M F S 1 2 3
LOCK Normal Emergency engine
(OFF) Stop stop switch
ACC
ON
START
Engine control
unit
Drive unit relay STARTER SW (S)

D2
STARTER SW (M) -1
D3
STARTER SW (M) -2
D 14
MAIN RELAY OUT -1
A8
MAIN RELAY OUT -2
A9
ECU POWER (+VB) -1
A 24
ECU POWER (+VB) -2
Control unit main relay D 22
A 10
GND (POWER GND)
A 26
GND (POWER GND)
D 11
GND (ANAROG GND)
A 13
GND (ANAROG GND)
D 12
D 16
SPV SIG
A 20
GND FAIL SIG
A 16
SPV(+)
SPV(-) Drive
Spill valve SPV(+) unit
SPV(-)
A 12
Timer control valve
SIG B 12
GND
DATA A 3
Injection rate adjusting CLK A 17
read-only memory
C6
Engine speed sensor C 12
SIG
C5
TDC sensor GND
C 11
Magnet valve surge OUT 1 A 18
Magnet valve surge OUT 2 A 19
B 16
SIG
Boost pressure sensor B9
Intake shutter 3-way magnet valve A2
+5V +5V
B3
SIG-1 SIG-1
Accelerator position sensor B 11
GND
1 B6
+5V
2 B4
SIG-2 SIG-2
B 13
GND GND
Accelerator switch SW ACCSEL SW
B8
D 10
+5V B5
SIG
Idle adjusting variable resistor B 10
B2
Injection rate adjusting resistor
SIG
B1
Coolant temperature sensor
SIG B 15
Boost air temperature sensor
41126
13E-12
13E
Automatic transmission
control unit
D 17 (for automatic transmission control)
D 21 Exhaust brake switch
Cold start switch

D 19
A 25 Exhaust brake 3-way magnet valve

Anti-lock brake
control unit

(for automatic transmission control)
DCT
D5
D 13
K-LINE Multi-use tester II
+12V
SIG
A7 Vehicle speed sensor
Pulse divider GND
Engine rotation pulse output

SIG
C4
Automatic
Accelerator opening output transmission
SIG
A6
control unit
Idle up cancel
C8
R
D R
Inhibitor D
switch
D 20
D9 Diagnosis switch
Memory clear switch
D 15
A 22 (Amber)
Warning lamp
A 21 (Red)
SIG
C 10
Tachometer
To air conditioner magnet clutch

Dual pressure switch
41127
13E-13
TROUBLESHOOTING
1. INSPECTION PROCEDURES
Diagnostic Function
Whenever the starter switch is placed at ON, the diagnostic function is activated to check all the sensors, etc. If any of
them is found faulty, the warning lamp in the meter cluster is lit to alert the driver. At the same time, the fault location is
stored in memory, and the system enters the backup mode.
Warning Lamp Indications

(Red) (A mber)
Safety-critical error
ON OFF
(Vehicle must not be driven)
Non-safety-critical error
OFF ON
(Vehicle can be driven despite poor control feeling)
The stored fault location can be read as a diagnostic trouble code by the Multi-Use Tester II or the diagnosis switch.
CAUTION k
Check to ensure that the battery voltage is within the specified range.
Check all the harness and device connectors for looseness. Always remove a connector at least 20 seconds
after placing the starter switch at the LOCK position.
Do not forget to clear the diagnostic trouble code by the Multi-Use Tester II or memory clear switch after a fault
has been rectified.
As a rule, inspection operations should be performed with the starter switch at the LOCK position. Some
checks, however, may have to be made with the starter switch at the ON position. In such a case, use care to
make sure that no short circuit develops between pins of the connectors or with the body.
The resistance value of each component is affected by the temperature and the accuracy of the tester. The
reading, therefore, does not always fall within the standard limits. Note that the check values shown in the text
are the values obtained at normal temperature (10 to 35C)
Whether or not the system automatically returns to normal from the backup mode after a fault has been re-
moved depends on the diagnostic trouble code (fault location). When the system returns to normal, the warn-
ing lamp will be OFF.
Even when the fault has been removed and the system has been automatically returned to the normal mode, the
diagnostic trouble code of the fault remains stored in the engine control unit.
When a fault occurs at a point where the system is not automatically reset, perform the memory clear procedure
to let the system exit from the backup mode. P13E-17
13E-14
13E
Inspection Flowchart
The system inspection can be performed effectively by use of the Multi-Use Tester II. The types of system inspections may
be broadly divided as shown below in accordance with the trouble symptoms and diagnostic trouble code outputs.
Inspections based on diagnostic trouble codes stored in the engine control unit
Inspections of intermittent troubles
Vehicle brought into workshop
Read diagnostic trouble codes P13E-17
Trouble code output Normal code No communications can be made

output with Multi-Use Tester II.
Normal code output

after erasure
Identify cause for diagnostic Check for

trouble code issue and intermittent troubles
rectify P13E-19 P13E-35
If no communications can be made with all the other systems,

it is highly likely that the diagnostic circuit is faulty.
If no communications can be made with this system only, an open
Driving test circuit in the diagnostic output circuit or power supply circuit
(including the ground circuit) of this system is suspected.
If the same diagnostic trouble code is issued during test driving, reexamine the cause for the
diagnostic trouble code issue and rectify. P13E-19
If none of the diagnostic trouble codes stored in the engine control unit before the test driving
is issued, perform the checks on intermittent troubles in addition to the checks based on the
diagnostic trouble codes.
Erase the diagnostic trouble codes.

P13E-17
13E-15
TROUBLESHOOTING
2. CONNECTION OF MULTI-USE TESTER II
0 Special Tools
Loca-
Name and Shape of Special Tool Part No. Application
tion
Multi-Use Tester II MB991496 Inspection of system
19492
To supply power to Multi-Use Tester II

Multi-Use Tester II harness
MK327601 proper and communicate with vehicle
(for communications)
side electrical devices
19141
Read-only memory Data for inspection and control of

MK386562
pack (MRT-E7) engine control unit
19493
Memory card
(set in Multi-Use MB991500 To write data
Tester II proper)
20538
Multi-Use Tester II To use Multi-Use Tester II as a circuit

MB991499
harness tester
20536
Place the starter switch at the LOCK position.

Connect the a Multi-Use Tester II harness to b Multi-Use Tester II
and insert the c read-only memory in the tester.
Connect the connector A to the cigar lighter socket.
Connect the Multi-Use Tester II connector C (16 pins) to the data link
connector B (16 pins).
C A
b
a
B NOTE:
For the operating procedures for the Multi-Use Tester II, refer to
c
41125 the instruction manual for the Multi-Use Tester II.
13E-16
13E
3. READING AND ERASING DIAGNOSTIC TROUBLE CODES
Two types of methods are available for reading or erasing a diagnostic trouble code; one using the Multi-Use Tester II and
one using the vehicle side diagnostic functions.
(1) Method using Multi-Use Tester II

P Current Diagnostic Trouble Code
Check to see that the memory clear switch 1 is connected.
MEMORY
1 CLEAR Set the starter switch to ON.
Operate the Multi-Use Tester II to read the current diagnostic trouble
code and determine the fault location.
P Past Diagnostic Trouble Code

Set the starter switch to ON.
Disconnect the memory clear switch 1.
41117 Operate the Multi-Use Tester II to read the past registered diagnos-
tic trouble codes and determine the fault location.
P Erasing Diagnostic Trouble Codes

Operate the Multi-Use Tester II to erase all of the diagnostic trouble
codes stored in the engine control unit.
(2) Method Not Using Multi-Use Tester II (Method Using

Diagnostic Switch and Memory Clear Switch)
3 DIAG
2 CHECK P Current Diagnostic Trouble Code
Disconnect the diagnostic switch 2.
The diagnostic trouble code is displayed by flashes of the warning
lamp 3.
41118
13E-17
TROUBLESHOOTING
P Reading Diagnostic Trouble Code
Diagnostic trouble codes are indicated by the number of times the
10s digit Units digit warning lamp 3 flashes and their duration.
The flashing intervals also differ between the 10s digit and units
ON
digit.
10s digit: 1.2 second interval
OFF
Units digit: 0.4 second interval
Each diagnostic trouble code is displayed from the 10s digit followed
1.2 1.2 by the units digit. As for a code which has no 10s digit, units digit
0.4 only is displayed.
0.4 Each diagnostic trouble code is displayed three times in succession.
If there is no more code stored, the sequence is then repeated from
0.4
Diagnostic switch the beginning with each code indicated three times.
disconnected When the diagnostic switch 2 is connected, the engine control unit will
First diagnostic trouble code dis-
played (Diagnostic trouble code 12) immediately stop displaying codes.
ON
Second
OFF dagnostic
trouble
code
2.4 2.4 2.4 2.8 displayed
13705
P Past Diagnostic Trouble Codes

3 After reading the current diagnostic trouble codes (with the diagnostic
MEMORY
1 CLEAR switch 2 disconnected), disconnect the memory clear switch 1. Then

the warning lamp 3 will restart flashing.
This time, the warning lamp displays the past diagnostic trouble codes.
DIAG
2 CHECK Determine the fault locations based on the indicated codes.
41119
P Erasing Diagnostic Trouble Codes

Disconnect the memory clear switch 1 and the diagnostic switch 2 then
A second reconnect them. Then all the diagnostic trouble codes stored in the en-
or more 3 seconds gine control unit will be cleared.
Connected CAUTION k
If the contents of memory are not to be cleared after display of the
Released Memory cleared stored codes, set the starter switch to OFF with the memory clear
at this point
switch 1 disconnected. Thereafter, connect the memory clear
02739 switch.
When you change the combination of the injection pump and en-
gine control unit, you must rewrite the pump data stored in the
engine control unit. For this purpose, be sure to perform the diag-
nostic trouble code erasing procedure.
Whenever the engine control unit has been replaced with a new
one, be sure to erase the diagnostic trouble codes by disconnect-
ing the memory clear switch 1 and diagnostic switch 2 after con-
necting all the connectors. Upon completing the procedure, con-
firm that no diagnostic trouble codes is stored.
13E-18
13E
4. DIAGNOSTIC TROUBLE CODES AND CHECK ITEMS
4.1 Diagnostic Trouble Code List
Multi-Use Tester II Screen Display Multi-Use Tester II Screen Display
Diagnostic Where Diagnostic Where
Trouble Message Described Trouble Message Described
Code Code
06 EDU/SPV P13E-19 31 IDL VOLUME
07 OVER REV 32 BOOST PRES P13E-24
14 TDC SNSR P13E-20 33 ECU SYSTEM
15 NE SNSR 34 Q RESISTOR
16 ACCEL SNSR-2 41 FUEL TEMP P13E-25
19 AIR PRES SNSR P13E-21 44 BOOST TEMP
21 WTR TEMP SNSR 45 FUEL CUT SW
P13E-26
23 TCV 46 EDU RELAY
P13E-22
24 ACCEL SNSR-1 65 ACCEL SW
P13E-27
25 SPEED SNSR 66 STARTER SW (S)
26 PUMP ROM P13E-23
27 SILENCER M/V
4.2 Diagnostic Trouble Code Issued Conditions and Check Items

Perform service procedures taking the diagnostic trouble code issued conditions and the probable causes into consider-
ation.
06 EDU/SPV
Diagnostic trouble code 06 is intended for checking the drive unit and spill valve for anything abnormal. The
Code issued
code is issued when the FAIL signal is not input the specified number of consecutive times from the drive unit
condition
to the control unit despite the fact that the battery voltage is normal, the engine is running at a speed higher
[Reset condition]
than the idling speed, and the drive unit is outputting the spill valve drive signal. [Starter switch OFF]
Action taken by
Engine stopped
control unit
Warning lamp
(Red)
illuminated
Open or short circuit between Check on the basis of the service data of the Multi-Use Tester II.
control unit and drive unit, or P13E-28
between drive unit and spill valve No. 83: Spill valve operation check
Faulty drive unit Test the actuator by the Multi-Use Tester II. P13E-30
Faulty spill valve No. 9B: Spill valve operation check
Probable cause Check the drive unit.
and check item (Ask your DENSO service station to do the job.)
Check the spill valve.
P13E-36: Inspection of Electrical Devices 536
Check the circuit between the control unit and drive unit or the
circuit between the drive unit and spill valve.
P13E-48: Electrical wiring Diagram
13E-19
TROUBLESHOOTING
07 OVER REV
Code issued Diagnostic trouble code 07 is intended for checking whether the engine speed has reached an overspeed.
condition [Reset When the engine speed reaches an overspeed, the code is issued.
condition] (When the engine speed decreases to fall within the normal range, a reset is made.)
Action taken by
Spill valve operation stopped
control unit
Warning lamp
illuminated None
Faulty spill valve of injection pump Check the injection pump assembly (Ask your DENSO service
assembly station to do the job.)
Probable cause
Overrevved engine during driving
and check item
downhill
Faulty control unit
14 TDC SNSR
Diagnostic trouble code 14 is intended for checking the TDC sensor operation. It is issued when the TDC
Code issued
sensor signal is not input to the control unit the specified number of consecutive times while the engine is
condition
running.
[Reset condition]
[When normal TDC sensor signal input is restored, the system is reset.]
Action taken by
Injection timing feedback control stopped and open-loop control executed
control unit
Warning lamp (Amber)
illuminated
Open or short circuit between Perform checks at control unit connector. P13E-32
control unit and TDC sensor 01 : Measure resistance of TDC sensor.
Probable cause Faulty TDC sensor Check TDC sensor.
and check item Faulty control unit P13E-36: Inspection of Electrical Devices 316
Check circuit between control unit and TDC sensor.
P13E-48: Electrical Writing Diagram
15 NE SNSR
Code issued Diagnostic trouble code 15 is issued when the signal from the engine speed sensor is not input the specified
condition number of times to the control unit while the engine is in operation.
[Reset condition] [When the signal from the engine speed sensor returns to normal, a reset is made.]
Action taken by
Synchronous control of spill valve with timer control valve interrupted
control unit
Warning lamp
(Red)
illuminated
Open or short circuit in harness Perform checks on the basis of the service data of the Multi-Use
between control unit and engine Tester II. P13E-28
speed sensor No. 01: Measure engine speed.
Faulty engine speed sensor Perform checks at control unit connector. P13E-36
Probable cause 02 : Measure resistance of engine speed sensor.
Gap of engine speed sensor
and check item
maladjusted Check engine speed sensor.
Faulty control unit P13E-36: Inspection of Electrical Devices 263
Check circuit between control unit and engine speed sensor.
P13E-48: Electrical Wiring Diagram
13E-20
13E
16 ACCEL SNSR-2
Diagnostic trouble code 16 is intended for checking the accelerator position sensor 2 for an abnormal voltage.
Code issued
The code is issued when the voltage of the accelerator position sensor 2 is out of the specified limits. When
condition
diagnostic trouble code 24 is also registered, the portion between the accelerator position sensors is faulty.
[Reset condition]
[When the voltage of the accelerator position sensor 2 falls within the specified limits, a reset is made.]
1 : Ordinary controls are made by using only accelerator position sensor 1
Action taken by
2 : When accelerator position sensor 1 is also faulty, controls are made on the assumption that the pedal is
control unit
depressed 30% when accelerator switch is OFF and 0% when accelerator switch is ON.
Warning lamp 1 : None
illuminated 2: (Amber)
between control unit and Tester II. P13E-28
accelerator position sensor 2 No. 0B: Accelerator pedal opening measurement.
Faulty accelerator position sensor No. 0C: Measurement of accelerator position sensor output
2 voltage.
Faulty control unit Perform checks at control unit connector. P13E-32
Probable cause
03 : Measurement of accelerator position sensor 2 output
and check item
voltage
Check accelerator position sensor 2.
Check circuit between control unit and accelerator position
sensor 2.
19 AIR PRES SNSR

Diagnostic trouble code 19 is intended for checking the atmospheric pressure sensor (built into the control
Code issued
unit) for anything abnormal. The code is issued when a voltage signal from the atmospheric pressure sensor
condition
is out of the specified limits.
[Reset condition]
[When the output voltage of the atmospheric pressure sensor falls within the specified range, a reset is made.]
Action taken by
Controls achieved on the assumption that atmospheric pressure is 100 kPa {29.9 in. Hg, 760 mmHg}.
control unit
Warning lamp None
illuminated
Faulty atmospheric pressure Perform checks on the basis of the service data of the Multi-Use
Probable cause
sensor (built into control unit) Tester II. P13E-28
and check item
Faulty control unit No. 14: Atmospheric pressure measurement.
21 WTR TEMP SNSR

Diagnostic trouble code 21 is intended for checking for open or short circuit in the harness of the coolant
Code issued
temperature sensor or anything abnormal in coolant temperature sensor. The code is issued when the output
condition
voltage from the coolant temperature sensor is out of the specified limits.
[Reset condition]
[When the output voltage of the coolant temperature sensor falls within the specified range, a reset is made.]
Action taken by
Controls achieved on the assumption that the coolant temperature is 80C {178F}
control unit
Warning lamp
None
illuminated
between control unit and coolant Tester II. P13E-28
temperature sensor No. 10: Engine coolant temperature measurement
Probable cause Faulty coolant temperature sensor Check coolant temperature sensor.
and check item Faulty control unit P13E-36: Inspection of Electrical Devices 262
Check circuit between control unit and coolant temperature
sensor.
13E-21
TROUBLESHOOTING
23 TCV
Diagnostic trouble code 23 is intended for checking the harness of the timer control valve for open or short
circuit and checking the timer control valve for anomalies. The code is issued when the real advance angle
Code issued
position of the timer continues to be out of the specified limits under the condition that fuel injection timing
condition
feedback control is in progress after completion of engine warmup.
[Reset condition]
[When the advance angle re-enters the specified range with the engine at a speed of less than 1200 rpm, a
reset is made.]
Action taken by Controls are made on the assumption that the coolant temperature is 20C {-4F} when the engine is started,
control unit and 120C {248F} during operation.
Warning lamp None
illuminated
between control unit and timer Tester II. P13E-28
control valve No. 09: Timer advance angle measurement
Probable cause
Faulty timer control valve Check timer control valve.
and check item
Check circuit between control unit and timer control valve.
24 ACCEL SNSR-1
Diagnostic trouble code 24 is intended for checking the accelerator position sensor 1 for abnormal voltage.
Code issued The code is issued when the output voltage of the accelerator position sensor 1 is out of the specified limits.
condition When diagnostic trouble code 16 is also registered, the portion between the accelerator position sensors is
[Reset condition] faulty.
[When the output voltage of the accelerator position sensor 1 re-enters the specified range, a reset is made.]
1 : Ordinary controls are continued by using only the accelerator position sensor 2.
Action taken by
2 : When accelerator position sensor 2 is also faulty, controls are made on the assumption that the pedal is
control unit
depressed 30% when accelerator switch is OFF and 0% when accelerator switch is ON.
accelerator position sensor 1 No. 0B: Accelerator pedal opening measurement
Faulty accelerator position sensor No. 0C: Measurement of accelerator position sensor output
1 voltage.
Faulty control unit Perform checks at control unit connector. P13E-32
Probable cause
04 : Measurement of accelerator position
and check item
sensor 1 output voltage
Check accelerator position sensor 1.
Check circuit between control unit and accelerator position
sensor 1.
13E-22
13E
25 SPEED SNSR
Diagnostic trouble code 25 is intended for checking the harness of the vehicle speed sensor for open/short
Code issued
circuit and checking the vehicle speed sensor for abnormaliti es. The code is issued when there are no pulse
condition
inputs from the vehicle speed sensor to the control unit in the specified time duration.
[Reset condition]
[When a pulse is input, a reset is made.]
Action taken by
ISC (Idle Speed Control) disabled
control unit
Warning lamp
illuminated None
between control unit and vehicle Tester II. P13E-28
speed sensor No. 0D: Vehicle speed measurement.
Faulty vehicle speed sensor Perform checks at control unit connector. P13E-32
Probable cause
Faulty control unit 05 : Measurement of vehicle speed signal voltage.
and check item
Check vehicle speed sensor.
Check circuit between control unit and vehicle speed sensor.
26 PUMP ROM
Diagnostic trouble code 26 is intended for checking for an error in the loaded pump read-only memory data
necessary for control of the injection rate. The code is issued when any of the following situations occurs.
Code issued Loaded read-only memory has unmatched data.
condition Read-only memory data cannot be read.
[Reset condition] Loaded data exceeds the upper limit of correction.
There is a mismatch between control unit backup data and loaded data.
[No automatic reset takes place.]
Action taken by
Initial values used
control unit
Warning lamp
None
illuminated
Open or short circuit in harness Check injection rate adjusting read-only memory. (Ask your
between control unit and injection DENSO service station to do the job.)
Probable cause rate adjusting read-only memory Check circuit between control unit and injection rate adjusting
and check item Faulty injection rate adjusting read- read-only memory.
only memory P13E-48: Electrical Wiring Diagram
Faulty control unit
27 SILENCER M/V
Code issued Diagnostic trouble code 27 is intended for checking the harness of the intake silencer 3-way magnet valve for
condition open/short circuit.
[Reset condition] [No automatic reset takes place.]
Action taken by
Intake silencer control disabled
control unit
Warning lamp
(Amber)
illuminated
Open or short circuit in harness Check intake silencer 3-way magnet valve.
between control unit and intake P13E-36: Inspection of Electrical Devices 565
Probable cause silencer 3-way magnet valve Check circuit between control unit and intake silencer 3-way
and check item Faulty intake silencer 3-way magnet valve.
magnet valve P13E-48: Electrical Wiring Diagram
Faulty control unit
13E-23
TROUBLESHOOTING
31 IDL VOLUME
Diagnostic trouble code 31 is intended for checking the harness of the idle adjusting potentiometer for open or
Code issued short circuit and checking the idle adjusting potentiometer for abnormalities.
condition The code is issued when the voltage of the idle adjusting potentiometer continues to be out of the specified
[Reset condition] limits for the predetermined period of time.
[When the voltage of the idle adjusting variable resistor re-enters the specified range, a reset is made.]
Action taken by
Operation mode fixed to auto idle
control unit
Warning lamp
None
illuminated
between control unit and idle Tester II. P13E-28
adjusting potentiometer No. 0E: Measurement of idle adjusting variable resistor voltage.
Faulty idle adjusting potentiometer Perform checks at control unit connector. P13E-32
Faulty control unit 06 : Measurement of idle adjusting variable resistor output
Probable cause
voltage.
and check item
Check idle adjusting potentiometer.
Check circuit between control unit and idle adjusting
potentiometer.
32 BOOST PRES
Diagnostic trouble code 32 is intended for checking the harness of the boost pressure sensor for open or short
Code issued circuit and checking the boost pressure sensor for abnormalities.
condition The code is issued when the output voltage of the boost pressure sensor continues to be out of the specified
[When the voltage of the boost pressure sensor re-enters the specified range, a reset is made.]
Action taken by
Controls are made on the assumption that the boost pressure is 100 kPa {29.9 in. Hg, 760 mmHg}
control unit
Warning lamp
None
illuminated
between control unit and boost Tester II. P13E-28
pressure sensor No. 15: Boost pressure measurement
Probable cause
Faulty boost pressure sensor Check boost pressure sensor.
and check item
Check circuit between control unit and boost pressure sensor.
33 ECU SYSTEM
Diagnostic trouble code 33 is issued in the following cases.
Code issued 1 : A/D converter out of order
condition [When A/D converter returns to normal, a reset is made.]
[Reset condition] 2 : Mutual monitoring error, interruption processing error
[When starter switch is turned OFF, a reset is made.]
Action taken by 1 : All Fail Safe functions against a faulty A/D input are activated.
control unit 2 : Engine stopped
Probable cause
Faulty control unit
and check item
13E-24
13E
34 Q RESISTOR
Diagnostic trouble code 34 is intended for checking the harness of the injection rate adjusting resistor for open
Code issued or short circuit and checking the injection rate adjusting resistor for abnormalities.
condition The code is issued when the output voltage of the injection rate adjusting resistor continues to be out of the
[Reset condition] specified limits for the predetermined period of time.
[When the voltage of the injection rate adjusting resistor re-enters the specified range, a reset is made.]
Action taken by
The injection rate correction value is fixed to No. 1 value.
control unit
Warning lamp
None
illuminated
between control unit and injection Tester II. P13E-28
Probable cause rate adjusting resistor No. 13: Resistor No. check of injection rate adjusting resistor.
and check item Faulty injection rate adjusting Check circuit between control unit and injection rate adjusting
resistor resistor.
Faulty control unit P13E-48: Electrical Wiring Diagram
41 FUEL TEMP
Diagnostic trouble code 41 is intended for checking the harness of the fuel temperature sensor for open or
Code issued short circuit and checking fuel temperature sensor for abnormalities.
condition The code is issued when the output voltage of the fuel temperature sensor continues to be out of the specified
[When the voltage of the fuel temperature sensor re-enters the specified range, a reset is made.]
Action taken by
Control is made on the assumption that fuel temperature is 40C {104F}
control unit
Warning lamp
None
illuminated
between control unit and fuel Tester II. P13E-28
temperature sensor No. 11: Fuel temperature measure.
Faulty fuel temperature sensor Perform checks at control unit connector. P13E-32
Probable cause
Faulty control unit 12 : Measurement of fuel temperature sensor resistance.
and check item
Check fuel temperature sensor.
Check circuit between control unit and fuel temperature sensor.
44 BOOST TEMP
Code issued Diagnostic trouble code 44 is intended for checking the harness of the boost air temperature sensor for open
condition or short circuit and checking the boost air temperature sensor for abnormalities.
[Reset condition] [When the voltage of the boost air temperature sensor re-enters the specified range, a reset is made.]
Action taken by
Control is made on the assumption that boost air temperature is 80C {176F}
control unit
Warning lamp
None
illunimated
Open or short circuit in harness Check boost air temperature sensor. P13E-36
between control unit and boost air 303 : Inspection of Electrical Devices
Probable cause temperature sensor Check circuit between control unit and boost air temperature
and check item Faulty boost air temperature sensor.
sensor P13E-48: Electrical Wiring Diagram
Faulty control unit
13E-25
TROUBLESHOOTING
45 FUEL CUT SW
Diagnostic trouble code 45 is intended for checking the harness of the emergency engine stop switch for open
Code issued or short circuit and checking the emergency engine stop switch for abnormalities.
condition The code is issued when a fault is detected in the circuit with both emergency engine stop switch and starter
[Reset condition] switch at the ON position (without starting the engine).
[When the emergency engine stop switch is set to OFF, a reset is made.]
Action taken by
Engine start inhibited
control unit
Warning lamp
(Red)
illuminated
emergency engine stop switch No. 42: Operation check of emergency engine stop switch.
Faulty emergency engine stop Perform checks at control unit connector. P13E-32
switch 11 : Measurement of emergency engine stop switch
Probable cause
Faulty control unit operating voltage.
and check item
Check emergency engine stop switch.
Check circuit between control unit and emergency engine stop
switch.
46 EDU RELAY
Diagnostic trouble code 46 is issued in the following cases.
1 : Drive unit relay is not ON with drive unit relay ON command issued.
Code issued [When the drive unit relay is turned ON by the drive unit relay ON command, and the voltage exceeds 16V, a
condition reset is made.]
[Reset condition] 2 : Drive unit relay is not OFF with drive unit relay OFF command issued.
[When the drive unit relay is turned OFF by the drive unit relay OFF command, and the voltage exceeds 16V,
a reset is made.]
Action taken by 1 : Drive unit relay OFF
control unit 2 : Ordinary controls continued
Warning lamp 1: (Amber)
illuminated 2 : None
Open or short circuit in harness Check drive unit relay.
Probable cause between control unit and drive unit P13E-36: Inspection of Electrical Devices 228
and check item relay Check circuit between control unit and drive unit relay.
Faulty drive unit relay P13E-48: Electrical Wiring Diagram
13E-26
13E
65 ACCEL SW
Diagnostic trouble code 65 is intended for checking the harness of the accelerator switch for open or short
circuit and checking the accelerator switch for abnormalities.
Code issused
The code is issued when the accelerator position sensor 1 or 2 shows an opening of more than 20% with the
condition
accelerator switch ON.
[Reset condition]
[If the accelerator switch turns OFF when the accelerator position sensor shows an opening of more than
20%, a reset is made.]
Action taken by
Ordinary controls continued
control unit
Warning lamp
None
illuminated
accelerator switch No. 43: Check of accelerator switch operating signal.
Faulty accelerator switch Perform checks at control unit connector. P13E-32
Probable cause
Faulty control unit 09 : Measurement of accelerator switch operating voltage.
and check item
Check accelerator switch.
Check circuit between control unit and accelerator switch.
66 STARTER SW (S)
Diagnostic trouble code 66 is intended for checking the harness of the starter switch for open or short circuit
Code issued and checking the starter switch for abnormalities.
condition The code is issued when a start signal is input with the engine running at a speed higher than the specified
[Reset condition] speed.
[When the start signal is no longer input, a reset is made.]
Action taken by
Ordinary controls continued
control unit
Warning lamp
None
illuminated
between control unit and starter Tester II. P13E-28
switch No. 41: Start signal ON/OFF check.
Faulty starter switch Perform checks at control unit connector. P13E-32
Probable cause
Faulty control unit 13 : Measurement of starter switch signal voltage.
and check item
Check starter switch.
Check circuit between control unit and starter switch.
13E-27
TROUBLESHOOTING
5. SERVICE DATA OF MULTI-USE TESTER II
Screen Display of Multi-Use Tester II
Condition When Checking Judging Criteria
N o. Item Name Data
1 ENGINE SPEED LLLL. rpm Racing (Engine running) Synchronized with tachometer
3 INJ VOL LLL. L % Starter switch ON 0%
9 TCV ANG DIFF LLL. L deg Warm engine running at idle 0 deg
Accelerator pedal released 0%
Slowly depressed Slowly increased
0B ACCEL (%) LLL. L %
Accelerator pedal fully
100 %
depressed
Accelerator pedal slowly
0C ACCEL (V) L. LLL V depressed from released 0.85 to 4.15 V
position
0D VEHICLE SPEED LLL. L MPH During driving Synchronized with speedometer
0E IDL VOL SNSR L. LLL V Slow to fast 2.6 to 1.2 V
Equivalent to atmospheric
Engine cold
temperature
10 WATER TEMP LLL. L F Engine warmup in progress Slowly increased
Engine stopped after warmup Slowly decreased
Equivalent to atmospheric
Engine cold
temperature
11 FUEL TEMP LLL. L F Engine warmup in progress Slowly increased
Engine stopped after warmup Slowly decreased
Matches No. marked on
13 Q RESISTOR LLLL
injection rate adjusting resistor.
Altitude 0 m 13.5 mmHg
14 AIR PRESS LLLL. mmHg Altitude 600 m 12.7 mmHg
Altitude 1200 m 11.7 mmHg
15 BOOST PRESS LLLL. mmHg Engine speed 3400 rpm 260 mmHg
16 BATT VOLTAGE LL. LL V Starter switch ON Matches battery voltage.
17 PTO-ACCEL (%) LLL. L % When PTO is used (MIN-MAX) 0 to 100 %
18 PTO-ACCEL (V) L. LLL V When PTO is used (MIN-MAX) 1 to 3.0 V
Matches No. marked on power
19 PTO RESISTOR LLLL
take-off resistor.
Engine cranked by starter switch ON
41 START SIG ON/OFF Starter switch at any other
OFF
position than S
Switch ON ON
42 FUEL CUT SW ON/OFF
Switch OFF OFF
Accelerator pedal depressed ON
43 ACCEL SW ON/OFF
Accelerator pedal released OFF
When air conditioner
ON
compressor is in operation
44 A/C SW ON/OFF
When air conditioner
OFF
compressor is idle
Warming switch ON ON
45 COLD START SW ON/OFF
Warming switch OFF OFF
13E-28
13E
Condition When Checking Judging Criteria
N o. Item Name Data
Diagnostic switch ON OFF
46 DIAGNOSIS SW ON/OFF
Diagnostic switch OFF ON
Memory clear switch ON OFF
47 DIAG RESET SW ON/OFF
Memory clear switch OFF ON
Exhaust brake switch ON (when
ON
exhaust brake is active)
51 EXH.BRAKE SW ON/OFF
Exhaust brake switch OFF
OFF
(when exhaust brake is inactive)
Transmission at neutral ON
53 NEUTRAL SW ON/OFF Transmission at any other
OFF
position than neutral
Automatic transmission select
ON
lever at R, D, 2 or L
55 IDL-UP CNCL ON/OFF
At any other position than
OFF
mentioned above
61 SILENCER M/V B Gr17
When exhaust brake is active ON
71 EXH. BRAKE M/V ON/OFF
When exhaust brake is inactive OFF
Starter switch ON (engine not
ON
made to start)
73 DIAG LAMP (R) ON/OFF
No error generated after engine
OFF
has started
Starter switch ON (engine not
ON
made to start)
No error generated after engine
74 DIAG LAMP (U) ON/OFF OFF
has started
When warmup system is
OFF
inactive
When engine is running ON (ON OFF repeated)
83 SPV ON/OFF
When engine is stationary OFF
13E-29
TROUBLESHOOTING
6. ACTUATOR TEST BY MULTI-USE TESTER II
Operation Check Procedures
No. Item Name
9B SPV Operating sound of solenoid valve
9C TCV-OFF No operating sound of solenoid valve
9D TCV-ON Operating sound of solenoid valve
91 SILENCER M/V B Gr17
94 EXH. BRAKE M.V ON/OFF sound of magnetic valve
97 DIAG LAMP (R) ON/OFF state of warning lamp (Red)
98 DIAG LAMP (A ) Operating state of warning lamp (A mber)
99 A/C SIG High idling speed
9A IDL-UP CNCL Low idling speed
13E-30
13E
MEMO
13E-31
TROUBLESHOOTING
7. CHECKS AT CONNECTOR OF CONTROL UNIT
This method of checks is useful for checking whether all the signals of the control unit are transmitted without any error
through the vehicle side harness and connector.
The numbers in the table correspond to the call numbers used in 4. DIAGNOSTIC TROUBLE CODES AND CHECK
ITEMS for referencing this section.
Pin Configuration of Control Unit
C: CC12B D: CC22A
6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12
A: CC26A B: CC16A
A
13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
B 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9
C
D
35643
No. Item Reference Page

01 Resistance of TDC sensor
02 Resistance of engine speed sensor
03 Output voltage of accelerator position sensor 1 P13E-33
04 Output voltage of accelerator position sensor 2
05 Signal voltage of vehicle speed sensor
06 Output voltage of idle adjusting potentiometer
09 Voltage of accelerator switch
11 Voltage of emergency engine stop switch P13E-34
12 Resistance of fuel temperature sensor
13 Voltage of starter switch (start signal)
13E-32
13E
Checking Procedures
CAUTION k
Each item is checked by one of two methods; one by disconnecting the connectors and one by leaving the connec-
tors connected.
Pay heed to the following points.
Be sure not to touch any other pin than the one to be checked.
Especially, use utmost care that a short circuit is never produced between pins by the tester.
All the illustrations of the connectors in the table show the connectors on the control unit side. Be careful not
to confuse the pins with those to be checked.
Check Item Checking Procedure
01 [Conditions]
Starter switch OFF
Resistance of TDC
Disconnect connector and make checks at vehicle side harness connector (25C {77F}).
sensor
[Judging Criteria]
Between pins: C 5 C W
1.5 0.2 k
02 [Conditions]
Starter switch OFF
Resistance of engine
Disconnect connector and make checks at vehicle side harness connector.
speed sensor
[Judging Criteria]
Between pins: C 6 C E
230 25
03 [Conditions]
Starter switch OFF
Output voltage of
Leave vehicle side harness connected (make checks from back side of connector).
accelerator position
sensor 2 [Judging Criteria]
Between pins ( ): B R B 8
When accelerator pedal is released: 0.85V
When accelerator pedal is depressed: 4.15V
04 [Conditions]
Starter switch OFF
Output voltage of
accelerator position
sensor 1 [Judging Criteria]
Between pins ( ): B W B 6
When accelerator pedal is released: 0.85V
When accelerator pedal is depressed: 4.15V
05 [Conditions]
Starter switch ON
Signal voltage of
Leave vehicle side harness connected (make checks from back side of vehicle side connector).
vehicle speed sensor
Using chassis dynamometer or something else, slowly rotate wheels.
[Judging Criteria]
Between pins ( ): A I A R
Hi: Approx. 8V
Lo: 0.5V or less
13E-33
TROUBLESHOOTING
Check Item Checking Procedure
06 [Conditions]
Starter switch ON
Output voltage of idle
adjusting potentiometer
[Judging Criteria]
Between pins ( ): C 5 C Q
When knob is pulled: Approx. 1 to 3V
When knob is pushed all the way: Approx. 3.6 to 4.3V
09 [Conditions]
Starter switch ON
Voltage of accelerator
switch
[Judging Criteria]
Between pins ( ): D Q B 8
When accelerator pedal is depressed: 0V
When accelerator pedal is released: 5V
11 [Conditions]
Starter switch ON
Voltage of emergency
engine stop switch
[Judging Criteria]
Between pins ( ): D D D U
Switch at stop position: 0V
Switch at normal position: 24V
12 [Conditions]
Starter switch OFF
Resistance of fuel
temperature sensor
[Judging Criteria]
Between pins: B E B U
2.5 1.0 k
13 [Conditions]
Voltage of starter
Starter switch (S position)
switch (starter signal)
[Judging Criteria]
Between pins ( ): D 2 D W
24V
13E-34
13E
8. CHECKS ON INTERMITTENT TROUBLES
A intermittent trouble often occurs in a specific condition. Therefore, pin-
pointing the condition will make it easy to estimate the cause. To pinpoint
the condition for a intermittent trouble, ask the customer in detail about
the driving condition when the trouble occurs, weather, occurrence fre-
quency and symptoms, and reproduce the symptoms of the trouble.
Depending on the condition where the trouble occurs, determine whether
the cause of the trouble is vibration, temperature or any other factor.
If the probable cause is vibration, perform the following checks on the
relevant connectors harnesses, etc. and check whether the symptoms of
02597 the trouble are reproduced.
Lightly move the connector up and down and to the right and left.
Lightly move the harness up and down and to the right and left.
Lightly shake the sensors and other devices by hand.
Lightly shake the wiring harness located in the moving components
such as the suspension.
The connectors and other parts to be checked are identifiable from the
descriptions in the Probable Causes or the Checking Procedures for the
displayed diagnostic trouble code.
02598
02599
13E-35
INSPECTION OF ELECTRICAL EQUIPMENT
001 Checking Combination Switch
Perform continuity checks according to the following table.
AQ15A Connector Connection Table
5 6
OFF
ON
: There must be continuity between the pins.
If there is anything wrong, replace the switch.
AQ13A AQ15A 10913
E 002 Checking Starter Switch

If there is anything wrong, replace the starter switch. B Gr37
(1) Continuity Check
D AP2A AN6A
C
2 1 3 4 2 6 5
Key not in
LOCK position
07057 Key in position
(OFF)
ACC
ON
START
B M A F/M S K1 K2
(2) Checking Key Interlock Solenoid

AN2A
LOCK ACC ON START Remarks
1 2
Plunger C is locked
Rotat- and key D cannot be
ing removed.
range
of key Plunger C is free and
D key D can be
removed.
: Apply voltage across these pins.
DC 12V
E: Key interlock solenoid
4 5 6 7
014 Checking Cold Start Switch
1 5
ON
OFF
1 2 3
14220
13E-36
13E
8 mm 156 Checking Emergency Engine Stop Switch
Emergency Normal position Perform continuity checks according to the following table.
stop
1 2 3
position
Normal position
Emergency stop position
B Gr13A
24102
157 Checking Idle Adjusting Potentiometer

A B Disconnect the harness B of the idle adjusting variable resistor A from
the vehicle side harness C, and connect the inspection harness D be-
tween them.
Set starter switch to ON.
Measure the output voltage of the idle adjusting variable resistor A
according to the following table.
2 3
D Output voltage PULL
1 to 3 V
Standard (Knob in pulled position)
C value Output voltage PUSH
3.6 to 4.3 V
3 (Knob in pushed position)
2 If the reading is out of the standard value range, replace the idle ad-
justing potentiometer A.
1
D
LA3A
LA3A 02778
Output Characteristics
Output Voltage (V)
4.3
PUSH
3.6
3
PUSH
1
0 300
Rotation angle 02779
13E-37
180 Checking Relay (Normally closed type 4-pin)
Perform continuity and operation checks according to the following table.
2
1 2 3 4
When not energized
When energized
2 1 3 4 1 : There must be continuity between the pins.

4 : Apply a voltage of 12 V DC across these pins.
3 : Continuity between these pins must be lost.
07387 If there is anything wrong, replace the relay.
181 Checking Relay (Normally open type 4-pin)

1 2 3 4
2 When not energized
4 2 1 3
When energized
4
1
3
: Apply a voltage of 12V DC across these pins.
00432
If there is anything wrong, replace the relay.
1 2 3 4
2 When not energized
4 2 1 3
When energized
4 1
3 : There must be continuity between the pins.
: Apply a voltage of 12V DC across these pins.
07142
3 2 1 Perform continuity and operation checks according to the following table.
1 2 3 4 6
6 2 134 When not energized
When energized
5
4 : There must be continuity between the pins.
36915
: Apply a voltage of 12 V DC across these pins.
13E-38
13E
1 262 Checking Coolant Temperature Sensor
Put the coolant temperature sensor in a container filled with engine oil.
Heat the engine oil to various specified temperatures while stirring the
2 engine oil.
Measure the resistance value between pins 1 and 2 (body).
0C {32F} (8.62 k)
Standard 20C {68F} (3.25 k)

value 40C {104F} (1.5 k)
09079 60C {140F} 620 62
Reference value in parentheses
If the reading is out of the standard value, replace the coolant tempera-
ture sensor. B Gr14
263 Checking Engine Speed Sensor

2 1 Measure the resistance value between pins 1 and 2.
Standard value (at 20C {68F}) 230 25
If the reading is out of the standard value range, replace the engine
speed sensor. Ask your DENSO service station to replace it.
36798
265 Checking Vehicle Speed Sensor

A Slowly rotate portion A of the vehicle speed sensor with a voltage of
2 1
12V DC applied across pins 1 and 3.
Measure the maximum value (high pulse voltage B) and minimum value
B (low pulse voltage C) of the voltage generated across the pins 1 and
4 3 2.
D C
D: Tester (to check 25 pulses)
E Standard Low pulse 0.5 V or less
35180
value High pulse 81V
If the reading is out of the standard value, replace the vehicle speed
sensor.
304 Checking Boost Air Temperature Sensor

Place the boost air temperature sensor in glycerin in a container.
Raise the glycerin temperature to the specified values and stir the glyc-
erin.
Measure the resistance between pins 1 and 2.
boost air temperature sensor. B Gr15
0C {32F} 5880 588
Standard
1 2 20C {68F} 2450 245
13729 value
80C {176F} 322 48
13E-39
316 Checking TDC Sensor
Standard value (at 25C {77F}) 1.5 0.2 k
If the reading is out of the standard value, replace the TDC sensor.
2 1
36800
318 Checking Boost Pressure Sensor

<Checking by use of Multi-Use Tester II>
P13E-28
NOTE:
The boost pressure checking conditions differ between when the
boost pressure is checked by use of the Multi-Use Tester II and
when it is checked without use of the Multi- Use Tester II. So the
standard values also differ.
<Checking without use of Multi-Use Tester II>

A
Disconnect the harness D of the boost pressure sensor from the chas-
sis side harness E and connect the 0 inspection harness between
C them.
Too Name and Shape Part No.
Inspection Harness
MC854336
B
02806
E
Mount pressure gauge A for measurement of the boost pressure.
C: To inlet manifold
D Set the starter switch to ON.
Measure the output voltage of the boost pressure sensor B according
to the following table.
0
1 Connector Pin
3 2 Item
1 Power (+) 2 GND (-) 3 Output (+)
41111
Power voltage
* Output voltage
(Refer to the output
characteristics shown at left.)
*: Start the engine before measurement.
13E-40
13E
Output Characteristics
Temperature25C{77F} 2-3 5V
4.67
4.5
Voltage (V)
0.5 V/34.3 kPa {10.0 in. Hg, 255 mmHg}

3.22
Standard Value 1.86 V/33.7 kPa {9.84 in. Hg, 250 mmHg}
1.86 1-2
0.5
3.22 V/98.7 kPa {29.1 in. Hg, 740 mmHg}
0 4.5 V/163.7 kPa {48.4 in. Hg, 1230 mmHg}
0 33.7 163.7
{0, 0} {9.84, 250} {48.4, 1230}
-34.3 98.7 If the results of the above mentioned checks show any deviation from
{-10.0, -255} {29.1, 740} the standard values, replace the boost pressure sensor B.
Boost Pressure (kPa {in.Hg, mmHg})
41444
323 Checking Fuel Temperature Sensor

2 Measure the resistance between pins 1 and 2
1 Standard value (at 20C {68F}) 2.5 1.0 k
If the reading is out of the standard value range, replace the fuel tem-
perature sensor. Ask your DENSO service station to replace it.
36801
B 324 Checking Accelerator Position Sensor

A [Inspection]
K
C 1 2 3 4 5 Measure the output voltage of the accelerator position sensor A from
the back side of harness connector B according to the following table.
J
G
H
34503
Accelerator Position Sensor 1 Accelerator Position Sensor 2 Accelerator Switch

2 1 2 5 2 3
Lever C position
Idling position D 0.85 0.1 V 0.85 0.1 V 4V or more
Standar- Accelerator switch
d value 1.0 0.24 V 1.0 0.24 V
operating position E 1V or less
Full load position F 4.0 0.1 V 4.0 0.1 V
, : Polarity when voltage is measured
D: Where accelerator control arm G is in contact with stopper H
E: Where voltage across pins 2 and 3 is reduced to 1V or less by
slowly depressing the accelerator pedal
F: Where accelerator control extension J is in contact with stopper bolt
K
If the output voltage is out of the standard value range, adjust by the
following procedures.
13E-41
[Adjustment]
M Adjust the output voltage at the idling position D by loosening the screw
N
L and moving the accelerator position sensor A.
L
K After the adjustment, retighten the screw.
Adjust the output voltage at the full load position F by loosening the nut
M and adjusting the stopper bolt K.
L After the adjustment, lock the bolt with the nut.
34504
351 Checking Pulse Divider

4 3 2 1 Wire the pulse divider A as shown.
10 9 8 7 6 5
B: Vehicle speed sensor (Use 25-pulse pins.)
C: Tester
E Slowly rotate the shaft D of the vehicle speed sensor B by hand and
25P OUT 3
25P OUT 4 F measure the maximum value (high pulse voltage E) and the minimum
25P OUT 9 value (low pulse voltage F) of the voltage generated across each of the
A
25P OUT Q
C output pins (3, 4, 9, Q) and pin 8 of the pulse divider A.
8
2 Standard Low pulse voltage F 0.5V or less
D 25P IN 7 value High pulse voltage E 81V
SIG 4
If the reading is out of the standard value, replace the pulse divider A.
2
1
B
2 1
4 3
41116
1 536 Checking Spill Valve

2
Standard value (at 20C {68F}) 1.5 0.5
If the reading is out of the standard value range, replace the spill valve.
Ask your DENSO service station to replace it.
36802
13E-42
13E
565 Checking 3-Way Magnet Valve
C Perform the following checks. If there is anything wrong, replace the 3-
way magnet valve.
(1) Operation Check
Apply DC voltage across pins 1 and 2 and slowly increase, beginning
A at 0V.
Measure the voltage at the time when the 3-way magnet valve is oper-
ated.
B (Determine whether the magnet valve is ON or OFF on the basis of its
07115 operating sound.)
Standard value (Lowest operating voltage) 11 V or less
(2) Continuity and Air Tightness Checks

Input Port Output Port Exhaust Port
A B C
ON
OFF
Negative pressure at the time of check: 100 kPa {30 in.Hg, 750 mmHg}
584 Checking Timer Control Valve

Standard value (at 20C {68F}) 11.3 3
If the reading is out of the standard value range, replace the timer
control valve. Ask your DENSO service station to replace it.
1 2 36805
13E-43
LOCATIONS OF PARTS
1 to 15
4 5 [AU10A] [AU13A] [AU16C]
6
3
2
10
8
9
7
11
[CC12A]
[CC16A]
12
[CC26A]
41130
1 Connection of cab harness and column harness 8 Connection of cab harness and meter harness
2 Starter switch 9 Emergency engine stop switch
3 Combination switch 10 Fuel injection rate adjustment resistor
4 Warming up switch 11 Automatic transmission control unit
5 Meter cluster 12 Accelerator pedal sensor
6 Idling speed adjustment potentiometer
7 Fuse box
Connector type shown in [ ]
13E-44
13E
16 to 30
[CC12B]
[CC16A] [CC22A] 17 20
18
16
[CC26A]
19 21
26
22
23, 24
25
27
28
Wiper motor
41131
16 Engine control unit 24 Memory clear switch

17 Relay box 25 Multi-use tester-II connector
18 Exhaust brake cut relay 26 Pulse divider
19 Drive unit 27 Cab ground
20 Drive unit relay 28 Cab ground
21 Electric control main relay
22 Diode
23 Diagnosis switch
13E-45
LOCATIONS OF PARTS
31 to 40 32
31
36 35 34 33
38
37
41132
31 Connected of cab harness and chassis harness 37 Inhibitor swtich

32 Exhaust brake 3-way magnetic valve 38 Vehicle speed sensor
34 Battery
35 Chassis ground
36 Chassis ground
13E-46
13E
41 to 50
41
43
42
44
45 46 47
48
49
36785
41 Top dead center (TDC) sensor 46 Engine speed sensor

42 Coolant temperature sensor 47 Spill valve
43 Boost pressure sensor 48 Injection rate adjusting read-only memory
44 Starter 49 Timer control valve
45 Fuel temperature sensor 50 Missing number
13E-47
13E-48 13E-49
Group 13
' 99 Minor Change

Table of Contents
BACK HOME

13
GROUP 13 FUEL AND ENGINE CONTROL
SPECIFICATIONS ............................................................................ 13 - 2
STRUCTURE AND OPERATION ..................................................... 13 - 4
TROUBLESHOOTING ...................................................................... 13 -32
READING AND ERASING DIAGNOSIS CODES............................. 13 -36
SERVICE PROCEDURES USING MUT-II ........................................ 13 -42
INSPECTION BASED ON DIAGNOSIS CODE ................................ 13 -44

Checking and Adjusting Injection Timing ................................................ 13 -48
Bleeding Air from Fuel System ................................................................. 13 -51
Cleaning Gauze Filter ................................................................................. 13 -51
Replacing Fuel Filter .................................................................................. 13 -52
ENGINE CONTROL .......................................................................... 13 -53
FUEL TANK ...................................................................................... 13 -58
FUEL FILTER.................................................................................... 13 -59
WATER SEPARATOR ...................................................................... 13 -60
INJECTION PUMP ............................................................................ 13 -62
INJECTION NOZZLE ........................................................................ 13 -66
INSPECTION OF OTHER DEVICES ................................................ 13 -70
ELECTRIC CIRCUIT AND PART INSTALLATION LOCATIONS ..... 13 -82
13-1
SPECIFICATIONS
Injection Pump
Item Specifications
Manufacturer ZEXEL
Body model MD-TICS (Pre-stroke control type)
Governor type RED-III Electronic control governor
Feed pump model KD
Injection Nozzle
Item Specifications
Manufacturer ZEXEL
Model and type DLLA hole type 1-spring nozzle
Nozzle orifice quantity 5
Orifice diameter mm {in.} 0.25 {0.0098}
Fuel Filter Type

Item Specifications
Filter type Spin-on type
13-2
13
MEMO
13-3
Fuel System (Flow of Fuel)
1
Supplied fuel
Excessive fuel
5
7 4
6
P 31527
1 Injection nozzle 6 Feed pump

2 Fuel filter 7 Injection pump
3 Fuel tank 8 Overflow valve
4 Water separator 9 Pre-stroke actuator
5 Electronic governor
Fuel in fuel tank 3 is sucked up by feed pump 6 which is driven by the cam action of injection pump 7 and is filtered through
fuel filter 2 which removes dirt and other foreign particles.
Filtered fuel is sent to the injection pump where the fuel pressure is boosted and injected through injection nozzle 1 into
the combustion chamber.
When fuel pressure is higher than the specified value, overflow valve 8 opens to let the fuel return to the fuel tank.
13-4
13
Engine Control
1 Emergency engine stop handle
2 Starter switch
3 Engine stop lever
4 Engine stop cable
1 6 Lever
2 7 Accelerator pedal position sensor
4
* : Electronic governor
3
B A : Engine-stop position
B : Engine start-up position
7 A C : Full-load position
C 5 D : Idling position
D A
B *
P 31528
Accelerator switch
The accelerator switch is integrated in the accelerator pedal position sensor 7. It detects the pressing of accelerator
pedal assembly 5.
Accelerator pedal position sensor
Accelerator pedal position sensor 7 detects the movement of accelerator pedal assembly 5, and sends an electric
signal to the electronic governor control unit. Lever 6 of the accelerator pedal position sensor is constantly pulled by the
return spring towards idle position D.
Emergency engine stop button
In normal condition, turn starter switch 2 to the ACC position to electrically shut down the engine operation.
In the case the engine does not stop when the starter switch is turned to the ACC position due to malfunction of the
electronic governor system or other cause, stop the engine by pulling emergency engine stop handle 1 to move stop
lever 3 of electronic governor * to engine-stop position A.
CAUTION
When the engine is stopped by pulling engine stop handle 1, set starter switch 2 to the ACC or LOCK position
to reset the control unit computer.
Restarting the engine without resetting the computer results in unstable engine speed control.
13-5
Fuel Gauge Electric Circuit
1 Fuse box
1 2
2 Meter cluster
3
3 Fuel gauge
4 Fuel gauge sending unit
5 Float
The fuel gauge circuit indicates the amount of

fuel remaining in the fuel tank by means of a
gauge.
4
5
F
E
12960
Water Separator
1 Water level ring
A : From fuel tank

B : To feed pump
A
B The water separator is installed between the fuel tank and the feed
pump. Any water present in the fuel is separated by the baffle
plate and the screen assembly.
27687
13-6
13
Fuel Filter
1 Fuel filter
2
2 Fuel filter head
A : From feed pump

B : To injection pump
A
Pressurized fuel is delivered from the feed pump of the
injection pump to the fuel filter which separates water from
the fuel. Dirt and other foreign particles are removed from the
fuel by fuel filter 1.
06892
13-7
Configuration of Electronic Governor and Pre-stroke Control Injection Pump System
5 6 7 8 9
4
3
10
34
33
11
32
12
13
31
14
30
15
16
29 35
17
26 28
27 18
19
25 20
24
23 21
22
31529
A : To exhaust brake 3-way magnetic valve ^ Gr 54
13-8
13
Part Main function/operation Data signal
1 Starter switch Sensing of start signal h : Start signal
2 Fuse box
3 Engine speed sensor Sensing of engine speed D : Engine speed signal
4 Sub control rack position sensor Sensing of control rack position C : Control rack position signal (backup)
Pre-stroke actuator
5 Pre-stroke position sensor A : Pre-stroke position signal
Drive unit B : Actuator drive signal
6 Pre-stroke control type injection pump Alteration of pre-stroke (advancement of

fuel injection timing)
7 Control rack position sensor Sensing of control rack position G : Control rack position signal
8 Backup engine speed sensor Sensing of engine speed F : Engine speed signal (backup)
9 Linear DC motor Activation of rack E : Linear DC motor drive signal
10 Electronic governor
11 Boost temperature sensor Detection of engine intake air

H : Boost temperature signal
temperature
12 Meter cluster
13 Tachometer J : Tachometer drive signal
14 Warning lamp (Orange) Indication of system faults and diagnosis K : Lamp illumination signal
15 Warning lamp (Red) codes L : Lamp illumination signal
16 Indicator lamp M : Lamp illumination signal
17 Auxiliary brake switch ON/OFF switching of Exhaust brake N : Exhaust brake ON signal
Sensing of accelerator pedal depression
18 Accelerator pedal position sensor P : Accelerator pedal position signal
amount
Turns OFF when accelerator pedal is
19 Accelerator pedal switch Q : Accelerator pedal depression signal
depressed
Idling speed adjustment
20 Shortening of warmup time R : Warmup time shortening signal
potentiometer
21 Fuel injection rate adjustment resistor Correction of fuel injection rate S : Injection volume correction signal
T : Accelerator position signal

22 Automatic transmission control unit Automatic transmission control
U : Engine speed signal
23 Diagnosis switch Generation of diagnosis codes X : Diagnosis code signal

24 Memory clear switch Eraser of diagnosis codes Y : Diagnosis code eraser signal
25 MUT-II connector (16 pin) Connection of MUT-II
26 Relay box
27 Pre-stroke cut relay Closes contacts upon plunger pre-stroke

Z : Pre-stroke operation signal
operation
28 Exhaust brake relay Closes contacts upon exhaust brake

a : Exhaust brake operation signal
operation
29 Transmission neutral relay Contact closed when transmission is in b : Transmission neutral signal
neutral
30 Boost pressure sensor Sensing of boost pressure d : Boost pressure signal
31 Coolant temperature sensor Sensing of engine coolant temperature e : Coolant temperature signal
Turns OFF when clutch pedal is
32 Clutch pedal switch f : Clutch pedal depression signal
depressed
Turns OFF when transmission neutral is
33 Transmission neutral switch
selected
34 Warming switch Shortening of warmup time g : Warmup time shortening signal
35 Electronic governor control unit Control of overall system
13-9
The electronic governor and pre-stroke control injection pump system combines an electronic governor 10 with an
injection pump 6 that has an electronically controlled pre-stroke adjustment feature.
The injection pumps plunger lift speed varies in accordance with the engine speed, causing concomitant variations in
the injection pipe pressure.
Variations in the injection pipe pressure make it difficult to achieve an optimum spray from the injection nozzles and the
optimum air/fuel mixture.
To compensate for changes in the injection pipe pressure, the injection pump plunger pre-stroke is increased at low and
mid- range speeds, thus ensuring that fuel injection takes place late in the cam lift, when plunger movement is relatively fast.
At high speeds, the plunger pre-stroke is decreased, thus ensuring that fuel injection takes place in early in the cam lift,
when plunger movement is relatively slow. Excessive increases in injection pipe pressure are thus prevented.
By adjusting the plunger pre-stroke in this manner, the pre-stroke control injection pump 6 ensures that the spray and
air/ fuel mixture are always optimally suited to combustion.
The overall benefits are higher engine torque and cleaner exhaust emissions than are possible with a conventional
injection pump.
Control operations are performed by the electronic governor control unit 35, which receives data from sensors on the
engine and other vehicle components, processes them, and issues appropriate drive signals to the pre-stroke actuator
5 (located at the rear of the injection pump) and to the linear DC motor 9 (located inside the electronic governor).
The systems control functions (including auxiliary functions) are shown in the following table.
Data source
Item Operation
Sensor(s) Data signal(s)
Fuel injection rate The fuel injection rate is optimized to match engine operating 3, 7, 18, 19, 21, D, G, P, Q,
control conditions. P13-12 28 S, b
Pre-stroke control The timing sleeve position is altered, thereby changing the 3, 5, 18, 31 D, A, B, P,
pre-stroke and advancing the fuel injection timing. P13-13 e
In cold weather and other conditions that are unfavorable for

Control rack prelimi- engine startup, the control rod is caused to move slightly in the h, P, Q, e
1, 18, 19, 31
nary operation fuel increase direction, thus enhancing startabilily. This opera-
tion takes place when the starter switch is turned ON.

Warmup time short- In cold weather, the engines idling speed is increased to
18, 19, 20 P, Q, R
ening function shorten the time required for warmup. P13-14

Overrun prevention In the event of an abnormal increase in engine speed, the
function control rack is pulled in the fuel decrease direction to prevent 3 D
the engine from overrunning.

Emergency vehicle In the event of a fault in the control rack position sensor 7, the
operation function control rack position is sensed by the sub control rack position
(used in event of sensor 4. If both rack position sensors develop faults, thus
3, 4, 7 D, C, G
control rack position preventing detection of the rack position and optimization of
sensor fault) the fuel injection rate, the fuel injection rate is controlled in
accordance with engine speed signals only. P13-16
The auxiliary braking devices (exhaust brake) are controlled by

Auxiliary brake con- the electronic governor control unit 35. (In a conventional 3, 16, 18, 19, 29, D, M, P, Q,
trol function system, the auxiliary braking devices are controlled by 32, 33 b, f
switches, relays, and dedicated controllers.) P13-17
The status of each system sensor is monitored continuously

Fault diagnosis during engine operation. In the event of a fault, a warning
function ALL ALL
lamp is illuminated to alert the driver and data related to the
fault are stored in memory. P13-34

In the event of a fault, a backup mode is selected and remedial
Fail-safe function ALL ALL
action is taken in accordance with the type of fault. P13-38

Reverse engine In the event of reverse engine operation, the control rack is
operation pulled in the fuel decrease direction to stop the engine. 3 D
prevention function
: Auxiliary function
13-10
13
System Block Diagram
Input signals Output signals
Fuel injection
Backup engine speed sensor 8 Linear DC motor 9
rate control
Control rack position sensor 7
Injection
pump Pre-stroke position sensor (integral
part of pre-stroke actuator 5)
Sub control rack position sensor 4 Drive unit (integral part of Fuel injection
pre-stroke actuator 5) timing control
Engine speed sensor 3
Boost pressure sensor 30
Engine
Coolant temperature sensor 31 Fault diagnosis
Warning lamp 14, 15
Boost temperature sensor 11 indication
Trans- Electronic
Transmission neutral switch 33 Indication of
mission governor Indicator lamp 16 auxiliary brake
control operation
Starter switch 1
unit 35
Auxiliary brake switch 17
Accelerator pedal position sensor
18
Idling speed adjustment potentio-
meter 20
Chassis
Fuel injection rate adjustment
resistor 21
Diagnosis switch 23
Memory clear switch 24
Clutch pedal switch 32
Accelerator pedal switch 19
13-11
Fuel Injection Rate Control
Data signals Electronic governor

control unit 35
Acc Digital signals
Idling charac- *
Ne teristics
Vl
Running Selection of Selection of

Acc maximum injec- minimum injec-
Ne characteristics tion rate value tion rate value
Target control
rack position
Fuel injection
rate adjustment
resistor 21
Ne Full rack Start mode

PB characteristics evaluation
Acc
Ne Starting
Tw characteristics
Starter switch
Sub control rack Feedback control Servo

position sensor 4 circuit
Analog signals
Actuator Drive Servo D/A

Rack
(linear DC motor 9) circuit circuit converter
Acc: Accelerator pedal position

Ne: Engine speed Control rack posi-
tion sensor 7
Tw: Engine coolant temperature Feedback control
Vl: Idling speed adjustment potentiometer voltage
PB: Boost pressure
D/A converter: Digital-to-analog converter
* Idling speed control limited only to low idling speed control
Operation of electronic governor control unit 35

During engine operation, control is effected in accordance with the idling characteristics and running characteristics.
The maximum fuel injection rate value is selected in accordance with the output signals.
After this selection, the control unit calculates and determines the minimum injection rate to prevent the injection rate
selected in accordance with the full rack characteristics from exceeding the maximum injection rate. The target control
rack position is thus determined. (During engine startup, control is effected in accordance with the starting characteris-
tics, with the target rack position determined directly in accordance with the data signals.)
The determined control rack position signal is converted into a continuous analog signal. By way of the servo circuit and
drive circuit, the signal is applied to the linear DC motor 9, which moves the rack.
Operation of control rack position sensor 7
The control rack position sensor 7 monitors the operation of the linear DC motor 9. In accordance with the position of the
control rack, the sensor determines whether the linear DC motor is operating in accordance with the target, and it
transmits feedback signals to the electronic governor control unit 35.
In accordance with the feedback signals, the electronic governor control unit 35 calculates the actual control rack
position. If the actual position differs from the target, the control unit issues a correction command.
Through repetition of this process, the system ensures that the control rack position complies with the target at all times.
13-12
13
Pre-stroke control
Data signals
Electronic governor control unit 35
ON Engine in operation
Ne
Rac Basic map
START
Engine
stationary
Target
pre-stroke
Ne Pre-stroke position
Start map learning function
Tw
Analog signals
Drive unit
Timing sleeve
(integral part of pre-stroke Drive circuit Servo circuit D/A converter
movement
actuator 5)
Pre-stroke position sensor

(integral part of pre-stroke actuator 5) Feedback control
Rac: Control rack position

Ne: Engine speed
Tw: Engine coolant temperature
D/A converter: Digital-to-analog converter
Operation of electronic governor control unit 35

During engine operation, control is effected in accordance with the basic map.
The pre-stroke position learning function compensates for pre-stroke position sensor adjustment errors and other
injection pump errors using the pre-stroke position sensor output voltage, thereby enabling determination of the target
pre-stroke.
The determined target pre-stroke value is converted into a continuous analog signal. By way of the servo circuit and
drive circuit, the signal is applied to the drive unit. The drive unit moves the timing sleeve to alter the pre-stroke.
During engine startup, control is effected in accordance with the start map.
Operation of pre-stroke position sensor (integral part of pre-stroke actuator 5)
The pre-stroke position sensor monitors the operation of the drive unit. In accordance with the position of the timing
sleeve, the sensor determines whether pre-stroke control is being performed in accordance with the target, and it
transmits feedback signals to the electronic governor control unit 35.
In accordance with the feedback signals, the electronic governor control unit 35 calculates the actual timing sleeve
position. If the actual position differs from the target, the control unit issues a correction command.
Through repetition of this process, the system ensures that the timing sleeve position complies with the target at all
times. The appropriate pre-stroke is achieved as a result.
13-13
Warmup time shortening function
Data signals
Engine coolant temperature
Accelerator pedal position Target control rack

Comparison Idling speed control
position
potentiometer
The warmup time shortening function increases the engines idling speed in accordance with the coolant temperature,
thereby shortening the time required for the engine to warm up. Control is effected automatically or manually in
accordance with the position of the idling speed adjustment potentiometer 20. Automatic control is selected by pushing
the potentiometer, and manual control is selected by pulling it.
Automatic control (Potentiometer pushed)
Automatic control is selected when the idling speed adjustment
potentiometer 20 is pushed.
When the coolant temperature is low, the engines idling speed is
automatically increased to shorten the time required for warmup.
If the coolant temperature increases from T to T (see the graph), the
engine speed is decreased from N to N, thus returning to its standard
idling level.
PUSH
31517
Engine speed (rpm)
0 T T
Coolant temperature (C)
02709
13-14
13
Manual control (Potentiometer pulled)
When the idling speed adjustment potentiometer 20 is pulled, the
automatic mechanism is deselected. The driver can then adjust the
idling speed as desired by rotating the potentiometer. (Rotation of the
potentiometer causes the potentiometers output voltage to change
accordingly.)
With the output voltage between 0 and V, the engine speed stays at
PULL the N to N level.
If the output voltage is increased from V to V (see the graph), the
engine speed decreases from N until it reaches its standard idling
31518
level N.
Engine speed (rpm)
0 V V
Output voltage (V)

02711
13-15
Emergency vehicle operation function (Used in event of control rack position sensor
fault)
Fault in Control rack position sensor 7
In the event of a fault in the control rack position sensor 7, detection of the control rack position is performed using the sub
control rack position sensor 4. This enables more-or-less normal vehicle operation.
Fault in control rack position sensor 7 and sub control rack position sensor 4
Target speed
Target duty ratio Linear DC motor Linear DC motor
Comparison
drive circuit activation (UP)
Actual speed
In the event of faults in both the control rack position sensor 7 and sub control rack position sensor 4, the position of the
rack, which is controlled by the linear DC motor 9, cannot be sensed directly. The fuel injection rate cannot be controlled
normally with the engine in this condition. As an emergency measure, therefore, control operations are performed in
accordance with engine speed data signals only. For this function, target engine speeds for given degrees of accelerator
pedal depression are pre-programmed into the electronic governor control unit 35. Control is effected as follows:
The target engine speed is compared with the actual engine speed (this is indicated by the engine speed sensor 3).
The target duty ratio is determined in accordance with the result of the comparison. In accordance with the target duty
ratio, a drive signal is transmitted to the UP-side (speed increasing side) circuit to effect control over the engine speed.
If the target engine speed exceeds the actual engine speed or vice versa, the UP-side circuits ON time period is altered
such that the target engine speed is maintained.
The target duty ratio is the ratio of the time periods during which the linear DC motors UP-side and DOWN-side (speed
decreasing side) circuits are energized. It is calculated as follows:
UP-side circuit ON time period
Duty ratio = 100%
UP-side circuit ON time period + DOWN-side circuit ON time period
CAUTION
When this function is activated, the warning lamp 14, 15 flashes to indicate that the engine must be inspected
immediately. P13-34
13-16
13
Auxiliary brake control function
Auxiliary brake switch 17

(Exhaust brake switch)
Clutch pedal switch 32

Electronic governor Exhaust brake
Accelerator pedal switch 19 control unit 35 operation
Transmission neutral switch 33
Engine speed sensor 3
The auxiliary brake control function acts upon the auxiliary braking devices, i.e., the exhaust brake, when the following
conditions are satisfied:
Clutch pedal switch 32: OFF (clutch pedal released)
Accelerator pedal switch 19: ON (accelerator pedal released)
Transmission neutral switch 33: ON (transmission not in neutral)
13-17
Electronic Governor Control Unit
BZ16A BZ12A
CM35A CM28A
27 28 29 30 31 32 33 34 43 44 45 46 47 48
35 36 37 38 39 40 41 42 49 50 51 52 53 54
CM30A
BZ26A
CM35A
BZ16A
BZ12A 77 78 79 80 JAE 81 82 83 84
BZ22A 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
100 101 102 103 104 105 106 107 108 109 110 111
BZ26A CM28A
112 113 114 115 JAE 116 117 118
1 2 3 4 5 6 7 8 9 10 11 12 13 119 120 121 122 123 124 125 126 127 128 129 130
14 15 16 17 18 19 20 21 22 23 24 25 26 131 132 133 134 135 136 137 138 139
BZ22A CM30A
140 141 142 143 JAE 144 145 146
55 56 57 58 59 60 61 62 63 64 65 147 148 149 150 151 152 153 154 155 156 157 158 159
66 67 68 69 70 71 72 73 74 75 76 160 161 162 163 164 165 166 167 168 169
24942
Con- Termi- Connected to Con- Termi- Connected to Con- Termi- Connected to

nector nal nector nal nector nal
1 19 Pre-stroke cut relay 37
Linear DC
2 motor 20 (DATA) 38 potentiometer (GND)
DDS-3
BZ Accelerator pedal position
3 21 (STB) 39 sensor II (GND)
16A
4 BZ 22 40
5 (Red) 26A 23 Start signal 41
Warning lamp
6 (Orange) 24 42
Control unit power supply Boost pressure sensor
7 DDS-3 (CLK) 25 43
(starter switch terminal M) (SIG)
8 26 Control unit GND 44 Accelerator (SIG)
control unit (SIG)
pedal position
9 27 45 sensor I (+5V)
BZ 10 Memory clear switch 28 46 Engine speed sensor (SIG)

26A Backup engine speed
11 Diagnosis switch 29 47
sensor (SIG)
Control unit power supply Idling speed adjustment
12 30 48
(starter switch terminal M) potentiometer (SIG) BZ
Control unit GND Accelerator pedal position 12A
13 (analog GND) 31 sensor II (SIG)
49 Boost pressure sensor (GND)
BZ
16A Boost temperature Accelerator pedal position
14 32 sensor (SIG) 50 sensor I (GND)
Linear DC
motor
15 33 Accelerator pedal switch 51 Boost pressure sensor (+5V)
16 34 52 Engine speed sensor (GND)
Idling speed adjustment Backup engine speed

17 35 potentiometer (+5V)
53 sensor (GND)
18 36 54
13-18
13
Con- Termi- Connected to Con- Termi- Connected to Con- Termi- Connected to
nector nal nector nal nector nal
55 94 132 Tachometer (SIG)

56 95 133 output (SIG)

57 (OSC) 96 134
Control rack
58 (MDL) 97 CM 135
position
59 (GND) 98 MUT-II (K-line) 28A 136 (GND)
sensor Tachometer
60 (SHIELD) 99 137 output (GND)
61 100 Control unit GND 138

62 Pre-stroke (OSC) 101 (power GND) 139
63 position sensor (MDL) 102 140 Warming switch
64 Pre-stroke actuator 103 141 Automatic transmission

control unit (SIG)
CM Automatic transmission
6655 Pre-stroke cut relay (+24V) 35A 104 142 control unit (GND)
BZ Accelerator pedal position
22A 66 Control unit GND 105 (OSC) 143 sensor II (+5V)
Sub control Fuel injection rate adjust-
67 106 (MDL) 144
rack position ment resistor (GND)
107 sensor 145
68 (OSC) (GND)
69 Control rack (MDL) 108 (SHIELD) 146
70 position sensor (GND) 109 147
71 (SHIELD) 110 148

72 111 149

73 Pre-stroke (GND) 112 150
74 position sensor (SHIELD) 113 Exhaust brake switch 151
75 Pre-stroke actuator 114 152
Pre-stroke power supply
76 115 153
(GND) CM

77 116 30A 154 Transmission neutral relay
78 117 155

79 118 156
Fuel injection rate adjust-
80 119 157 Clutch pedal switch
ment resistor (SIG)

81 CM 120 158
82 28A 121 159
83 122 160
84 123 161
CM control unit (GND)
35A 85 124 162
Exhaust brake relay Coolant temperature
86 125 163
sensor (SIG)
87 126 164
88 127 165
89 128 166

90 129 167 Idle up prohibit switch
91 130 168
92 131 169
93 control unit
13-19
Electronic governor control unit
Electronic governor
Electronic governor control unit Starter switch
Backup engine
speed sensor
Control rack
position sensor
Linear DC motor
Pre-stroke actuator Warning lamp (red)

Warning lamp (orange)
Pre-stroke
position Memory clear switch
sensor
Drive unit Diagnosis switch
Pre-stroke power
supply Exhaust brake cut-off relay
Engine speed sensor
Sub control rack

position sensor
Pre-stroke cut relay
Coolant temperature
sensor
Warming switch
Accelerator pedal Exhaust brake switch

position sensor
Accelerator pedal
switch Neutral switch Transmission
neutral relay
Boost pressure
sensor
Clutch pedal switch
Idling speed adjust-

ment potentiometer
Fuel injection rate

adjustment resistor Exhaust
brake relay
(For Zexel tester) Exhaust brake 3-way
magnetic valve
MUT-II Gear position switch
Tachometer Automatic transmission

control unit
Boost air temperature

sensor
31530
13-20
13
Engine speed sensor
The engine speed sensor 1 is a pickup type. It converts the rotation
speed of a injection pump into electric signals.
Signals generated by the engine speed sensor are fed to the elec-
tronic governor control unit which uses them as correction values in its
calculation of the target pre-stroke position.
1
13762
Coolant temperature sensor

The coolant temperature sensor 1 is a thermistor type. It converts the
engine coolant temperature into electric signals.
Signals generated by the coolant temperature sensor are fed to the
electronic governor control unit which uses them as correction values
in its calculation of the target rack position.
31835
Sub control rack position sensor

The sub control rack position sensor 1 provides backup detection of
the control rack position in the event of a fault in the control rack
1 position sensor.
The sub control rack position sensor 1 converts the degree of control
rack movement into electric signals.
Signals generated by the sub control rack position sensor are fed to
the electronic governor control unit which uses them as correction
values in its calculation of the target rack position.
13964
Boost pressure sensor

The boost pressure sensor 1 feeds boost pressure information to the
1 electronic governor control unit. During turbocharged engine operation, it
enables the full rack signal (maximum fuel injection rate value) charac-
teristics to be selected by the control unit in accordance with the engine
speed.
A : To intake manifold
A 24948
13-21
Boost air temperature sensor
Boost air temperature sensor 1 is a thermistor type that converts the
intake air temperature, immediately after its passage through the
intercooler, into an electric signal.
This electric signal is transmitted to the pre-stroke control unit as the
boost air temperature signal, which is used as the correction value by
the electronic governor control unit to determine the desired pre-
stroke position value.
1
13764
Accelerator pedal position sensor and accelerator pedal switch

The accelerator pedal position sensor 1 provides the electronic gover-
1 nor control unit with information on the degree to which the accelerator
2 pedal 2 is depressed.
The accelerator pedal switch detects whether the accelerator pedal is
currently depressed or released.
Accelerator switch is integrated in accelerator pedal position sensor 1.
P 31465
13-22
13
P13-12
Idling speed adjustment potentiometer

P13-14
Linear DC motor
P13-28
Control rack position sensor

P13-28
Backup engine speed sensor

P13-29
13-23
Pre-stroke Control Injection Pump Unit
8
11
17
7 12 9
18
13
10
6 14
5
15 16
4
3 A
B
1
D
C P 31531
1 Camshaft 13 Timing sleeve

2 Tappet 14 Timing rod
3 Plunger spring 15 Control rod
4 Plunger 16 Pre-stroke actuator
5 Pump housing 17 Drive unit
6 Pin 18 Pre-stroke position sensor
7 Delivery valve spring
8 Ball A : Sub-control rod position sensor
9 Spring B : Engine speed sensor
10 Delivery valve C : Mechanical timer
11 Delivery valve holder D : Electronic governor
12 Plunger barrel
The injection pump is provided with a mechanism that enables variation of the plunger pre-stroke.
Variation of the plunger pre-stroke enables the creation of air/fuel mixture and spray conditions that are optimally suited
to combustion. The overall benefits are higher engine torque and cleaner exhaust emissions than are possible with a
conventional injection pump.
13-24
13
Pre-stroke
The term pre-stroke refers to the stroke dimension E of a plunger 4
from the plungers bottom dead center position to the point at which its
13
fuel inlet hole G is closed by the timing sleeve 13 and fuel feed begins.
E This stroke dimension is constant in a conventional injection pump.
G
4
13087
Variable pre-stroke mechanism

12
14 F : Lead
17 G : Inlet hole
13 H : Outlet hole
In contrast to the fixed plunger barrel arrangement of a conventional

6 injection pump, each plunger barrel 12 in the pre-stroke control type
H
F injection pump incorporates a vertically moveable timing sleeve 13.
4
Movement of the timing sleeve is effected by the timing rod 14, pin 6,
G 13088 and drive unit 17.
When the drive unit 17 rotates the timing rod 14, the pin 6 moves the
timing sleeve 13 up or down accordingly.
Since the timing sleeve 13 incorporates a fuel outlet hole H, the pre-
stroke changes in accordance with the movement of the timing sleeve.
Fuel feed action

M
J : Fuel intake
K : Start of pressurization
4 L : End of pressure feed
H
As the plunger 4 moves downward from its top dead center position
F 14 and its inlet hole G opens, fuel flows into the pressure chamber M
N owing to the vacuum pressure created by the plungers downward
J K L movement and the fuel pressure produced by the feed pump.
G
13089 When the plunger 4 moves upward but its lift dimension is still small,
the fuel in the pressure chamber M escapes into the sump N through
the inlet hole G in the plunger. Thus, the pressure in the pressure
chamber does not increase.
As the plunger 4 moves further upward and the inlet hole G is closed
by the timing sleeve 13, the fuel starts to be pressurized. The pressure
increases as the plunger moves upward, and the injection pump starts
to feed the pressurized fuel to each injector.
When the lead F in the plunger 4 becomes aligned with the outlet hole
H in the timing sleeve 13, the fuel in the pressure chamber M returns
to the sump N, thus completing the pressure feed cycle.
Adjustment of the injected fuel volume is achieved by rotation of the
plunger 4, which alters the position of the outlet hole H in the timing
sleeve 13 relative to the lead F in the plunger.
13-25
Fuel injection timing and fuel injection characteristics
Changes in the position of the timing sleeve 13 cause concomitant
Injection timing
advance angle Cam lift
changes in the pre-stroke, which in turn alter the fuel injection timing.
Cam speed
A decrease in the pre-stroke causes the fuel inlet hole G in the plunger
4 to close earlier such that the fuel injection timing is advanced.
Effective stroke
of plunger at
This arrangement provides highly responsive control over the injection
Cam
speed low speeds timing and thus enhances the engines cold startability.
Pre-stroke at
low speeds
Cam lift
Cam angle
Pre-stroke at
Effective stroke of high speeds
plunger at high speeds
13090
Delivery valve
R P : Start of pressure feed
S
Q : End of pressure feed
7 8
The delivery valve 10 keeps constant the residual pressure R in the
9 injection pipe at all engine speeds. This operation prevents the gen-
eration of bubbles in the fuel (this is known as cavitation) and thus
10 enables fuel injection at a high pressure.
When the plunger 4 moves upward and the pressure of the fuel
pushed by the plunger overcomes the residual pressure R in the
4 injection pipe and the preset force of the delivery valve spring 7, the
P Q delivery valve is pushed upward and delivery of the pressurized fuel
01829 begins.
As soon as fuel delivery is complete, the fuel in the injection pipe
rapidly returns to the plunger side and the delivery valve closes.
Surplus fuel slowly returns through the orifice S, thus reducing the
pressure in the injection pipe.
When the preset force of the spring 9 in the delivery valve 10 is exactly
offset by the pressure in the injection pipe, the ball 8 closes the orifice
S, thus ensuring that the residual pressure R in the injection pipe
remains constant.
13-26
13
MEMO
13-27
Electronic Governor
1 2
8
6
5 4
P 31532
1 Housing 5 Linear DC motor

2 Control rack position sensor 6 Link
3 Cover 7 Emergency engine stop lever
4 Coil assembly 8 Sensing gear
Linear DC motor
A 2 The linear DC motor 5 moves the coil assembly 4 vertically in
accordance with signals from the electronic governor control
unit. Via the link 6, this movement is transmitted to the control
rack A, which moves longitudinally to increase and decrease
the fuel quantity.
7 Control rack position sensor

The control rack position sensor 2 senses whether the con-
4 trol rack A is moved to the correct position by the linear DC
motor 5. In the event of a discrepancy between the actual
control rack position and the target control rack position (this
6 is determined by the electronic governor control unit), the
5 control unit instructs the linear DC motor to perform a correc-
tive movement.
P 31533
13-28
13
Emergency engine stop lever
The emergency engine stop lever 7 is connected to the link 6. Via a
cable, it enables the link to be moved from the drivers seat. In the event
of a system fault that prevents the engine from being stopped normally,
operation of the emergency engine stop lever forces the control rack A to
move to the position at which fuel injection is terminated. This operation
takes place irrespective of the position of the linear DC motor 5.
Backup engine speed sensor

The backup engine speed sensor B is fitted inside the governor. It
converts the rotation speed of the sensing gear 8 into electric signals and
feeds the signals to the electronic governor control unit to provide an
indication of the engine speed.
B
8
15722
13-29
Feed Pump
1 Eye bolt on fuel outlet side
1 2 Check valve
3 Check valve
13 4 Push rod
5 Piston
6 Piston spring
2 7 Eye bolt on fuel inlet side
12 10 3
11 8 Gauze filter
9 Feed pump housing
4 10 Check valve
5
6 11 Check valve
9
12 Check valve spring
13 Priming pump
8
7
13768
The feed pump is a double-action type pump which, with four check valves operating, sucks and discharges fuel
during both strokes of pistons 5.
Push rod 4 makes contact with the injection pump camshaft directly, moving piston 5.
Priming pump 13 can be manually operated, when the injection pump is not operating, to suck up fuel and thus can be
used for air bleeding.
Gauze filter 8 eliminates large foreign particles from the fuel sucked up from the fuel tank to prevent clogging of the
feed pump. This gauze filter must be cleaned with diesel fuel periodically.
F D The rotation of injection pump camshaft A, pushes up push rod 4 and

3 B piston 5, and the pressure in inner chamber B increases. This closes
check valve 3, and check valve 10 opens to let the fuel in inner chamber
B flow through outer chamber C to fuel filter D.
10 When the pressure in inner chamber E decreases, check valve 11
G C
E closes, and check valve 2 opens to let fuel flow from fuel tank F through
2 11 outer chamber G to inner chamber E.
4 5
A 13098
13-30
13
When injection pump camshaft A rotates further, it pushes down push
F D
B rod 4 and piston 5, and the pressure in inner chamber E increases. This
3 10
closes check valve 2, and check valve 11 opens to let the fuel in inner
chamber E flow through outer chamber C to fuel filter D.
When the pressure in inner chamber B decreases, check valve 10
G C
closes, and check valve 3 opens to let fuel from fuel tank F flow through
25 11 outer chamber G to inner chamber B.
E
4
A
13099
Injection Nozzle
A 1 Washer
B 2 Spring
3 Nozzle tip
4 Needle valve
A : From injection pump

B : To fuel tank
As the pressure of the fuel delivered from the injection pump over-
1
comes the repercussive force of spring 2, needle valve 4 is pushed up
2 to allow the fuel to spray out the opening at the tip of the nozzle .
3 Injection pressure can be adjusted by increasing or decreasing the

4 number of washers 1.
06904
13-31
TROUBLESHOOTING
Symptoms
Engine does not reach maximum speed

Engine maximum speed too high
Engine stops soon after starting
Warning lamp illuminates

Accelerator pedal too stiff
Insufficient engine output
Unstable engine output
Engine difficult to start
Unstable engine idling
Defective fuel supply

Remarks
Engine will not start
Engine will not stop

Engine knocks
Possible causes
Defective pre-stroke injection pump system
Injection pump
Defective injection pump proper *
proper
Defective mounting (poorly adjusted

injection timing)
Defective overflow valve operation
Defective pre-stroke actuator
Fuel feed pump Gauze filter clogged
Check valve not operating
Sticky piston
Sticky push rod
Defective check valve operation
Piston worn
Defective governor *
Injection nozzles Sticky needle valve
Valve opening pressure too low
Blocked injection orifice
Poor airtightness in nozzle
Valve opening pressure too high
Broken spring
Defective sliding action in needle valve
Defective valve opening pressure
Weakness/deterioration in spring
Fuel filter Clogged filter
Fuel tank empty
Fuel pipes blocked and/or fuel leaking from connections
Air or water in fuel system
Low-quality fuel in use
* : Must be serviced by ZEXEL service station.
13-32
13
Symptoms
Engine does not reach maximum speed

Engine maximum speed too high
Engine stops soon after starting
Warning lamp illuminates

Accelerator pedal too stiff
Unstable engine output
Engine difficult to start
Unstable engine idling
Defective fuel supply

Engine will not start
Remarks
Engine will not stop

Engine knocks
Possible causes
Engine control Incorrect accelerator pedal stopper

bolt adjustment
Rusted accelerator pedal arm
Defective accelerator pedal position

sensor
Cracked fuel pipe
Leaky fuel tank
Incorrect oil viscosity ^ Gr 12
Incorrect valve clearance ^ Gr 11
Defective cylinder head gasket ^ Gr 11
Wear and/or carbon deposits on valve and valve seat ^ Gr 11
Weakness/deterioration in valve spring ^ Gr 11
Worn/damaged piston ring(s) ^ Gr 11
Worn/damaged piston ring groove(s) ^ Gr 11
Worn piston and cylinder liner ^ Gr 11
Defective starter switch ^ Gr 54
13-33
TROUBLESHOOTING
Fault Diagnosis Function
While the starter switch is in the ON position, the fault diagnosis function continuously monitors relevant sensors for
faults.
In the event that a fault is detected, the function illuminates a warning lamp (red or orange) in the meter cluster to
alert the driver, memorizes the location of the fault, and switches to a backup mode.
The memorized fault location can be read as a diagnosis code using an MUT-II or the diagnosis switch.
Warning lamp illumination

(Orange) (Red)
1. Safety-critical error
OFF ON
(vehicle must not be driven)
2. Non-safety-critical error (vehicle
can be driven despite poor control ON OFF
feeling)
CAUTIONS
The fault diagnosis function requires a battery voltage of 12 V or higher.
In the event of fault detection, check the harnesses and connectors for looseness. Before undoing any
connector, turn the starter switch to the LOCK position and wait for 20 seconds.
After rectifying a fault, delete the fault code using the MUT-II or memory clear switch.
As a general rule, inspections should be performed with the starter switch in the LOCK position. If any
inspection requires that the starter switch be in the ON position, be careful to avoid short circuits between
connector terminals and with the vehicle body.
All component resistances shown in this manual assume a temperature range of 10 to 35C {50 to 95F}. ln
practice, component values may not comply with standard values owing to temperature effects and/or to
inaccuracy in the test instrument.
After the rectification of a fault, the systems ability to return to normal operation automatically depends upon
the diagnosis code, i.e., the fault location. When the system returns to normal operation, the warning lamp
goes out.
When the system returns to normal operation after the rectification of a fault, the diagnosis code remains
stored in electronic governor control unit.
13-34
13
Inspection Procedure
Inspection of the electronic governor and pre-stroke control injection pump system can be performed most effectively
using an MUT-II. Types of system inspection can, in accordance with fault systems and diagnosis codes, be broadly
classified as follows:
Inspections based on diagnosis codes stored in the control unit
Inspections based on symptoms
Inspections of intermittent faults
Start
Read diagnosis code.

Without MUT-II: P13-36
With MUT-II: P13-40
Error code output Normal code output
Perform test drive.

Normal code output No
after deletion abnormality Fault occurs
Perform inspection Perform intermittent- Perform inspection

based on diagnosis fault inspection. based on symptom.
code. P13-44 ^ Gr 00
Perform test drive.
If diagnosis code is issued during test drive, perform inspection based on diagnosis code.
If diagnosis code stored in control unit is not issued during test drive, perform intermittent-fault
inspection in addition to inspection based on diagnosis code.
Delete diagnosis code

Without MUT-II: P13-36
With MUT-II: P13-40
13-35
READING AND ERASING DIAGNOSIS CODES
Without MUT-II
Current diagnosis code
Turn ON the starter switch.
1
Disconnect the diagnosis switch 1.
13883
The diagnosis code is indicated by flashing of warning lamp 2

(red) or warning lamp 3 (orange).
2 3
31534
Diagnosis code indication

Tens Ones Diagnosis codes are indicated by the numbers and
durations of the warning lamp flashes.
ON
Flashes for units of ten and units of one have different
lengths, as follows:
Units of ten: 1.2 seconds
OFF Units of one: 0.4 second
For each diagnosis code, units of ten are given first, fol-
1.2 1.2 lowed by units of one. For a code that has no units of ten,
0.4
only units of one are given.
0.4 Each diagnosis code is indicated three times. If there are no
Diagnosis new codes, the sequence is then repeated from the begin-
switch
0.4
disconnected
ning with each code indicated three times.
When the diagnosis switch 1 is connected, the control unit
Initial indication immediately stops the indication of codes.
(example diagnosis code: 12)
ON Second
OFF indication
2.4 2.4 2.4 2.8

13705
13-36
13
Past diagnosis codes
With the diagnosis switch 1 disconnected, disconnect the memory clear
1 4
switch 4 after reading the current diagnosis code(s). The warning
lamp will begin to flash again, this time to indicate any past diagnosis
code(s). Verify the fault location in accordance with the code(s).
13884
Diagnosis code eraser

1 sec. or To eraser all stored diagnosis codes from the control unit, disconnect
longer 3 sec.
and reconnect the memory clear switch 4.
CAUTION
Connect
Stored codes are cleared only by disconnection and reconnec-
tion of the memory clear switch 4.
To prevent the memory contents from being cleared after the
Memory cleared
indication of stored codes, turn OFF the starter switch with the
Disconnect memory clear switch 3 disconnected then connect the memory
02739 clear switch.
13-37
Diagnosis Codes Table
Diagnosis Warning Electronic control unit countermeasure(s) in the case of
Fault location Drive ability
code lamp failure (back-up mode)
01 Normal
Pre-stroke actuator
03 Orange Provides control with 0 as correction value.
learning function
Sub-control rack position
06 Orange Normal control using the main control rack position sensor
sensor
11 Governor servo Red *1 Engine stopped by the pull-down function.
Pre-stroke control stop engine revolution speed limit (approx-
12 Pre-stroke servo Orange
imately 1800 rpm)
Pre-stroke control stop engine revolution speed limit (approx-
13 Pre-stroke sensor Orange
imately 1800 rpm)
Back-up engine speed Orange Control using the main engine speed sensor
14
sensor
Calculate the engine revolution speed from the pulse count of
15 Engine speed sensor Orange
the back-up engine speed sensor.
Both the back-up engine
sensor and the main
14+15 Red Do not start the engine.
engine speed sensors
are faulty upon start-up.
Accelerator pedal position
16 Orange Control using the accelerator pedal sensor I
sensor II
21 Water temperature sensor Orange Set the water temperature to 80 C {176F}.
Control rack position
22 Orange Switch to the sub-control rack position sensor control.
sensor
Accelerator pedal position
24 Orange Control using the accelerator pedal position sensor II.
sensor I
Both accelerator pedal
position sensor I and Set the maximum accelerator depression angle to 30 degrees
24+16
accelerator pedal position
Red
even if the accelerator pedal is depressed.

sensor II are faulty
31 Idling adjustment volume Orange Set to auto idling.
32 Boost pressure sensor Orange Set the boost pressure to 0 kpa {0 mmHg, 0 in. Hg}. *2
RAM (ECU internal
33 Red Do not start the engine.
memory circuit)
Boost temperature sensor
Orange Normal control assuming the boost temperature is
41
80 C {176 F}.
Reverse engine
45 Orange *1 Engine stopped by the pull-down function. *2
operation
65 Accelerator switch Orange Limited accelerator depressing angle (Approximately 30%)
*1 : Thepull-down function indicates the rack pull-back action. In the event : Driveable
of an engine over-run or severe accident, the rack is pulled back : Back-up mode driving possible
immediately to the no-injection direction in order to protect the engine. : Undriveable
*2 : Driveable if the starter switch is turned OFF once and then restarted
again.
13-38
13
MEMO
13-39
With MUT-II
0 Special tools
MUT-II PLUS MB991496-A
19492
MUT Inspection of electronic governor and

Communication MK327601 pre-stroke control injection pump system
19141
ROM Pack MK327927

(MRT-E4)
19493
Connecting the MUT-II

B Turn the starter switch to the LOCK position.
Connect the 2 MUT Communication Harness to the 1 MUT-II, and
insert the 3 ROM Pack.
Plug connector A into the cigarette lighter socket.
Fit connector C onto MUT connector B (16 pin) in the relay box.
A
C NOTE
2 3
Instructions for operation of the MUT-II are given in the separate
1
31469
MUT-II Reference Manual.
13-40
13
<Inside cab>
To verify the service data START SIG, connect the MUT-II as fol-
B
lows:
Turn the starter switch to the LOCK position.
4 insert the 3 ROM Pack.
Attach the (+) clamp D (red) of the 4 Battery Clamp Harness to the
batterys (+) terminal E. Attach the () clamp F (black) of the 4
H C Battery Clamp Harness to the batterys () terminal G.
2 3
A Fit the connector A into the socket H of the 4 Battery Clamp
1 31471
Harness.
<Outside cab>
G E F 4 CAUTION
D Connect the (+) clamp D (red) of the 2 Battery Clamp Harness
before connecting the () clamp F (black).
P 31470
Current diagnosis codes

Turn the starter switch to the ON position.
Determine the fault location(s) in accordance with the past MUT-II
diagnosis code(s).

diagnosis code(s).
Diagnosis code erasure

Using the MUT-II, erase all diagnosis codes stored in the control unit.
Diagnosis codes
Diagnosis codes are indicated as shown in the following table. For details of these codes, refer to the Without MUT-II
section. P13-36
Display item
Diagnosis code Fault Diagnosis code Fault
03 PS OFFSET 22 RACK SNSR
06 SUB RACK SNSR 24 ACCEL. SNSR-1
11 GOV. SERVO 31 IDLE VOLUME
12 PS SERVO 32 BST PRES SNSR
13 PS SNSR 33 RAM
14 SUB NE SNSR 41 BST TEMP SNSR
15 NE SNSR 45 ENG. REVERSE
16 ACCEL. SNSR-2 65 ACCEL SW
21 WTR TEMP SNSR
13-41
SERVICE PROCEDURES USING MUT-II
Service operations can be performed most effectively using the following MUT-II functions:
Reading of diagnosis codes
Using the diagnosis code function, it is possible to read diagnosis codes stored in the control unit.
Erasure of diagnosis codes

By selecting the diagnosis code erasure function from the special function menu, it is possible to erase diagnosis codes
stored in the control unit.
Indication of service data

When required for service operations, data in the control units random-access memory can be displayed as numeric
values or graphs.
Service data
MUT-II display Inspection procedure

No. Data signal Type of data Inspection condition Evaluation criterion
11 ENGINE SPEED . rpm Gradual acceleration (during engine Synchronization with tachometer
operation)
12 TARGET RACK . mm Starter switch ON 3 mm
13 REAL RACK . mm Starter switch ON 3 mm
Accelerator pedal gradually depressed
14 ACCEL. VOLT . V from throttle-fully-open to throttle-fully- 1 to 3 V
closed position
Engine cold Same as ambient temperature
15 WATER TEMP . F Engine warming up Gradual increase
Engine stopped after warmup Gradual decrease
16 BOOST PRESS . mmHg Engine running at high idling speed 270 mmHg or higher
400 < Ne 2,000 5.5 or greater
VII
17 PS ANG. DIFF. . deg

Ne: Engine speed 5.5 or smaller
18 SUPPLY VOLT . V Starter switch ON 7 to 16 Volts
Throttle completely closed 0%
19 ACCEL. STROKE . % Pedal gradually depressed Gradual increase
Throttle completely open 100 %
Engine cold Same as ambient temperature
20 BOOST TEMP . F Engine warming up Gradual increase
Engine stopped after warmup Gradual decrease
21 START SIG ON/OFF Engine cranked using starter switch ON
33 ACCEL. SW ON/OFF Accelerator pedal depressed OFF
34 DIAGNOSIS SW ON/OFF Diagnosis switch turned ON/OFF ON/OFF
35 DIAG. RESET SW ON/OFF Memory clear switch turned ON/OFF ON/OFF
37 CLUTCH SW ON/OFF Clutch pedal depressed ON
38 NEUTRAL SW ON/OFF Transmission in neutral OFF
42 EXH. BRAKE SW ON/OFF Switch ON ON
51 A/C SW ON/OFF Air conditioner switch turned ON or OFF ON/OFF
61 EXH. BRAKE SIG ON/OFF Exhaust brake operating ON
75 IDLE UP CNCL ON/OFF Idle up prohibited (other than N range) ON
13-42
13
MEMO
13-43
INSPECTION BASED ON DIAGNOSIS CODE
Diagnosis code
Diagnosis
display Cause Remedy
code
condition (s)
03 Indicates that pre-stroke Faulty timing rod, timing sleeve or other Repair or replace the injection pump
learning function has not parts in the injection pump assembly. assembly. *
been excuted.
Faulty adjusment or pre-stroke position Repair or replace the injection pump
sensor assembly. *
Faulty electronic governor control unit Replace the electronic governor control unit
06 Displayed if the output Open or short in harness wire or poor Inspect the harness and the connector
voltage of the control rack connector contact between the P13-82
position sensor is less sub-control rack position sensor and the
than 0.06 V or more than electronic governor control unit
3.5 V. Open, short, or poor connector contact in Inspect the sub-control rack position sensor
the sub-control rack position sensor P13-74
11 Displayed if the difference Open or short in harness wire or poor Inspect the harness and the connector
between the target control connector contact between the linear DC P13-82
rackposition and the actual motor and the electronic governor control
control rack position is unit
1mm {0.039 in.}. Open or shorted wire in the linear DC Inspect the linear DC motor P13-77
motor connector
Poor adjustment of the emergency Inspect the emergency engine stop button
engine stop cable (The lever is pulled in P13-79
the stop direction)
Faulty injection pump assembly rack Repair or replace the injection pump
movement or poor governor actuator link assembly. *
12 Displayed if the difference Open or short in harness wire or poor Inspect the harness and the connector
between the target timing connector contact between the pre-stroke P13-82
rod angle and the actual actuator, pre-stroke cut relay, and
timing rod angle is 2. electronic governor control unit
Open or shorted wire in the pre-stroke cut Inspect the pre-stroke cut relay P13-73
relay
Faulty pre-stroke actuator Repair or replace the injection pump
assembly. *
Faulty timing rod, timing sleeve, etc. in Repair or replace the injection pump
the injection pump assembly assembly. *
*: Contact your MFTA representative for current injection pump repair and replacement procedures.
13-44
13
Diagnosis code
Diagnosis
code
condition (s)
voltage of the pre-stroke connector contact between the pre-stroke P13-82
position sensor is less position sensor and the electronic
than 0.9 V or more than governor control unit
3.4 V. Open or shorted pre-stroke position Inspect the pre-stroke actuator P13-75
sensor coil
14 Displayed if the pulse Open or short in harness wire or poor Inspect the harness and the connector
count of the back-up connector contact between the back-up P13-82
engine speed sensor is engine speed sensor and the electronic
less than that of the main governor control unit
engine speed sensor. Faulty back-up engine speed sensor Repair or replace the injection pump
assembly. *
15 Displayed if the pulse Open or short in harness wire or poor Inspect the harness and the connector
count of the main engine connector contact between the speed P13-82
speed sensor is less than sensor and the electronic governor
that of the back-up engine control unit
speed sensor. Open or shorted wire or improperly Inspect the engine speed sensor main unit
assembled coil in the engine speed P13-78
sensor main unit
16 Displayed if the output Open or short in harness wire or poor Inspect the accelerator position sensor
voltage of the accelerator connector contact between the using MUT-II P13-42
pedal position sensor is accelerator pedal position sensor II and Inspect the harness and the connector
less than 0.5 V or more the electronic governor control unit P13-82
than 4.5 V. Internal malfunction or faulty adjustment Inspect the accelerator pedal position
of the lever portion of the accelerator sensor P13-54
pedal position sensor II Inspect the accelerator pedal position
sensor using MUT-II P13-42
21 Open or short in harness wire or poor Inspect the harness and the connector
connector contact between the coolant P13-82
temperature sensor and the electronic
governor control unit
Faulty coolant temperature sensor Inspect the coolant temperature sensor
P13-74
Inspect the coolant temperature sensor
using MUT-II P13-42
13-45
INSPECTION BASED ON DIAGNOSIS CODES
Diagnosis code
Diagnosis
code
condition (s)
voltage of the control rack connector contact between the control P13-82
position sensor I is less rack position sensor and the electronic
4.5 V. Open or shorted wire in the coil or poor Inspect the control rack position sensor
control rack position sensor contact P13-76
Inspect the control rack position sensor
using MUT-II P13-42
Faulty movement of the injection pump Repair or replace the injection pump
assembly control hook or poor governor assembly. *
actuator link.
24 Displayed if the output Open or short in harness wire or poor Inspect the accelerator position
voltage of the accelerator connector contact between the sensor using MUT-II P13-42
pedal position sensor I is accelerator pedal position sensor and Inspect the harness and the connector
less than 0.5 V or more the electronic governor control unit P13-82
than 4.5 V. Internal malfunction or poor adjustment Inspect the accelerator position sensor I
of the accelerator pedal position sensor I P13-54
lever
31 Displayed if the output Stuck idling speed adjustment potentio- Reset the knob to PUSH or PULL
voltage of the idling meter knob (between PUSH and PULL)
adjustment volume is less Open or short in harness wire or poor Inspect the harness and the connector
than 0.6 V or mor than connector contact between the idling P13-82
4.6 V. speed adjustment potentiometer and the
electronic governor control unit
Open wire in the switch portion of the Inspect the idling speed adjustment
idling speed adjustment potentiometer potentiometer P13-73
or faulty internal movement
voltage of the boost connector contact between the boost P13-82
pressure sensor is less pressure sensor and the electronic
4.8 V. Internal malfunction of boost pressure Inspect the boost pressure sensor using
sensor MUT-II P13-42
Inspect the boost pressure sensor
P13-75
Clogged boost hose or faulty assembly Inspect the boost hose
13-46
13
Diagnosis code
Diagnosis
code
condition (s)
33 Displayed if the electronic Faulty electronic governor control main In order to reset the electronic governor
governor control unit is unit control unit, temporarily turn the starter
faulty. switch OFF and erase the diagnostic
codes by pressing the memory clear
switch P13-37
Replace the electronic governor control unit
if the diagnostic codes persist after
performing the above procedure
41 Displayed if the output Open or short in harness wire and poor Inspect the harness and the connector
voltage of the boost connector contact between the boost P13-82
temperature sensor is temperature sensor and the electronic
more than 4.9 V. governor control unit
Open or shorted wire or poor assembly Inspect the boost temperature sensor
of the boost temperature sensor coil P13-79
Inspect the boost temperature sensor
using MUT-II P13-49
45 Faulty phase of engine speed sensor Inspect the engine speed sensor
and backup engine speed sensor P13-78
Repair or replace the injection pump
assembly. *
65 Faulty accelerator switch Open or short in harness wire or poor Inspect the harness and the connector
connector contact between the accelera- P13-82
tor switch and theelectronic governor
control unit
Open or shorted wire in the accelerator Inspect the accelerator switch
switch (Accelerator switch is built in the accelerator
pedal position switch.) P13-54
13-47
Checking and Adjusting Injection Timing
Service standards
Fuel injection timing (BTDC) 3 0.5 Adjust
Tightening torque Unit : Nm {Ibfft, kgfm}

6 Union nut 29 to 49 {22 to 36, 3 to 5}
7 Delivery valve holder 100 to 110 {76 to 83, 10.5 to 11.5}

36 {1.42}
05999
15, 16 Universal extension MH061099 Inspection and adjustment of fuel injection

timing
14 {0.55}
05163
[Inspection]
NOTE
Set the starter switch to LOCK or ACC before starting opera-
tion.
Pull governor stop level 1 toward STOP direction.

1
3 Remove cable end 3 of engine stop cable 2.
2
P 31536
Remove union nut 4 of the injection pipe, delivery valve holder 5,

stopper 6, delivery valve spring 7 and delivery valve 8 from the
4 injection pump of No.1 cylinder.
After removing these parts, install delivery valve holder 5.
5
CAUTION
6 Be sure to keep all the removed parts in diesel fuel to keep them
7 free from dirt.
8
P 31537
13-48
13
Mount extra injection pipe 9 on No.1 cylinder. Direct the free end the
9 pipe downwards so that the fuel discharge can be clealy of served.
A : Oil tray
A
P 31538
Turn the crankshaft more than 180 in the direction of engine rotation
and bring No.1 cylinder to approximately 30 before top dead center
the compression cycle.
NOTE
Refer to the location where there are 30 gradations, since angle
gradations on the crankshaft pulley side only extend to 20.
0
13772
Turn the engine in the direction of engine rotation slowly while dis-
charging fuel from injection pipe 9, deliver fuel using priming pump 10
A : Oil tray
When the discharge of fuel from injection pipe 9 becomes intermittent,
10 turn the crankshaft slower, stop turning the crankshaft when the
discharge stops completely.
9
P 31539
12 Make sure that indent 11 on the crankshaft pulley and pointer 12 on

the timing gear case show the standard fuel injection timing.
11
11 0
12 06911
13-49
Adjust fuel injection timing as follows if it does not conform to the
standard value.
[Adjustment]
Loosen injection pump mounting nuts 13, 14.
13 : 4 points (on flange)
14 : 1 point
13
0
14 P 31540
When fuel injection timing is retarded, tilt injection pump 15 torward

crankcase side B.
B
C When fuel injection timing is advanced, tilt injection pump 15 towards
C.
15
13775
Adjustment of one graduation on indented scale 16 of the timer case

17 16
flange adjusts fuel injection timing by 6.
17 : Pointer
Tighten nuts 13, 14 at specified torque, and remeasure fuel injection
timing
13 14
P 31541
After making sure that the fuel injection timing conforms to the stand-
ard value, install delivery value 8, delivery value spring 7 and stopper
4 6, then tighten delivery value holder 5, and union nut 4.
Tighten each part at specified torque.
5
6
7
8
P 31537
With stop level 1 pulled toward the STOP direction, insert cable end 3
through the stop lever slot.
Adjust engine stop cable 2 after installing it. P13-55
1
3
2
P 31536
13-50
13
Bleeding Air from Fuel System
Loosen the fuel filter air plug 1.
1
P 31542
Turn the priming pump knob 2 counterclockwise until it pops up.

2 Move the priming pump knob 2 up and down to feed fuel through the
fuel filter.
When fuel emerging from the fuel filter air plug 1 no longer contains
air bubbles, tighten the air plug securely.
P 31543
Move the priming pump knob 2 up and down five or six more times.
2
Then, press the knob down and screw it clockwise to lock it in position.
WARNING
catch fire.
of heat.
P 31544
Cleaning Gauze Filter

Remove the eyebolt 1 from the suction port side A of the fuel feed
2 pump.
1 Remove the gauze filter 2 from the eyebolt 1.
A Clean the gauze filter 2 in diesel fuel.
Refit the gauze filter 2 and eyebolt 1 in the opposite order to that in
which they were removed.
Bleed all air out of the fuel system. P13-51
Start the engine and check that no fuel leakage occurs.
WARNING
P 31545 To minimize the risk of fire, wipe up any spilled fuel.
of heat.
After refitting the gauze filter, check that no fuel leakage occurs.
13-51
Replacing Fuel Filter
- Lubricant
1 Gasket between fuel filter and fuel filter head Engine oil As required
0 Special tool Unit : mm {in.}

94.2 {3.71}
1 Filter wrench MH061572 Fuel filter removal
01882
[Removal]
0 : Filter Wrench
WARNING
0 Fuel is highly flammable. Keep it away from flames and sources
of heat.
06872
[Installation]
WARNING
Use of an unsuitable fuel filter 1 can lead to fuel leaks and fires.
Be sure to use a genuine filter.
To fit the fuel filter 1, turn it until the gasket B touches surface A of the
5 fuel filter head 2. Then, tighten the filter by 1 to 1 1 turn. Be sure to
8
turn the filter by hand.
B A B
A Bleed all air out of the fuel system. P13-51
WARNING
After fitting the fuel filter 1, start the engine and check that no
fuel leakage occurs. Any leaking fuel could cause a fire.
3
06874
13-52
ENGINE CONTROL 13
P 31546
Removal sequence
1 Accelerator pedal assembly P13-56 3 Emergency engine stop cable
2 Accelerator pedal position sensor assembly
* : Injection pump assembly
Service standards
Output voltage of
14
accelerator pedal Sensor II: Idle position
0.85 0.1 V Adjust or replace
position sensor
4 5
Sensor I: Full-load
position
4 4.15 0.1 V Adjust or replace
P 31477
Output voltage of accelerator Electrical conduc-
2 3
switch tion between ter-
minals and 1.00 0.24 V Adjust or replace
of accelerator
switch
P 31477
13-53
ENGINE CONTROL
2 2 Inspection of accelerator pedal position sensor assembly
Disconnect connector A of accelerator pedal position sensor 2 from
harness B on the cab side. Prepare inspection harness C, and
connect it between the above two connectors. Note: This harness is
A
not necessary with MUT-II PLUS tester.
Set the starter switch to the ON position.
Measure the output voltages of accelerator pedal position sensor 4
and the accelerator switch according to the table below. Adjust, if
necessary.
C Connector terminal
B Accelerator position sensor
inspection harness
22 3
Item
3
44 Sensor II Sensor I
Accelerator
switch
1 1 55 1 4 4 5 2 3
Output voltage *a + +

(Idle position)
C
Output voltage *b + +
(Full-load position)
P 31478
Output voltage *c
(Accelerator switch +
activating point)
Accelerator *a : Measure voltage with accelerator pedal at idle position.

switch ON *b : Measure voltage with the accelerator pedal at full-load
OFF position.
Accelerator *c : Press accelerator pedal gradually from idle position. Measure
pedal 4.15 0.1
voltage when electrical conduction stops between connector
position
sensor 1.0 0.24 terminals 2 and 3 of accelerator pedal position sensor 2.
output D : Idle position
voltage (V) 0.85 0.1
0 E : Full-load position
D 80 E
P 31479
If measured value *a and *b deviate from the standard values,

adjust the following adjusting bolts.
2
G
F Adjustment item Adjusting bolt
E
*a Idle position output voltage Screw F
F *b Full-load position output voltage Full-load stopper bolt G
If the measured output voltage at accelerator switch activating

point *c deviates from the standard value, replace accelerator
pedal position sensor 2.
D
P 31480
13-54
13
A
5 Installation of emergency engine stop cable
Mount stop button A on emergency engine stop cable 5 and press
the button firmly in position.
P 31481
With stop lever B of the governor contacting stopper bolt C, adjust

5 E F
nut E so that inner cable D of emergency stop cable 5 is taut. Then,
D tighten nut F to secure it in place.
After installation, start the engine. Pull the stop button to make sure
that the engine stops operating.
C
B
P 31547
13-55
ENGINE CONTROL
Accelerator Pedal Assembly
2 Clevis pin
3 Accelerator pedal
4 Stopper bolt
5 Accelerator pedal bracket
*
* : Accelerator pedal position sensor assembly P13-57
Assembly sequence
3- Follow the disassembly sequence in reverse.
5
31891
- Lubricant
3 Slide-contacting surfaces of accelerator pedal and bracket Chassis grease [NLGI No.1 (Ca soap)] As required
A
1
Service procedure
Removal of accelerator pedal assembly
Pinch hook B of stopper A of accelerator pedal 3 using pliers C and
rotating approximately 45 pull out the stopper towards the front of the
B vehicle.
3
45
CAUTION
Take care not to damage stopper A itself during removal, do not
C pull it out too forcibly.
05900
13-56
13
Accelerator Position Sensor Assembly
Removal sequence
1 Return spring
6
3 Bushing
4 Bushing
5 Accelerator control extension
6 Accelerator pedal position sensor
7 7 Bracket
5
4- Installation sequence
2
-4
1
1
-3
3-
P 31483
- Lubricant
Location Points of application Specified Lubricant Quantity
13-57
FUEL TANK
8
1 9
2
10
3
5
7 4
13737
Work before removal

WARNING
Keep drop lights away because of the risk of explosion.
NOTE
Removal sequence
1 Suction hose 6 Bolt 10 Fuel tank
2 Return hose 7 Fuel tank bracket * : Chassis harness ^ Gr 54
3 Drain plug 8 Screw
4 Nut 9 Fuel gauge sending unit ^ Gr 54
5 Fuel tank band
Tightening torque Unit : Nm {Ibf.ft, kgfm}

8 Screw (Fuel gauge sending unit mounting) 1.0 to 1.5 {0.7 to 1.1, 0.1 to 0.15}
13-58
FUEL FILTER 13
4 1 Eye bolt
1
2 Fuel feed pipe
1 3 Fuel filter
4 Air vent plug
5 Fuel filter head
2 Assembly sequence
5
13879

1 Eye bolt 25 to 34 {18 to 25, 2.5 to 3.5}
- Lubricant

90.2 {3.55}
01882
13-59
WATER SEPARATOR
1 Fuel hose
3 2 Water separator assembly
3 Air vent plug
11 4 Drain plug
5 O-ring
10 6 Ring nut
7 Case
8 Screen assembly
8 9 Water level ring
10 O-ring
11 Head
9
2
6 Assembly sequence
5 1
1
4 Operations after assembly
27170
Bleed all air out of the fuel system. P13-51
WARNING
Fuel is highly flammable. Keep it away from flames and sources of heat.
After assembling the water separator, start the engine and check that no fuel leakage occurs. Any leaking fuel
could cause a fire.
Tightening torque Unit : Nm {lbt.ft, kgfm}

3 Air vent plug 8 to 12 {5.8 to 8.7, 0.8 to 1.2}
6 Ring nut 23 to 27 {17 to 20, 2.3 to 2.8}
13-60
13
MEMO
13-61
INJECTION PUMP
4
7
6
11
8
5
*a
19

18
*b 22
13
12 *d
-
17 15
*c 14 9
16

10
*f 2 20
*e 1 3
21
P 31548 P 31549
Removal sequence
1 Harness (6 pin) 17 Fuel suction pipe
2 Harness (4 pin) 18 Eye bolt
3 Harness (3 pin) 19 Oil pipe
4 Harness (10 pin) 20 Eye bolt
5 Harness (3 pin) 21 Oil pipe
6 Engine stop cable P13-55 22 Pump stay
7 Eye bolt 23 Injection pump assembly
8 Fuel feed pipe 24 O-ring
9 Eye bolt
10 Fuel feed pipe *a : Pre-stroke actuator P13-13, 24
11 Injection pipe *b : Sub control rod position sensor P13-21
12 Overflow valve *c : Engine speed sensor P13-21
13 Fuel return pipe *d : Electronic governor P13-28
14 Eye bolt *e : Timing gear case ^ Gr 11
15 Oil pipe *f : Front plate ^ Gr 11
16 Eye bolt : Non-reusable parts
13-62
13
WARNING
CAUTION
Be sure to protect all openings by covering them after removal of hoses and pipes because the engine
performance is adversely affected if dirt and foreign particles enter injection pump assembly 23.
Do not hold the control lever when lifting injection pump assembly 23. Also, do not remove the control lever
because removal of the lever might cause poor performance of the pump.

7 Eye bolt (Fuel feed pipe mounting) 25 to 29 {18 to 22, 2.5 to 3}
11 Injection pipe (Union nut fastening) 29 to 49 {22 to 36, 3 to 5}
12 Overflow valve 25 to 29 {18 to 22, 2.5 to 3}
14 Eye bolt (Oil pipe mounting) 9.8 to 13 {7.2 to 9.4, 1 to 1.3}
16 Eye bolt (Fuel suction pipe mounting) 25 to 29 {18 to 22, 2.5 to 3}
18 Eye bolt (Oil pipe mounting) 20 to 29 {14 to 22, 2 to 3}
20 Eye bolt (Oil pipe mounting) 20 to 29 {14 to 22, 2 to 3}
- Lubricant
24 Entire body of O-ring Engine oil As required

23 Socket wrench 12 {0.47} 31391-14100 Removal and installation of injection pump

assembly
06876
36 {1.42}
05999
13-63
INJECTION PUMP
S
Service procedure
Injection pump assembly
[Removal]
Refer to Removal sequence on page 13-62.
0
13751
B [Installation]
To bring No. 1 cylinder piston to top dead center in the compression
cycle, align pointer B of timing gear case *e with indent mark 0 on
0 *e
crankshaft pulley A by turning the crankshaft pulley clockwise using
0 cranking handle. At this point, make sure that the intake and
A exhaust valves of No. 1 cylinder are not depressed by the push rod. If
they are depressed, make another full rotation of the crankshaft
0 0 pulley.
B 06204
Align indent C on the timer case with indent D on the injection pump
gear.
D
13752
By aligning guide bar E of the timer case with guide hole F of the front
plate, push in the idler gear up to a fraction of an inch short of
engaging the injection pump gear.
F E
13753
13-64
13
Making sure that alignment mark C on the timer case aligns with
D
indent D on the injection pump gear, push in the injection pump
assembly.
As this fitting is taking place, the indent will turn in direction G.
G C
08317
13-65
INJECTION NOZZLE
P13-67
2 1 Injection pipe
15 2 Leak-off pipe
1
3 Bolt
14 4 Bridge
5
5 O-ring
13
16 3 6 Injection nozzle assembly
12
7 Retaining nut
8
8 Tip packing
4 9
10 9 Straight pin
11 10 Needle valve
* 11 Nozzle
7 12 Pressure pin
13 Spring
14 Adjusting shim
15 Nozzle holder
06955
16 Nozzle gasket
* : Cylinder head ^ Gr 11
Assembly sequence
WARNING
CAUTION
Be sure not to touch the slide-contact area of needle valve 10 because any scratches or corrosion might spoil
the airtightness of nozzle 11. It must be handled with utmost care.
Never change the combination of needle valve 10 and nozzle 11 for each cylinder.
Be sure to protect all openings by covering them after removal of hoses and pipes because the engine perfor-
mance is adversely affected if dirt and foreign particles enter injection nozzle assembly 6.
NOTE
Remove carbon deposits and clean injection nozzle assembly 6 before working on it, then test the injection
pressure and jet spray condition, and check for fuel leakage before disassembly. If no fault is found, do not
disassemble.
Service standards
6 Valve opening pressure 2 2
21.6 MPa {3130 lbf/ in , 220 kgf/cm } Adjust

1 Union nut (Injection pipe mounting) 25 {18, 2.5}
3 Bolt (Bridge mounting) 25 {18, 2.5}
13-66
13
0 Special tools
Nozzle cleaning tool 105789-0010 Cleaning of injection nozzle assembly
ZEXEL code number
Service procedure
Attach injection nozzle assembly 6 to nozzle tester A, and conduct the
following inspection.
WARNING
Never touch the spray from nozzle 11 or let your hands get too
close to the spray point during the test.
NOTE
Before inspection, bleed the air out in a couple of bursts by
pressing nozzle tester A lever.
(1) Valve opening pressure

Raise the pressure of nozzle tester A by operating the lever, and
A measure the pressure that the gauge registers when the pressure is
released which will be observed by the sudden movement of the
gauge indicator.
If the measured value deviates from the standard value, disassem-
6 ble the nozzle and clean, and adjust it using adjusting shims 14.
Variation of 0.05 mm {0.0020 in.} thickness in adjusting shims 14
causes a difference of 735 kPa {105 lbf/in2, 7.5 kgf/cm2} of pres-
06930 sure, for example, to alter the pressure for 98 kPa {14 lbf/in2,
1 kgf/cm2}, a thickness of 0.0067 mm {0.00026 in.} is required.
If the performance cannot reach the standard value even after
adjustment, replace injection nozzle assembly 6.
(2) Spray condition

Test injection spray condition by quick lever actions of nozzle tester
A, 4 to 6 actions per second.
B : Even spray from all five orifices (Good)
C : Even and symmetrical spray (Good)
D : Asymmetrical spray (Faulty)
E: Spray direction deviates from the nozzle axis line (Faulty)
F: Thin and insufficient spray (Faulty)
B C D E F G G: Irregular spray (Faulty)
06931
If faulty spray cannot be corrected, disassemble injection nozzle
assembly 6 and clean every part and repeat the test.
If faulty spray still occurs after repeating test, replace the injection
nozzle assembly.
Make sure that there is no post-spray dripping after injection.
13-67
INJECTION NOZZLE
(3) Fuel air tightness and leakage at related contact points
Maintain interior pressure of nozzle at 1960 kPa {285 lbf/in2,
20 kgf/cm2} lower than the valve opening pressure, and check and
see if any fuel seeps out of the nozzle tip within 10 seconds.
If any fault is found, disassemble injection nozzle assembly 6 and
clean every part and repeat the test. If any fault is still found,
replace the injection nozzle assembly.
6
05388
Injection nozzle assembly

[Disassembly]
10 A
CAUTION
Be sure not to touch sliding part A of needle valve 10 with your
hands.
Never change the combination of removed needle valve 10 and
nozzle 11 for each cylinder.
06932
[Cleaning]
B Clean needle valve 10 and nozzle 11 with diesel fuel (cleaning solvent).
Remove carbon deposits with 0 cleaning tool in the following manner:
Clean needle valve 10 by removing carbon deposits from its tip using
cleaning bar B of 0 cleaning tool.
10 CAUTION
Never use a wire brush or hard steel for cleaning.
01892
To clean nozzle 11, remove carbon deposits from the orifices of the
C nozzle using needle cleaner C of 0 cleaning tool, by inserting it into
the orifices and turning it.
Needle cleaner diameter : 0.25 mm {0.0098 in.} or less
11
01893
13-68
13
Clean the seat of nozzle 11 using cleaning needle D of 0 cleaning
D tool.
11
Use FUSO carbon remover to remove hard-to-remove, burnt-on
carbon deposits.
01894
[Inspection]
Immerse needle valve 10 and nozzle 11 in diesel fuel (cleaning sol-
vent) and clean them thoroughly.
Check and see if needle value 10 drops by its own weight into the
10 nozzle from the position where a third of its length is pulled out.
(Repeat this several times rotating the needle valve.)
If needle valve 10 does not drop smoothly, repeat cleaning and repeat
the test. If any fault is still found, replace both the needle valve and
11
nozzle 11 together as a set.
01911
13-69
INSPECTION OF OTHER DEVICES
2 9 *a
*b
< Left side of engine >
31550
1 Idling speed adjustment potentiometer 13 Engine speed sensor

2 Relay box 14 Exhaust brake 3-way magnetic valve
3 Exhaust brake cut relay < A/T > 15 Transmission neutral switch < M/T >
Transmission neutral relay < M/T > 16 Boost temperature sensor
4 Pre-stroke cut relay 17 Emergency engine stop button
5 Exhaust brake relay < M/T > 18 Clutch pedal switch
6 Sub control rack position sensor 19 Fuel injection rate adjustment resistor
7 Engine coolant temperature sensor
8 Pre-stroke actuator *a : Electronic governor
9 Boost pressure sensor *b : Injection pump
10 Control rack position sensor M/T : Manual transmission
11 Backup engine speed sensor A/T : Automatic transmission
12 Linear DC motor
13-70
13
Output voltage of idling
speed adjustment Knob pulled 1 to 3 V
23
potentiometer
1 Replace
Knob 3.6 to 4.3 V
pushed
16184
14 92.5 to 101.5
6
Resistances of sub control 13 92.5 to 101.5
Repair or replace
the injection pump
assembly. *
34
rack position sensor
185 to 203
13725
20C {68F} (3.25 k)
Engine coolant Between terminal
7 40C {104F} (1.5 k) Replace
temperature sensor and body
60C {140F} (620 62 k)
Resistance of 23 5.5 to 6.1
pre-stroke actuator 13 11.0 to 12.2
Repair or replace
12
8 the injection pump
(measured at 5.5 to 6.1 assembly. *
connector)
13714 45 2.45 to 2.95
34
<Connector: 3 pin>
31.5 to 36.5
<3 pin>
39
16165
<Connector: 10 pin> 18.0 to 21.0
<10 pin>
Repair or replace
the injection pump
Resistances
16160
49 13.5 to 15.5
assembly. *
of control
10
rack position <Governor actuator>
sensor G C 31.5 to 36.5
F
E G
A G F 18.0 to 21.0
D
C
B
C F 13.5 to 15.5
24816
The values in ( ) are reference values
13-71
Unit : mm {in.}
12
<Connector: 3 pin>

16165
<Connector: 10 pin>
12
Repair or
replace the in-
jection pump
Resistances 16160
9.0 to 9.8 assembly. *
12 of linear DC
<Governor actuator>
motor
F AB
E G
D A
C
B
24816
12
Resistance of
13 engine speed sensor 3 2 1 2.1 to 2.5 k Replace
(at 25C {77F})
14013
14 Minimum operating voltage of 11 V or less Replace

3-way magnetic valve
14318
0C {32F} 5880 588
Resistance valve of boost
16 20C {68F} 2455 245 Replace
temperature sensor
80C {176F} 322 32
Tightening torque Unit : Nm {lbt.ft, kgfm}

7 Coolant temperature sensor 34 6.9 {25 5, 3.5 0.7}
13 Lock nut of engine speed sensor 24 to 35 {17 to 26, 2.4 to 3.6}
13-72
13
1 A
1
Service procedure
Inspection of idling speed adjustment potentiometer
Disconnect the harness A of the idling speed adjustment potentiometer
1 from the cab-side harness B. Then, connect an inspection harness
C between harnesses A and B. (The inspection harness must be
made specially for this procedure, but is not necessary with MUT II
PLUS tester.)
Check the output voltages of the idling speed adjustment
potentiometer 1 in accordance with the following table.
C
Connector terminal
B Accelerator pedal position sensor
2 3
Item inspection harness
1: Power 2: GND () 3: Output(+)
supply (+)
1 Output voltage with

knob pulled
+
Output voltage with

C knob pushed
02778
Output characteristics
If the output voltages are out of specification, replace the idling speed
4.3 adjustment potentiometer 1.
}
Output voltage (V)
PUSH
3.6
3
1
} PULL
0 300
34
Angle of rotation
02779
2 Inspection of pre-stroke cut relay and exhaust brake

cut relay (normally-closed type with 4-pin connector)
Perform continuity checks in accordance with the following table.
1 1 2 3 4
2 13 4 4
+
3 Not energized
07387
Energized
+
: Continuity exists between terminals.

+ : Terminals across which 12 V DC is applied
: Continuity no longer exists between terminals
Replace the relay if any abnormality is evident.
13-73
5 Inspection of exhaust brake relay (Open type 4 pin)
Follow the table below to inspect continuity :
2 1 2 3 4
No current
4 2 1 3
+ Current
4 1 +
3 07142 : There is continuity between terminal and .

+ : Indicates that 12 volts DC is applied to the line between
the terminals.
6
Inspection of sub control rack position sensor

6 Measure the resistances between the following terminals : 1 and 4 ;
1 and 3 3; and . 4
If any resistance is out of specification, replace the sub control rack
position sensor 6.
2 1
4 3 Have replacement performed by the nearest MFTA Dealer.
7
13799
1
Inspection of engine water temperature sensor
Put the engine water temperature sensor 7 in a container of engine oil.
Heat the oil to each of the specified temperatures. Stir the oil to ensure
that it heats up evenly.
At each of the specified temperatures, measure the resistance be-
tween the terminal 1 and body of the engine water temperature
sensor 7.
If the measurements are out of specification, replace the engine water
temperature sensor.
13722
Standard value
Item (reference values) Limit Remedy
Engine coolant Between 20C {68F} (3.25 k)ohms

temperature terminal 40C {104F} (1.5 k)ohms Replace
sensor and body 60C {140F} (620 62 k)ohms
13-74
13
8 Inspection of pre-stroke actuator
Perform the following inspections. If any abnormality is evident, have
inspection and repair performed by the nearest MFTA Dealer.
CAUTION
The pre-stroke actuator 8 must be inspected when the engine is
cold.
(1) Measurements on connectors

Measure the resistance between terminals 2 and 3; 1 and 3; 1
24
and ; and .5
3 2 1
6 5 4
9
13790
Inspection of boost pressure sensor

B Mount pressure gauge A for boost pressure measurement as shown
A
in the diagram.
Connect the MUT-II . P13-42.
6
Set the MUT-II for boost pressure measurement
Start the engine. Compare the value displayed on the MUT-II and the
value indicated by pressure gauge A. If the values are different,
replace boost pressure sensor 9.
B : To inlet manifold.
20580
13-75
F Inspection of control rack position sensor
Measurements on connectors
Measure the resistances between the following terminals: 3-pin connec-
3
tors 4
and ; 10-pin connectors 3and ; 94 and . 9
P 31551
Measurements on actuator
*b
Remove the governor cover A from electronic governor *b.
CAUTION
Remove only the cover A. Do not remove the governor actua-
tor itself. Removal of the governor actuator would necessitate
adjustments using a special tool.
When removing the governor cover A, do not apply undue
force to the governor actuator by pressing it with your hand or
31552 foot.
A
Measure the resistances between the following terminals: G and

C ; G and F ; C and F .
F
E G
D A
24816
Inspection of continuity between actuator and connectors

Check that continuity exists between the terminals shown in the fol-
lowing table.
F G
<3 pin> E A Connector terminal Actuator Used for
terminal
3
D
3 pin G Control rack position sensor (GND)
3
C
B
G Control rack position sensor (GND)
10 pin 4 C Control rack position sensor (OSC)
<10 pin>
24819 9 F Control rack position sensor (MDL)
13-76
13
H Inspection of linear DC motor
(1) Measurements on connectors

Measure the resistance between terminals 1 and 2 on each connec-
tor.
P 31551
13-77
I Engine speed sensor
[Inspection]
(1) Main unit

Measure the resistance between terminals 1
and . 2
If the measured value deviates from the standard value, replace
3 2 1 engine speed sensor 13.
CAUTION
Be sure to check the tightening torque of engine speed
3 13785
sensor 13. If the tightening torque is insufficient, the sensor
J
may not output a signal.
C Inspection of 3-way magnetic valve

Carry out the following inspection. If any fault is found, replace 3-way
magnetic valves 14 :
Air circuit table (There is air continuity between terminals and .)
+ Input Output Exhaust
A port A port B port C
ON
OFF
B 07115
(1) Operation inspection

Apply voltage between terminals 1 2
and , increasing gradually
from 0 volt.
Measure voltage (minimum operating voltage) when magnetic
valves 14 starts operating. (You can tell if the magnetic valves are
ON or OFF by listening for an operating sound.)
(2) Airtightness inspection

When magnetic valve is ON :
Close output port B.
Apply 12 volts DC between terminals 1 and .2
Make sure that there is no air suction from exhaust port C when
negative pressure (100 kPa {30 in.Hg, 750 mmHg}) is applied
to input port A.
When magnetic valve is OFF :
Close exhaust port C.
Make sure that there is no air suction from output port B when
negative pressure (100 kPa {30 in.Hg, 750 mmHg}) is applied
to input port A.
13-78
13
L Inspection of boost temperature sensor
Place boost temperature sensor 16 in glycerin in a container.
Raise the glycerin temperature to the specified values and stir the glycerin.
Measure the resistance between terminals 1 and . 2
Item Standard value Limit Remedy
0C
If the measured value5880
{32F} 588
deviates from the standard value,
ohms replace boost
temperature
20C {68F} ^ Gr15245 ohms
sensor. 2455 Replace
1 2 80C {176F} 322 32 ohms
M
13729 If the measured value deviates from the standard value, replace boost
temperature sensor. ^ Gr 15
Inspection of emergency engine stop handle
A
Push emergency engine stop handle 17 all the way.
In this step, make sure that stop lever A of the governor is in contact
with stopper bolt B.
If the stop lever does not contact the stopper bolt, turn nut C until they
contact, and tighten nut D to secure it in place.
Inner wire E of stop cable F should be taut. If not, make adjustment.
CAUTION
P 31481 Be careful not to make the tension of inner wire E too high,
since excess tension prevents stop lever A from fully contact-
ing stopper bolt B.
F C D
N
A P 31547
Inspection of clutch switch

4+0.5 mm {0.240.02 in.}
1 2
OFF
+1.5 +0.059
4 0
mm {0.16 -0 in.}
ON
OFF ON
If any fault is found, replace clutch switch 18. ^ Gr 21
07120
13-79
ELECTRIC CIRCUIT AND PART INSTALLATION LOCATIONS
7 Relay box 4 Meter cluster 22 27
15 Fuse box 2 28 26
Battery Prestroke
Starter switch ^Gr 54 Transmission Exhaust ^Gr 54 Electronic governor actuator Sub 29
^Gr 54 ^Gr 54 ^Gr 54 9 neutral relay brake
relay
cut Tachometer
control
14 12 13 Exhaust 10 Prestroke Manual Automatic Warming up Linear Control Back up Prestroke rack Engine
To starter To engine cut relay trans- trans- DC rack engine Drive engine
start relay MUT Diagnosis Memory brake relay mission mission switch
motor
position speed unit speed position speed
relay connector switch clear switch sensor sensor sensor sensor sensor
8 3
6 b
c
Electronic d
governor High current
control unit Meter fuse box
Cab 21
n
Cab Chassis
a
w v
t s Tightened
To dual together
To Cab ground
p q r engine pressure Magnet Exhaust Trans-
To Diode switch brake Boost Boost Engine
^Gr 23 start clutch mission
*1 : Manual transmission ^Gr 23
Diode Idling speed connector Chassis connector 3-way neutral
pressure temperature water
*2 : Automatic transmission Exhaust brake relay ground sensor sensor temperature
Fuel injection switch Clutch 11 adjustment
^Gr 54 magnetic switch sensor
MUT: Multi-use tester pedal Automatic transmission ^Gr 54 potentiometer valve
rate adjustment Combination
Accelerator switch control unit 30
pedal sensor
resister switch 5 20 23 25 24
17 1 18 16
19
13-82
20
u
1 7 8 9
6 e f g
2
1 Combination switch
a 2 Starter switch
3 Warming up switch
4 Meter cluster
5 Idling speed adjustment potentiometer
h j k m 6 Electronic governor control unit
3 4 10 7 Relay box
b c d v 25 24 23 w 22 21
8 Transmission neutral relay < M/T >
5
6 Exhaust brake cut relay < A/T >
< Manual transmission > 9 Prestroke cut relay
10 Exhaust brake relay
u 20 30 11 Diode
12 Diagnosis switch
13 Memory clear switch
14 Multi-use tester connector
15 Fuse box
11 16 Automatic transmission control unit
17
17 Fuel injection rate adjustment resister
n 12, 13 18 Clutch pedal switch
19 Accelerator pedal sensor
16 20 Exhaust brake 3-way magnetic valve
15 22 Battery
14
23 Boost pressure sensor
24 Engine water temperature sensor
25 Boost temperature sensor
16
26 Sub control rack position sensor
s
v 25 24 23 w 22 21 27 Pre-stroke actuator
p 28 Electronic governor
29 Engine speed sensor
26 24 27 23 28 30 Transmission neutral switch < M/T >
q
19
* : Wiper motor
r
t M/T : Manual transmission
*
18
30983
29
<Left side of engine >

Group 13
Table of Contents
BACK
HOME
Pub No. TWSE9501-13

13
GROUP 13 FUEL AND ENGINE CONTROL
SPECIFICATIONS .................................................................................. 2

Inspection and Adjustment of Fuel Injection Timing .................................... 28
Inspection and Adjustment of No-Load Minimum and
Maximum Revolution........................................................................................ 31
Inspection and Adjustment of Idling Actuator < with Cab Cooler > ............. 32
PRE-STROKE CONTROL INJECTION PUMP SYSTEM

Troubleshooting Procedure ............................................................................. 34
Electric Circuit and Position of Parts Installation ......................................... 40
Inspection by Individual Diagnosis Code....................................................... 42
Inspection of Temporary Faults ...................................................................... 60
ENGINE CONTROL .............................................................................. 62
FUEL TANK .......................................................................................... 67
WATER SEPARATOR .......................................................................... 68
FUEL FILTER........................................................................................ 70
INJECTION PUMP ................................................................................ 72
INJECTION NOZZLE ............................................................................ 76
13-1
SPECIFICATIONS
Injection Pump
Item Specifications
Manufacturer ZEXEL
Body model MD-TICS (Pre-stroke control type)
Governor type RLD all-speed mechanical governor with boost compensator
Feed pump model KD
Injection Nozzle
Item Specifications
Manufacturer ZEXEL
Model and type DLLA hole type 1-spring model
Number of orifices 5
Orifice diameter mm {in.} 0.25 {0.0098}
Fuel Filter Type

Item Specifications
Filter type Spin-on type
13-2
13
MEMO
13-3
Fuel System (Flow of Fuel)
Supplied fuel
Excessive fuel
10
3
5
9 6
7
8 4
13755
1 Injection nozzle 6 Governor

2 Fuel filter 7 Feed pump
3 Fuel tank 8 Injection pump
4 Water separator 9 Overflow valve
5 Boost compensator 10 Pre-stroke actuator
Fuel in fuel tank 3 is sucked up by feed pump 7 which is driven by the cam action of injection pump 8 and is filtered through
fuel filter 2 which removes dirt and other foreign particles.
Filtered fuel is sent to the injection pump where the fuel pressure is boosted and injected through injection nozzle 1 into
the combustion chamber.
When fuel pressure is higher than the specified value, overflow valve 9 opens to let the fuel return to the fuel tank.
13-4
13
Engine Control
1 Idling control knob
2 Starter switch
1 A
3 Accelerator arm assembly
8 5 Fuel-cut motor
6 Engine-stop cable
7 Accelerator control cable
8 Idling control cable
9 Engine-stop lever
10 Idling control lever
2
3 10 A : Idling revolution rising
B : Engine-stop position
4 7 C : Engine start-up position
E D : Full-load position
E : Idling position
D
9
C
7
B
6 6
5
13756
(1) Idling control knob

Idling control knob 1 is for making fine adjustment to the idling revolution of the engine. Turning the knob clockwise
raises the revolution. It works in the same way as accelerator pedal assembly 4 does when it is depressed.
(2) Fuel-cut motor

Fuel-cut motor 5 is connected to starter switch 2, and it is activated by the starter switch being turned ON (or to S).
This brings engine-stop lever 9 of the governor to engine-stop position B (or engine start-up position C), and stops
(or starts) the engine. P13-6
(3) Accelerator pedal

When accelerator pedal assembly 4 is freed from foot pressure, the governor return spring forces idling control lever
10 to idling position E, restoring the pedal to its original position.
13-5
Engine Stopping Circuit
1 Starter switch
1 2 Fuel-cut relay
2 3 Fuel-cut motor
4 Engine-stop cable
5 Engine-stop lever
6 Governor
7 7 Fuse box
A : Power source
A 3 B : Power source
C D 4 C D 5 C : Engine-stop position
B
D : Engine start-up position
6
06885
At engine start-up (starter switch ON)

2 E Electric current flows as illustrated, and coil E of fuel-cut relay 2 is
magnetized.
06886
Contact point F of fuel-cut relay 2 closes, and fuel-cut motor 3 is

2 F activated.
Engine-stop cable 4 is pushed out, and engine-stop lever 5 moves to
engine start-up position.
A
3
4 5
06887
13-6
13
Engine-stop lever 5 moves to engine start-up position D, and fuel is
2
ready to flow. Contact point H of fuel-cut motor 3 opens, and the fuel-
cut motor stops.
A
3
D 4 D5
H
06888
When engine is at standstill (starter switch OFF)

2 J
Electric current from the starter switch is broken, and contact point J of
fuel-cut relay 2 closes, and fuel-cut motor 3 is activated.
Engine-stop cable 4 is pulled to bring engine-stop lever 5 to engine-
A stop position.
3 4 5
06889
When engine-stop lever 5 reaches engine-stop position C, fuel flow

2 stops and the engine stops. Simultaneously, contact point K of fuel-
cut motor 3 opens, and the fuel-cut motor stops.
A K
3 4
C C 5
6
B
06890
13-7
Fuel Gauge Electric Circuit
1 Relay and fuse box
1 2 2 Meter cluster
3 3 Fuel gauge
4 Fuel gauge unit
5 Float
The fuel gauge circuit indicates the amount of

fuel remaining by means of a gauge.
5
F
E
12960
Water Separator
1 Water level ring
A : From fuel tank

A B : To feed pump
The water separator is installed between the fuel tank and the feed
pump. Any water present in the fuel is separated by the baffle plate and
B
the screen assembly.
12963
13-8
13
Fuel Filter
1 Fuel filter
2 2 Fuel filter head
A : From feed pump

A B : To injection pump
Pressurized fuel is delivered from the feed pump of the injec-

tion pump to the fuel filter which separates water from the fuel.
Dirt and other foreign particles are removed from the fuel by
fuel filter 1.
06892
13-9
Structure of Pre-stroke Control Injection Pump System
7 8 9 10 11
1
6
2
4 5
3
14 13 12
A B C D E F
12 volts DC G
M H
L J
K
18
17 16 15
13758
Part name Main function Main signal

1 Starter switch Detection of start signal A : Start signal
2 Fuse box
3 Diagnosis switch Transmission of diagnosis code signal L : Diagnosis code signal
4 Memory clear switch Clearing of diagnosis code M : Diagnosis code clearing signal
(Uses Fuse No. F4)
5 Multi-use tester connector Connection of multi-use tester
6 Boost air temperature sensor Detection of engine intake air C : Boost air temperature signal
temperature
7 Alternator Detection of engine revolution D : Alternator L terminal signal
8 Water temperature sensor Detection of engine coolant B : Engine coolant temperature signal
temperature
9 Pre-stroke actuator
Pre-stroke position sensor G : Pre-stroke position signal
Drive unit H : Actuator drive signal
10 Control rod position sensor Detection of control rod position E : Control rod position signal
11 Mechanical governor Control of fuel injection quantity
(Mechanical control)
12 Pre-stroke control injection pump Change of pre-stroke
(Adjustment of fuel injection timing)
13 Engine revolution sensor Detection of engine revolution F : Engine revolution signal
14 Mechanical timer (Dummy timer) Absorption of torsional vibration,
smoothing of revolution
15 Meter cluster
16 Warning lamp Indication of system abnormality, J : Lamp lighting signal
indication of diagnosis code
17 Tachometer K : Tachometer drive signal
18 Pre-stroke control unit Control of entire system
13-10
13
The pre-stroke control injection pump system uses, in the injection pump body, electronically controlled pre-stroke
control injection pump 12, mechanical governor 11, and mechanical timer 14.
The lifting speed of the plunger in the injection pump varies with the engine revolution. Because of this, the pressure in
the injection pipe also changes.
This change of pressure in the injection pipe means the appropriate state of fuel injection and air/fuel mixture from the
injection nozzle is no longer obtainable.
In low- and medium-range engine revolution, the amount of pre-stroke is made larger so that the fuel is injected at the
point the plunger lifting speed increases during the second half of cam lift. P13-18
On the other hand, in high-range engine revolution, the amount of pre-stroke is made smaller so that the fuel is injected
while the plunger lifting speed remains low during the first half of cam lift. This prevents the pressure in the injection
pipe from becoming excessively high.
Because of this variation in the amount of pre-stroke, pre-stroke control injection pump 12 can obtain the appropriate
injection state and air/fuel mixture for combustion.
Thus, engine torque is larger than engines that use a normal injection pump. Also, the exhaust gas emission is cleaner.
Control is achieved by making the pre-stroke adjustable in conjunction with the drive of pre-stroke actuator 9, which is
mounted on the rear of the injection pump body. This pre-stroke actuator is activated by commands received from pre-
stroke control unit 18, which processes data signals received from the various sensors installed on the engine and
vehicle body.
This system also has a trouble diagnosis function and a fail-safe function. The following table shows control items.
Information source
Control item Control description
Sensor Data signal
Pre-stroke control Adjusts the fuel injection timing by changing the timing sleeve 6 to 10, A to H
position to change the pre-stroke 13, 12
Trouble diagnosis function Checks and diagnoses the status of the sensors of the pre-stroke ALL ALL
control injection pump system while the engine is running.
Warns the driver, via warning lamp 16, if any trouble occurs,
and memorizes the data on the trouble P13-13
Fail-safe function When trouble occurs, backup mode is activated and countermeasures ALL ALL
for the trouble are taken P13-13
* Fuel injection quantity control Controlled by mechanical governor 11 P13-20
* : This is not controlled by the pre-stroke control injection pump system but by ordinary mechanical control.
Input signal Output signal
Control rod position sensor 10

Injection

pump
Drive unit
Fuel injection timing
(Built in pre-stroke actuator 9) (Built in pre-
Pre-stroke control unit 18
control
stroke actuator 9)

Water temperature sensor 8
Engine
Engine revolution sensor 13

Alternator 7
Trouble diagnosis in-

Warning lamp
16
Starter switch 1 dication
Vehicle
Diagnosis switch 3
Memory clear switch 4
13-11
Pre-stroke control
Data signal
Pre-stroke control unit 18
ON
Ne Selection of Selection of
Engine start
Basic map maximum minimum
Rod value value
START
Ne Coolant temperature
correction map Engine stop
Tw
Ne Boost air temperature Desired pre-

Tb correction map stroke value
Ne Pre-stroke position
Limit map
Tw learning function
Ne
Start map
Tw
Analog signal
Timing Drive unit (Built in pre-

sleeve Drive circuit Servo circuit Digital/Analog
stroke actuator 9) Converter
movement

(Built in pre-stroke actuator 9)
Feedback control
Ne : Engine revolution Rod : Control rod position

Tw : Engine coolant temperature Tb : Engine intake air temperature
Digital/Analog converter : Converts digital signals into analog signals
Control by Pre-stroke Control Unit 18

The control unit commands the system while the engine is running, and selects the maximum value of the desired pre-
stroke value based on data signals received from the basic map, coolant temperature correction map, and boost air
temperature correction map.
After the maximum value has been selected, the limit map selects and processes the minimum value so that the
desired pre-stroke value does not exceed the maximum value.
The desired pre-stroke value is further determined by the pre-stroke position learning function. This corrects any
deviation in positional adjustment by the pre-stroke position sensor and any deviation by the injection pump, correcting
the output voltage of the pre-stroke position sensor.
The pre-stroke thus determined is converted into continuous analog signals by the Digital/Analog converter and
transmitted through the servo circuit and drive circuit to actuate the drive unit. The drive unit moves the timing sleeve
position to change the pre-stroke.
Control at the time of engine start up is handled by the start map.
Control by Pre-stroke Position Sensor (built in pre-stroke actuator 9)

The pre-stroke position sensor monitors the operating condition of the drive unit by feeding back signals to pre-stroke
control unit 18 and judging whether the pre-stroke is controlled in accordance with the desired value by noting the
timing sleeve position.
When pre-stroke control unit 18 receives the feedback signals, it computes the actual measured value of the timing
sleeve position, and if there is any difference between the desired and actual values, it issues a correction command.
This operation is repeated to constantly maintain the timing sleeve position at the desired position, thus determining the
final pre-stroke.
13-12
13
Trouble diagnosis function, fail-safe function
Memory of trouble
indication code
Individual sensors, Trouble diagnosis Warning lamp

pre-stroke actuator
Backup mode
The trouble diagnosis function detects and diagnoses troubles reported by the various sensors and the pre-stroke
actuator, while the engine is running. If any trouble occurs, this function warns the driver by lighting warning lamp
and at the same time stores the trouble point in memory as a diagnosis code.
The fail-safe function is put into operation simultaneously and the trouble is treated accordingly in the backup mode.
In the backup mode, the pre-stroke control starts when trouble occurs. If the trouble does not affect the operation of the
engine, fixed data from the backup mode is used to treat the trouble. If the trouble dangerously affects the operation of
the engine, the pre-stroke control stops.
If the function goes into backup mode, the function stays in that mode until the starter switch is set to LOCK. When a
normal signal is returned, control of the system returns and warning lamp goes off.
There are two kinds of diagnosis code, current and previous.
Current diagnosis code : Indicates data when the engine has been running with the starter switch set to ON since
the abnormality occurred.
Previous diagnosis code : Indicates previous data when the engine was stopped with the starter switch set to ACC
or LOCK after the abnormality occurred.
Table of diagnosis codes

Diagnosis Abnormal item Countermeasures taken by pre-stroke control unit
code (Backup mode)
01 Normal
03 Pre-stroke learning function Controls with correction value assumed to be 0
04 Pre-stroke actuator power source Stoppage of pre-stroke control
05 Engine revolution sensor Controls with engine revolution assumed to be 0
(No pulse)
12 Pre-stroke servo system Stoppage of pre-stroke control
13 Pre-stroke position sensor Stoppage of pre-stroke control
15 Engine revolution sensor Controls with engine revolution assumed to be 0
(Wiring breakage)
21 Water temperature sensor Controls with water temperature assumed to be 80C {176F}
22 Control rod position sensor Controls with control rod position assumed to be full load
41 Boost air temperature sensor Controls with boost air temperature assumed to be 80C {176F}
It is possible to run the vehicle even if the pre-stroke control develops an abnormality. However, do not run the vehicle for a long period of time, run it
only for the time necessary to obtain repairs.
13-13
Pre-stroke Control Unit
The pre-stroke control unit monitors and computes data
signals received from the various sensors and, using its
internal computer, converts the computed results into con-
trol signals (pre-stroke actuator drive signals).
These signals operate the various instruments to control the
system.
AH26A
AH22A
AH26A
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
AH22A
27 28 29 30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48
13759
Connector AH26A Connector AH22A

Terminal No. Connecting destinations Terminal No. Connecting destinations
1 Drive unit 27 Pre-stroke cut relay (Contact point)
2 28 Multi-use Tester (SEL)
4 Boost air temperature sensor 30
5 Water temperature sensor 31 Tachometer (SIG)
6 Pre-stroke position sensor (OSC) 32 Multi-use tester (SIG)
7 Pre-stroke position sensor (MDL) 33 DDS-III (DATA)
8 Control rod position sensor (OSC) 34 DDS-III (CLOCK)
9 Control rod position sensor (MDL) 35 DDS-III (STB)
10 Engine revolution sensor (SIG) 36
11 37 Control unit power source (12 volts DC)
12 38 Pre-stroke actuator power source
13 39 Alternator terminal L
14 Drive unit 40 Starter switch terminal S
15 41
16 Pre-stroke cut relay (Coil) 42 Tachometer (GND)
17 43
18 44
19 Pre-stroke position sensor (GND) 45 Warning lamp
20 Pre-stroke position sensor (SHIELD) 46 Ground
21 Control rod position sensor (GND) 47 Ground (CASE GND)
22 48 Ground (POWER GND)
23 Engine revolution sensor (GND)
24
25
26 Memory clear switch (Using F4 fuse)
13-14
13
Starter switch
12 volts Pre-stroke control unit

DC Pre-stroke actuator
Pre-stroke
position sensor
Memory clear
switch Drive unit
(Fuse No.F4)
Pre-stroke cut relay
Control rod
position sensor
(12 volts DC)
Engine revolution
sensor
Diagnosis switch
Warning lamp Water temperature

sensor
Boost air
temperature sensor
Tachometer
L Alternator
Multi-use tester
Checker (for testing by ZEXEL)
14462
13-15
Engine Revolution Sensor
Engine revolution sensor 1 is a pick-up type that detects the revolution
of the injection pump and converts the revolution value into an electric
signal.
engine revolution signal, which is used as the correction value by the
1
control unit to determine the desired pre-stroke position value.
13762
Water Temperature Sensor

Water temperature sensor 1 is a thermistor type that converts the
coolant temperature into an electric signal.
engine coolant temperature signal, which is used as the correction
value by the control unit to determine the desired pre-stroke position
value.
1
13761
Boost Air Temperature Sensor

Boost air temperature sensor 1 is a thermistor type that converts the
intake air temperature, immediately after its passage through the
intercooler, into an electric signal.
boost air temperature signal, which is used as the correction value by
the control unit to determine the desired pre-stroke position value.
1
13764
Control Rod Position Sensor

Control rod position sensor 1 is a resistor type that converts the
amount of movement of the control rod into an electric signal.
1 This electric signal is transmitted to the pre-stroke control unit as the
control rod position signal, which is used as the correction value by
the control unit to determine the desired pre-stroke position value.
13963
Pre-stroke Position Sensor P13-10, 12
13-16
13
Injection Pump Body
8
17
7 9
11 18
12 10
13
6
14
5
15 16
3 A
2 B
D
C
13765
1 Camshaft 13 Timing sleeve

2 Tappet 14 Timing rod
3 Plunger spring 15 Control rod
4 Plunger 16 Pre-stroke actuator
5 Pump housing 17 Drive unit
6 Pin 18 Pre-stroke position sensor
7 Delivery valve spring
8 Ball A: Control rod position sensor P13-16
9 Spring B: Engine revolution sensor P13-16
10 Delivery valve C: Mechanical timer (Dummy timer)
11 Delivery valve holder D: Mechanical governor P13-20
12 Plunger barrel
The injection pump has a variable pre-stroke mechanism.

Because of the variation in the amount of pre-stroke, the appropriate injection state and air/fuel mixture for combustion
can be obtained, thus the engine torque is larger than when a normal injection pump is used and the exhaust gas
emission is cleaner.
13-17
Pre-stroke
Pre-stroke is stroke E whose range is from the bottom dead point of
13 plunger 4 to the starting point of pressurized delivery of fuel, at which
point suction port G is closed by timing sleeve 13. An ordinary injection
E
pump has a fixed stroke length.
4
13087
12 Pre-stroke variable mechanism

14
17 F : Indent
G : Suction port
13 H : Exhaust port
In a conventional injection pump, plunger barrel 12 is fixed. In the pre-
stroke control injection pump system, vertically movable timing sleeve
6 13 is fitted in the fixed plunger barrel.
H
F Timing rod 14, pin 6 and drive unit 17 are installed to operate timing
4
sleeve 13.
G 13088 The operation of drive unit 17 rotates timing rod 14, causing pin 6 to
move timing sleeve 13 vertically.
As timing sleeve 13 is fitted with fuel exhaust port H, the pre-stroke
changes in accordance with the movement of the timing sleeve.
M Pressurized fuel delivery

J : Ongoing suction
K : Start of pressurization
4 L : Delivery ends
H
When suction port G opens as plunger 4 moves down from the top
dead point, fuel is delivered into pressure chamber M by both the
F 13 negative pressure caused by the downward movement of the plunger
N and the pressure of the fuel itself delivered by the feed pump.
J K L When the lift of plunger 4 is low enough, the pressure in pressure
G 13089 chamber M does not increase as the fuel in the pressure chamber
flows via suction port G into fuel reservoir N, even if the plunger lifts.
As plunger 4 lifts further and suction port G is closed by timing sleeve
13, pressurization of the fuel starts. The pressure increases as the
plunger lifts further, making the injection pump start pressurized fuel
delivery.
When indent F on plunger 4 meets exhaust port H of timing sleeve 13,
the fuel in pressure chamber M is pushed back to fuel reservoir N,
stopping pressurized fuel delivery.
Adjustment of the fuel quantity to be injected is made by changing the
relative meeting position of exhaust port H of timing sleeve 13 and
indent F, by the rotation of plunger 4.
13-18
13
Fuel injection timing and fuel injection characteristics
The pre-stroke changes according to changes in the position of timing
sleeve 13, whereby the fuel injection timing can be advanced or
Angle adjustment for retarded.
fuel injection timing By making the pre-stroke smaller, suction port G of plunger 4 closes
Cam lift
early, making the fuel injection timing quicker accordingly.
Cam speed
By making the pre-stroke larger, suction port G of plunger 4 closes

late, making the fuel injection timing slower accordingly.
Plunger The quick response of the fuel injection timing improves engine start -
effective
Cam speed stroke at up performance at low temperatures.
low speed
Pre-stroke
Cam lift
at low
speed
Plunger effective
stroke at high speed
Pre-stroke at
high speed
Cam angle
13090
R Delivery valve
S P : Start of pressurized delivery
7 Q : End of pressurized delivery
8
Delivery valve 10 keeps residual pressure R in the injection pipe at a
9 certain level throughout the entire engine revolution range preventing
cavitation and allowing high-pressure injection.
10
When the fuel pressure on plunger 4 side, as the plunger is lifted,
overcomes the combined force of residual pressure R in the injection
pipe and the repercussive force of delivery valve spring 7 of the
4
P Q 01829 plunger, delivery valve 10 is pushed up and pressurized fuel delivery
starts.
Fuel in the injection pipe returns quickly to plunger 4 side the moment
pressurized delivery from the plunger ends, and the delivery valve is
closed.
The excess fuel is returned slowly through orifice S, reducing the
pressure in the injection pipe.
When the repercussive force of spring 9 in delivery valve 10 equalizes
with the pressure in the injection pipe, ball 8 closes orifice S and
residual pressure R in the injection pipe is kept at a specified level.
13-19
Governor
22
1
21
20
2
19
3
4
5
6
18
7
8
17
9
16 10
15 11
13
14 12
13766
1 Control lever 12 Cancel spring A

2 Adjusting lever shaft 13 Shifter
3 Control rod 14 Idling spring
4 Cancel spring B 15 Idling screw
5 Start spring 16 Tension lever
6 Governor spring 17 Governor shaft
7 Torque cam 18 Guide lever
8 Flyweight holder 19 Floating lever
9 Flyweight 20 Idling set bolt
10 Sleeve 21 Full-speed set bolt
11 Tension lever shaft 22 Supporting lever
The governor is a mechanical type that uses centrifugal force generated by flyweights 9, its characteristics are between
those of a minimum/maximum speed governor and those of an all-speed governor. Because there is no repercussive
force from governor spring 6 or control lever 1, when the accelerator pedal is depressed, the repercussive force
transmitted to the accelerator pedal, via the control lever, is quite light, making accelerator pedal operation easy.
13-20
13
Boost Compensator
Boost compensator 1 is a device that automatically adjusts the quantity
of fuel to be injected to suit the increase in the intake air mass delivered
into the engine cylinders by the turbocharger.
1
13767
Feed Pump
1 Eye bolt on fuel outlet side
1 2 Check valve
3 Check valve
13 4 Push rod
5 Piston
6 Piston spring
2 7 Eye bolt on fuel inlet side
12 10 3 8 Gauze filter
11 9 Feed pump housing
4 10 Check valve
5 11 Check valve
9 6
12 Check valve spring
13 Priming pump
8
7
13768
The feed pump is a double-action type pump which, with four check valves operating, sucks and discharges fuel during
both strokes of pistons 5.
Push rod 4 makes contact with the injection pump camshaft directly, moving piston 5.
Priming pump 13 can be manually operated, when the injection pump is not operating, to suck up fuel and thus can be
used for air bleeding.
Gauze filter 8 eliminates large foreign particles from the fuel sucked up from the fuel tank to prevent clogging of the feed
pump. This gauze filter must be cleaned with gas oil periodically.
F D The rotation of injection pump camshaft A, pushes up push rod 4 and

3 B piston 5, and the pressure in inner chamber B increases. This closes
check valve 3, and check valve 10 opens to let the fuel in inner chamber
B flow through outer chamber C to fuel filter D.
10 When the pressure in inner chamber E decreases, check valve 11
G C closes, and check valve 2 opens to let fuel flow from fuel tank F through
E
2 11 outer chamber G to inner chamber E.
4 5
A 13098
13-21
F D When injection pump camshaft A rotates further, it pushes down push
B
3 10 rod 4 and piston 5, and the pressure in inner chamber E increases. This
closes check valve 2, and check valve 11 opens to let the fuel in inner
chamber E flow through outer chamber C to fuel filter D.
G C When the pressure in inner chamber B decreases, check valve 10
closes, and check valve 3 opens to let fuel from fuel tank F flow through
25 11 outer chamber G to inner chamber B.
4 E
A 13099
Injection Nozzle
1 Washer
A 2 Spring
B 3 Nozzle tip
4 Needle valve
A : From injection pump

B : To fuel tank
As the pressure of the fuel delivered from the injection

pump overcomes the repercussive force of spring 2, needle
1
valve 4 is pushed up to allow the fuel to spray out the
2 opening at the tip of the nozzle.
3 Injection pressure can be adjusted by increasing or de-

4 creasing the number of washers 1.
06904
13-22
13
MEMO
13-23
TROUBLESHOOTING
Symptoms
Engine revolution does not reach specified

Engine output does not develop full power
Engine maximum revolution too high
Accelerator pedal hard to depress

Engine output inconsistent
Fuel supply insufficient

Engine starts but stalls
Engine idling unstable
Engine does not start
Engine does not stop

maximum speed
Engine knocks
Possible causes
Pre-stroke control faulty
(Warning lamp lights) P13-34
Plunger stuck
Control rod stuck
Delivery valve stuck
Tappet worn
Camshaft worn
Injection timing adjusted incorrectly
Plunger worn
Delivery valve seated incorrectly
Injection timing too fast
Injection pump body Plunger sliding stroke short
Plunger spring damaged
Control rod not moving smoothly
Tappet worn, not moving smoothly
Delivery valve spring damaged
Airtightness incorrect due to delivery valve

holder loosened
Control pinion loosened
Plunger spring setting faulty
Delivery valve holder tightened excessively
Injection amount of each cylinder uneven
Overflow valve stuck
Gauze filter clogged
Check valve malfunctioning
Piston stuck
Fuel feed pump Push rod worn
Push rod stuck
Check valve sliding movement faulty
Piston worn
13-24
13
Symptoms




maximum speed
Engine knocks
Possible causes
Full-speed stopper position short of standard value
Governor spring weak
Control lever position adjusted incorrectly
Flyweight malfunctioning
Idling spring weak
Governor Linkage bent
Linkage friction excessive or linkage too loose
Round nut loosened
Idling set bolt adjusted incorrectly
Control lever sliding movement faulty
Stop mechanism damaged
Needle valve stuck
Valve opening pressure too low
Injection nozzle clogged
Nozzle airtightness incorrect
Injection nozzle Valve opening pressure too high
Spring fractured
Needle valve sliding movement faulty
Valve opening pressure faulty
Spring fatigued
Fuel filter Filter clogged
No fuel in fuel tank
Fuel pipe clogged or fuel leakage from connections
Air or water in fuel system
Low-quality fuel being used
13-25
TROUBLESHOOTING
Symptoms




maximum speed
Engine knocks
Possible causes
Accelerator pedal stopper bolt adjusted incorrectly
Accelerator pedal arm rusted
Accelerator control cable connection faulty
Engine control
Accelerator control cable sliding movement faulty
Engine stop cable damaged or stretched
Engine stop cable adjusted incorrectly
Fuel pipe cracked
Fuel tank airtightness incorrect
Oil viscosity unsuitable ^ Gr 12
Valve clearance incorrect ^ Gr 11
Head gasket faulty ^ Gr 11
Valve and valve seat worn and carbon deposits ^ Gr 11
Valve spring fatigued ^ Gr 11
Piston ring worn or damaged ^ Gr 11
Piston ring groove worn or damaged ^ Gr 11
Piston and cylinder worn ^ Gr 11
Starter switch faulty ^ Gr 54
Glow relay faulty ^ Gr 54
Multipurpose timing control unit faulty ^ Gr 54
Fuel-cut motor faulty ^ Gr 54
Fuel-cut relay faulty ^ Gr 54
13-26
13
MEMO
13-27
Inspection and Adjustment of Fuel Injection Timing
Service standards
Fuel injection timing 7 Adjust

6 Union nut 100 to 110 {76 to 83, 10.5 to 11.5}
7 Delivery valve holder 29 to 49 {22 to 36, 3 to 5}

36 {1.42}
05999
15, 16 Universal extension MH061099 Inspection and adjustment of fuel injection

timing
14 {0.55}
05163
[Inspection]
NOTE
1 4
Set the starter switch to LOCK or ACC before starting opera-
tion.
Loosen lock nut 1 of control cable bracket 2 and remove from the
bracket slit.
3 Pull governor stop lever 3 toward STOP direction.
Remove cable end 5 of engine stop cable 4.
5
2
13769
Remove union nut 6 of the injection pipe, delivery valve holder 7,

stopper 8, delivery valve spring 9 and delivery valve 10 from the
6 injection pump of No.1 cylinder.
After removing these parts, install delivery valve holder 7.
7
CAUTION
8 Be sure to keep all the removed parts in gas oil to keep them free
9 from dirt.
10
13770
13-28
13
Mount extra injection pipe 11 on No.1 cylinder. Direct the free end of
11 the pipe downwards so that the fuel discharge can be clearly ob-
served.
A : Oil tray
A
13771
Turn the crankshaft more than 180 in the forward running direction
and bring No.1 cylinder to approximately 30 before top dead center in
the compression cycle.
NOTE
Refer to the location where there are 30 gradations, since angle
gradations on the crankshaft pulley side only extend to 20.
0
13772
Turn the engine in the forward running direction slowly while discharg-
ing fuel from injection pipe 11, deliver fuel using priming pump 12.
A : Oil tray
When the discharge of fuel from injection pipe 11 becomes intermit-
12 tent, turn the crankshaft slower, stop turning the crankshaft when the
discharge stops completely.
11
0
13773
Make sure that indent 13 on the crankshaft pulley and pointer 14 on

14
the timing gear case show the standard fuel injection timing.
13
13 0
14 06911
13-29
Adjust fuel injection timing as follows if it does not conform to the
standard value.
[Adjustment]
Loosen injection pump mounting nuts 15, 16.
15 : 4 points (on flange)
16 : 1 point
15
0
16 13774
When fuel injection timing is retarded, tilt injection pump 17 toward

B crankcase side B.
C When fuel injection timing is advanced, tilt injection pump 17 away
from crankcase C.
17
13775
19 18 Adjustment of one graduation on indented scale 18 of the timer case

flange adjusts fuel injection timing by 6.
19 : Pointer
Tighten nuts 15, 16 at specified torque, and remeasure fuel injection
timing.
15 16
13776
After making sure that the fuel injection timing conforms to the stand-
ard value, install delivery valve 10, delivery valve spring 9 and stopper
8, then tighten delivery valve holder 7, and union nut 6.
6
Tighten each part at specified torque.
7
8
9
10
13770
1 4 With stop lever 3 pulled toward the STOP direction, insert cable end 5
through the stop lever slit.
Fix to control wire bracket 2 with lock nut 1.
Adjust engine stop cable 4 after installing it. P13-64
3
5
2
13769
13-30
13
Inspection and Adjustment of No-load Minimum and Maximum Revolution
Service standards
No-load minimum revolution Manual 700 to 750 rpm Adjust
(Idling revolution) transmission
Automatic * 750 to 800 rpm Adjust
transmission
No-load maximum revolution 3650 to 3750 rpm Adjust
* : Revolutions per minute in P range
Before inspecting the vehicle do the following :

Run the engine to bring the coolant temperature up to approxi-
mately 80 to 90C {176 to 194F}.
Put transmission in neutral. (For automatic transmission, put
transmission into the P range.)
Set the steering wheel at center and straight position.
1 (1) No-load minimum revolution (Idling revolution)

Make sure that control lever 1 strikes idling set bolt 2, and in this
3
state, check and see if the minimum revolution is within the stand-
ard value.
If the minimum revolution deviates from the standard value, adjust

2
using idling set bolt 2.
4 After adjustment increase the revolution from between 2800 rpm to

13777 3400 rpm once, and check the minimum revolution.
(2) No-load maximum revolution

Make sure that adjusting lever 1 strikes full-speed set bolt 3, and in
this condition, check and see if the maximum revolution is within the
standard value.
If the maximum revolution deviates from the standard value, adjust

using full-speed set bolt 3.
CAUTION
Never change the fixed position of full-load stopper bolt 4.
NOTE
Ensure that the engine does not stall or hunt when adjusting
lever 1 is moved from the full-speed position to the idling
position quickly. If performance is faulty, adjust it to within
standard values.
13-31
Inspection and Adjustment of Idling Actuator < with Cab Cooler >
Service standards
Idling revolution 62525 rpm Adjust
Idling revolution under idling operation Manual 950 to 1000 rpm Adjust
transmission
Automatic 850 to 900 rpm Adjust
transmission
Before inspecting the vehicle do the following:

Run the engine to bring the coolant temperature up to approxi-
mately 80 to 90C {176 to 194F}.
Put transmission in neutral. (For automatic transmission, put
transmission into the P range.)
[Inspection]
Make sure that idling speed is within the standard value.
If idling speed deviates from the standard value, adjust idling speed.
P13-31
Apply vacuum of more than 47 kPa {14 in.Hg, 350 mmHg} to
2 activate actuator 3, and in that state, make sure that the idling
1 speed is within the standard value.
If the idling speed deviates from the standard value, adjust in the
following manner.
[Adjustment]
Activate actuator 3 by applying vacuum of more than 47 kPa
3 4
13778 {14 in.Hg, 350 mmHg}.
Loosen lock nut 1, and adjust idling speed by turning adjusting
screw 2 until idling speed conforms to the standard value.
After depressing the accelerator pedal several times, make sure

that the idling speed is within the standard value.
NOTE
If adjustment using adjusting screw 2 fails to meet the stand-
ard value, loosen actuator mounting bolts 5 and adjust by
shifting the position of actuator 3. Then, tighten mounting
bolts 4 at specified torque.
13-32
13
MEMO
13-33
Troubleshooting Procedure
The pre-stroke control type injection pump system has a trouble diagnosis function, this function is used for troubleshoot-
ing.
This means you have to read the diagnosis code memorized in the pre-stroke control unit, and carry out an inspection
based on this code. There are two ways of reading the code; with a multi-use tester, and without a multi-use tester.
In the case of trouble that does not have a diagnosis code, the normal 01 code is indicated, and it is necessary to carry out
a check depending on the situation. In this case, inspect the electric circuits and their relative devices.
Can the trouble be reproduced?

Yes No
Read diagnosis code:

With multi-use tester P13-35
Without multi-use tester P13-37

Abnormal code output Normal code output (01)
Checking by individual diagnosis Inspection of temporary faults P13-60

code P13-42 Inspection of electric circuits and their
devices relevant to the trouble
13-34
13
Inspection with multi-use tester
0 Special tools
Tool name and shape Part No. Application
Multi-use tester sub-assembly MC858999
02803
Multi-use tester harness MB991231 Inspection of system
02804
ROM pack MC858989
02805
Inspection flow chart
Set the starter switch to ON (Do not start the engine)

Connect the multi-use tester to the pre-stroke control unit P13-36

Read the diagnosis code with the multi-use tester ^ Multi-use Tester Operation Manual
NOTE
The diagnosis code that can be read with the multi-use tester is the current diagnosis code only.
To inspect the previous diagnosis code, follow the procedure in Inspection without Multi-use
Tester P13-37

Conduct an inspection based on the multi-use tester inspection code data list P13-36

Start the engine

Warning lamp does not light NG

while the engine is running

OK
Inspection is finished

Disconnect the memory clear switch (Fuse No. F4) for more than one second, and reconnect it to
clear the memory
Connect the diagnosis switch
13-35
Connection of Multi-use Tester to Pre-Stroke Control Unit
Set the starter switch to LOCK.
Connect 1 multi-use tester harness to multi-use tester connector 2
2
of cab harness 1 and to cigarette lighter socket 3.
3
Connect 1 multi-use tester harness to 2 multi-use tester sub-
assembly.
Connect 3 ROM pack to 2 multi-use tester sub-assembly.
NOTE
Refer to the Multi-use Tester Operation Manual for details regard-
ing the operation of the multi-use tester.
1
1 2 3
13813
Inspection with Multi-use Tester

Inspection using service data is possible as well as by diagnosis code indication (self-diagnosis) using the multi-use
tester. This enables you to compare the indicated figures (service data) that represent the data signals from the various
sensors on the vehicle with the judgement standards, and judge whether they are good or bad. The service data code is
indicated as well as the diagnosis code.
Self-diagnosis Inspection using Service Data

Indicated on multi-use tester Indicated on multi-use tester Inspection procedure
Trouble item Service
Diagnosis Inspection
(Inspected data Data signal name Service data Condition at inspection Judgement standard
code procedure
instrument) code
03 PS OFFSET P13-42
04 PS VOLTAGE
05 NE NO PULS
12 PS SERVO 12 PS ANG DIFF . deg Engine running Within 5.5 deg
13 PS SNSR 400<Ne<=2000 Within 2CA
Ne : Engine revolution
15 NE SNSR 15 ENGINE SPEED rpm Racing Synchronization with
tachometer
16 CTRL ROD ADJ V Starter switch set to ON Within 0.04 V
21 WTR TEMP 21 WATER TEMP F While engine is cool Equivalent to ambient
SNSR temperature
While engine is warmed Gradually rising
up temperature
Engine is stopped after Gradual falling
warming up temperature
22 CTRL ROD 22 CTRL ROD V Engine running 3 V or less
SNSR VOLT
41 BST TEMP 41 BOOST TEMP F At high idling 4.9 V or less
SNSR
13-36
13
Inspection without multi-use tester
Set the starter switch to ON (Do not start the engine)

Inspect and repair the warning lamp
NG Bulb burnt out
Warning lamp lights
Wiring breakage, short circuit
OK
Poor connection

Disconnect the diagnosis switch

Locate the trouble point by reading the current diagnosis code while checking the way the
warning lamp flashes P13-38
If the warning lamp does not flash but stays lit, the trouble is at the pre-stroke control unit
power source

Disconnect the memory clear switch (Fuse No. F4)

Locate the trouble point by reading the previous diagnosis

code while checking the way the warning lamp flashes

Inspect by individual diagnosis code P13-42

Start the engine

Warning lamp does not light NG

while the engine is running

OK
Inspection is finished

Disconnect the memory clear switch (Fuse No. F4) for more than one
second, and reconnect it to clear the memory
Connect the diagnosis switch
13-37
Reading of Diagnosis Code with Warning Lamp
CAUTION
Make sure you read the current diagnosis codes first, then read
1 the previous diagnosis codes.
You must take care not to disconnect memory clear switch 2
(Fuse No. F4) before removing diagnosis switch 1 (1-pin
connector without locking device) because this would make it
impossible for the system to indicate the current diagnosis code.
Note that if memory clear switch 2 is reconnected after being
disconnected, it will clear all the diagnosis codes.
Current diagnosis code

When diagnosis switch 1 is disconnected, the pre-stroke control unit
starts diagnosis of the trouble and indicates the current diagnosis
2
codes by flashing warning lamp within the meter cluster.
13779
The diagnosis codes are read by the number of flashes and the
Tens unit Ones unit duration of flashes of warning lamp .
The flash duration differs for the tens unit and the ones unit.
Lamp lights
Tens unit : Every 1.2 seconds
Ones unit : Every 0.4 seconds
Lamp The number of flashes indicates the numeral for each unit.
goes off
1.2 1.2 The diagnosis code indication shows the tens unit first, then the
0.4
ones unit. However, when the tens unit begins with a zero, only
the ones unit is shown.
0.4 A diagnosis code is shown by the repetition of three consecutive
0.4 indications. After the code indication, if another code does not exist,
Disconnecting of the indication returns to the first code and is again shown three times.
diagnosis switch When diagnosis switch 1 is connected, the pre-stroke control unit
immediately terminates code indication.
Second indication
First indication
Lamp
lights.
Lamp Previous diagnosis code
goes off
After reading the current diagnosis codes (with diagnosis switch 1
2.4 2.4 2.4 2.8
disconnected), disconnect memory clear switch 2 (Fuse No. F4).
13705 Warning lamp starts flashing again. This flashing indicates the
previous diagnosis codes, and by interpreting these codes, the location
of the trouble is determined.
13-38
13
Diagnosis code Warning lamp flashing pattern
01 (Normal)
03 (Pre-stroke learning faulty)
04 (Pre-stroke actuator power source faulty)
05 (Engine revolution sensor no pulse faulty)
12 (Pre-stroke servo system faulty)
13 (Pre-stroke position sensor faulty)
15 (Engine revolution sensor wiring breakage faulty)
21 (Water temperature sensor faulty)
22 (Control rod position sensor faulty)
41 (Boost air temperature sensor faulty)

13970
Clearing diagnosis codes

By disconnecting memory clear switch 2 (Fuse No. F4) once and recon-
necting it, all the diagnosis codes memorized in the pre-stroke control
unit are cleared.
CAUTION
Clearing of diagnosis codes must be done using memory clear
switch 2.
2
One 13757
second or Three
more seconds
Connection
Memory is cleared
Release
02739
13-39
Electric Circuit and Position of Parts Installation
14
b
13
c
11
12
10
b
9
16
b
a
2
3
4
18
6
1
17
15
10568
13-40
13
F18 F20 F25 5
7
3 (F4) 4 6
2 b
a 1
9 8
13 12 11
10
17 14
18 c
15
16
13780
1 Starter switch 11 Control rod position sensor

2 Meter cluster 12 Pre-stroke actuator
3 Memory clear switch (F4 fuse) (with built-in pre-stroke position sensor)
4 Fuse box 13 Water temperature sensor
5 Pre-stroke cut relay 14 Boost air temperature sensor
6 Relay box 15 Diode < Manual transmission >
7 Alternator 16 Pre-stroke control unit
8 High-current fuse box 17 Transmission neutral relay
9 Battery < Manual transmission >
10 Engine revolution sensor 18 Diagnosis switch
13-41
Inspection by Individual Diagnosis Code
Diagnosis code 03 Pre-stroke learning faulty

Inspect the injection NG
Timing rod, timing sleeve faulty Repair or replace
pump body

OK
Inspect the pre-stroke NG Pre-stroke position sensor

Repair or replace
position sensor adjusted incorrectly

OK
Replace the pre-stroke control unit.
When diagnosis code 03 is indicated, inspect the injection pump body and the pre-stroke position sensor. However,
special tools and equipment are necessary for this work, so it is recommended that the work be carried out by a ZEXEL
service station. If the inspection result shows normal, replace the pre-stroke control unit.
13-42
13
MEMO
13-43
Diagnosis code 04 Pre-stroke actuator power source faulty

Inspect the harness and NG
Wiring breakage, harness short circuit Repair or replace
connector Connector not connected properly

OK
Inspect the pre-stroke cut NG Wiring breakage, coil short circuit Repair, adjust or

relay P13-45 Installation faulty replace

OK
1 Fuse box
Gr 54
Drive unit
3 Relay box
2 Pre-stroke
cut relay
5 Pre-stroke control unit a
Cab b Chassis
Gr 54 Gr 54
Cab Chassis
ground ground
13781
13-44
13
F25 3
13782
1 Fuse box 4 Pre-stroke actuator

2 Pre-stroke cut relay 5 Pre-stroke control unit
3 Relay box
2
Service procedure
Inspection of pre-stroke cut relay
Follow the table below to inspect continuity.
1 2 3 4
No current

2 1 3 4 Current

07387 : There is continuity between terminals and .

: Indicates that 12 volts DC is applied to the line
: Indicates that continuity is lost between the terminals.
If any fault is found, replace pre-stroke cut relay 2.
13-45
Diagnosis code 05 Engine revolution sensor faulty
(No pulse error : Output signal from the sensor is weak or unstable)

OK

Inspect the engine revolution

sensor. P13-48
NG Wiring breakage, coil short circuit Repair, adjust or

Inspect the output voltage of Installation faulty replace
alternator terminal L ^ Gr 54

OK
1 Pre-stroke control unit
Gr 54
To meter
cluster
(Charging)
b 2 Alternator
a
Engine revolution
Cab Chassis sensor
Gr54 Gr54
Cab Chassis
ground ground
13783
13-46
13
13784

2 Alternator
3 Engine revolution sensor
Service standards
3 Resistance value of engine revolution 1-2 2.30.2 k Replace
sensor (at 25C {77F})
3 2 1
14013

3 Engine revolution sensor 25 to 34 {18 to 25, 2.5 to 3.5}
13-47
3
Service procedure
Inspection of engine revolution sensor
1
Measure the resistance between terminals 2
and .
engine revolution sensor 3.
NOTE
When the engine revolution sensor is replaced, tighten at speci-
3 2 1
fied torque.
3 13785
13-48
13
MEMO
13-49
Diagnosis code 12 Pre-stroke servo system faulty

Inspect the harness and NG Wiring breakage, harness short circuit
Repair or replace

OK
Inspect the pre-stroke NG Copper plate mounting nut loose

actuator P13-52 Wiring breakage, coil short circuit
Repair, adjust
Rotor rotation faulty

or replace
Spring faulty
OK
Inspect the injection pump

NG
Timing rod, timing sleeve faulty Repair, adjust or
body
replace

OK

: To be carried out by a ZEXEL service station
1 Pre-stroke control unit 2 Pre-stroke actuator
Cab Chassis
Gr 54
Chassis
ground
Gr 54
Cab ground
13786
13-50
13
13787

Service standards
Resistance value of pre-stroke 2-3 5.5 to 6.1
actuator (at connector point) Replace
1-3 11.0 to 12.2 (to be
carried out
3 2 1 1-2 5.5 to 6.1
by a
ZEXEL
6 5 4 service
4-5 1.0 to 1.3 station)
2 13714
Resistance value of pre-stroke
- 11.0 to 12.2
actuator (Actuator body) Replace
- 5.5 to 6.1 (to be
E D C B A

carried out
by a

- 5.5 to 6.1 ZEXEL
service

- 1.0 to 1.3 station)
13789
13-51
2
Service procedure
Inspection of pre-stroke actuator
Inspect the following points and if any fault is found, have the unit
inspected and repaired by a ZEXEL service station.
NOTE
Inspection of pre-stroke actuator 2 must be carried out when the
engine is cold.
(1) Inspection at connector point

Measure resistance between terminals 2-3, 1-3, 1-2 and
45
- .
3 2 1
6 5 4
13790
(2) Inspection of pre-stroke actuator body

A
Remove cover A from pre-stroke actuator 2.
CAUTION
Remove only cover A from pre-stroke actuator 2, never remove
the actuator body itself. If the actuator is removed, it requires
special tools to replace and adjust it.
When removing cover A, do not exert excessive force on pre-
stroke actuator 2 with your hands or by treading on it, etc.
2
13791
E D C B Measure resistance between terminals -, -, - and -.

A
13878
(3) Inspection of continuity between pre-stroke actuator and

connector
E D C B
Make sure that continuity exists between terminals as listed in the
A
table below.
Pre-stroke
Connector
actuator Application
terminal
3 2 1 body
6 5 4 4 Pre-stroke actuator driving power source
5

Pre-stroke actuator driving power source
6

13792
GND Shield
1 Pre-stroke position sensor (GND)
2

Pre-stroke position sensor (MDL)
3

Pre-stroke position sensor (OSC)
13-52
13
(4) Inspection of copper plate mounting nut
Check that copper plate mounting nut B was not loosened when the
cover of pre-stroke actuator 2 was removed.
If nut B is loose, tighten it.
B 13793
Diagnosis code 13 Pre-stroke position sensor faulty


connector P13-50 Connector not connected properly

OK
Inspect the pre-stroke NG

Wiring breakage, coil short circuit Repair, adjust
position sensor or replace

OK
Replace the pre-stroke control unit. : To be carried out by a ZEXEL service station
Diagnosis code 15 Engine revolution sensor faulty

(Wiring breakage error : No output signal transmitted by the sensor)

OK
Inspect the engine revolution
using the multi-use tester
P13-36

NG
Inspect the harness and Wiring breakage, harness short circuit

NG
Repair or replace
connector P13-46 Connector not connected properly

OK
Inspect the engine revolution NG Wiring breakage, coil short circuit Repair, adjust

sensor P13-48 Installation faulty or replace

OK
13-53
Diagnosis code 21 Water temperature sensor faulty

OK
Inspect the engine coolant
temperature using the multi-
use tester P13-36
NG

Inspect the harness and Wiring breakage, harness short circuit
NG
Repair or replace

OK
Inspect the water tempera- NG Wiring breakage, coil short circuit Repair, adjust or

ture sensor P13-55 Installation faulty replace

OK
b Gr 54
1 Pre-stroke
control unit
Chassis ground
2 Water temperature
a sensor
Cab Chassis
Gr 54
Cab ground
13794
13-54
13
13795

2 Water temperature sensor
Service standards
2 Resistance value of water temperature 20C {68F} 3250 Replace
sensor 40C {104F} 1500 Replace
60C {140F} 62062 Replace
2
Service procedure

Inspection of water temperature sensor
Place water temperature sensor 2 in engine oil in a container.
Raise the oil temperature to the specified values and stir the oil.
Measure the resistance between terminal 1 and the body.
If the measured value deviates from the standard value, replace water
temperature sensor 2. ^ Gr 14
13722
13-55
Diagnosis code 22 Control rod position sensor faulty

Inspect the control rod posi-
OK tion sensor power output
voltage using the multi-use
tester P13-36

NG


OK
Inspect the control rod NG Wiring breakage, coil short circuit

Repair, adjust
position sensor P13-56 Installation faulty
or replace

OK

: To be carried out by a ZEXEL service station
Control rod
1 Pre-stroke-control unit 2 position sensor
Cab Chassis
Gr 54
Chassis ground
Gr 54
Cab ground
13796
13-56
13
13797

2 Control rod position sensor
Service standards
2 Resistance value of control rod 1-4 92.5 to 101.5 Replace
position sensor (To be
1-3 92.5 to 101.5
carried out
by a
2 1
3-4
ZEXEL
4 3 185 to 203 service
13725 station)
2
2
Service procedure
Inspection of control rod position sensor
14 13
Measure resistance between terminals - , - and - . 34
control rod position sensor 2.
Replacement work is to be carried out by a ZEXEL service station.
2 1
4 3
13799
13-57
Diagnosis code 41 Boost air temperature sensor faulty

OK Inspect the engine intake air
temperature using the multi-
use tester P13-36

NG
Inspect the harness NG

and connector Connector not connected properly

OK
Inspect the boost air tempe- NG Wiring breakage, coil short circuit Repair, adjust or

rature sensor P13-59 Installation faulty replace

OK
b Gr 54
Chassis ground
2 Boost air
temperature sensor
Cab Chassis
Gr 54
Cab ground
13727
13-58
13
13801

2 Boost air temperature sensor
Service standards
2 Resistance value of boost air 0C {32F} 5880588 Replace
temperature sensor 20C {68F} 2455245 Replace
80C {176F} 32232 Replace
2
Service procedure

Inspection of boost air temperature sensor
Place boost air temperature sensor 2 in rape seed oil in a container.
Raise the oil temperature to the specified values and stir the oil.
Measure the resistance between terminals 1 2
and .
If the measured value deviates from the standard value, replace boost
air temperature sensor 2. ^ Gr 15
13729
13-59
Inspection of Temporary Faults
02597
illustrated.
as illustrated.
suspensions.
02598 The inspection subjects include possible causes related to the diagno-
sis code outputs and faults, as well as the connectors and other parts
in the inspection procedure.
02599
13-60
13
MEMO
13-61
ENGINE CONTROL
1
2
3
*1
*3
*2
8
9 5
13742
1 Idling control knob 9 Fuel-cut motor ^ Gr 54
2 Clip 10 Engine stop cable
3 Nut
4 Idling control cable *1 : Accelerator arm assembly P13-66
5 Cable clip *2 : Accelerator pedal assembly P13-65
6 Clevis pin *3 : Injection pump assembly P13-72
7 Accelerator control cable *4 : Frame ^ Gr 41
8 Bolt
Assembly sequence
CAUTION
Be sure when laying and routing cables, not to let them contact metal edges.
13-62
13
8 Bolt (Fuel-cut motor mounting) 4.9 to 5.9 {3.6 to 4.3, 0.5 to 0.6}
1
4
Service procedure
Installation of idling control cable
Rotate idling control knob 1 counterclockwise until the inner cable
protrudes at its maximum.
07876
1 While maintaining this state, install accelerator arm assembly *1.

4
*1
08306
*1
7 Accelerator control cable
[Installation]
Mount accelerator control cable 7 to accelerator arm assembly *1.
08307
Make sure that the accelerator pedal does not move by turning idling
A
control knob 1 clockwise as far as it will go.
*3 Mount the engine end of accelerator control cable 7 to control lever A
of injection pump assembly *3.
Tighten the accelerator control cable 7 using adjustor nut B so that the
accelerator pedal does not move.
7 NOTE
When mounting accelerator control cable 7, do not move control
lever A.
B 13743
13-63
ENGINE CONTROL
C [Adjustment]
Turn the starter switch ON, and press down on the accelerator pedal
until control lever A hits stopper bolt C.
A 13744
Adjust the height of stopper bolt D of accelerator pedal assembly *2 in

3 to 5 mm such a manner that the clearance between stopper bolt contact sur-
{0.11 to 0.20 in.}
face E and the stopper bolt conforms to the specified value.
E
D
*2
06923
B
F Installation of engine stop cable
Mount engine stop cable 10 to stop lever A of injection pump assem-
10 bly *3.
Turn the starter switch to ACC or LOCK. Fasten using mounting nut B
while keeping stop lever A pressed against stopper bolt C.
After installation, start the engine using the starter switch, and make
sure that the engine stops when the switch is turned to ACC.
A
C
*3
13745
13-64
13
Accelerator Pedal Assembly
2 Clevis pin
3 Accelerator pedal
4 Stopper bolt
5 Accelerator pedal bracket
*
* : Accelerator arm assembly P13-66
Assembly sequence
3- Follow the disassembly sequence in reverse.
5
07848
- Lubricant
3 Slide-contacting surfaces of accelerator pedal and bracket Chassis grease [NLGI No.1 (Ca soap)] As required
A
1
Service procedure
Removal of accelerator pedal assembly
Pinch hook B of stopper A of accelerator pedal 3 using pliers C and
rotating approximately 45 pull out the stopper towards the front of the
B vehicle.
3
45
CAUTION
Take care not to damage stopper A itself during removal, do not
C pull it out too forcibly.
05900
13-65
ENGINE CONTROL
Accelerator Arm Assembly
1 Accelerator sensor ^ Gr 54
3 < Automatic transmission >
3 2 Sensor rod < Automatic transmission >
2 3 Bushing linkage
4 Washer
5 Accelerator arm
* 6 Bushing
-6 7 Spring
4 8 Collar
6 9 Accelerator lever
-
10 Bushing
8
11 Accelerator switch ^ Gr 35, 54
7
9 12 Nut
10
12 5 * : Support assembly ^ Gr 35
Assembly sequence
verse.
- Lubricant
6 Slide-contacting surfaces of bushing and support assembly Chassis grease [NLGI No.1 (Ca soap)] As required
1
Service procedure
Installation of accelerator sensor
Install accelerator sensor 1 onto support assembly * and fasten
B temporarily with nut A.
A Adjust accelerator sensor 1 by moving it so lever B comes into contact
C with idling stopper C during idling operation.
* Tighten nut A after adjustment.
* 1
G
A
13747
Installation of accelerator switch

Screw in accelerator switch 11 and fasten with nut 12 in such a way
* that the clearance between the accelerator switch and support assem-
11.50.5 mm bly * is set to the standard value.
{0.450.020 in.}
12 Inspect and adjust the exhaust brake system. ^ Gr 35
11
07971
13-66
FUEL TANK 13
8
1 9
2
10
3
5
7 4
13737
Work before removal

WARNING
Keep naked lights away because of the risk of explosion.
Wipe up any spilled fuel beacuase it can cause a fire.
NOTE
Removal sequence
1 Suction hose 6 Bolt * : Chassis harness ^ Gr 54
2 Return hose 7 Fuel tank bracket
3 Drain plug 8 Screw
4 Nut 9 Fuel gauge unit ^ Gr 54
5 Fuel tank band 10 Fuel tank

8 Screw (Fuel gauge unit mounting) 1.0 to 1.5 {0.7 to 1.1, 0.1 to 0.15}
13-67
WATER SEPARATOR
1 Fuel feed hose
2 Water separator assembly
4 3 Air vent plug
3 4 Connector
5 Drain plug
13 6 O-ring
1 7 Ring nut
12
8 Case
9 Baffle plate and screen assembly
4 10 Water level ring
11 11 Clean screen
12 O-ring
9 2
13 Head
10
7
8 1 WARNING
6 Fuel ignites easily. Do not get it near
5 flame or heat.
Wipe up any spilled gas oil because it
can cause a fire.
13748
Assembly sequence
verse.

5 Drain plug 2.9 to 3.9 {2.2 to 2.9, 0.3 to 0.4}
7 Ring nut 5.9 to 7.8 {4.3 to 5.8, 0.6 to 0.8}
13-68
13
MEMO
13-69
FUEL FILTER
4 1 Eye bolt
1 2 Fuel feed pipe

1 3 Fuel filter
4 Air vent plug
5 Fuel filter head
2 Assembly sequence
5
13879

1 Eye bolt 25 to 34 {18 to 25, 2.5 to 3.5}
- Lubricant

90.2 {3.55}
01882
13-70
13
3
Service procedure
Fuel filter
WARNING
Wipe up any spilled gas oil because it can cause a fire.
0
[Removal]
06872
[Installation]
5 WARNING
B You must use a genuine replacement part filter because using
B A A unsuitable fuel filter 3 can cause fuel leakage and a fire.
Install by tightening by three-quarters to one full turn after contact

3 surface A of fuel filter head 5 contacts gasket B of fuel filter 3. Be sure
to tighten by hand.
06874 After installation, run the engine to check for fuel leakage.
13-71
INJECTION PUMP
17
6 5 18
19
10
7
*1
4 20
12
*2
14 11
- 22
13
*3
8
16
15 9

*5 2
1 3
*4
13754 13750
Removal sequence
1 Harness (Pre-stroke actuator) 16 Fuel suction pipe
2 Harness (Control rod position sensor) 17 Vacuum hose
3 Harness (Engine revolution sensor) 18 Eye bolt
4 Accelerator control cable P13-62 19 Boost hose
5 Engine stop cable P13-62 20 Pump stay
6 Eye bolt 21 Injection pump assembly
7 Fuel feed pipe 22 O-ring
8 Eye bolt
9 Fuel feed pipe *1 : Pre-stroke actuator P13-10, 12
10 Injection pipe *2 : Control rod position sensor P13-16
11 Overflow valve *3 : Engine revolution sensor P13-16
12 Fuel return pipe *4 : Timing gear case ^ Gr 11
13 Eye bolt *5 : Front plate ^ Gr 11
14 Oil pipe : Non-reusable parts
15 Eye bolt
13-72
13
WARNING
CAUTION
performance is adversely affected if dirt and foreign particles enter injection pump assembly 21.
Do not hold the control lever when lifting injection pump assembly 21. Also, do not remove the control lever
because removal of the lever might cause poor performance of the pump.

10 Injection pipe (Union nut fastening) 29 to 49 {22 to 36, 3 to 5}
11 Overflow valve 25 to 29 {18 to 22, 2.5 to 3}
13 Eye bolt (Oil pipe mounting) 9.8 to 13 {7.2 to 9.4, 1 to 1.3}
15 Eye bolt (Fuel suction pipe mounting) 25 to 29 {18 to 22, 2.5 to 3}
18 Eye bolt (Boost hose mounting) 12 to 15 {8.7 to 11, 1.2 to 1.5}
- Lubricant
22 Entire body of O-ring Engine oil As required

21 Socket wrench 12 {0.47} 31391-14100 Removal and installation of injection pump

assembly
06876
36 {1.42} 05999
13-73
INJECTION PUMP
Q
Service procedure
Injection pump assembly
[Removal]
13751
B [Installation]
To bring No. 1 cylinder piston to top dead center in the compression
cycle, align pointer B of timing gear case *4 with indent mark 0 on
0 *4 crankshaft pulley A by turning the crankshaft pulley clockwise using
0 cranking handle. At this point, make sure that the intake and
A exhaust valves of No.1 cylinder are not depressed by the push rod. If
they are depressed, make another full rotation of the crankshaft pul-
0 0 ley.
B 06204
Align indent C on the timer case with indent D on the injection pump
gear.
D
13752
By aligning guide bar E of the timer case with guide hole F of the front
plate, push in the idler gear up to a fraction of an inch short of
engaging the injection pump gear.
F E
13753
13-74
13
Making sure that alignment mark C on the timer case aligns with
D
indent D on the injection pump gear, push in the injection pump
assembly.
As this fitting is taking place, the indent will turn in direction G.
C
G
08317
13-75
INJECTION NOZZLE
P13-77
2 1 Injection pipe
2 Leak-off pipe
1 15 3 Bolt
4 Bridge
5 14 5 O-ring
13 6 Injection nozzle assembly
16 3 7 Retaining nut
12
8 8 Tip packing
4 9 9 Straight pin
10 10 Needle valve
11 11 Nozzle
*
12 Pressure pin
7
13 Spring

14 Adjusting shim
15 Nozzle holder
06955
16 Nozzle gasket
* : Cylinder head Gr 11
Assembly sequence
verse.
WARNING
CAUTION
Be sure not to touch the slide-contact area of needle valve 10 because any scratches or corrosion might spoil
the airtightness of nozzle 11. It must be handled with utmost care.
Never change the combination of needle valve 10 and nozzle 11 for each cylinder.
performance is adversely affected if dirt and foreign particles enter injection nozzle assembly 6.
NOTE
Remove carbon deposits and clean injection nozzle assembly 6 before working on it, then test the injection
pressure and jet spray condition, and check for fuel leakage before disassembly. If no fault is found, do not
disassemble.
Service standards
6 Valve opening pressure 21.6 MPa {3130 lbf/in2, 220 kgf/cm2} Adjust

1 Union nut (Injection pipe mounting) 25 {18, 2.5}
3 Bolt (Bridge mounting) 25 {18, 2.5}
13-76
13
0 Special tools
Nozzle cleaning tool 105789-0010 Cleaning of injection nozzle assembly
ZEXEL code number
Service procedure
Attach injection nozzle assembly 6 to nozzle tester A, and conduct the
following inspection.
WARNING
Never touch the spray from nozzle 11 or let your hands get too
close to the spray point during the test.
NOTE
Before inspection, bleed the air out in a couple of bursts by
pressing nozzle tester A lever.
(1) Valve opening pressure

Raise the pressure of nozzle tester A by operating the lever, and
A measure the pressure that the gauge registers when the pressure is
released which will be observed by the sudden movement of the
gauge indicator.
If the measured value deviates from the standard value, disassem-
6 ble the nozzle and clean, and adjust it using adjusting shims 14.
Variation of 0.05 mm {0.0020 in.} thickness in adjusting shims 14
causes a difference of 735 kPa {105 lbf/in2, 7.5 kgf/cm2} of pres-
06930 sure, for example, to alter the pressure for 98 kPa {14 lbf/in2,
1 kgf/cm2}, a thickness of 0.0067 mm {0.00026 in.} is required.
If the performance cannot reach the standard value even after
adjustment, replace injection nozzle assembly 6.
(2) Spray condition

Test injection spray condition by quick lever actions of nozzle tester
A, 4 to 6 actions per second.
A: Even spray from all five orifices (Good)
B: Even and symmetrical spray (Good)
C: Asymmetrical spray (Faulty)
D: Spray direction deviates from the nozzle axis line
(Faulty)
E: Thin and insufficient spray (Faulty)
A B C D E F
06931 F: Irregular spray (Faulty)
If faulty spray cannot be corrected, disassemble injection nozzle

assembly 6 and clean every part and repeat the test.
If faulty spray still occurs after repeating test, replace the injection
nozzle assembly.
Make sure that there is no post-spray dripping after injection.
13-77
INJECTION NOZZLE
(3) Fuel air tightness and leakage at related contact points
Maintain interior pressure of nozzle at 1960 kPa {285 lbf/in2,
20 kgf/cm2} lower than the valve opening pressure, and check and
see if any fuel seeps out of the nozzle tip within 10 seconds.
If any fault is found, disassemble injection nozzle assembly 6 and
clean every part and repeat the test. If any fault is still found,
replace the injection nozzle assembly.
05388
6 Injection nozzle assembly

[Disassembly]
10 A
CAUTION
Be sure not to touch sliding part A of needle valve 10 with your
hands.
Never change the combination of removed needle valve 10 and
nozzle 11 for each cylinder.
06932
[Cleaning]
B
Clean needle valve 10 and nozzle 11 with gas oil (cleaning solvent).
Remove carbon deposits with 0 cleaning tool in the following manner:
Clean needle valve 10 by removing carbon deposits from its tip using
cleaning bar B of 0 cleaning tool.
10 CAUTION
Never use a wire brush or hard steel for cleaning.
01892
To clean nozzle 11, remove carbon deposits from the orifices of the
C
nozzle using needle cleaner C of 0 cleaning tool, by inserting it into
the orifices and turning it.
Needle cleaner diameter : 0.25 mm {0.0098 in.} or less
11
01893
13-78
13
Clean the seat of nozzle 11 using cleaning needle D of 0 cleaning
D
11 tool.
Use FUSO carbon remover to remove hard-to-remove, burnt-on
carbon deposits.
01894
[Inspection]
Immerse needle valve 10 and nozzle 11 in gas oil (cleaning solvent)
and clean them thoroughly.
Check and see if needle value 10 drops by its own weight into the
10 nozzle from the position where a third of its length is pulled out.
(Repeat this several times rotating the needle valve.)
If needle valve 10 does not drop smoothly, repeat cleaning and repeat
11 the test. If any fault is still found, replace both the needle valve and
nozzle 11 together as a set.
01911
13-79
Group 14 - Cooling
Group 14A - Cooling

2001 Model Change
<4M50>
BACK HOME
Service Manual
Group 14A
Cooling
<4M50T2>
Table of Contents
BACK HOME
MAY. 2000
GROUP 14A COOLING
TROUBLESHOOTING .......................................................................... 14A- 4

Replacing Coolant and Cleaning Cooling System .................... 14A- 6
Air Bleeding of Cooling System .................................................. 14A- 8
Gas Leak Testing .......................................................................... 14A- 8
RADIATOR ............................................................................................ 14A-10
COOLING FAN, V-RIBBED BELT AND WATER PUMP ....................... 14A-18
WATER HOSE & PIPE.......................................................................... 14A-24
THERMOSTAT ...................................................................................... 14A-26
14A-1
SPECIFICATIONS
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Kind of cooling system Forced water circulation system
Water pump type Belt-driven involute type
Thermostat type Wax-pellet, bottom bypass type (with jiggling valve)
Automatic cooling fan coupling type Continuous control type
Radiator type Tube and corrugated fin type
Coolant capacity L {qts} 13 {14}

Cooling System (Flow to Coolant)
1 Radiator
2
1 2 Cylinder head
3 Crankcase
4 Crankcase drain cock
5 Oil cooler
6 Thermostat
3 7 Water pump
8 Cooling fan
9 Radiator drain cock
6 4
5
8 7
9
29544
14A-2
14A
Water Pump
1 Case
2 Unit seal
3 Impeller
4 Unit bearing
1 5 Pulley
A: Drain hole
5 3
4
A
29545
Thermostat
1 Oil cooler
1 B 2 Thermostat
3 Thermostat cover
2
D
E A: From radiator
B: From cylinder head
C: To water pump
D: With high coolant temperature
C E: With low coolant temperature
3
Thermostat 2 is a bottom bypass type that uses wax-
charged pellets as its regulating element. As the wax
changes from solid to liquid in with temperature increases,
the total wax volume changes. As a result, the position of
A the valve, changed by the coolant temperature, regulates
29546
the flow of coolant from the radiator and cylinder head (by-
pass side) before entering the engine to control the coolant
temperature (inlet control type).
14A-3
TROUBLESHOOTING
Symptoms
Overheating (insufficient cooling)
Excessive coolant loss

Remarks
Abnormal noise
Overcooling
Possible causes
Loose or damaged
V. ribbed belt Excessive tension
Oil on belt
Water pump fitted poorly
Unit bearing defective
Water pump Impeller defective
Unit seal defective
Loose fit between unit bearing and flange and/or impeller
Case fitted poorly
Thermostat Valve opening temperature too high; valve remains closed
Valve opening temperature too low; valve remains open
Space between core and fins clogged
Radiator
Core cracked and/or soldered joints separated
Cooling fan Fan shroud fitted poorly
Bearing defective
Automatic cooling Bimetal damaged
fan coupling Bimetal contaminated with foreign particles
Silicone oil leaking
Oil cooler fitted poorly
Oil cooler B Group 12A
Gasket defective
Cylinder head fitted poorly
Cylinder head B Group 11A
Gasket defective
Coolant quantity insufficient
Coolant passages dirty and/or clogged
Hoses fitted poorly
Ambient temperature extremely low
14A-4
14A
MEMO
14A-5
Replacing Coolant and Cleaning Cooling System
1 Pressure cap
2 Drain cock
3 Water drain plug
3

2
29573

2 Drain cock 2 {14.5, 0.2}
3 Water drain plug 24.54.9 {18.13.6, 2.50.5}
Using the radiator for extended periods without cleaning the cooling system will cause overheating since rust and scale
will accumulate. The cooling system must be cleaned periodically.
P Draining the coolant

Before draining the coolant, loosen the pressure cap 1 to reduce the pressure in the cooling system.
WARNING k
To avoid being scalded, make sure the coolant has cooled sufficiently before loosening the pressure cap 1.
Unless care is taken, opening the pressure cap 1 when the coolant is hot can cause the coolant to spray out.
Cover the pressure cap with a cloth, and loosen the cap slowly to bleed off the pressure before opening it fully.
P Cleaning procedure
Run the engine and keep the coolant at a temperature of approximately 90C {194F} such that the thermostat valves
remain open and the coolant circulates continuously in the radiator.
To increase the coolant temperature quickly, cover the front of the radiator with cardboard or a similar material.
If cleaning is carried out after a large amount of rust has accumulated, the radiator may start to leak. Carefully
examine the radiator for leaks after cleaning the cooling system.
Soft water to be used should have the following properties.
CAUTION k
Do not use hard water as it causes scale and rust.
Required properties of soft water

Total hardness 300 ppm or less Total dissolved solids 500 ppm or less
Sulfate SO -4 100 ppm or less pH 6 to 8
Chloride CI- 100 ppm or less
14A-6
14A
Method of cleaning the cooling system depends on its condition.
P Ordinary condition P Extremely dirty coolant P Clogged radiator
Cleaning using water Cleaning using Radipet 7 or equivalent
Drain the coolant
Make a solution of FUSO Radiator Cleaner

(Radipet 7 or equivalent) in a 5 to 10% ratio to
the total volume of coolant
(Work procedure)
Fill the radiator with the solution
Keep the solution temperature at 90C {194F}

and let the engine idle for 30 minutes
CAUTION k
Be sure to allow the engine to idle for 30
minutes only. Circulating the solution in
the system for more than an hour might
cause the system to breakdown
Drain the water and the solution
Fill with soft water (boiled preferably)
Keep the water temperature at 90C {194F} and let the

engine idle for 10 minutes
Drain the water
If the drained water is clear, cleaning has

been successful. If it is still muddy, repeat
the procedure
DANGER k
If FUSO DIESEL LONG LIFE COOLANT solution gets in your eyes accidentally, you must immediately rinse your
eyes with copious amounts of water, and be sure to consult a doctor.
WARNING k
FUSO DIESEL LONG LIFE COOLANT is inflammable. Do not put it near unprotected lights.
NOTE:
After cleaning with solution, fill with coolant as quickly as possible.
To prevent freezing of the coolant and corrosion of the cooling system, use specified coolant solution of FUSO
DIESEL LONG LIFE COOLANT. (See the Owners Handbook for use of these materials. )
14A-7
Air Bleeding of Cooling System
Remove the pressure cap. Then, introduce cooling water little by little
up to the water outlet pipe neck. Do not pour water up to the outlet port
brim, otherwise water would overflow out of the outlet port after the
engine is started as water will expand due to temperature rise.
With the pressure cap removed, run the engine at idle. While keeping
temperature at 90C {194F}, bleed the cooling system completely.
After bleeding the cooling system of air, add coolant to the water outlet
pipe and reservoir tank as required.
Gas Leak Testing

The presence of air or exhaust gas in the coolant increases corrosion and
rust in the cooling system. Check for air or exhaust gas in the coolant
using the following procedure.
Open the pressure cap.
A WARNING k
Make sure the coolant is cool before loosening the pressure cap.
If the coolant is hot, it may spray out.
Run the engine and let the coolant temperature reach approximately
90C {194F}.
29574 If bubbles A appear continuously, there is air or exhaust gas in the
coolant.
If the coolant contains air, the cylinder head bolts, water pump mount-
ing bolt, or hose connections may be loose. Alternatively, the hoses
may be damaged.
If the coolant contains exhaust gas, it is possible that the cylinder head
gasket is damaged or that the cylinder head is cracked.
14A-8
14A
MEMO
14A-9
RADIATOR
1 Clamp
2 Upper hose
3 Clamp
1 2
9 4 Clamp
5 Lower hose
3 6 Radiator support
7 Baffle plate
8 8 Support cushion
5
9 Radiator assembly P. 14A-12
7
verse.
6 8
29301

1, 4 Clamp 3 to 4.5 {2.2 to 3.3, 0.3 to 0.45}
3 Clamp 1.5 to 2 {1.1 to 1.4, 0.15 to 0.2} Wet
Lubricant
3 Threads of clamp Engine oil As required
14A-10
14A
R Service procedur-
A 8 Support cushio
14 mm Install the support cushion 8 with its shorter threaded part A on the radia-
{0.55 in.} tor side
8
22 mm
{0.87 in.}
05802
14A-11
RADIATOR
Radiator Assembly
6

4
7
3
5

4

4
Q
1
9 2
5 4
41248
1 Radiator shroud 5 Side member 9 O-ring
2 Drain cock 6 Upper tank 10 Core
3 Radiator assembly 7 O-ring
4 Bolt 8 Lower tank : Non-reusable part
CAUTION k
Do not disassemble the radiator assembly 3 unless defects are evident.
The upper tank 6 and lower tank 8 are made of plastic and could crack if subjected to undue shock. Handle them
with care.
Replace the core 10 if the clinching tabs that hold the upper tank 6 or lower tank 8 have two paint marks,
showing that the tabs have been bent back twice. P. 14A-13
P Assembly sequence
Service standards
3 Radiator air leakage 0 cm3 {0 cu.in.} Rectify or
(with air pressure of 150 kPa {21 psi, 1.5 kgf/cm2}) replace
14A-12
14A
2 Drain cock 2 {1.4, 0.2}
4 Bolt (side member mounting) 13 {9.4, 1.3}
0 Special tool
6, 8 Lock & Break Tool Obtain locally or Upper tank,
use sublet repair lower tank removal
R Service procedure
3 Radiator inspection
B Fit a hose A, and radiator cap tester B onto the radiator upper tank 6.
C A Fit a plug C onto the radiator lower tank 8, then immerse the radiator in
a tank of water.
Using the radiator cap tester B, apply the specified air pressure of 150
kPa {21 psi, 1.5 kgf/cm2}, and check for air leakage.
If air leakage is apparent, repair or replace the radiator assembly 3.
8 7 07386
Replace the following parts according to the leaking locations.

6, 8
Leaking location Part to replace
Tank root D O-ring 7 or 9
D
Tank 6 Tank 6, O-ring 7
Tank 8 Tank 8, O-ring 9
Tube fitted area E Core 10, O-ring 7, 9
* Tube F (TIG welded), O-ring 7, 9
F 7, 9
E Tube F Core 10, O-ring 7, 9
24679
*: When repaired
6, 8 CAUTION k
Replace the core 10 if its clinching tabs that hold the upper tank 6
or lower tank 8 have two paint marks G, evidence of the tabs hav-
ing been bent back twice.
The tabs are provided with one paint mark each time they are
bent back. Count the paint marks on each of upper and lower
G
tabs separately.
G
10 24714
14A-13
RADIATOR
A B 6 8 Upper tank and lower tank
C
Remove and reinstall the tanks using the 0 Lock and Break Tool.
A Attachment (for tank removal
B Attachment locking bol
C Slide handl
D D Stopper/adjuster bol
E E Attachment (for tank installation
24680
[Rexmoval]
A Fit attachment A onto the end of the 0 Lock and Break Tool, set it to
the illustrated dimension and lock it in position with the stopper/ad-
0 juster bolt D.
D
1.2 to 1.4 mm {0.047 to 0.055 in} 24681
Using the 0 Lock and Break Tool, bend up the tabs F of the core 10
0 that hold the tank 6, 8.
Straighten the tabs F completely as shown by gripping the 0 Lock and
Break Tool.
6, 8
F 24682
0 After straightening all the tabs F, grasp the inlet or outlet pipe and re-
move the tank 6, 8.
6, 8 If the tank 6, 8 is difficult to remove, tap it with a rubber or plastic
hammer G.
24683
6, 8 CAUTION k
The tanks 6 and 8 are made of plastic and may crack if subjected
to undue shock. Handle them with care.
G
24684
14A-14
14A
[Inspection]
Check the tank mounting channels H of the core 10 for foreign mat-
ters.
If foreign matter is stuck inside the mounting channels, rub them away
with sandpaper (approx. #1000) or blow them out with compressed air.
H
CAUTION k
10 If any foreign matter (even a single hair) remains when the O-ring
7, 9 and tank 6, 8 are fitted, leakage can occur. Carefully inspect
24685
and clean each tank mounting channel H entirely.
Clean the core contacting surface J of the tank 6, 8 and inspect it for
J
J damage. Replace the tank if any defect is evident.
CAUTION k
Perform procedure with bare hands to prevent foreign matter from
sticking to the surface J.
6, 8
24686
[Installation]
Install the tank 6, 8 in position. Check that the sub-plate K of the core
is in close contact with the tank. If there is any space, tap the sub-plate
K G
lightly with a rubber or plastic hammer to eliminate space.
6, 8
7, 9 CAUTION k
Handle the parts with bare hands to prevent foreign matter from
sticking to the O-ring 7, 9 and tank 6, 8.
24688
Fit attachment E onto the end of the 0 Lock and Break Tool, set it to
the illustrated dimension and lock it in position with the stopper/ad-
E juster bolt D.
D 0
10 mm {0.394 in.} 24689
14A-15
RADIATOR
Clinch the tabs F of the core 10 to hold the tank 6, 8 in the illustrated
order.
1 to 4: Two center tabs on each side
5 to 8: Remaining tabs in illustrated sequence
0: Lock and Break Tool (with attachment E)
NOTE :
The sides 1 and 2 do not allow the 0 Lock and Break Tool to be
used for clinching. Clinch these sides using a pair of pliers with
tape wrapped around its jaws.
24690
6, 8
6, 8
F
0
7, 9
24691
Check that the tabs has been clinched to the following dimensions.
M:14.65 to 15.05 mm {0.576 to 0.592 in.} (Sides N and P)
10.05 to 10.45 mm {0.395 to 0.411 in.} (Sides Q and R)
6, 8 Check for leaks. P. 14A-13

Provide a paint mark to the sub-plate K of the core 10 to indicate that
the tabs have been bent up and then down.
M NOTE:
Provide one paint mark after each removal of the tank.
7, 9
Q
N P
24692
W Core
10 If water leaks from the tube fitted area A, replace the core 10 or repair it
by the following method.
A
24693
14A-16
14A
[Repair]
NOTE:
Repair is carried out by tungsten inert gas arc (TIG) welding, which
requires the skill of a trained welder.
WARNING k
To avoid danger, dry the core 10 completely before welding.
B C Clean both edges B of the leaky tube and their surroundings C using a
stainless steel wire brush. Scrub the surface until it glistens with ex-
posed aluminum.
24694
Since both ends of the tube are covered with weld metal, make a small
hole E in the tube D to allow air venting.
NOTE:
Absence of the small hole E causes escaping air to produce small
pin holes in the weld.
E D
24695
Connect a grounding wire G from the support F of the core 10 to an

10 appropriate object.
CAUTION k
F Improper connection of the grounding wire G causes a short cir-
cuit during welding work and the core could be fused at the welded
portion.
G
24696
Cover both ends of the tube with welding metal.
H H: Tungsten inert gas arc weld (TIG)
Welding conditions:
Welding rod: A4043 (approx. 2 mm { 0.0079 in.} in diameter)
Welding current: 80A AC
After welding, check for the following defects. Rectify the weld or re-
place the core 10 if any of the defects is evident.
Undercut
10
Bead crack
Crack in base metal
24697
CAUTION k
Weld with sufficient care. Poor welding may cause leakage to re-
cur.
14A-17
COOLING FAN, V-RIBBED BELT AND WATER PUMP
*b
*a

8
7

6
10
2
*c

1
9
5
3
4
29768
1 Nut 9 Nut
2 Cooling fan 10 Fan pulley
3 Nut
4 Automatic cooling fan coupling *a: Altenator B ELECTRICAL
5 V-ribbed belt (for water pump) *b: Compressor
6 Bolt *c: Front case B Group 11A
7 Water pump assembly : Non-reusable part
8 Gasket
P Assembly sequence
Follow the disassembly sequence in reverse
14A-18
14A
Service standard Unit: mm {in.}

5 V-ribbed belt tension When belt is new 9 to 11 (0.35 to 0.43) Adjust
(for water pump) When belt in use is re-tensioned 11 to 13 (0.43 to 0.51)

1 Nut (cooling fan mounting) 4.9 {3.6, 0.5}
3 Nut (for automatic cool fan coupling mounting) 12.7 {9.4, 1.3}
6 Bolt (for water pump assembly mounting) 23.5 {17.4, 2.4}
9 Nut (for fan pulley mounting) 196.1 {145, 20}
0 Special tools
V-ribbed belt tension

5 Belt Tension Gauge Obtain Locally measurement
03612
14A-19
R Service Procedure
4
4 Automatic cooling fan coupling
[Inspection
Inspect the automatic cooling fan coupling 4 in accordance with the fol-
lowing procedure. If any defect is apparent, replace the unit
Check for leakage of oil from the coupling body
Rotate the automatic cooling fan coupling 4 by hand and check fo
irregular movement or abnormal noise caused by a defect in the bear-
ing
Check for excessive axial play in the automatic cooling fan coupling
29772 when the engine is cool
[Cleaning
A
If any foreign particles have adhered to the bimetal A, brush them of
gently
29773
5 V-ribbed belt tension

C 5 [Inspection]
NOTE
Before checking for tension, crank the engine one turn or mor
B
clockwise
A
E
D Apply force of approximately 98 N {22 lbf, 10 kgf} to the span center of th
V-ribbed belt 5, and measure the extent of belt deflection A
29774
B Alternator pulle
C Air conditioner compressor pulley or tention pulle
D: Fan pulley
E: Water pump pulley
14A-20
14A
G P Use of belt tension gauge
Set the upper O-ring G of the 0 Belt Tension Gauge to a push load of
98 N {22 lbf, 10 kgf} on scale H.
H
Set the lower O-RING J of the 0 Belt Tension Gauge to the belts
0 specified maximum deflection value on scale K.
K
03613
Apply the 0 Belt Tension Gauge to the center of the V-ribbed belt 5
and push L until the upper O-ring G reaches the flange M.
L G
0
M
5
03614
Measure the deflection A of the V-ribbed belt 5. If the measurement

A does not comply with the standard value, adjust the tension in accor-
dance with the following procedure.
03615
[Adjustment]
(1) Tension adjustment of V-ribbed belt for water pump
CAUTION k
Excessive tension in the V-ribbed belt 5 may damage the belt and
related bearings.
Keep the V-ribbed belt 5 free of oil. If the belt becomes oily, it may
slip, resulting in overheating of the engine and insufficient charg-
ing of the battery.
14A-21
P N [Without air-conditioner]
Loosen the tensioner pulley mounting sleeve N, then adjust the ten-
5 sion of the V-ribbed belt 5 using the adjustment bolt P.
When the adjustment is completed, securely tighten the sleeve N.
29777
[With air-conditioner]
Loosen the alternator mounting nuts Q and R, then adjust the tension
Q 5 of the V-ribbed belt 5 using the adjustment bolt S.
S When the adjustment is completed, securely tighten the nuts Q and R.
R
29778
14A-22
14A
MEMO
14A-23
WATER HOSE & PIPE
1 Pressure cap
2 Belt
*a 3 Water outlet pipe
4 Gasket
5 O-ring
2
6 Bolt
1 7 Water outlet case
8 Gasket
9 Bolt
3 10 Heater elbow
11 Gasket

4 8
*a: Cylinder head B Group 11A
*b: Breather cover B Group 11A
: Non-reusable part
P Assembly sequence
7 11 verse.
6
5 10

9

*b
29432
Service standards
1 Valve opening pressure of pressure cap 9015 kPa Replace
{12.82.2 psi, 0.9 0.15 kgf/cm2}
Tightening torque Unit: Nm {lbf.ft, kgfm

2 Bolt (for water outlet pipe mounting) 23.5 {17.4, 2.4}
6 Bolt (for water outlet case mounting) 23.5 {17.4, 2.4}
9 Bolt (for heater elbow mounting) 23.5 {17.4, 2.4}
14A-24
14A
R Service procedure
1 Pressure cap inspection
( 1 Pressure valve opening pressur
If the gauge reading deviates from the standard value, replace the pres-
sure cap 1
1
00194
(2) Vent valve inspection

Observe the water level B in the reservoir tank A.
Run the engine at a high speed. Stop the engine when a small amount
B of coolant has overflowed into the reservoir tank A.
1 Wait for a while in this condition. When the coolant returns to the ambi-
ent temperature, check to see if the water level in the reservoir tank A
A has returned to the level at which it was observed before the engine
was started.
If the water level has not dropped, the vent valve C is faulty. Replace
the pressure cap 1.
C 05812
NOTE:
If the pressure cap 1 is removed before the coolant temperature
drops to the ambient temperature, the vacuum in the radiator is
lost, preventing the coolant from returning to the radiator.
14A-25
THERMOSTAT
1 Clamp
7 2 Water pipe
3 Rubber hose
4 Bolt
5 Thermostat cover
6 Thermostat
5
3
1 B ELECTRICAL
* 2
*: Oil cooler B Group 12A
6

1 verse.

29434
Service standards
6 Thermostat Valve opening temperature 76.52C {17036F}
Valve lift/temperature 10 mm or more/90 {194F}
Tightening torque Unit: Nm {lbf.ft, kgfm
R Service procedur
6 Thermostat
6 [Inspection
A C Place the thermostat in a container of water. Then, carry out the followin
E inspection procedure while stirring the water with a rod A to ensure that i
is heated evenly. If the measurements do not comply with the standar
values, replace the thermostat 6
( 1 Valve opening temperatur
Support the thermostat 6 with wire E to keep it away from the hea
source D
F D Gradually heat the water until it reaches the valve opening tempera-
00218
ture
Maintain this temperature for approx five minutes and check that the
valve B is open.
When the water temperature drops below 65 C {149 F}, check the
the valve B is completely closed.
C: Thermometer
(2) Valve lift
Heat the water to slightly higher than the valve opening temperature.
With the valve B fully open, maintain this water temperature for five
minutes. Measure the extent of valve lift F.
14A-26
14A
MEMO
14A-27
Group 14
Cooling
Table of Contents
BACK
HOME
Pub No. TWSE9501-14

14
GROUP 14 COOLING
SPECIFICATIONS .................................................................................. 2
TROUBLESHOOTING ............................................................................ 6

Replacing Coolant and Cleaning Cooling System .......................................... 8
Air Bleeding of Cooling System ...................................................................... 10
Gas Leakage Test ............................................................................................. 10
RADIATOR............................................................................................ 12
COOLING FAN AND V-BELT ............................................................... 14
WATER PUMP ...................................................................................... 18
THERMOSTAT ...................................................................................... 20
14-1
SPECIFICATIONS
Item Specifications
Kind of cooling system Forced water circulation system
Water pump type Belt-driven involute type
Thermostat type Wax-pellet, bottom bypass type (with jiggling valve)
Automatic cooling fan coupling type Continuous control type
Radiator type Tube and corrugated fin type
Coolant capacity L {qts} 13 {14}

Cooling System (Flow of Coolant)
1 Radiator
1 3 2 Thermostat
2
3 Oil cooler
4 Crankcase drain plug
5 Water pump
6 Cooling fan
7 Radiator drain cock
5
4
6
7
06359
14-2
14
Water Pump
1 Case
2 Unit seal
3 Impeller
4 1 4 Ball bearing
5 Flange
A : Drain hole
3
5
11264
Thermostat
1 Thermostat cover
2 Thermostat
A 3 Thermostat case
B C
A : To radiator
B : When low coolant temperature
1 C : When high coolant temperature
2 D : From cylinder head
E : To water pump
3 Thermostat 2 is a bottom bypass type that uses wax pellets

D as its regulating element. As the wax changes its form from
solid to liquid according to changes in temperature, the
volume of the wax changes. Therefore, the position of the
E
06361 valve, changed by the coolant temperature, regulates the
flow of the coolant to the radiator and water pump (bypass
side) and controls the coolant temperature.
14-3
Cooling System Electric Circuit
Water temperature gauge circuit
1 Fuse box
2 Meter cluster
3 Water temperature gauge
* : To multipurpose control unit ^ Gr 54
11056
This circuit detects the coolant temperature by changes of resistance in water temperature sensor 4 and relays the signal
to water temperature gauge 3 in meter cluster 2 to indicate the temperature.
Overheating Circuit
1 Fuse box
2 Meter cluster
3 Overheating buzzer
4 Overheating switch
5 Overheating relay
6 Parking brake switch
11057
When this circuit detects extremely high coolant temperature, it sounds overheating buzzer 3 to warn the driver of the
abnormal condition. To stop the buzzer, first stop the vehicle, then pull up the parking lever.
14-4
14
When overheating switch is activated
15 (Contact point)34Ground
Buzzer 3 sounds.
12197
When parking brake switch is activated

15 (Coil)6Ground
Buzzer 3 stops sounding as the contact
points of overheating relay 5 opens.
12198
14-5
TROUBLESHOOTING
Symptoms
Overheating (Low cooling effect)
Coolant loss excessive

Remarks
Noise occurs
Overcooling
Possible causes
Loose or damaged
V-belt Tension excessive
Oily
Water pump installation faulty
Unit bearing faulty
Water pump Impeller faulty
Unit seal faulty
Unit bearing-to-flange and to-impeller fitting loose
Case installation faulty
Thermostat Valve opening temperature too high, valve remains closed
Valve opening temperature too low, valve remains open
Space between core and fins clogged
Core cracked or soldered area separated
Radiator
Pressure cap airtightness poor
Water level sensor leaking water
Bearing faulty
Automatic cooling Bimetal damaged
fan coupling Bimetal contaminated with foreign particles
Silicon oil leaking
Oil cooler installation faulty ^ Gr 12
Oil cooler
Gasket faulty ^ Gr 12
Cylinder head installation faulty ^ Gr 11
Cylinder head
Gasket faulty ^ Gr 11
Coolant quantity insufficient
Coolant passage furred and clogged
Water hose installation faulty
Exterior temperature extremely cold
14-6
14
MEMO
14-7
Replacing Coolant and Cleaning Cooling System
1 Pressure cap
2 Radiator drain plug
3 Crankcase drain plug
1
2
06362

3 Crankcase drain plug 34 to 39 {25 to 29, 3.5 to 4.0}
Using the radiator for a long period of time without cleaning it will cause overheating because rust and scale deposits
will accumulate inside the cooling system. Periodical cleaning is recommended.
Draining coolant
First loosen pressure cap 1, to lower the pressure in the cooling system, before draining coolant.
WARNING
It is dangerous to open pressure cap 1, when the coolant temperature is high, without taking due care
because the hot water would spray out. Be sure to cover the pressure cap with a cloth and loosen slowly to
bleed the pressure before opening fully.
Cleaning procedure
Keep the coolant temperature at approximately 90C {194F} so that the thermostat valve remains open and the
coolant continues to circulate in the radiator.
For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator with
corrugated cardboard or something similar.
Set the temperature adjusting lever of the heater controller at maximum so that the coolant can circulate freely in the
heater piping area.
In cases where a great amount of rust has accumulated it often happens that as a result of cleaning the radiator
starts leaking. Conduct a thorough check for leakage after cleaning.
Soft water to be used should have the following properties.
CAUTION
Do not use hard water as it causes scale and rust.
Required properties of soft water

Total hardness 300 ppm or less Total dissolved solids 500 ppm or less
Sulfate SO4 100 ppm or less pH 6 to 8

Chloride Cl 100 ppm or less
14-8
14
Method of cleaning the cooling system depends on its condition.
Ordinary condition Extremely dirty coolant Clogged radiator
Cleaning using water Cleaning using Radipet 7 or equivalent
Drain the coolant
Make a solution of FUSO Radiator Cleaner (Radipet 7 or

equivalent) in a 5 to 10% ratio to the total volume of
coolant
(Work procedure)
Fill the radiator with the solution
Keep the solution temperature at 90C {194F} and let

the engine idle for 30 minutes
CAUTION
Be sure to allow the engine to idle for 30
minutes only. Circulating the solution in the
system for more than an hour might cause
the system to breakdown
Drain the water and the

solution
Fill with soft water (boiled preferably)
Keep the water temperature at 90C {194F} and let the engine
idle for 10 minutes
Drain the water
If the drained water is clear, cleaning has

been successful. If it is still muddy, repeat the
procedure
DANGER
If FUSO DIESEL LONG LIFE COOLANT solution gets in your eyes accidentally, you must immediately rinse
your eyes with copious amounts of water, and be sure to consult a doctor.
WARNING
FUSO DIESEL LONG LIFE COOLANT is inflammable. Do not put it near naked lights.
NOTE
After cleaning with solution, fill with coolant as quickly as possible.
To prevent freezing of the coolant and corrosion of the cooling system, use specified coolant solution of FUSO
DIESEL LONG LIFE COOLANT. (See the Owners Handbook for use of these materials.)
14-9
Air Bleeding of Cooling System
Remove the pressure cap and keep the coolant temperature at 90C
{194F} while letting the engine idle and bleed the air out completely.
Keep the temperature adjusting lever of the heater controller at maxi-
mum so that the coolant can circulate freely in the heater piping area.
After completing adequate air bleeding of the cooling system, refill
coolant sufficiently enough for the radiator and the reservoir tank.
Gas Leakage Test

Air or exhaust gas in the coolant increases corrosion and rusting in the
system. Therefore, carry out the following test:
Remove the pressure cap.
A
WARNING
Be sure that the coolant temperature is low enough so that hot
coolant does not spout out when you loosen the pressure cap.
Run the engine to bring the coolant temperature to approximately

90C {194F}.
If air bubbles A continuously rise from the coolant, it is an indication
06363 that air or exhaust gas has gotten into the coolant.
If it is air, it is possible that the cylinder head bolts, the water pump
mounting bolts or the hose connections are loose, or that the hose is
damaged.
If it is exhaust gas, it is possible that the cylinder head gaskets are
damaged, or that the cylinder head is cracked.
14-10
14
MEMO
14-11
RADIATOR
2 6
1 3-
4
9 5
8 10
11 7
10845
1 Hose clamp 9 Baffle plate
2 Inlet hose 10 Radiator drain plug
3 Hose clamp 11 O-ring
4 Hose clamp 12 Support cushion
5 Outlet hose 13 Radiator
6 Upper radiator shroud
7 Lower radiator shroud : Non-reusable parts
8 Radiator support
Assembly sequence
Service standards
Remedy
Location Maintenance item Standard value Limit and
remarks
13 Radiator air leakage (Air pressure of 150 kPa 0 cm3 {0 cu. in.} Correct
{21 lbf/in2, 1.5 kgf/cm2}) or replace

1, 4 Hose clamp 3.9 {2.9, 0.4}
3 Hose clamp 1.5 to 2 {1.1 to 1.4, 0.15 to 0.2} Wet
- Lubricant
14-12
14
14 mm
A H
Service procedure
Support cushion
Place support cushion 12 so that thread part A (shorter than the other
{0.55 in.} side) comes to the radiator side for mounting.
12
22 mm
{0.87 in.}
05802
A
B
I Inspection of radiator
Install radiator cap tester B by connecting hose A to the radiator inlet
C
hole.
Plug any other openings C with plugs, and immerse the radiator in a
water tank.
Apply specified air pressure of 150 kPa {21 lbf/in2, 1.5 kgf/cm2} using
13
cap tester B, and check if there is any air leakage.
If you find air leakage, correct or replace radiator 13.
07386
14-13
COOLING FAN AND V-BELT
*2
8
7
3 5
*1
12209
1 V-belt (Compressor) 7 Bolt
2 V-belt (Fan) 8 Coupling plate
3 Nut 9 Water pump pulley
4 Cooling fan
5 Nut *1 : Tension pulley ^ Gr 54
6 Automatic cooling fan coupling *2 : Cooler compressor ^ Gr 54
Assembly sequence
CAUTION
Be sure to replace automatic cooling fan coupling 6 as an assembly if it is faulty because it is a unit
construction.
Be sure to replace V-belts 2 as a set to maintain even tension between them.
14-14
14
1 V-belt tension (Air-conditioner) 16 to 20 {0.63 to 0.79} Adjust
2 V-belt tension (Fan) 12 to 16 {0.47 to 0.63} Adjust

03612
D
1 12
Service procedure
[Inspection]
V-belt
C Measure the extent of flex A when the center of V-belts 1, 2 as illustrated

is depressed with a force of 98 N {72 lbf, 10 kgf}.
A B : Alternator pulley
C : Water pump pulley
B A D : Cooler compressor pulley (Air-conditioner)
E E : Tension pulley
2
F : Crankshaft pulley
F 11518
Use of special tool belt tension gauge

G
Set upper O-ring G of 0 belt tension gauge to 98 N {72 lbf, 10 kgf}
(push load) on graduation H.
H Set lower O-ring J of 0 belt tension gauge to graduation K (maxi-
0 mum flex of belt).
K 03613
Place 0 belt tension gauge at the center of V-belts 1, 2 perpen-

dicularly as illustrated and push top L all the way down until upper
L G
O-ring G hits upper edge M.
M
1, 2
03614
14-15
COOLING FAN AND V-BELT
A measured value deviates from the standard value, adjust as fol-
lows.
1, 2
03615
[Adjustment]
N
(1) Adjustment of V-belt tension for fan
2
Loosen alternator mounting bolts N (two places), and adjust the
P After adjustment, tighten the bolts and nuts securely.
CAUTION
N 06370
between them.
Be careful not to let oil stick to V-belts 2, if oil gets onto the belts,
it causes slipping, resulting in overheating and insufficient bat-
tery charging.
(2) Adjustment of V-belt tension for air-conditioner

V-belt 1 by adjusting bolt R.
After adjustment, tighten the bolts and nuts securely.
CAUTION
Bear in mind that excessive tension of V-belt 1 might damage the
belt and bearings that engage with the V-belt.
Q R Be careful not to let oil stick to V-belt 1, if oil gets onto the belt, it
causes slipping, resulting in poor performance of the air-condi-
1 05810 tioner.
14-16
14
6 Automatic cooling fan coupling
[Inspection]
Carry out the following inspection of automatic cooling fan coupling 6 and
if any fault is found, replace the unit.
Check for any leakage of lubricating oil sealed in the coupling body.
Rotate automatic cooling fan coupling 6 by hand, and check for any
6 irregularity in rotation related to the coupling bearing or any abnormal
noise.
Check for any excessive play of automatic cooling fan coupling 6 in
06366
the axial direction when the engine is cool.
[Cleaning]
If there are any foreign particles sticking to bimetal A, remove them by
brushing lightly.
06367
14-17
WATER PUMP
Removal sequence
1 Water pump assembly
2 O-ring
2-
12210
CAUTION
Be sure to replace water pump assembly 1 as an assembly if it is faulty because it is a unit construction.
Never apply engine oil to the O-ring because it will cause the O-ring to swell.
- Lubricant
2 Periphery of O-ring Soapy water As required
14-18
14
MEMO
14-19
THERMOSTAT
1 Pressure cap
2 Water filler
3 O-ring
2
4 Thermostat cover
3- 5 Thermostat cover gasket
6 Thermostat
4
7 Thermostat case
8 Thermostat case gasket
9 Bypass pipe

10 O-ring
(Water temperature gauge and multi-
purpose timing control unit)
^ Gr 54
7 12 Overheating switch ^ Gr 54

(Pre-stroke control type injection pump)
11
^ Gr 54
8 *
* : Cylinder head
10
- 13
9 Assembly sequence

12 10846 Follow the disassembly sequence in reverse.
CAUTION
Be sure to apply soapy water to O-ring 3,
10 for easier fitting. Never use engine oil
because it will cause the O-ring to swell.

Remedy
Location Maintenance item Standard value Limit and
remarks
1 Pressure cap valve opening pressure 8815 kPa {132.1 lbf/in2, Replace
0.90.15 kgf/cm2}
6 Thermostat Valve opening temperature 822C {18036F} Replace
Extent of valve lift (95C {203F}) 10 {0.39} or more Replace

11 Water temperature sensor 346.9 {255.1, 3.50.7}
12 Overheating switch 27 to 41 {20 to 30, 2.8 to 4.2}
13 Water temperature sensor 346.9 {255.1, 3.50.7}
- Lubricant
3, 10 O-ring Soapy water As required
14-20
14
1
Service procedure
Inspection of pressure cap
(1) Pressure valve opening pressure
pressure cap 1.
1 00194
(2) Inspection of vent valve

Take note of the liquid level B of reservoir tank A beforehand.
Run the engine at a high revolution and before the overflow reaches
the capacity of tank A stop the engine.
B
1 Leave things for a while. Check the time it takes for the coolant
A temperature to return to the ambient temperature, and check
whether the coolant level in tank A is the same as before running
the engine.
If the coolant level has not returned to that before running the
C 05812 engine, it means vent valve C is faulty, therefore replace pressure
cap 1.
NOTE
Do not remove pressure cap 1 before the coolant temperature
decreases to the ambient temperature. If you do the coolant
will not return to reservoir tank A because negative pressure in
the radiator is lost.
5
A 5 Mounting of thermostat cover gasket
Mount thermostat cover gasket 5 on thermostat case 7 in the direction as
illustrated.
6 A : Sealant application surface
11375
14-21
THERMOSTAT
A
B 6
6 Thermostat
[Inspection]
C
Stir the water using stick A to maintain an even water temperature in the
E
container, then carry out the following tests. If the measured value
deviates from the standard value, replace thermostat 6.
(1) Valve opening temperature

Hold thermostat 6 with wire E so as not to get the thermostat too
close to heat D.
Heat the water gradually to raise the temperature to the valve
F D
opening temperature.
00218
Maintain this temperature for five minutes and make sure that valve
B has opened.
Make sure that valve B has closed when the water temperature has
dropped to 65C {149F}.
C : Water temperature gauge
(2) Extent of valve lift

Measure valve lift F, while maintaining the water temperature a little
higher than the valve opening temperature, with valve B fully open for
five minutes.
14-22
Group 15 - Intake & Exhaust
Group 15A - Intake & Exhaust

2001 Model Change
<4M50>
BACK HOME
Service Manual
Group 15A
Intake and Exhaust
<4M50T2>
Table of Contents
BACK HOME
MAY. 2000
GROUP 15A INTAKE AND EXHAUST
SPECIFICATIONS / STRUCTURE AND OPERATION ........................ 15A- 2

1. Air Cleaner ............................................................................................. 15A- 2
2. Turbocharger Assembly ....................................................................... 15A- 3
TROUBLESHOOTING .......................................................................... 15A- 4

1. Measurement of Turbocharger Boost Pressure ................................. 15A- 5
AIR DUCT AND AIR CLEANER ........................................................... 15A- 8
TURBOCHARGER ............................................................................... 15A-11
INTERCOOLER .................................................................................... 15A-16
INTAKE MANIFOLD ............................................................................. 15A-18
EXHAUST MANIFOLD ......................................................................... 15A-20
EXHAUST PIPE AND MUFFLER ......................................................... 15A-21
15A-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Air cleaner element Cyclone paper filter type
Model TD05
Turbocharger
Manufacturer Mitsubishi Heavy Industries
Intercooler type Tube and corrugated fin (air cooled)

1. Air Cleaner
1 Air box
2 Air cleaner assembly
3 Unloader valve
The air cleaner assembly 2 utilizes a single

element.
The air box 1 and the air cleaner assembly 2
incorporate an unloader valve 3.
The unloader valve vibrates due to a vacuum
fluctuation when the engine speed drops
below a predetermined level, automatically
1
discharging accumulated water and dust.
05937
15A-2
15A
2. Turbocharger Assembly
1 Actuator
2 Compressor cover
2 3 4 5 6 7 8 9 3 Compressor wheel
4 Thrust sleeve
5 Thrust bearing
6 Bearing
7 Bearing housing
8 Turbine back plate
9 Turbine housing
10 Shaft and turbine wheel
11 Piston ring
12 Thrust ring
13 Oil deflector
1 14 Insert
3 to 14: Cartridge assembly
14 13 12 11 10
29580
P Waste gate mechanism

The waste gate mechanism has actuator assembly 1 to let extra ex-
haust gas escape. By so doing, the boost pressure is properly con-
trolled to prevent the turbine wheel from overrunning and prevent an
excessive pressure in the intake manifold.
The boost pressure is led from compressor cover 2 through a rubber
2 3 10
hose to chamber A of actuator assembly 1. When the boost pressure
C that acts on chamber A is below the setting, the actuator assembly
C does not operate, and the waste gate valve remains closed, and ex-
haust gas D is blown against turbine wheel 10.
B
1
A D
01510
10 When the boost pressure that acts on chamber A exceeds the setting,
3 the waste gate valve is opened. As a result, the amount of exhaust gas
blown against turbine wheel 10 decreases, the rotating speed of com-
pressor wheel 3 also decreases, and the boost pressure falls.
C B
D
A 06538
15A-3
TROUBLESHOOTING
Symptoms
Strange sound or vibration in intake and

Excessive oil consumption
Remarks
White exhaust gas

Black exhaust gas
exhaust system
Possible causes
Clogged air cleaner element T T T

Deformed front pipe, muffler, tail pipe T
Improperly mounted front pipe, muffler, tail pipe T
Incorrect valve clearance T B Group 11A
Defective head gasket T B Group 11A
Worn valve and valve seat and deposited carbon T B Group 11A
Sagging valve spring T B Group 11A
Worn or damaged piston ring T T B Group 11A
Worn or damaged piston ring groove of piston T T B Group 11A
Malfunctioning cooling equipment T T B Group 14A
Excessive engine oil T B Group 12A
Seizure of major moving parts T B Group 11A
Turbo- Cartridge Defective bearing T T T
charger assembly
Carbon deposited on shaft and turbine wheel T T
Shaft and turbine wheel interfering with turbine
T T
back plate
T T
housing
Bent shaft and turbine wheel T T T
Damaged shaft and turbine wheel T T T
Compressor wheel interfering with compressor
T T
housing
Thrust sleeve and thrust bearing seizure T T T
Damaged compressor wheel T T T
Oil leaks due to worn piston ring and insert T T
Improperly mounted piston ring T
Unsmooth sliding of internal parts due to
T T
clogged lubrication oil pipe and eyebolt
Damaged oil seals due to clogged oil return
T T
pipe
Improperly mounted compressor housing T T T T
Improperly mounted turbine housing T T
Intercooler Foreign substances deposited on intercooler front core T
15A-4
ON-VEHICLE INSPECTION AND ADJUSTMENT 15A
1. Measurement of Turbocharger Boost Pressure
Service standards
34.7 kPa {10.2 in.Hg, 260 mmHg}/
Boost pressure (at ambient temperature of 20C
3750 rpm Inspect/
{68F} and atmospheric pressure of 100 kPa {29.9
136 kPa {10.2+29.9 in.Hg/260+760 adjust
in.Hg, 760 mmHg})
mmHg} when measured by MUT
0 Special tool
30
0 400
20
0 50
0
10
0 60
0
70
0
76
0
Boost pressure gauge Obtain Locally Measurement of boost pressure
P01524
Before measuring the boost pressure, clean or replace the air cleaner
3 0 element.
Disconnect the vacuum hose 1 at the boost pressure sensor 2 side.
1 Connect the pipe 4 (MH062049 [component part of MH062047]) be-
tween the vacuum hose 1 fitted to the gas filter assembly 3 and the 0
3 Boost Pressure Gauge.
4
Warm up the engine, then measure the boost pressure at the engines
maximum idling speed. At the same time, measure the engine speed
and ambient temperature.
1 0
37457
Correct the measurement to determine the boost pressure under stan-

1.1
correction coefficient (Kt)
dard conditions. (The boost pressure varies in accordance with the

ambient temperature and engine speed.)
1.0
Boost pressure
[Correction for ambient temperature]

0.9
From the graph, determine the boost pressure correction coefficient Kt
0.8 for the ambient temperature.
-20 -10 0 10 20 30 40
{-68}{-14} {14}{68}{86}{104}
Ambient temperature C {F} 01522
15A-5
[Correction for engine speed]
From the engine speed during boost pressure measurement, subtract the
median of the maximum idling speed. From the result, determine the boost
Boost pressure correction value
5.3 pressure correction value (Pa) in accordance with the graph.

{1.57, 40}
Median: 3,750 rpm
2.7
{0.79, 20}
(kPa {in.Hg, mmHg})
0 [Calculation of corrected boost pressure]

{0, 0}
If the measured boost pressure is P, the corrected boost pressure Pb is
-2.7
{-0.79, -20}
determined as follows:
-5.3 Pb = KtP + Pa
{-1.57, -40} Pb: Corrected boost pressure
-100 -50 0 50 100
P: Measured boost pressure
Engine speed (rpm) Kt: Boost pressure correction coefficient for ambient temperature
Pa: Boost pressure correction value
(Differece between the median of
the no-load maximum engine speed If Pb is out of specification, the turbocharger must be inspected and ad-
and the actual engine speed used justed.
for boost pressure measurement)
06165
15A-6
15A
MEMO
15A-7
AIR DUCT AND AIR CLEANER
R
12
6 11
8 4
10
*
7
5
9
U I 3
14
15
20
15
1
21
2
P
O
41249
1 Clamp 9 Clamp 17 Rubber seal
2 Connector 10 Bolt 18 Air cleaner cap
3 Bolt 11 Bolt 19 Air cleaner element
4 Bolt 12 Bracket 20 Air cleaner case
5 Air inlet duct 13 Air duct
6 Clamp 14 Clamp *: Turbocharger P. 15A-11
7 Clamp 15 Bolt : Non-reusable parts
8 Air hose 16 Air box
P Assembly sequence

1, 6, 7, Clamp 2.9 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
9, 14
3, 4 Bolt (air inlet duct mounting) 4 to 6 {2.9 to 3.6, 0.4 to 0.5}
10, 11 Bolt (air duct bracket mounting) 12 to 15 {8.7 to 11.0, 1.2 to 1.5}
15 Bolt (air box bracket mounting) 4 to 6 {2.9 to 3.6, 0.4 to 0.5}
21 Bolt (air box mounting) 12 to 15 {8.7 to 11.0, 1.2 to 1.5}
15A-8
15A
R Service procedure
8 R Installation of air duct
A Fit clamp 7 over protrusions A of air duct 8.
Push air duct 8 in until it hits air cleaner case 14.
14
7
41250
A U Installation of air box

Align slit A of air box 16 with key B of air cleaner case 14.
B
16 17 20 09959
I Installation of rubber seal

A 17
Align slit A of rubber seal 17 with key B of air cleaner case 20.
20
B
06166
O Installation of air cleaner cap

: Alignment mark
20
19
18
13152
15A-9
P Air cleaner element
19
[Cleaning]
Blow compressed air of 685 kPa {100 lbf/in2., 7 kgf/cm2} or less through
CAUTION k
13150 Do not tap or hit air cleaner element 19 to remove dust.
the outside.
[Inspection]
19 surface of air cleaner element 19 is damaged, replace the air cleaner
element.
NOTE:
13151
ment interval.
15A-10
TURBOCHARGER 15A
1 Bolt
2
2 Insulator
3 Eyebolt
4 Oil pipe
1 *a 5 Bolt
3
6 Oil return pipe
16 7 Gasket
4 8 Nut
9 Front pipe
19
10 Nut
11 Exhaust pipe stay
15
12 Nut
12 O
13 Exhaust pipe
*b 14 Coupler gasket
8
15 Clamp
7 16 Air inlet hose
11 14 17
17 Nut
6
10 13 18 Turbocharger assembly P. 15A-13
5 19 Gasket
9 *a: Exhaust manifold P. 15A-20

8
*b: Rubber hose P. 15A-16
P Reassembly sequence

1 Bolt (for insulator mounting) 11.8 {8.7, 1.2}
3 Eyebolt (for oil pipe mounting) 23.5 {17, 2.4}
5 Bolt (for oil return pipe mounting) 4.9 {3.6, 0.5}
8 Nut (front pipe mounting) 20 to 25 {14 to 18, 2 to 2.5}
10, 12, Nut (for exhaust pipe stay, exhaust pipe,
41.2 {30, 4.2}
17 turbocharger assembly mounting)
15 Clamp 8.8 0.98 {5.8 0.7, 0.9 0.1}
Lubricant
18 Turbocharger assembly oil hole (supply at time of installation) Engine oil As required
15A-11
TURBOCHARGER
R Service procedure
A O Installation of turbocharger assembly
18 Before installing the turbocharger assembly 8, pour engine oil into the oil
hole A to ensure smooth operation of the internal parts.
29475
15A-12
15A
Turbocharger assembly
P Operation before disassembly
P. 15A-14
X 1 Hose
2 Actuator
8 3 Bolt
4 Coupling
7 5 Turbine housing
6 Snap ring
4
7 Compressor cover
5 8 O-ring
3 9 Cartridge assembly
T
6
: Non-reusable part
9
P Assembly sequence

2 P. 15A-14
29476
NOTE
Cartridge assembly 9 cannot be disassembled. Replace the entire assembly if the turbine wheel or compressor
wheel becomes damaged or if the assembly does not rotate smoothly or is otherwise defective.

0.1
Axial play in shaft 0.05 to 0.09 {0.0020 to 0.0035} Replace
{0.0039}
Cartridge Turbine wheel 0.58
9 assembly Play at right side
0.40 to 0.53 {0.016 to 0.021}
{0.023}
angle to axial Replace
direction Compressor 0.72
0.55 to 0.66 {0.022 to 0.026}
wheel side {0.028}

3 Bolt (Coupling securing) 3.9 to 4.9 {2.9 to 3.6, 0.4 to 0.5} Wet

3 Threads of bolt Molybdenum disulfide grease As required
8 Entire periphery of O-ring Engine oil As required
15A-13
TURBOCHARGER
R Service procedure
9 P Operations before disassembly
7 4 Make alignment marks A on the coupling 4, turbine housing 5, com-
pressor cover 7, and cartridge assembly 9.
5
A
29477
P Cleaning after disassembly

Visually check the disassembled parts for scorches, abrasion, and other
marks that may be difficult to see after cleaning. Replace any part that
appears defective.
Immerse the disassembled parts in a non-flammable solvent A and
A remove the parts from the solvent and blow them dry with compressed
C B air B. Before this procedure, remove adhering matter if any using a
plastic scraper on a wire brush C.
Immerse the parts in the solvent A again.
01529 Blow the parts dry with compressed air B.

A Manually rotate the wheel A of the cartridge assembly 9 to check that
it turns smoothly.
06170
5 Removal of turbine housing

CAUTION k
While using care to prevent damage to the turbine housing, lightly
strike its entire circumference with a rubber hammer or similar
tool.
Since the blades of the turbine wheel are easily bent, use care to
make sure that they do not hit turbine housing 5.
29478
15A-14
15A
6 Installing snap ring
A
Fit snap ring 6 onto compressor cover 7 with its tapered surface A
facing upward.
WARNING k
6
When fitting snap ring 6, hold it down to prevent it from flying off.
7
01532
7 Removal of compressor cover

CAUTION k
While using care to prevent damage to compressor cover 7, lightly
strike its entire circumference with a rubber hammer or similar
tool.
Since the blades of the compressor wheel are easily bent, use
care to make sure that they do not hit the compressor cover.
7
01533
9 Inspection of cartridge assembly

9 (1) Axial play in shaft and turbine wheel assembly
If the measurement exceeds the specified limit, replace cartridge as-
sembly 9.
06175
(2) Play at right angle to shaft direction in shaft and turbine wheel
9 assembly
Play on turbine wheel side
If the measurement exceeds the specified limit, replace cartridge
assembly 9.
06176
Play on compressor wheel side

9 If the measurement exceeds the specified limit, replace cartridge
assembly 9.
06177
15A-15
INTERCOOLER
T 1 Clamp
7 2 Air inlet hose
T 8 3 Clamp
7 *c 4 Air inlet pipe
*b
10 5 Clamp
T
6 Air inlet hose
9
T 7 Clamp
12 1 8 Rubber hose
T
11 9 Clamp
10 Air inlet pipe
11 Clamp
*a
12 Air inlet hose
13 Intercooler
2 *a: Radiator B Group 14A

1T *b: Intake manifold P. 15A-18
*c: Turbocharger assembly P. 15A-13
4
3 P Reassembly sequence
6 T Follow the disassembly sequence in reverse.
R 5
T
29109
Service standard
Intercooler air leakage
13 0 cm3 {0 cu.in.} Replace
(at air pressure of 150 kPa {21 psi, 1.5 kgf/cm2})

1, 3, 5, Clamp 2.9 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
9, 11
7 Clamp 3.9 to 4.9 {2.9 to 3.6, 0.4 to 0.5}
R Service procedure
R Inspection of intercooler
Fit a cap over one of the air ports A on the intercooler 13, connect a hose
A to the other port, and immerse the intercooler in a tank of water. Then,
apply the specified air pressure (150 kPa {21 lbf/in2, 1.5 kgf/cm2}) via the
hose and check for air leakage.
If leakage is apparent, replace the intercooler 13.
01552
15A-16
15A
MEMO
15A-17
INTAKE MANIFOLD
X
13
12
X
10
5
T
4
T
6
*a
3
11
T 2
8 *b
7 1
T T
37459
1 Nut 7 Nut 13 Gasket A
2 Actuator assembly 8 Spring
3 Pressure hose 9 Intake manifold B *a: Cylinder head B Group 11A
4 Bolt 10 Gasket B *b: Vacuum hose B Group 17A
5 Boost pressure sensor 11 Bolt : Non-reusable part
6 Pressure hose fitting 12 Intake manifold A

Butterfly valve intake manifold +0.5
+0.5 +0.02
+0.02
2, 9 clearance
Clearance B 4.0 00
{0.16 0
0
} Replace
15A-18
15A

1 Nut (actuator assembly mounting) 8 {5.8, 0.8}
4 Bolt (boost pressure sensor mounting) 4.9 {3.6, 0.5}
6 Pressure hose fitting 14.7 to 19.6 {11.0 to 14.0, 1.5 to 2.0}
7 Nut (intake manifold B mounting) 10.8 {8.0, 1.1}
11 Bolt (intake manifold A mounting) 44.1 {33.0, 4.5}
R Service procedure
2 9 Clearance between butterfly valve and intake manifold B
A Apply a vacuum of more than 67 kPa {19.7 in.Hg, 500 mmHg} to the
actuator assembly 2 to bring the double nut into contact with its bracket.
While keeping this condition, adjust the clearance B between the butterfly
B
valve A and the intake manifold B 9 for the specified standard value using
the oblong holes C in the actuator assembly bracket.
C 2
9
37832
15A-19
EXHAUST MANIFOLD
1 Bolt
2 Insulator
3 Lower insulator
4 Nut
5 Spacer
1 6 Exhaust manifold
6 7 Gasket
2
7
*: Cylinder head B Group 11A
: Non-reusable part
4
3 *a
40998

1 Bolt (insulator manifold mounting) 18.0 {13.0, 1.8}
4 Nut (exhaust manifold mounting) 41.2 {30.0, 4.2}
R Service procedure
*a
8 Installation of gasket
Fit the gasket 8 with the side having projections A facing the cylinder
A 8 head *a.
A: Projections
A A
29183
15A-20
EXHAUST PIPE AND MUFFLER 15A
14
1 Nut
2 Tail pipe
3 Nut
4 Bolt
6 1 5 Exhaust pipe bracket
7 2 6 Nut
* 7 Bolt
8 Nut
15
10 Nut
6 11 Front pipe
5 8 12 Exhaust brake unit B Group 35
9 3 4 13 Front pipe
14 Bolt
11
12 15 Muffler
13
*: Exhaust manifold
13254
WARNING k
Never hit or kick muffler 15, or the catalyst in the muffler will be damaged.
A small amount of water sometimes collects inside muffler 15. Never touch this water, if you do by mistake,
wash it off immediately with clean water.

1, 8 Nut (Tail pipe and muffler mounting) 26 to 33 {20 to 25, 2.7 to 3.4}
R Service procedure
9 Installation of front pipe assembly
A Install front pipe assembly 9 so that the offset tolerance in the vertical and
9 horizontal sections between the front and back of bellows A conforms to
the specified value.
CAUTION k
Be sure when installing front pipe assembly 9, that bellows A are
5 mm {0.20 in.} or less not bent or stretched, since the bellows are designed to reduce the
external noise of the vehicle but not to absorb dimensional errors in
07701
the installation of pipes.
15A-21
Group 15
Intake and Exhaust
Table of Contents
BACK
HOME
Pub No. TWSE9501-15

15
GROUP 15 INTAKE AND EXHAUST
SPECIFICATIONS .................................................................................. 2

Measurement of Turbo Boost Pressure ........................................................... 6
AIR DUCT AND AIR CLEANER ............................................................. 8
TURBOCHARGER ............................................................................... 12
INTERCOOLER .................................................................................... 18
INTAKE MANIFOLD ............................................................................. 20
EXHAUST MANIFOLD ......................................................................... 22
EXHAUST PIPE AND MUFFLER ......................................................... 24
15-1
SPECIFICATIONS
Items Specifications
Air cleaner element Cyclone paper filter type
Turbocharger Model TD05
Manufacturer MITSUBISHI HEAVY INDUSTRIES
Intercooler type Air-cooled, tube and corrugated fin type

Air Cleaner
2 1 Air box
2 Air cleaner assembly
3 Unloader valve
1
Air cleaner assembly 2 uses a single element.
Air box 1 and air cleaner assembly 2 are fitted with unloader
valve 3. Water, dust and dirt that collect in the unit are
automatically vented by vibration caused by the change of
negative pressure when the engine revolution falls below
the specified revolution.
3 13241
Turbocharger
1 Actuator
1 2 3 4 5 6 7 8 2 Compressor wheel
3 Thrust sleeve
4 Thrust bearing
5 Bearing
6 Bearing housing
7 Turbine backplate
8 Turbine housing
9 Shaft and turbine wheel
10 Piston ring
11 Thrust ring
12 Oil deflector
13 Inserter
14 Compressor cover
2 to 13 : Cartridge assembly
14 13 12 11 10 9
13242
15-2
15
Waste gate mechanism
The waste gate mechanism relieves the boost pressure of excess
exhaust gas using actuator 1. This controls the boost pressure appro-
priately and prevents the turbocharger from overrunning, and prevents
excessive pressure in the intake manifold.
The boost pressure is fed into chamber A of actuator 1 from compres-
14
9 sor cover 14 via a rubber hose. When boost pressure C, acting on the
chamber, is lower than the preset value, the actuator does not operate
and waste gate valve B remains closed, therefore exhaust gas D is
blown against shaft and turbine wheel 9.
C
B
1
D
A 01510
9 As the boost pressure acting on chamber A increases to become

2 higher than the preset value, waste gate valve B is opened and the
exhaust gas blown against shaft and turbine wheel 9 decreases.
Therefore the rotation of compressor wheel 2 decreases, causing the
boost pressure to decrease.
C B
D
A 06538
Operation of over-boost valve

Over-boost valve E operates when the boost pressure increases
abnormally because of faulty operation of the waste gate mechanism.
04953
If boost pressure C of over-boost valve E increases to become higher

than the preset value, the excessive boost pressure is discharged into
C the atmosphere, protecting the engine from excessive boost pressure.
E
When the valve is operating, a pipe-blowing sound is generated.
D 01513
15-3
Muffler
1 Muffler
2 Catalytic converter
1
A : Exhaust gas intake
Converter 2 is built into muffler 1 to decrease the amount of

A
particulate matter (PM) in the exhaust gas.
13243
15-4
TROUBLESHOOTING 15
Symptoms
Noise and vibration in intake/exhaust systems

Oil consumption excessive
Engine output insufficient
Remarks
Exhaust gas whitish

Exhaust gas dark

Possible causes
Air cleaner Air cleaner element clogged
Bearing faulty
Carbon deposits on shaft and turbine wheel

backplate
Shaft and turbine wheel interfering with turbine housing
Cartridge assembly
Shaft and turbine wheel bent

Shaft and turbine wheel broken
Compressor wheel interfering with compressor housing
Turbocharger Thrust sleeve and thrust bearing seized
Compressor wheel broken
Engine oil leaking because piston ring and inserter worn
Piston rings installation faulty
Parts not sliding smoothly because oil lubrication

pipe and eye bolt clogged
Oil seals damaged because oil return pipe clogged
Compressor housing installation faulty
Turbine housing installation faulty
Intercooler Foreign particles on intercooler front core
Butterfly valve does not open
Actuator
Butterfly valve opening and closing adjusted incorrectly
Front pipe, muffler and tail pipe deformed
Front pipe, muffler and tail pipe installation faulty
Valve clearance faulty ^ Gr 11
Head gasket faulty ^ Gr 11
Valve and valve seat worn and carbon deposits ^ Gr 11
Valve spring fatigued ^ Gr 11
Piston ring worn and damaged ^ Gr 11
Piston ring groove worn and damaged ^ Gr 11
Engine oil excessive ^ Gr 12
Main moving parts seized ^ Gr 11
Fuel injection quantity uneven or excessive ^ Gr 13
15-5
Measurement of Turbo Boost Pressure
Service standards
Boost pressure (Air temperature 20C {68F}, 36 kPa Inspect
Atmospheric pressure 100 kPa {29.9 in. Hg, {10.6 in. Hg, and adjust
760 mmHg}) 270 mmHg}/
3700 rpm
0 Special tools
Boost pressure gauge MH061366 Measurement of turbo boost pressure
01524
0 Before measuring the turbo boost pressure, clean or replace the air
cleaner element.
Remove boost compensator hose 1 and attach 0 boost pressure
gauge.
After warming up the engine, measure the boost pressure at the no-
load maximum engine speed. Also measure the engine speed and the
air temperature.
1
11383
1.1 Correct the boost pressure at standard conditions. (Since the boost
Boost pressure coefficient
pressure varies depending on the air temperature and engine speed.)

[Correction for air temperature]
1.0
Identify boost pressure coefficient depending on the air temperature
from the graph.
0.9
0.8
20 10 0 10 20 30 40
{4} {14} {32} {50} {68} {86}{104}
Air temperature C {F}
01522
15-6
15
Boost pressure correction value
5.3 [Correction for engine speed]
{1.57, 40}
Subtract the engine speed actually used for measuring the boost pres-
2.7 sure from the median of the no-load maximum engine speed. Identify the
{0.79, 20}
(kPa {in. Hg, mmHg})
0
boost pressure correction value (Pa) according to the graph.
{0, 0} Median value : 3700 rpm
2.7
{0.79, 20}
[Calculation of corrected boost pressure]
5.3
{1.57, 40} Given the measured boost pressure to be P, corrected boost pressure
100 50 0 50 100
Pb can be calculated from the following equation:
Engine speed (rpm)
(Difference between the median of Pb = ktP + Pa
the no-load maximum engine speed Pb : Corrected boost pressure
and the actual engine speed used
for boost pressure measurement) P : Measured boost pressure
kt : Boost pressure correcting coefficient depending on air tem-
06165
perature
Pa : Boost pressure correction value
If Pb is lower than the limit, the turbocharger must be inspected and

adjusted.
15-7
4
6
3
5
7

9
14
13149
1 Clamp 10 Air box
2 Connector 11 Rubber seal
3 Air inlet duct 12 Air cleaner cap
4 Clamp 13 Air cleaner element
5 Clamp 14 Air cleaner case
6 Air hose
7 Clamp * : Turbocharger P15-12
8 Air duct : Non-reusable parts
9 Clamp
Assembly sequence

1, 4, 5, Clamp 2.9 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
7, 9
15-8
15
8 A
8
Service procedure
Installation of air duct
Fit clamp 7 over protrusions A of air duct 8.
Push air duct 8 in until it hits air cleaner case 14.
14
7
08786
A
B
F Installation of air box
Align slit A of air box 10 with key B of air cleaner case 14.
10 11 14 09959
A 11
G Installation of rubber seal
Align slit A of rubber seal 11 with key B of air cleaner case 14.
14
06166
14
H Installation of air cleaner cap
: Alignment mark
13
12
13152
15-9
13
I Air cleaner element
[Cleaning]
Blow compressed air of 685 kPa {100 lbf/in2, 7 kgf/cm2} or less through
CAUTION
13150 Do not blow compressed air through air cleaner element 13 from
the outside.
[Inspection]
13
element.
NOTE
ment interval.
13151
15-10
15
MEMO
15-11
TURBOCHARGER
Removal sequence
1 Bolt
2 2 Insulator
3 Eye bolt
*4 4 Oil pipe
1
5 Oil return pipe

6 O-ring
3 7 Bolt
8 Seal ring
9 Exhaust pipe
10 Nut
11 Turbocharger assembly P15-14
*1 12 Gasket
-
4 *1 : Air hose P15-8

*2 *2 : Air inlet hose P15-19
*3 : Front pipe P15-24
*4 : Exhaust manifold P15-22
7 10
9 5
*3 6-
11400

1 Bolt (Insulator mounting) 12 {8.7, 1.2}
3 Eye bolt 17 to 23 {12 to 17, 1.7 to 2.3}
7 Bolt (Exhaust pipe mounting) 41 to 54 {30 to 40, 4.2 to 5.5}
10 Nut (Turbocharger assembly mounting) 41 to 54 {30 to 40, 4.2 to 5.5}
- Lubricant
11 Supply when installing turbocharger assembly Engine oil As required
15-12
15
A 8
Service procedure
Installation of seal ring
Offset splits A of seal rings 8 at 180.
A
8
9 07573
11
A G Installation of turbocharger assembly
When installing turbocharger assembly 11, supply engine oil via oil port
A as required to ensure that parts move smoothly.
13244
12 A
*4
H Installation of gasket
Install gasket 12 to exhaust manifold *4 in the direction as illustrated.
A : Grommet lip
13245
15-13
TURBOCHARGER
Turbocharger Assembly
Work before disassembly
-3 P15-15
- 1 Hose
8
2 Actuator
3 Bolt
4 Coupling
5 Turbine housing
6 Snap ring
7 Compressor cover
8 O-ring
9 Cartridge assembly
2 13246
Assembly sequence
Inspection after assembly
P15-15
NOTE
Since cartridge assembly 9 is a unit construction, if the turbine wheel or the compressor wheel is damaged, or
the cartridge assembly does not revolve smoothly, or any other fault is found, replace the assembly as a unit.

9 Cartridge Play in the shaft direction 0.05 to 0.09 {0.0020 to 0.0035} 0.1 {0.0039} Replace
assembly Play at right angles to Turbine 0.40 to 0.53 {0.016 to 0.021} 0.58 {0.023} Replace
the shaft wheel side
Compressor 0.55 to 0.66 {0.022 to 0.026} 0.72 {0.028} Replace
wheel side

3 Bolt (Coupling mounting) 3.9 to 4.9 {2.9 to 3.6, 0.4 to 0.5}
- Lubricant
3 Thread area of bolt Molybdenum disulfide grease As required
8 Periphery of O-ring Engine oil As required
15-14
15
Service procedure
9 4
5 Put alignment marks A on coupling 4, turbine housing 5, compressor
cover 7 and cartridge assembly 9.
7
A
13247

Turn the turbine wheel and the compressor wheel of cartridge assembly
9 to make sure that they turn smoothly.
4
13248
Installation of coupling
5 Install coupling 4 onto turbine housing 5 in the direction as illustrated.
4
45
5
13249
Removal of turbine housing
CAUTION
When removing turbine housing 5, tap all around the circumfer-
A ence lightly using rubber-headed hammer A so as not to damage
the turbine housing.
Do not hit the turbine wheel near turbine housing 5, since the
blade of the turbine wheel can be easily bent.
5
57
06174
Cleaning of turbine housing and compressor cover

Visually inspect related parts before cleaning to check if there are any
burns or scratches as these would not be seen after cleaning. If any
fault is found, replace the faulty parts.
A Remove any foreign particles before cleaning by scraping them off
C B using plastic scraper or bristle-headed brush C. Immerse the disas-
sembled parts in nonflammable solvent A (DAIDO KAGAKU KOGYO
DAICLEANER T-30), then take them out and blow compressed air B
01529 on them.
15-15
TURBOCHARGER
A
6 Installation of snap ring
Install snap ring 6 into compressor cover 7 with taper surface A upward.
WARNING
Use your hand to hold snap ring 6 in place to prevent it from
springing out.
6
7
01532
Removal of compressor cover
CAUTION
When removing compressor cover 7, tap all around the circum-
ference lightly so as not to damage the compressor cover.
Avoid hitting the compressor wheel near compressor cover 7,
since the blade of the compressor wheel can be easily bent.
9
7
01533
Inspection of cartridge assembly

9
(1) Play in the shaft direction of the shaft and turbine wheel
assembly
cartridge assembly 9.
06175
9 (2) Play at right angles to the shaft of the shaft and turbine wheel
assembly
Play on turbine wheel side
If the measured value is higher than the limit, replace cartridge
assembly 9.
06176
Play on compressor wheel side

9 If measured value is higher than the limit, replace cartridge assem-
bly 9.
06177
15-16
15
MEMO
15-17
INTERCOOLER
3 *3 *2
1 Clamp
*1 2 Air inlet hose
3 3 Clamp
4 Air inlet hose
7 5 Clamp
6 Bolt
1 7 Air inlet pipe
8 Clamp
9 Air inlet hose
10 Bolt
5 6 11 Boost air temperature sensor ^ Gr 13
9 12 Intercooler
8
*1 : Radiator ^ Gr 14
*2 : Exhaust manifold P15-22
*3 : Turbocharger P15-12
10 2
Assembly sequence
1 verse.
11 13250
Service standards
12 Air leakage from intercooler 0 cm3 {0 cu. in.} Replace
(Air pressure : 150 kPa {21 lbf/in2, 1.5 kgf/cm2})

1, 3, 5, 8 Clamp (Air inlet hose mounting) 2.9 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
6 Bolt (Air inlet pipe mounting) 12 to 15 {8.7 to 11, 1.2 to 1.5}
10 Bolt (Intercooler mounting) 12 to 15 {8.7 to 11, 1.2 to 1.5}
11 Boost air temperature sensor 14.72 {111.4, 1.50.2}
15-18
15

4
Service procedure
Installation of air inlet hose
Align alignment mark of air inlet hose 4 with padded part A of air inlet
pipe 7.
A
7 06179
H Inspection of intercooler
Fit plug A on one of the air inlets of intercooler 12 and connect a hose
A
to the other, then lower the intercooler into the water tank. Apply air at
the specified pressure (150 kPa {21 lbf/in2, 1.5 kgf/cm2}) from the hose
side and check for air leaks.
If air leaks, replace intercooler 12.
12 01552
15-19
INTAKE MANIFOLD
1 Over-boost valve
2 Bolt
3 Intake manifold assembly ^ Gr 35
4 Gasket
1
3 * : Cylinder head ^ Gr 11
Assembly sequence
verse.
*
4
13251

1 Over-boost valve 31 {23, 3.2}
2 Bolt (Intake manifold assembly mounting) 16 to 24 {12 to 17, 1.6 to 2.4}
15-20
15
MEMO
15-21
EXHAUST MANIFOLD
*2
10
1 9
2
3
4
*1
13252
1 Insulator 10 Rear exhaust manifold
2 Nut
3 Distance piece *1 : Cylinder head ^ Gr 11
4 Exhaust manifold assembly *2 : Insulator P 15-12
5 Gasket : Non-reusable parts
6 Front exhaust manifold
7 Seal ring
8 Expansion ring
9 Joint
Assembly sequence

2 Nut (Front exhaust manifold and rear exhaust 41 to 54 {30 to 40, 4.2 to 5.5}
manifold mounting)
15-22
15
5 5
Service procedure
Installation of gasket
Install gasket 5 on cylinder head *1 in the direction as illustrated.
A : Grommet lip
A
*1
13253
7
78 Installation of seal ring and expansion ring
Offset splits A of seal rings 5 at 180.
7 9 Align so that expansion ring 8 protrusions B and splits A of seal rings 7
A
do not meet.
B
8
A 8
01563
15-23
EXHAUST PIPE AND MUFFLER
14
1 Nut
2 Tail pipe
3 Nut
4 Bolt
6 1 5 Exhaust pipe bracket
7
2 6 Nut
* 7 Bolt
8 Nut
15 10 Nut
6 11 Front pipe
5 8 12 Exhaust brake unit ^ Gr 35
4 13 Front pipe
3 14 Bolt
11
15 Muffler
12
13
* : Exhaust manifold
verse.
13254
WARNING
Never hit or kick muffler 15, or the catalyzer in the muffler will be damaged.
A small amount of water sometimes collects inside muffler 15. Never touch this water, if you do by mistake,
wash it off immediately with clean water.

1, 8 Nut (Tail pipe and muffler mounting) 26 to 33 {20 to 25, 2.7 to 3.4}
15-24
15
9
A
9
Service procedure
Installation of front pipe assembly
Install front pipe assembly 9 so that the offset tolerance in the vertical
and horizontal sections between the front and back of bellows A con-
forms to the specified value.
CAUTION
Be sure when installing front pipe assembly 9, that bellows A are
not bent or stretched, since the bellows are designed to reduce
the external noise of the vehicle but not to absorb dimensional
5 mm {0.20 in.} or less
07701
errors in the installation of pipes.
15-25
Group 21
Clutch
Table of Contents
BACK
HOME
Pub No. TWSE9501-21

21
GROUP 21 CLUTCH
SPECIFICATIONS .................................................................................. 2

Clutch Fluid (Brake Fluid) Replacement and Air Bleeding ............................. 6
Clutch Pedal Free Play ....................................................................................... 8
CLUTCH PEDAL .................................................................................. 10
CLUTCH MASTER CYLINDER ............................................................ 12
CLUTCH POWER CYLINDER ............................................................. 14
WORK BEFORE REMOVAL AND INSTALLATION OF

CLUTCH BODY .................................................................................... 16
CLUTCH BODY .................................................................................... 18
CLUTCH CONTROL .............................................................................. 22
21-1
SPECIFICATIONS
Item Specifications
Clutch Model C4W30
Drive type Strap drive
Clutch disc Type Dry, single plate type
Pressure plate Type Diaphragm spring type
Control type Hydraulic pressure type
Clutch master cylinder Manufacturer NISSIN KOGYO
Clutch power cylinder Manufacturer NISSIN KOGYO

Clutch Control
4 5
1 6
7
12385
1 Clutch pedal 6 Clutch cover assembly

2 Clutch master cylinder 7 Push rod
3 Fluid tank 8 Clutch power cylinder
4 Flywheel
5 Clutch disc A : Hydraulic pressure
21-2
21
Clutch Master Cylinder
B
A
12
3
6
8 7 5 4
08189
1 Valve stem 5 Spring seat A : From fluid tank

2 Return spring 6 Valve spring B : To clutch power cylinder (hydraulic
3 Pressure cup 7 Valve case pressure)
4 Piston 8 Valve seal
1 When clutch pedal is depressed

4 As piston 4 is pressed in the direction as illustrated, valve spring 6 of
valve stem 1 forces down valve seal 8 to close the fluid tank port.
Then, the hydraulic pressure in the master cylinder increases to
transmit hydraulic pressure B to the power cylinder.
8
6 B 03461
When clutch pedal is released

6 1 2 4 As the clutch pedal is released, hydraulic pressure B from the power
cylinder and return spring 2 push back piston 4.
At the same time, valve stem 1 is retracted by spring seat 5 and
compresses valve spring 6 to open the fluid tank port.
Thus released, hydraulic pressure B in the master cylinder returns
piston 4 to its original position.
B 5
03462
21-3
Clutch Body
1 Clutch housing
2 2 Strap plate
1
3 3 Clutch cover
4 Pivot ring
5 Diaphragm spring
4 6 Clutch release bearing
5 7 Clutch release rocker arm
8 Rocker arm pivot
12 6 9 Pressure plate
10 Clutch disc
11 Flywheel
12 Drive pinion
11 7
8
10
9
12386
When clutch pedal is released

11 Pressure plate 9, activated by diaphragm spring 5, forces
clutch disc 10 against flywheel 11.
Clutch disc 10 forced against flywheel 11 runs together with
the flywheel and transmits power from the engine to trans-
mission drive pinion 12.
12
5
10
9
12387
When clutch pedal is depressed

11 2 Hydraulic pressure generated within the clutch master cylin-
3 der activates the power cylinder. This pushes out clutch
4 release bearing 6 via clutch release rocker arm 7 to com-
press diaphragm spring 5. The diaphragm spring supported
6 by pivot ring 4 retracts pressure plate 9, which is connected
to clutch cover 3 via the strap plate 2. The resulting clear-
ance between clutch disc 10 and flywheel 11 cuts off the
transmission of engine power.
7
5
10
9
12388
21-4
TROUBLESHOOTING 21
Symptoms
Clutch makes noise on disengagement

Clutch makes noise on engagement
Clutch does not engage smoothly
Clutch pedal hard to depress

Clutch disengaged but drags
Judder when vehicle starting

Remarks
Clutch slips
Possible causes
Diaphragm spring heights uneven
Pressure plate warped or faulty
Clutch cover
Diaphragm spring fatigued
assembly
Rivets loose
Strap plate bent
Disc deformed
Disc rivets loose
Disc torsion spring fatigued or fractured
Spline worn
Clutch disc
Spline rusted
Facing worn
Facing surface hardened
Facing oily or greasy
Pedal free play inadequate
Pedal free play excessive
Clutch pedal Pedal stroke inadequate
Return spring fatigued
Pedal friction surfaces faulty
Piston and piston cup sliding movement faulty
Clutch master
Spring fatigued
cylinder
Brake fluid port clogged
Piston and piston cup sliding movement faulty
Clutch power
Spring fatigued
cylinder
Brake fluid port clogged
Clutch control Release bearing faulty
Transmission drive pinion spline worn ^ Gr 22
Engine idling speed too slow ^ Gr 13
Engine mounting fatigued ^ Gr 10
Flywheel warped, deformed or stepped wear ^ Gr 11
Flywheel pilot bearing faulty ^ Gr 11
Air mixed in clutch hydraulic system
Clutch hydraulic system leaking
21-5
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding
1 Bleeder screw 10.8 to 14.7 {8 to 11, 1.1 to 1.5}
- Fluid
4 Fluid tank Brake fluid As required
WARNING
tank in common. Therefore, replacement the clutch fluid must be
carried out simultaneously with that of the brake fluid. ^ Gr 35
clutch system and brake system to swell, resulting in faulty
clutch operation, as well as ineffective braking and brake
dragging.
brake fluid when refilling, because this will result in faulty clutch
and brake operations.
purpose to prevent contamination from different quality fluids or
mineral oils.
CAUTION
paintwork.
(1) Replacement of brake fluid

1 2 Attach vinyl pipe 2 to bleeder screw 1 of the clutch power cylinder.
Loosen bleeder screw 1 and depress clutch pedal 3 several times
to drain brake fluid completely.
12389
21-6
21
Supply new brake fluid to the MAX level of fluid tank 4. Depress
clutch pedal 3 repeatedly until the old brake fluid discharged from vinyl
pipe 2 is replaced by the new brake fluid.
MAX
MIN
4
11773
(2) Air bleeding of clutch system

1 2 NOTE
Carry out this operation maintaining the brake fluid level in fluid
tank 4 between MAX and MIN.
12389
Attach vinyl pipe 2 to bleeder screw 1 of the clutch power cylinder as in

the replacement procedure.
Fill fluid tank 4 with brake fluid, and loosen bleeder screw 1 of the
clutch power cylinder, then depress clutch pedal 3 continuously.
Keep depressing clutch pedal 3, and tighten bleeder screw 1 when air
MAX
MIN is bled completely.
Depress clutch pedal 3 several times again, then keep it depressed at
its fullest extent.
4 With the clutch pedal depressed, loosen bleeder screw 1 to drain
11773 brake fluid containing air. Release the pedal after tightening the
bleeder screw.
Repeat this operation until air is no longer present in the fluid being
drained.
When this operation is completed, tighten bleeder screw 1 at specified
torque.
Check that brake fluid is at the MAX level of fluid tank 4, and supply
new brake fluid if necessary.
Check for brake fluid leakage from each of the parts with clutch pedal
3 depressed.
21-7
Clutch Pedal Free Play

2 Push rod stroke 4 {0.16} Adjust
or replace
or replace
Inspect and adjust the free play of the clutch pedal, by noting the stroke
of the clutch power cylinder push rod, after the clutch pedal has been
correctly adjusted.
[Inspection]
2 Bleed air from the clutch system P21-7
Adjust the clutch pedal P21-11
Disconnect return spring 1 and check the free play of push rod 2 by
hand. If the measured value deviates from the standard value, adjust
as follows:
1 12393
[Adjustment]
A 3 2 Loosen nut 3 and turn flat parts A of push rod 2 to extend push rod
until it stops.
Then, return flat parts A of push rod 2 by the following value and
retighten nut 3.
Amount of return : Approximately three and one fifth of a turn
If push rod 2 cannot be returned by the above amount, the clutch disc
12394 is worn beyond the limit and needs replacing.
Install return spring 1, and check that there is no space between push
2 4 5 rod cap 4 and clutch release rocker arm 5 by moving push rod 2.
1 12395
21-8
21
[Confirmation]
Push clutch pedal 6 with your hand until you feel a resistance and
measure free play B.
If the measured value deviates from the standard value, readjust or
replace the clutch disc.
B : 36 to 53 mm
{1.42 to 2.09
in.}
6
03480
21-9
CLUTCH PEDAL
1 Fluid hose
8 2 Fluid hose
3 Clevis pin
4 4 Nut
5 Clutch master cylinder P21-12
6 Clutch switch ^ Gr 54
7 Lock nut
8 Nut
5 9 Clevis pin
10 Spring holder
11 Return spring
7 3 12 Plate
21 -
17 13 Nut
14 Spring assist rod
15 Collar
16 Bushing
16 18 17 Bushing
- 15 19
18 Bushing
19 Pedal pad
14 20 Clutch pedal
9 21 Clutch pedal support
13
- 12
-
- 10
verse.
12390 Adjustment after assembly

P21-11

Standard value
11 Installed load of return spring 185 N {41 lbf, 18.7 kgf} 165 N {37 lbf, Replace
(Installed length 37 {1.46}) 16.8 kgf}
15, 16 Clearance between collar and bushing [14] 0.02 to 0.26 0.3 {0.012} Replace
{[0.55] 0.00079 to 0.010}

8 Nut (Clutch pedal mounting) 16.7 to 25.5 {12 to 19, 1.7 to 2.6}
- Lubricant
3 Clevis pin Chassis grease [NLGI No.1 (Ca soap)] As required
10 to 12 Friction surfaces of spring holder, return spring and plate Chassis grease [NLGI No.1 (Ca soap)] As required
15 External surface of collar Chassis grease [NLGI No.1 (Ca soap)] As required
21-10
21
Service procedure
Adjustment after assembly
Adjustment of clutch pedal

* 5
Adjust clevis * of clutch master cylinder 5 so that clutch pedal 20 is
installed as illustrated. P21-13
1803 mm
{7.090.12 in.}
20 165 mm
{6.50 in.}
03696
A
12 Removal and installation of fluid hose
Remove fluid hose 1 from the fluid tank and clutch master cylinder 5,
and fit stopper A after draining is completed.
Remove fluid hose 2 from clutch master cylinder 5 after removing pipe
1 B from the cab, then fit stopper C to pipe B.
5
C After installation, bleed the system. P21-7
2
B
08195
A
6
6 Installation of clutch switch
After adjusting clutch pedal 20, adjust the clearance between the thread
end of clutch switch 6 and pedal stopper A so that it is within the standard
value, and tighten lock nut 7.
20
CAUTION
Do not allow the thread end of clutch switch 6 to come into
contact with pedal stopper A of clutch pedal 20 because this will
cause the clutch to slip.
0.5 to 1.5 mm 7
{0.020 to 0.059 in.} 12391
G Adjustment of return spring installation length

Adjust return spring 11 to the installed length as illustrated using lock
nut 13.
13
371 mm
{1.460.039 in.}
11
05952
21-11
CLUTCH MASTER CYLINDER
1 Clevis
2 Lock nut
3 3 Retaining ring
4 4 Stop plate
5 Push rod
6 Clip
7 Packing
8 - 8 Union collar
7 9 Piston assembly
10 Cylinder body
6
Assembly sequence
87

10 6 9 5 4 3 2 1
10
- Repair kit : Clutch master cylinder kit
08196

9, 10 Clearance between piston assembly and [22.22] 0.02 to 0.10 0.2 {0.0079}
cylinder body {[0.87] 0.00079 to 0.0039}

2 Lock nut (Push rod mounting) 19 to 27 {14 to 20, 1.9 to 2.8}
- Lubricant
9, 10 Friction surfaces of piston assembly and cylinder body Rubber grease 0.2 to 0.3 g
{0.0071 to
0.011 oz}
21-12
21
1
125
Service procedure
Adjustment of push rod length
If the length, as illustrated, deviates from the specified value, loosen
2 nut 2, and adjust the length of push rod 5 by turning clevis 1.
Measure the length while push rod 5 is touching stop plate 4.
After adjustment, tighten nut 2 at specified torque.
5 118 mm
{4.65 in.}
03490
9 9 Piston assembly
[Removal]
A B Remove retaining ring 3, stop plate 4 and push rod 5.
Block port A of cylinder body 10, and apply compressed air from B as
illustrated to remove piston assembly 9.
WARNING
3 You must apply compressed air gradually when you remove
4 piston assembly 9. If you applied compressed air strongly at one
10
5 08197 time, the piston assembly would be violently ejected.
C [Installation]
Before installing the assembly, apply rubber grease to friction surface C
C of piston assembly 9 and cylinder body 10.
10 08198
21-13
CLUTCH POWER CYLINDER
Removal sequence
1 Fluid hose
2 Return spring
3 Bolt
3 4 Clutch power cylinder assembly
P21-15
*2 - *1 : Push rod cap

*2 : Clutch release rocker arm
2
4
*1 Installation sequence
- Follow the removal sequence in reverse.
1 12392

3 Bolt (Clutch power cylinder mounting) 38 to 59 {28 to 43, 3.9 to 6.0}
- Lubricant
*1, *2 Contact areas of push rod cap edge and clutch release rocker armWheel bearing grease [NLGI No.2 (Li soap)] As required
21-14
21
Clutch Power Cylinder Assembly
1 Push rod cap
2 Lock nut
3 Push rod
4 Dust cover
5 Piston cup
1 6 Piston
7 2 7 Bleeder cap
8 8 Bleeder screw
3
9 Cylinder body
4- : Non-reusable parts
6-
5- Assembly sequence
9- Follow the disassembly sequence in re-
12397 verse.
Repair kit : Power cylinder kit

Standard value
6, 9 Clearance between piston and cylinder body [20.64] 0.02 to 0.11 0.2 {0.0079} Replace
{[0.81] 0.00079 to 0.0043}

8 Bleeder screw 10.8 to 14.7 {8 to 11, 1.1 to 1.5}
- Lubricant
4 Engagement part of cylinder body Rubber grease As required
5, 6, 9 The area extending approximately 15 mm {0.59 in.} from the Rubber grease As required
end surface of cylinder body
Piston, piston cup (installation point) and internal surface of Rubber grease As required
cylinder body
21-15
WORK BEFORE REMOVAL AND INSTALLATION OF CLUTCH BODY
3
1
5
14121
Work sequence before removal

1 Place wheel chocks.
2 Disconnect the negative battery cable. ^ Gr 54
3 Jack up the front axle using a garage jack.
4 Support the front frame on rigid racks.
5 Remove the transmission. ^ Gr 22
WARNING
Since the parking brake will be removed, naturally it cannot be used. Therefore, you must chock the wheels
securely so the vehicle does not move.
Supporting a vehicle on a garage jack only is extremely dangerous, so always support the frame on rigid
racks.
Leave the garage jack and rigid racks in place until the entire operation is completed. Never remove them
during the operation.
CAUTION
Keep the transmission in neutral throughout the operation.
Work sequence after installation

Follow the work sequence before removal in reverse.
21-16
21
MEMO
21-17
CLUTCH BODY
Removal sequence
1 Bolt
2 Clutch cover assembly
*
3 Clutch disc
* : Flywheel ^ Gr 11
- A : Positioning pins (two points)
WARNING
Be careful when you handle pressure

1 plate and lever assembly 2 because it is
rather heavy.
A Installation sequence
CAUTION
12398 Be careful not to get oily substances on
clutch disc 3 surfaces because this will
cause the clutch to slip.

2 Flatness of pressure plate 0.05 {0.0020} or less 0.2 {0.0079}
Friction surface of pressure plate (Measured at 5.5 {0.22} 4.5 {0.18} Replace
specified positions)
Clearance between diaphragm spring and pivot ring Play Replace
Finger heights of diaphragm spring uneven 1.0 {0.039} or less 1.3 {0.051} Correct
3 Clutch disc Radial runout 1.0 {0.039} or less 1.5 {0.059} Replace
Lateral runout 1.0 {0.039} or less 1.5 {0.059} Replace
Play in rotation of spline 0.05 to 0.23 {0.0020 to 0.0091} 0.5 {0.020} Replace
Depth from facing surface to rivet 1.8 to 2.4 {0.071 to 0.094} 0.2 {0.0079} Replace

1 Bolt (Clutch cover assembly mounting) 32 to 49 {24 to 36, 3.3 to 5.0}
- Lubricant
3 Spline of clutch disc Molybdenum disulfide grease 3.2 to 4.2 g
[NLGI No.2 (Li soap)] {0.11 to
0.15 oz}
21-18
21
Clutch alignment arbor 120 {4.72} MH061387 Holding of clutch disc

20 {0.79}
28.94 {1.14}
01270
28.94
{1.14}
Sleeve MH061425 Inspection of installed height of diaphragm

spring
45 {1.77}
03509
2, 3
Plate MH061424 Adjustment of diaphragm spring

400 {15.7}
03510
Adjust wrench MH061426 Adjustment of diaphragm spring

260
45 {1.77} {10.2}
03508
3
A
2
Service procedure
Clutch cover assembly
[Removal]
2
Insert 0 clutch alignment arbor into pilot bearing A on flywheel * to
0 hold clutch disc 3, and remove clutch cover assembly 2.
* For installation, follow the removal sequence in reverse.
Install clutch disc 3 so that part No. B is visible.
Tighten bolts 1 gradually, in diagonal order, to specified torque.
1 12399
3
12400
21-19
CLUTCH BODY
[Flatness of pressure plate]
If the measured value is higher than the limit, replace clutch cover
2 assembly 2.
05973
2 [Friction surface of pressure plate]

Measure pressure plate friction surface C at specified position D
(measuring position of friction surface must be within the maximum and
minimum diameters), and if the measured value is lower than the limit,
replace clutch cover assembly 2.
D Maximum diameter 298 mm {11.7 in.}

Minimum diameter 192 mm {7.56 in.}
C 08830
[Inspection]
Check for play in diaphragm spring E.
2 If there is play, replace clutch cover assembly 2.
05966
[Inspection of installation height]

3 Place 1 plate on a surface plate and install clutch cover assembly 2.
Install 2 sleeve and 3 clutch alignment arbor, measure finger
F heights of diaphragm spring E to see if they are uneven, using feeler
2 2 gauge F. If the measured value is higher than the limit, correct the
heights.
1 E 03512
[Correction]
Correct uneven finger heights of diaphragm spring E using 4 adjust
wrench.
E 4
03513
21-20
21
3 3 Clutch disc
(1) Height of facing

Measure dimension A of clutch disc 3. If the measured value is lower
than the limit, replace the clutch disc.
A
12401
(2) Play in direction of revolution

C Reshape feeler gauge B for insertion into drive pinion spline C, and
measure play. If the measured value is higher than the limit, replace
clutch disc 3 or the drive pinion.
Carry out the same measurement on new clutch disc 3. If the meas-
ured value is higher than the limit, replace the drive pinion.
B
12402
(3) Applying grease

D Apply grease evenly to spline D entire tooth surface of clutch disc 3.
Apply grease to the grease groove of the spline up to its large diameter.
CAUTION
Be careful not to apply too much grease because excessive
grease causes grease leakage from spline D and makes the
clutch slippery.
3
14095
21-21
CLUTCH CONTROL
-
3 4
-
1
-2
1
-
12403
1 Return spring 4 Rocker arm pivot
2 Clutch release bearing 5 Clutch rocker arm cover
3 Clutch release rocker arm 6 Clutch housing
NOTE
Do not remove rocker arm pivot 4 unless it is faulty.
Assembly sequence

4 Rocker arm pivot 57 {42, 5.8}
- Lubricant
1 to 3 Friction surfaces of return spring, clutch release bearing, Wheel bearing grease [NLGI No.2 (Li soap)] As required
and clutch release rocker arm
21-22
Group 22
Manual Transmission
Table of Contents
BACK
HOME
Pub No. TWSE9501-22

22
GROUP 22 MANUAL TRANSMISSION
SPECIFICATIONS .................................................................................. 2

TRANSMISSION ASSEMBLY ................................................................ 7
REMOVAL AND INSTALLATION OF TRANSMISSION

ASSEMBLY............................................................................................. 8
GEAR SHIFTER UPPER ...................................................................... 10
REAR COVER AND REVERSE IDLER GEAR .................................... 16
TRANSMISSION BODY ....................................................................... 20
DRIVE PINION ASSEMBLY ................................................................. 28
MAINSHAFT ASSEMBLY ..................................................................... 30
COUNTERSHAFT ASSEMBLY
< NON-BACKLASH MECHANISM > .................................................... 36
TRANSMISSION CONTROL ................................................................ 40
22-1
SPECIFICATIONS
Item Specifications
Mode of control Floor shift remote control
Transmission model M035S5
1st 5.380
2nd 3.028
Gear ratio 3rd 1.700
4th 1.000
5th 0.722
Reverse 5.380
Oil capacity L {qts} Approximately 3.1 {3.3}

Transmission Assembly
2 3 4 5
10 9 8 7
14092
1 Drive pinion 6 1st and reverse constant-mesh assembly

2 4th and 5th synchronizer assembly 7 Main shaft
3 Shift rail 8 Reverse idler gear
4 2nd and 3rd synchronizer assembly 9 Countershaft
5 Shift fork 10 Non-backlash mechanism
The transmission changes revolution and torque generated by the engine into those that match the vehicles power
requirement (driving force). Revolution and torque are increased or decreased by making a selection from several sets
of engaged gears. The transmission uses an interlock mechanism to avoid double engagement and the non-backlash
mechanism reduces the idling noise of the transmission when the engine is idling.
22-2
22
Synchromesh Mechanism
Single cone type Double cone type 2

< 2nd and 3rd >
3
4
1 1
5 5
2
10
6 6
B
7
A
8
8
9 9
05751 10 05752
1 Synchronizer ring (Single cone type) 7 Mainshaft

Inner synchronizer ring (Double cone type) 8 Synchronizer hub
2 Shifting key 9 Synchronizer sleeve
3 Outer synchronizer ring (Double cone type) 10 Drive pinion (Single cone type)
4 Center cone (Double cone type) 2nd gear (Double cone type)
5 Overdrive gear (Single cone type)
3rd gear (Double cone type) A : Taper cone
6 Shifting key spring B : Dog clutch
The synchromesh mechanism synchronizes the rotating speed of mainshaft 7 and associated synchronizer hub 8 with the
rotating speed of the gears to be selected when shifting gear.
Single cone type

In this cone type, gear taper cone A acts as a cone clutch for synchronization with synchronizer ring 1. So the rotating
speed of the gear to be synchronized with synchronizer hub 8 gradually changes to the matching speed. When
synchronizer sleeve 9 moves into the appropriate position efficiently through this process and engages with the
synchronizer hub and dog clutch B of the gear to be selected, gear shift is completed.
Double cone type < only for 2nd and 3rd gear >
In this cone type, unlike the single cone type, inner synchronizer ring 1, center cone 4 and outer synchronizer ring 3 are
used instead of just the synchronizer ring. The center cone is between the inner synchronizer ring and the outer
synchronizer ring and reduces synchronizing time through more efficient operation of the cone clutch.
22-3
Interlock Mechanism
1 4th and 5th shift rail
< In neutral >
2 2nd and 3rd shift rail
1 2 3 3 1st and reverse shift rail
4 Interlock pin
The interlock mechanism is designed to avoid double en-

gagement of gears. When 2nd and 3rd shift rail 2 is shifted,
interlock pins other than interlock pin 4 in the 2nd and 3rd
shift rail are pushed by the 2nd and 3rd shift rail to lock other
4 03402 shift rails.
< On shifting >
03403
Non-Backlash Mechanism
1 Drive pinion
2 Countershaft constant mesh gear
1 3 Sub-gear spring
4 Sub-gear
5 Sub-gear plate
2
5 Sub-gear spring 3 is between sub-gear 4 and countershaft constant mesh
3 gear 2. The sub-gear is engaged with drive pinion 1 together with
countershaft constant mesh gear, being turned in the contracting direc-
tion of the sub-gear spring.
4
05753
1 The revolution of drive pinion 1 varies in accordance to the engine

revolution when idling.
Without a non-backlash mechanism, backlash t at point A would vary
between zero to the maximum, causing a gear grinding noise.
3 t
A
02192
With a non-backlash mechanism, sub-gear 4 maintains backlash t at zero

at point A regardless of change in revolution caused by the engine,
eliminating gear grinding noise, resulting in a reduction of idling noise.
4
3 t=0
A
02450
22-4
TROUBLESHOOTING 22
Symptoms
Gears slip out of engagement

Remarks
Noise when engine is idling
Noise when changing gear

Gears hard to engage
Noise while cruising

Possible causes
Mainshaft rear lock nut loose
Mainshaft thrust washer worn
Mainshaft bearing worn or damaged
Synchronizer ring and synchronizer sleeve
spline worn
Synchronizer ring and gears taper cone
area worn
Mainshaft pilot bearing worn or damaged
Transmission Drive pinion bearing worn or damaged
body faulty Non-backlash mechanism faulty
Countershaft bearing worn or damaged
Needle bearings of gears worn or damaged
Reverse idler gear and power take-off idler
gear backlash excessive
Mainshaft and countershaft bearings worn
or damaged
Mainshaft and countershaft gears backlash
excessive
Splines of gears worn
Gears damaged
Gear oil insufficient
Control cable joint play
Control rod joint lubricated insufficiently
Bushings worn
Control rod length adjusted incorrectly
Control rod bent
Control Set board assembly bushings worn
mechanisms faulty Shift rail steel ball and groove worn
Shift rail poppet spring fatigued or fractured
Shift rail friction movement faulty
Shift fork claw worn
Shift fork bent
22-5
TROUBLESHOOTING
Symptoms
Gears slip out of engagement

Remarks
Noise when engine is idling
Noise when changing gear

Gears hard to engage

Possible causes
Clutch faulty Clutch engagement poor
^ Gr 21
Clutch pedal play adjusted incorrectly
Single cone Contacting surfaces of synchro-
type nizer ring and gear assembly
taper cone worn
Double Contacting surfaces of synchro-
Synchronizer faulty cone type nizer inner and outer rings and
center cone worn
Shifting key worn
Shifting key spring deteriorated or damaged
Synchronizer sleeve worn or damaged
22-6
WORK BEFORE REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY 22
1
3
14096

2 Disconnect negative battery cable. ^ Gr 54
3 Jack up the front axle on a garage jack.
WARNING
racks.
CAUTION
Keep the transmission in neutral throughout the operation.

22-7
REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY
Removal sequence
1 2 3
11 1 Selector rod P22-40
2 Shift rod P22-40
3 Cross shaft P22-50
4 Harness (Ground)
5 Speedometer cable
6 Chassis harness
7 Parking brake ^ Gr 36
9 Inspection plug
10 Drain plug
7
11 Bolt
4 12 Transmission assembly
5 WARNING
- 6 8 07340 The engine is hot immediately after it has
stopped, so take care not to burn yourself.
NOTE
After removing propeller shaft 8, tie it to
the frame at the height of installation as-
sembly using a piece of rope, etc.
-9 10 - - 10

10 Drain plug 6915 {5111, 71.5}
11 Bolt (Transmission assembly mounting) 47 {35, 4.8} M101.25
82 {61, 8.4} M121.25

12 Spline of drive pinion Molybdenum disulfide grease As required
[NLGI No.2 (Li soap)]
Service procedure
Replacement of oil
[Draining]
When draining oil, check the quantity and quality of oil, especially for
small pieces of metal and metal dust.
Clean drain plug 10 before reinstalling it because it is magnetic.
[Filling]
Check that drain plug 10 is tightened in the transmission case at
specified torque.
01116
Pour in gear oil until the oil overflows from the inspection hole. (For oil
quantity, see specifications.)
22-8
22
H Transmission assembly
[Supporting transmission]
Support transmission assembly 12 on transmission jack A.
12
07611
[Removal]
Insert a screwdriver into the three removal grooves to remove trans-
12 mission assembly 12 from the engine.
CAUTION
Make sure that you remove hoses and cables correctly during
service operations.
06501
Move transmission assembly 12 backward until the spline of the drive

pinion is detached from the clutch.
CAUTION
Make sure that you pull transmission assembly 12 out in a
straight line. If you seesaw the transmission assembly violently,
you will damage the spline that connects the drive pinion and the
clutch.
01117
[Installation]
Check the spline of the drive pinion for rust. If rust is found, remove it
using a wire brush.
Rub grease onto the friction surfaces of the drive pinion using your
hand.
CAUTION
Make sure that you apply only the necessary amount of grease
because too much grease would drip and cause clutch slip.
07610
Support transmission assembly 12 on transmission jack A, and insert

the transmission assembly into the pilot bearing of the flywheel paying
attention to the drive pinion spline.
12 Tighten bolt 11 at specified torque to mount transmission assembly 12
to the engine.
07611
22-9
GEAR SHIFTER UPPER
-1 1 Bolt
2 Gear shifter upper assembly
3 Backup lamp switch
-2 4 Screw plug
5 Interlock pins (5)
6
6 Screws (2)
- 7- 7 Poppet spring plate
8 8 Poppet springs (3)
3 9
9 Steel balls (3)
*
*: Transmission body
-

4 Assembly sequence
03586


1 Bolt (Gear shifter upper assembly mounting) 24 {17, 2.4}
3 Backup lamp switch 29 to 39 {22 to 29, 3 to 4}
4 Screw plug 39 {29, 4}
6 Screw (Poppet spring plate mounting) 24 {17, 2.4}
- Sealant
1 Thread area of bolt THREEBOND 1215 As required
2 Contact surface of transmission case THREEBOND 1104J As required
3 Thread area of backup lamp switch THREEBOND 1215 As required
7 Contact surface of transmission case THREEBOND 1215 As required
22-10
22
A 3
5
Service procedure
Removal of interlock pin
1st and reverse shift rail A is provided with hole B (3 mm {0.12 in.})
for the removal of interlock pin 5.
B
4 5 07592
When 1st and reverse shift rail A is shifted into reverse, hole B for
A
removal of the interlock pin aligns with the interlock pin holes of the
B
other shift rails, backup lamp switch 3 installation hole and screw plug
4 hole.
Remove interlock pin 5 from back-up lamp switch 3 installation hole
side using a wire.
5 07593
22-11
GEAR SHIFTER UPPER
Gear Shifter Upper Assembly
1 Air breather
2 Neutral switch ^ Gr 54
5 3 Nut
6 3
4 Lock pin
5 Bushing
4 6 Gear selector lever
7 Washer
8 Gear selector lever
1
A 9 Spring pin
B 7 10 Torsion shaft
- 11 Spacer
12 4th and 5th return spring
-
13 Gear shift slide lever
- 14 Spring retainer
15 1st and reverse return spring
20
16 Spring retainer
17 Oil seal
18 Oil seal
16 2 19 Bushing
14 20 Selector lever case
-
8
A : Notch for spring pin
B : Recess for interlock switch
12
11
14019
NOTE
Do not remove bushing 19 except for replacement.
Assembly sequence
CAUTION
Make sure that you turn gear selector lever 8 while assembling it to prevent damage to the lip area of oil
seal 18.
22-12
22
12 4th and 5th return spring free length 39.25 {1.55} 37.25 {1.47} Replace
15 1st and reverse return spring free length 39.9 {1.57} 37.9 {1.49} Replace

2 Neutral switch 492.9 {362.2, 50.3}
3 Nut (Lock pin mounting) 6.9 {5.1, 0.7}

2 Thread area of neutral switch THREEBOND 1104J As required
19 Inner surface of gear selector lever shaft bushing and its Wheel bearing grease [NLGI No.2 (Li soap)] As required
friction surface
Contact surfaces between bushing outer surface and THREEBOND 1104J As required
selector lever case

Spring pin puller MH062445
M121.5 02399
9 Removal of spring pin
Reverse shaft puller 03726-82000
M121.25
02118
22-13
GEAR SHIFTER UPPER
9
Service procedure
Removal of spring pin
Tap spring pin 9 using an M4 tap.
Attach 1 spring pin puller with an M4 screw A of appropriate length,
and pull out spring pin 9 using 2 reverse shaft puller.
9
A
1
02400
45
FI Installation of torsion shaft and gear shift slide lever
When you install torsion shaft 10, position punch mark on the tip of
10 the torsion shaft end and gear shift slide lever 13 as illustrated.
20
13
07570
17
M Installation of oil seal
Apply grease to lip area A of oil seal 17, and press-fit evenly in the
A
06255
22-14
22
18 A
N Installation of oil seal
Apply grease to lip area A of oil seal 18 with bushing 19 press-fitted onto
selector lever case 20, and press-fit evenly in the direction as illustrated.
20
19
06254
O Bushing
[Removal]
20
Bushing 19 is press-fitted onto selector lever case 20. For replacement,
remove using a screwdriver.
CAUTION
Be careful not to damage selector lever case 20.
19
06250
[Press-fitting]
A Clean the inner surface of selector lever case 20, and drive bushing 19
evenly into the case using bar A (approximately 30 mm {1.18 in.})
taking care not to damage the case.
After press-fitting, apply sealant to bushing outer side B.
CAUTION
19
Make sure that you prevent sealant from sticking to the inner
20 surface of bushing 19.
B 06403
22-15
REAR COVER AND REVERSE IDLER GEAR
-
-
7
-9
-
4
10
11
-
15
17
18
*
16
14

13
12

13236
1 Bolt 8 Oil seal 15 Reverse idler gear shaft
2 Spring pin 9 Rear cover 16 Side washer
3 Speedometer gear 10 Speedometer worm 17 Side washer
4 O-ring 11 Pin 18 Reverse idler gear
5 Oil seal 12 Bolt
6 Speedometer gear bushing 13 Reverse idler gear cover * : Transmission body
7 Bolt 14 Gasket : Non-reusable parts
Assembly sequence
*181716151413121110
7
98
1
65432
22-16
22

3, 6 Clearance between speedometer gear and [12] 0.04 to 0.09 0.15 {0.0059} Replace
speedometer gear bushing {[0.47] 0.016 to 0.0035}
15, 18 Clearance between reverse idler gear shaft and [24] 0.05 to 0.08 0.20 {0.0079}
reverse idler gear {[0.94] 0.0020 to 0.0031}
18 End play of reverse idler gear 0.26 to 0.64 {0.010 to 0.025} 0.9 {0.035} Replace
side washer

7 Bolt (Rear cover mounting) 44 {33, 4.5}
12 Bolt (Reverse idler gear cover mounting) 19 {14, 1.9}

3 Friction surfaces of speedometer gear and speedometer Molybdenum disulfide base grease As required
gear bushing
7 Thread area of bolt (only 3 upper bolts) THREEBOND 1104J As required
9 Contact surfaces between rear cover and transmission case THREEBOND 1215 As required

Oil seal installer 16.5 {0.65}
8 MH062691 Installation of rear cover oil seal
06252
15 Reverse shaft puller 03726-82000 Removal of reverse idler gear shaft
M121.25 02118
22-17
REAR COVER AND REVERSE IDLER GEAR
2
2
Service procedure
Driving-in spring pin
the opposite direction to speedometer gear 3, as illustrated.
3 6
36
2 03576
Clearance between speedometer gear and speedometer

gear bushing
3
If the clearance is higher than the limit, replace faulty parts.
5
03577
Installation of oil seal
B Apply grease to lip area A of oil seal 5, and drive oil seal evenly into
speedometer gear bushing 6 in the direction as illustrated using bar B
(approximately 14 mm {0.55 in.}).
A 5
6
6
03578
Installation of speedometer gear bushing

M Due to its eccentric center arrangement, speedometer gear bushing 6
allows replacement of speedometer gear 3 with gears having a different
number of teeth by changing only the installation direction, the worm
gear does not have to be changed.
When installing the bushing, align stamped number, identical to the
number of speedometer gear teeth, with alignment mark M.
The identification mark is stamped on points N or P. The following table
shows the relationship between the identification marks and the number
6
of speedometer gear teeth:
Identification
A B C D L E F G H I J K
mark
Number of teeth 15 16 17 18 19 20 21 22 23 24 25 26
3 P N
Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.2
06256
22-18
22
Apply grease to lip area A of oil seal 8, and press-fit it.
8 0
A
03579
22-19
TRANSMISSION BODY
1 Bolt
2 Oil seal
3 Front bearing retainer
4 Snap ring
5 5 Bolt
6 Transmission case
7 Bolt
8 Bearing retainer
9 Shift rail and shift fork P22-26
10 Countershaft assembly P22-36
11 Drive pinion assembly P22-28
12 Mainshaft assembly P22-30
13 Clutch housing
8 7
NOTE
After removing parts 1 to 3, disassemble the
transmission assembly with clutch housing 13
2 placed stably on a flat surface.
Remove parts 9 to 12 as a group. Note that shift
rail and shift fork 9 can be disassembled on their
own when parts 9 to 12 are not disassembled.
P22-26
13
-
Assembly sequence
13
87654
- 1211109
1
-
32
1
14093
22-20
22
1 Bolt (Front bearing retainer mounting) 40 {30, 4.1}
5 Bolt (Transmission case mounting) 44 {33, 4.5}
7 Bolt (Bearing retainer mounting) 40 {30, 4.1}

2 Front bearing retainer oil seal lip area Wheel bearing grease [NLGI No.2 (Li soap)] As required
3 Contact surfaces between front bearing retainer and clutch THREEBOND 1215 As required
housing assembly
13 Contact surfaces between clutch housing assembly and THREEBOND 1215 As required
transmission case

2 Oil seal installer MH062714 Installation of front bearing retainer oil seal
89 {3.50}
09917
2, 3 Oil seal guide MH063322 Protection of front bearing retainer oil seal
36.5 {1.44}
09918
4 Snap ring expander MH061268 Removal and installation of snap ring
01137
6 Eye bolt MH062340 Lifting up transmission case
M101.5
01140
22-21
TRANSMISSION BODY
Unit : mm {in.}
10 Set pin MH063385 Removal of countershaft assembly

(for holding sub-gear)
39.5 {1.56}
14916
Steel lifting band MH063311
268 {10.6}
01141 Removal and installation of countershaft
10, 11, 12 assembly, drive pinion assembly and
mainshaft assembly
Eye nut MH063308
M241.5 01142
94 {3.70}
11, 12 Synchro guard 29 {1.14} MH063318 Prevention of synchronizer sticking when

driving-in mainshaft
06708
0 2
Service procedure
Apply grease to lip area A of oil seal 2, and press-fit into front bearing
retainer 3.
2
A
3 03694
0
11
3 Installation of front bearing retainer
Install 0 oil seal guide onto drive pinion 11 to protect oil seal 2 installed
on front bearing retainer 3. Then install the front bearing retainer.
2, 3
03695
22-22
22
4 Removal and installation of snap ring
0
08382
6 Removal of transmission case

When lifting up with a crane, install 0 eye bolts on transmission case
0 6 and pass a steel sling through them.
12
After removing bolt 5, lift transmission case 6 up with a crane and
10 keep hitting the rear ends of clutch housing 14, mainshaft assembly
12 and countershaft assembly 10 to remove the transmission case.
6
5
13
06274
After removing transmission case 6, fit the 2nd gear using 0 steel
lifting band to ensure safety.
12 CAUTION
Be sure to tighten 0 steel lifting band adequately enough to
prevent it from coming undone, but not excessively, because
excessive tightening would damage the gears, etc.
10
06276
22-23
TRANSMISSION BODY
3
9H to Removal and installation of shift rail and shift fork,
countershaft assembly, drive pinion assembly and
mainshaft assembly
12
[Removal]
9 When removing or installing shift rail and shift fork 9, countershaft
10
assembly 10, drive pinion assembly 11 and mainshaft assembly 12,
1 handle them as a group.
2 Insert 1 set pin into alignment hole C of countershaft constant mesh
gear A to hold sub-gear B.
After removing the case, install 3 eye bolt on mainshaft assembly 12
11 with 2 steel lifting band fitted so that the whole assembly can be
13
lifted up.
Fix shift rail and shift fork 9 to mainshaft assembly 12 using rubber
bands.
Attach wooden blocks to clutch housing 13. Then lift the whole assem-
1
bly (with drive pinion assembly 11) up with a crane to remove them.
C A During hoisting, hit the assembly using a mallet.
CAUTION
B 14917 Be sure to tighten 2 steel lifting band adequately enough to
prevent it from coming undone, but not excessively, because
excessive tightening would damage the gears, etc.
Be sure that you support mainshaft assembly 12, etc. with your
hand when lifting them because if the mainshaft assembly and
countershaft assembly 10 become detached, drive pinion assem-
bly 11 would fall.
[Installation]
4 Before installing parts, install 4 oil seal guide onto drive pinion 11 to
prevent damage to oil seal 2 of front bearing retainer 3.
13
06278
To drive-in drive pinion 11, mainshaft assembly 12 and countershaft

assembly 10, attach 0 synchro guard which prevents the drive pinion
and the mainshaft synchronizer sticking during installation.
12 NOTE
10
Remember to remove all special tools after use.
0
11 07591
22-24
22
MEMO
22-25
TRANSMISSION BODY
Shift Rail and Shift Fork
*1 (For disassembling shift rail and shift fork
only)
C 1 Spring pin
B 2 4th and 5th shift fork
A 0
3 Spring pin
4 4th and 5th shift rail jaw
5 4th and 5th shift rail
6 Spring pin
*2 7 2nd and 3rd shift fork
8 Spring pin
9 2nd and 3rd shift rail jaw
10 2nd and 3rd shift rail
11 Spring pin
12 1st and reverse shift fork
13 Spring pin
14 1st and reverse shift rail jaw

15 1st and reverse shift rail

*1 : Mainshaft assembly

*2 : Countershaft assembly
4
A
1st and 9
reverse
B
2nd and 3rd
C
4th and 5th 06279
The arrows indicate spring pin withdrawal and driving-in directions.
Assembly sequence

2, 7, 12 Shift fork claw tilt 0.1 {0.0039} or less 0.2 {0.0079} Replace
2, 7, 12, *1 Clearance between shift fork and synchronizer sleeve 0.3 to 0.6 {0.012 to 0.024} 1.0 {0.039} Replace
5, 10, 15 Deflection of shift rail 0.04 {0.0016} or less 0.05 {0.0020} Correct or
replace
22-26
22
1368GI
Service procedure
Driving-in spring pin
For installation of spring pins 1, 3, 6, 8, 11, 13, position the openings in
the direction of the shift rail axes.
CAUTION
Be careful when driving in spring pins 1, 3, 6, 8, 11, 13, that you
do not subject shift rails 5, 10, 15 to excessive strain, because
this would cause faults such as bent shift rails.
1, 3, 6, 8, Make sure you do not drive in spring pins 1, 3, 6, 8, 11, 13 fully,
11, 13
05756 leave 0 to 0.5 mm {0 to 0.020 in.} outside to prevent them from
slipping out.
A
5, 10, 15 B B 27H Tilt of shift fork claw
Measure the tilt (difference between B and B) of claw B-B against
hole A of shift rails 5, 10, 15 of shift forks 2, 7, 12 with the shift rails
upright.
2, 7, 12 If the tilt is higher than the limit, replace shift forks 2, 7, or 12.
D C : V-block
C D : Dial gauge
14946
27H* *1 Clearance between gear shift fork and

mainshaft synchronizer sleeve
If the measured value for clearance A is higher than the limit, replace
2, 7, 12 faulty parts.
*1
A
00294
5FK Deflection of shift rail

5, 10, 15.
5, 10, 15
NOTE
To measure the deflection of shift rails 5, 10, 15, turn them one
full revolution and read the dial gauge indicator. The deflection is
01127
22-27
DRIVE PINION ASSEMBLY
3
1 Snap ring
2 Drive pinion bearing
4 3 Pilot bearing
4 Drive pinion
Assembly sequence
07641

1 Snap ring expander MH061268 Removal and installation of snap ring
01137
2 Bearing puller and installer MH062697 Removal and installation of drive pinion
bearing
92.5 {3.64}
08978
22-28
22
1 1
Service procedure
Removal and installation of snap ring
0
09968
2 Drive pinion bearing

[Removal]
09920
[Installation]
Press-fit drive pinion bearing 2 with its snap ring groove facing the gear
side.
0
06283
22-29
MAINSHAFT ASSEMBLY
P22-32
1 Bearing
2 1st gear thrust washer
3 1st gear assembly
4 Needle bearing
22 5 Snap ring
23 6 Synchronizer sleeve
7 Synchronizer hub
8 Reverse gear assembly
9 Needle bearing
10 Snap ring
11 Synchronizer ring
23 12 Synchronizer sleeve
22 8 13 Shifting key
14 Shifting key spring
20
15 Synchronizer hub
9
16 5th gear assembly
17 Snap ring
31 18 2nd gear thrust washer
19 2nd gear assembly
20 Needle bearing
21 Snap ring
30
22 Synchronizer inner ring
23 Synchronizer center cone
24 Synchronizer outer ring
25 Synchronizer sleeve
26 Shifting key
27 Shifting key spring
7 28 Synchronizer hub
4 29 3rd gear assembly
3
30 Needle bearing
6
31 Mainshaft
* : Drive pinion
06296
Assembly sequence
313029
212019181716
28252627242322 10987654321
1512131411
22-30
22
3 End play of 1st gear assembly 0.15 to 0.46 {0.0059 to 0.018} 0.70 {0.028} Replace
3, 4, 31 Play in the diameter direction after assembling 0.02 to 0.06 {0.00079 to 0.0024} 0.12 {0.0047} Replace
1st gear assembly
8 End play of reverse gear assembly 0.15 to 0.46 {0.0059 to 0.018} 0.70 {0.028} Replace
8, 9, Play in the diameter direction after assembling 0.04 to 0.08 {0.0016 to 0.0031} 0.12 {0.0047} Replace
31 reverse gear assembly
11, 13 Clearance between synchronizer ring keyway 3.5 to 3.7 {0.14 to 0.15} 4.50 {0.18} Replace
and shifting key
11, 16 Clearance between synchronizer ring and 1.13 to 1.37 {0.044 to 0.054} 0.20 {0.0079} Replace
5th gear assembly
11, * Clearance between synchronizer ring and drive pinion 1.13 to 1.37 {0.044 to 0.054} 0.20 {0.0079} Replace
13, 15 Clearance between shifting key and synchronizer 0.05 to 0.20 {0.0020 to 0.0079} 0.50 {0.020} Replace
hub keyway
16 End play of 5th gear assembly 0.20 to 0.56 {0.0079 to 0.022} 0.80 {0.031} Replace
16, 31 Play in the diameter direction after assembling 0.05 to 0.09 {0.0020 to 0.0035} 0.20 {0.0079} Replace
5th gear assembly
19 End play of 2nd gear assembly 0.15 to 0.61 {0.0059 to 0.024} 0.80 {0.031} Replace
31 2nd gear assembly
19, 24 Clearance between 2nd gear assembly and 1.23 to 1.47 {0.048 to 0.058} 0.95 {0.037} Replace
synchronizer outer ring
24, 26 Clearance between synchronizer outer ring 4.7 to 5.0 {0.19 to 0.20} 5.70 {0.22} Replace
keyway and shifting key
24, 29 Clearance between synchronizer outer ring and 1.23 to 1.47 {0.48 to 0.058} 0.95 {0.037} Replace
3rd gear assembly
26, 28 Clearance between shifting key and synchronizer 0.05 to 0.20 {0.0020 to 0.0079} 0.50 {0.020} Replace
hub keyway
29 End play of 3rd gear assembly 0.15 to 0.46 {0.0059 to 0.018} 0.70 {0.028} Replace
31 3rd gear assembly
22-31
MAINSHAFT ASSEMBLY
1 Bearing puller and installer MH062697 Removal and installation of mainshaft rear
bearing
96.8 {3.81}
08978
5, 10, Snap ring expander MH061268 Removal and installation of snap ring
17, 21
01137
Service procedure
[Inspection]
E CD B A (1) End play of gears
A : 1st gear
B : Reverse gear
C : 2nd gear
D : 3rd gear
E : 5th gear
06286
(2) Play of gears in the diameter direction

01149
[Alignment marks]
A
(1) Single cone synchromesh
13
A Before disassembling synchronizer sleeve 12 and synchronizer hub
15, put alignment marks A on the places where shifting keys 13 are
installed. When reusing parts, align the alignment marks to assemble.
12
15 14109
22-32
22
(2) Double cone synchromesh
26 28
D Before disassembling synchronizer center cone 23, 2nd gear assem-
bly 19, and 3rd gear assembly 29, put alignment marks B on them.
C Similarly, put alignment marks C on synchronizer inner ring 22, and
B
synchronizer outer ring 24. When reusing parts, align the alignment
marks to assemble.
Before disassembling synchronizer sleeve 25 and synchronizer hub
24 28, put alignment marks D on the places where shifting keys 26 are
23 installed. When reusing parts, align the alignment marks to assemble.
22
29
19 22
23
D 24
B
C
25
1
14110
Bearing
[Removal]
09921
[Installation]
Press-fit bearing 1 with its snap ring groove facing the rear.
2N
09922
Installation of thrust washer

Install thrust washer with oil groove A facing gear side.
2, 18 06287
22-33
MAINSHAFT ASSEMBLY
5FMQ Removal and installation of snap ring
GITV
09969
Clearance between synchronizer ring or

13, 26
11, 24 synchronizer outer ring and shifting key
If the measured value for clearance A is higher than the limit, replace
faulty parts.
GL*
06290
A Clearance between synchronizer ring and gear

assemblies
11 16, *
Press in synchronizer ring 11 evenly, and measure all circumferences.
If the measured value for clearance A is lower than the limit, replace
faulty parts.
HU
06288
Installation of synchronizer sleeve
B To install synchronizer sleeves 12, 25, align three keyways A of

15, 28 12, 25
synchronizer hubs 15, 28 with the three stub teeth B of synchronizer
sleeves.
Before assembling synchronizer hubs 15, 28 and synchronizer sleeves
12, 25, align the alignment marks (made before disassembly).
B
A B B
IKVX
01129
Clearance between shifting key and

13, 26
synchronizer hub
A If the measured value for clearance A is higher than the limit, replace
15, 28
faulty parts.
06291
22-34
22
14, 27
13, 26
JW Installation of shifting key spring
Place shifting keys 13, 26 into keyways of synchronizer hubs 15, 28,
and install shifting key springs 14, 27 taking care to locate the open-
ings away from the shifting key positions.
Two openings of shifting key springs 14, 27 should not align with each
other.
01130
A
19, 29
OTY Clearance between 2nd, 3rd gear assembly and
synchronizer outer ring
Press in synchronizer inner ring 22, synchronizer center cone 23 and
24
synchronizer outer ring 24 evenly, and measure all circumferences.
23 If the measured value for clearance A is lower than the limit, replace
faulty parts.
22
06299
22-35
COUNTERSHAFT ASSEMBLY <NON-BACKLASH MECHANISM>
1 Countershaft front bearing
0
2 Snap ring
6
3 Sub-gear plate
4 Sub-gear
5 Sub-gear spring
6 Countershaft assembly
7 Countershaft rear bearing
3
WARNING
You must remove 0 set pin that was
installed before disassembling
countershaft assembly 6. When re-
moving the set pin, you must be very
careful not to let sub-gear spring 5
14918 rotate sub-gear 4, or you might hurt
your hand.
Assembly sequence
verse.
1 Bearing puller and installer MH062697 Removal and installation of countershaft

front bearing
72 {2.83} 08978
Removal and installation of countershaft

2 Snap ring expander MH061268 front bearing snap ring and sub-gear
snap ring
01137
Set pin MH063385 Securing of sub-gear
39.5 {1.56}
4 14916
Jig assembly MH063313 Installation of sub-gear
07576
MH062697 Removal and installation of countershaft

7 Bearing puller and installer rear bearing
76.8 {3.02} 08978
22-36
22
1
Service procedure
Countershaft front bearing
[Removal]
09924
[Installation]
Press-fit countershaft front bearing 1 with its snap ring groove facing the
gear side.
0
2
09925
2 Removal and installation of snap ring
45
06302
Sub-gear, sub-gear spring

5
Installation of sub-gear spring
A Install sub-gear spring 5, inserting longer bent end A of the sub-gear
B
spring into constant mesh gear spring installation hole B of
countershaft assembly 6. Press the spring in until its rim is wholly fitted
into the gear.
6
06491
Positioning of sub-gear
1
Turn sub-gear 4 to the right using 1 jig assembly, and insert 2 set
6 pin into alignment hole A, in the direction as illustrated to secure the
4 sub-gear, with all parts assembled except for snap ring 2 and
countershaft front bearing 1.
Turn the set pin so that the sub-gear and the constant mesh gear teeth
are positioned identically.
A
2 14919
22-37
COUNTERSHAFT ASSEMBLY <NON-BACKLASH MECHANISM>
7 Countershaft rear bearing
[Removal]
09926
[Installation]
Press-fit countershaft rear bearing 7 with its snap ring groove facing the
rear.
0
09927
22-38
22
MEMO
22-39
TRANSMISSION CONTROL
14
*
9
-

12
13
-
-
-
To shift rod No.3 -
To selector rod No.2 10

11
To shift - -
rod No.2
To selector rod No.3
13237
Removal sequence
1 Shift rod No.1 9 Change lever assembly P22-42
2 Selector rod No.1 10 Lever assembly P22-44
3 Shift rod No.2 11 No.1 cross lever assembly P22-46
4 Selector rod No.2 12 Shift lever assembly P22-48
5 Shift rod No.3 13 Selector lever assembly P22-49
6 Selector rod No.3 14 Cross shaft assembly P22-50
7 Shift rod No.4
8 Selector rod No.4 * : Transmission assembly

Nut (Ball joint mounting) 17 to 22 {12 to 16, 1.7 to 2.2}
Nut (Ball joint securing) 16 to 24 {12 to 17, 1.6 to 2.4}
7, 8 Knuckle (Turn buckle securing) 19 to 27 {14 to 20, 1.9 to 2.8}
- Lubricant
1 to 8 Rod installation points Chassis grease [NLGI No.1 (Ca soap)] As required
22-40
22
< Ball joint type >

A C B
18
Service procedure
to Installation of rod
Tighten nuts A, B at specified torque.
A : 16 to 24 Nm {12 to 17 lbf. ft, 1.6 to 2.4 kgfm}
B : 17 to 22 Nm {12 to 16 lbf. ft, 1.7 to 2.2 kgfm}
C : Spring washer
06304
< Split pin type > < Snap pin type > Apply grease to area G.
E Install split pin or snap pin D.
E : Washer
F : Bushing
E D
F
1 to 8
G
E D
F
1 to 8
G
06305
Turn the turn buckles of shift rod No.4 7 and selector rod No.4 8 to
adjust change lever assembly 9 position.
Left and right Fore-and-aft
direction H (mm {in.}) direction J (mm {in.})
(Distance from steering (Distance from instrument panel)
wheel center)
J 362 to 372 {14.3 to 14.6} 301 to 311 {11.9 to 12.2}
9
H 08379
Adjust the thread area dimension of rods 7, 8 that extends from both
ends of the turn buckles. Exposed threads should be almost identical
at left and right ends.
After adjustment, tighten lock nuts for turn buckles at specified torque.
Make sure that shift or select into positions can be performed smoothly.
18 mm {0.71 in.}
or less
7, 8
06307
22-41
Change Lever Assembly
1 Bolt
2 Bolt
2
3 3 Lever assembly
4 Wave washer
5 Spacer
6 Collar
7 Bolt
-6
8 Spacer
9 Collar
10 Return spring
11 Bushing
12 Cross sleeve
12 10 13 Change lever bracket
Assembly sequence
13
1
-9 873
12111096
7 5421
13
13238

1 Bolt (Change lever assembly mounting) 9.8 to 15 {7.2 to 11, 1.0 to 1.5}
2 Bolt (Lever assembly mounting) 17 to 25 {12 to 19, 1.7 to 2.6}
7 Bolt (Cross sleeve mounting) 17 to 25 {12 to 19, 1.7 to 2.6}
- Lubricant
6, 9 Periphery of collar Chassis grease [NLGI No.1 (Ca soap)] As required
22-42
22
A : 0.8 to 1.3 mm
45
Service procedure
Selection of spacer and installation of wave washer
Select spacer 5 to give specified clearance A when bolt 2 is tightened
{0.031 to 0.051 in.} at specified torque. Two thicknesses are available for the spacers:
2
0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
Obtain the specified clearance before inserting wave washer 4.
8
4, 5 06311
Selection of spacer
10
7 Select spacer 8 to give specified clearance A when bolt 7 is tightened
at specified torque. Two thicknesses are available for the spacers:
0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
Levers should operate smoothly after installation.
A : 0 to 0.3 mm 8
{0 to 0.012 in.}
G
06312
Installation of bushing
Press-fit bushings 11 (four bushings) into cross sleeve 12, and ream to
specified dimension A using a reamer.
12
A : 14 +0.07
+0.02 mm
+0.0028
{0.55 +0.00079 in.}
11
06313
22-43
Lever Assembly
1 Bolt
1 2 Bolt
17 3 Cover
- 4 Dust boot
16 5 Bushing
6 Lever bracket A
7 Nut
8 Lock pin
8 13 - 9 Lever
10 Spacer
11 Bushing
9 12 Shift lever
13 Selector lever
14 Cover
15 Dust boot
16 Bushing
17 Lever bracket B
2
12 17161514
913
11 10
1211 2187
5 6543
-
6
13239

1, 2 Bolt (Lever bracket mounting) 27 to 34 {20 to 25, 2.8 to 3.5}
7 Nut (Lock pin tightening) 9.8 to 15.0 {7.2 to 11, 1.0 to 1.5}
- Lubricant
4, 15 Pack interior of dust boot Chassis grease [NLGI No.1 (Ca soap)] As required
13 Periphery of selector lever Chassis grease [NLGI No.1 (Ca soap)] As required
22-44
22
5, 16 3, 14
34JK
Service procedure
Installation of cover and dust boot
Press in covers 3, 14 fully.
4, 15
Pack grease into interior space A of dust boots 4, 15.
A
06315
7 Tightening nuts
Tighten nut 7 at specified torque, pressing it to direction A at approxi-
F
mately 98 N {22 lbf, 10 kgf}.
9 7 12 13 10 Selection of spacer
Select spacer 10 to give specified clearance B when nut 7 is tightened
A B : 0 to 0.3 mm
{0 to 0.012 in.} 0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
08280
Lever 9, shift lever 12 and selector lever 13 should operate smoothly
after installation.
22-45
No.1 Cross Lever Assembly
1 Bolt
1 2 Bolt
3 Cover
4 Dust boot
13 - 5 Bushing
6 Lever bracket
11
7 Nut
12 8 Lock pin
9 Lever
16 11
17 10 Spacer
11 Bushing
-
12 Selector lever
13 Shift lever
14 Cover
15 Dust boot
16 Bushing
17 Lever bracket
Assembly sequence
2
17161514
13 109
9
1211 2187
8 6543
- 5
08385

1, 2 Bolt (Lever bracket mounting) 27 to 34 {20 to 25, 2.8 to 3.5}
7 Nut (Lock pin tightening) 9.8 to 15.0 {7.2 to 11, 1.0 to 1.5}
- Lubricant
4, 15 Pack interior of dust boot Chassis grease [NLGI No.1 (Ca soap)] As required
13 Periphery of shift lever Chassis grease [NLGI No.1 (Ca soap)] As required
22-46
22
5, 16 3, 14
4, 15
34JK
Service procedure
Installation of cover and dust boot
Press in covers 3, 14 fully.
Pack grease into interior space A of dust boot 4, 15.
7
06315
Tightening nut
A
13 9 Tighten nut 7 at specified torque pressing it to direction A at approxi-
F
mately 98 N {22 lbf, 10 kgf}.
10
Selection of spacer
Select spacer 10 to give specified clearance B when nut 7 is tightened
0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
7
Lever 9, selector lever 12 and shift lever 13 should operate smoothly
after installation.
B : 0 to 0.3 mm
{0 to 0.012 in.}
12
08386
22-47
Shift Lever Assembly
1 Bolt
1
2 Nut
3 Bushing
4 Shift lever
5 Spacer
4
6 Shift lever bracket
3

2 Assembly sequence
6 65
- 21
43
08417

1 Bolt (Shift lever bracket mounting) 27 to 34 {20 to 25, 2.8 to 3.5}
2 Nut (Shift lever mounting) 27 to 34 {20 to 25, 2.8 to 3.5}
- Lubricant
6 Periphery of shift lever bracket shaft Chassis grease [NLGI No.1 (Ca soap)] As required
A : 0 to 0.3 mm
{0 to 0.012 in.}
2
5
Service procedure
Selection of spacer
Select spacer 5 to give specified clearance A when nut 2 is tightened
0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
Shift lever 4 should operate smoothly after installation.

5
4
08419
22-48
22
Selector Lever Assembly
1
1 Bolt
6- 2 Nut
3 Bushing
4 Selector lever
4
5 Spacer
3 6 Selector lever bracket

2
Assembly sequence
65
21
43
06319

1 Bolt (Selector lever bracket mounting) 27 to 34 {20 to 25, 2.8 to 3.5}
2 Nut (Selector lever mounting) 27 to 34 {20 to 25, 2.8 to 3.5}
- Lubricant
6 Periphery of selector lever bracket shaft circumference Chassis grease [NLGI No.1 (Ca soap)] As required
4
A : 0 to 0.3 mm {0 to 0.012 in.}
2
5
Service procedure
Selection of spacer
Select spacer 5 to give specified clearance A when nut 2 is tightened
0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}.
Selector lever 4 should operate smoothly after installation.
5
06320
22-49
Cross Shaft Assembly
1 Nut
1 2 Cross shaft bracket
3 Bolt
4 Cross shaft bushing
5 Cross shaft boot
3 6 Cross shaft
-2 Assembly sequence
4
-
5 654213
-
6
06322

1 Nut (Frame mounting) 9.8 to 15 {7.2 to 11, 1.0 to 1.5}
3 Bolt (Transmission side mounting) 15 to 20 {11 to 14, 1.5 to 2.0}
- Lubricant
2 Pack pipe of cross shaft bracket Chassis grease [NLGI No.1 (Ca soap)] As required
4 Friction surfaces (inside and outside) of cross shaft bushing Chassis grease [NLGI No.1 (Ca soap)] As required
5 Pack interior of cross shaft boot Chassis grease [NLGI No.1 (Ca soap)] As required
22-50
Group 23 - Automatic
Transmission
Group 23 - Automatic
Transmission
1999 Minor Changes
BACK HOME
Group 23
Automatic Transmission
' 99 Minor Change

Table of Contents
BACK HOME

23
SPECIFICATIONS .............................................................................. 23- 2
STRUCTURE AND OPERATION ....................................................... 23- 4
TROUBLESHOOTING PROCEDURES ............................................. 23-40
TROUBLESHOOTING ........................................................................ 23-42

Stall Test .......................................................................................................... 23-52
Time Lag Test .................................................................................................. 23-53
Line Pressure Test .......................................................................................... 23-54
Road Test ......................................................................................................... 23-56
Inspection of Automatic Transmission Fluid ............................................... 23-58
Changing Automatic Transmission Fluid ..................................................... 23-59
REMOVAL AND INSTALLATION OF AUTOMATIC

TRANSMISSION ASSEMBLY ............................................................ 23-60
OIL COOLER ...................................................................................... 23-65
AUTOMATIC TRANSMISSION CONTROL........................................ 23-68
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS ........... 23-78
INSPECTION AND ADJUSTMENT OF OTHER DEVICES ................ 23-84
23-1
SPECIFICATIONS
Specifications
Vehicle model
Item FE639 FE649
Manufacturer Aisin Seiki Co., Ltd.
Transmission type M035A4
Torque converter Type 3-element, 1-stage, 2-phase (with lock-up clutch)
Stall torque ratio 1.82
Type Planetary gear type, 4 forward speeds, 1 reverse speed
1st 3.018
2nd 1.548
Gear ratio 3rd 1.000
4th 0.703
Rev 2.678
Range selector pattern P - R - N - D - 2 - L (Engine starts in P and N positions only)
Oil type DEXRON III type
Automatic transmission Total oil capacity L {qts} 13 {14}
fluid Quantity of oil required
in automatic transmission Approximately 4.5 {4.8}
fluid change L {qts}
23-2
23
Automatic Transmission Assembly
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
30902
1 Converter housing 13 1st and reverse brake

2 Torque converter 14 Rear planetary gear
3 Transmission case 15 Parking lock gear
4 Overdrive direct clutch 16 Output shaft
5 Overdrive brake 17 Overdrive input shaft
6 Overdrive one-way clutch 18 Oil pump
7 Overdrive planetary gear 19 Oil pan
8 Front clutch 20 Valve body
9 2nd brake 21 Input shaft
10 Rear clutch 22 Intermediate shaft
11 Front planetary gear 23 Extension housing
12 No. 2 one-way clutch 24 Speedometer drive gear
The automatic transmission is comprised of a torque converter with a lock-up mechanism and a fully automatic 4-speed
gear system.
Torque converter
The torque converter is driven by the engine crankshaft, and functions as the input device for the transmission. The
torque converter is a fluid coupling device that magnifies torque produced by the engine and absorbs shock that
generates when the vehicle accelerates from a standstill or when the transmission shifts. At a cruising speed, the lock-
up mechanism prevents slippage for improved power transmitting efficiency.
Transmission gear section
The gear system provides four forward speeds and one reverse speed. The gear section contains two one-way
clutches, three sets of planetary gears, each comprised of a sun gear, pinion gears and a ring gear, three sets of
hydraulic wet-type multi-plate clutches; and three sets of wet-type multi-plate brakes.
Hydraulic control section
The electronic control system uses a microcomputer to regulate the mechanism operations for precise shifting.
23-3
Control Mechanisms
Control system
Multi-plate clutches
Torque converter Overdrive input Multi-plate brakes
(lock-up piston) shaft One-way clutches Output shaft
Planetary gears
Oil pump
Vehicle speed
sensor
Control valves Valve body
Shift solenoid Shift solenoid Throttle pressure Lock-up Timing

1 2 solenoid solenoid solenoid
Accelerator Automatic transmission

sensor electronic control unit
A B
Engine electronic Engine speed
control unit sensor
: Power transmission
: Hydraulic control circuit
A : Accelerator position PWM signal
B : Engine speed signal : Electrical signal
30918
23-4
23
Shift control
(incl. O/D
Accelerator shift control)
position Shift
PWM signal solenoid 1
Throttle
Accelerator pressure
sensor control
Shift
Inhibitor solenoid 2
switch
Shift pattern
selector
Engine control Throttle
speed pressure
sensor solenoid
Overdrive Lock-up
OFF switch control Lock-up
solenoid
ATF
temperature
sensor 2-3 shift
Timing
timing
solenoid
ATF control
temperature
switch
Power mode Exhaust Exhaust

switch brake brake cut-
control off relay
Brake
switch
Fail-safe
Exhaust brake control
activation
signal
Vehicle speed
sensor
(mounted on
A/T) Diagnosis
memory
MUT
Self-
Diagnosis diagnosis
switch function
Warning
lamp
31522
23-5
The control functions can be roughly divided into shift control, lock-up control and 2-3 shift control. The electronic control
unit electronically controls these functions precisely in accordance with driving conditions.
Chart of control items, inputs and outputs

Control item Shift Shift
control pattern Throttle Lock-up 2-3 shift Exhaust Fail-safe Self-
(incl. selector pressure control control brake control diagnosis
Item overdrive control control control control
control)
Vehicle speed Mounted in spee-

sensor dometer cable (lo- Note 1
cated inside cabin)
In- Throttle position PWM signal
put Engine speed sensor Note 1
Accelerator sensor Note 1
Overdrive OFF switch
Inhibitor switch Note 1
temperature switch

temperature sensor

Power mode switch
Brake switch
Exhaust brake activation signal Note 1
Diagnosis switch Note 2
Out- Timing solenoid Note 1
put Lock-up solenoid Note 1
Throttle pressure solenoid Note 1
Exhaust brake cut-off relay Note 1
Warning lamp
Note 1 : The automatic transmission electronic control unit activates fail-safe functions when there is an abnormality in
the input/output signals.
Note 2 : The self-diagnosis function activates.
Shift control
Based on the accelerator operation signal transmitted from the accelerator sensor and the signal from the vehicle
speed sensor, the automatic transmission electronic control unit outputs signals according to the predetermined shift
curve. These signals are sent to shift solenoid 1, shift solenoid 2 and the timing solenoid mounted on the valve body,
and automatically shift to the optimum gear.
Throttle pressure control

The accelerator sensor detects the degree of throttle operation. This data is used to control the throttle pressure
solenoid, and the hydraulic pressure supplied from the reducing valve is maintained at the optimum level (throttle
pressure) according to the vehicles operating condition.
2-3 shift control

Based on the signal from the throttle sensor and the signal from the engine speed sensor, the automatic transmission
electronic control unit outputs a signal to the timing solenoid mounted on the valve body, and controls the discharge
timing of automatic transmission fluid to reduce shift shock.
23-6
23
Lock-up control
The lock-up mechanism eliminates slippage of the torque converter for improved power transmitting efficiency. Based on
the accelerator operation signal transmitted from the accelerator sensor and the signal from the vehicle speed sensor, the
automatic transmission electronic control unit outputs a signal according to the predetermined shift curve. This signal is
sent to the lock-up solenoid mounted on the valve body, and engages or disengages the lock-up mechanism.
Shift pattern selector control

12 23
This control function allows the selection between the economy mode
12 23 for fuel-saving operation and the power mode for improved accelera-
tion performance.
Throttle In the power mode, the shift points of the transmission are set to a
opening 3 4
3 4 higher vehicle speed than in the economy mode. The graph on the left
Power mode pattern
shows the shift points during down-shifting operations.
Normal pattern
Vehicle speed
P 29802
Fail-safe control
The fail-safe functions minimize adverse effects to the vehicle operation caused by malfunctioning of the vehicle speed
sensor, engine speed sensor, accelerator sensor, inhibitor switch or solenoids.
Accelerator sensor
This sensor prohibits lock-up control change and 2-3 shift timing control by determining the shift-point vehicle speed at
closed throttle position and the line pressure at maximum pressure, thus allowing vehicle operation.
Inhibitor switch
If the inhibitor switch malfunctions in a stationary or moving vehicle and there is no signal input to the automatic
transmission electronic control unit, the automatic transmission electronic control unit determines the transmission
position setting as the D range and prohibits shifting from 3rd to 4th gear. If the automatic transmission electronic
control unit receives two or more signals, the automatic transmission electronic control unit operates according to the
following priority order for the range selector position and enables vehicle operation: L > R > 2 > D > N >P. Since the
manual valve changes the hydraulic circuit in the valve body according to the range selector position, the vehicle
operates as follows.
Range selector lever position Inhibitor switch input signal Vehicle operating
condition
P P and other selector signals P
R R and other selector signals R
N N and other selector signals N
D D and other selector signals (excludes R, L and 2 range signals) D1D2D3D4
D and L range signals D1D2D3
D and R range signals D4
D and 2 range signals D1D2D3
2 2 and other selector signals (excludes R and L signals) 212223
2 and L range signals 212223
2 and R range signals 23
L L and other selector signals L1L2L3
23-7
Engine speed sensor
The 2-3 shift timing control becomes inactive to ensure proper vehicle operation.
Shift solenoid 1 and shift solenoid 2
If a solenoid malfunction occurs when the transmission is in the D, 2 or L range, the operating conditions of the
solenoids change as shown in the following table. The automatic transmission electronic control unit also deactivates
the lock-up solenoid and timing solenoid to allow vehicle operation.
Malfunctioning of
Range selector Normal Malfunctioning of S1 Malfunctioning of S2
S1 and S2
position
S1 S2 ST Gear S1 S2 Gear S1 S2 Gear S1 S2 Gear
1st 3rd 1st 4th
D range
2nd 3rd 4th 4th
3rd 3rd 4th 4th
4th 4th 4th 4th
1st 3rd 1st 3rd
2 range 2nd 3rd 3rd 3rd
3rd 3rd 3rd 3rd
1st 1st 1st 1st
L range 2nd 2nd 1st 1st
3rd 2nd 1st 1st
: Electric current supplied : Electric current not supplied : Malfunctioning : Fail-safe function
S1 : Shift solenoid 1 S2 : Shift solenoid 2 ST : Timing solenoid
The malfunctioning solenoid is deactivated to bring the line pressure to a maximum level, thus allowing vehicle
operation.
Timing solenoid and lock-up solenoid
The malfunctioning solenoid is deactivated to allow vehicle operation.
The warning lamp lights when an abnormality occurs during vehicle operation.
The warning lamp does not light if the abnormality causes minimum effect to vehicle operation.
The warning lamp lights in the case of the following malfunctions to indicate the abnormal condition since these
malfunctions significantly reduce vehicle performance.
Malfunction of vehicle speed sensor, malfunction of throttle position PWM signal, malfunction of shift solenoid 1,
malfunction of shift solenoid 2, malfunction of accelerator sensor, malfunction of timing solenoid, malfunction of
inhibitor switch, malfunction of throttle pressure solenoid.
CAUTION
The warning lamp lights only when the malfunction prevents proper vehicle operation.
The indicator lamp provides self-diagnosis information.

To facilitate the discovery of malfunctions that may not reproduce themselves frequently, the automatic transmission
electronic control unit stores in the memory information of malfunctions that occur during vehicle operation.
An input of a self-diagnosis start signal produces the output of the data from the memory, and causes the automatic
transmission warning lamp to flash according to the data.
CAUTION
The automatic transmission electronic control unit stores information of all malfunctions that occur after
the previous self-diagnosis operation.
23-8
23
Electronic Control Devices
1 Automatic transmission electronic
control unit
31508
1
3
31509
Automatic transmission electronic control unit

The automatic transmission electronic control unit is mounted near the
brake booster on the drivers seat side. It determines the vehicle
operating conditions based on signals sent from sensors, and outputs
signals to solenoids to regulate shift control, lock-up control and other
automatic transmission functions.
The automatic transmission electronic control unit is also equipped
with a self-diagnosis function for the detection of malfunctions of main
sensors and solenoids.
Accelerator sensor
Output
voltage (V) The accelerator sensor is mounted on the accelerator lever. It con-
4.150.1
verts the accelerator pedal operation to voltage and sends it to the
automatic transmission electronic control unit.
The output characteristic of the electric signal produced by the sensor
is shown in the graph on the left. This output signal is used to
0.850.1 determine the accelerator pedal angle and pressing speed.
Idle Full stroke

Full throttle P 29804
Throttle position PWM signal

Accelerator sensor voltage 0.5 V
A The accelerator sensor voltage detected by the electronic governor
B B
=10% control unit is converted to a PWM signal and output to the automatic
A
transmission electronic control unit. The PWM signal is a chopping
wave with a duty ratio shown in the diagram at the left.
Accelerator sensor voltage 4.5 V
B
=90%
B A
A
P 32400
23-9
This sensor is mounted on the extension housing of the transmission, and converts the vehicle speed to a pulse signal
by means of the parking lock gear and sends it to the automatic transmission electronic control unit.
Shift solenoids 1 and 2
These solenoids are mounted on the valve body, and control shifting by turning ON and OFF in accordance with the
signals sent from the automatic transmission electronic control unit.
The ON and OFF conditions of the two solenoids result in the following gear positions.
Shift solenoid 1 ON ON OFF OFF
Shift solenoid 2 OFF ON ON OFF
Gear position 1st gear 2nd gear 3rd gear 4th gear

The throttle pressure solenoid is mounted on the valve body. It adjusts
the throttle pressure based on the throttle opening signal sent from the
automatic transmission electronic control unit. The throttle pressure
Hydraulic adjustment characteristics are shown in the diagram.
pressure
Electric current 31512
Timing solenoid
This solenoid is mounted on the valve body, and regulates the 2-3 shift timing control by turning ON and OFF in
accordance with the signal sent from the automatic transmission electronic control unit.
Lock-up solenoid
The lock-up solenoid is mounted on the valve body. According to the signal sent from the automatic transmission
electronic control unit, the solenoid repeats ON and OFF operations, thereby opening and closing the drain circuit to
control the hydraulic pressure at a predetermined level. The lock-up solenoid is a duty-cycle type that can control the
ON and OFF time ratio in each cycle between 0 and 100%.
Automatic transmission fluid temperature switch
This switch is mounted on the oil cooler outlet section of the transmission case. It detects abnormal temperatures of the
automatic transmission fluid and turns on the warning lamp located on the meter cluster to indicate the abnormal
condition.
Automatic transmission fluid temperature sensor

Resistance ()
This sensor is mounted on the control valve in the transmission. It
coverts temperature changes into continuous electric signals and
sends to the automatic transmission electronic control unit. The char-
acteristics of the sensors electric output signal are shown at the left.
Based on this output signal, the automatic transmission electronic
control unit prohibits overdrive shifting and lock-up operation and also
performs partial correction of line pressure control.
Temperature (C)
07451
23-10
23
Engine speed sensor
The sensor converts the engine revolution speed to a pulse signal,
and outputs to the electronic governor control unit. This signal is then
transmitted from the electronic governor control unit to the automatic
transmission control unit.
Engine speed sensor

07959

(OD OFF switch) This switch is mounted on the range selector lever. It is operated by
the driver, and it allows switching between the 3-speed and 4-speed
modes.
OFF : Transmission shifts to 4th gear for improved fuel efficiency.
ON : Transmission does not shift to 4th gear, thus increasing the
engine brake effect and improving driveability on an up grade
incline.
14030
Power mode switch

This switch is provided on the instrument panel. It is used by the driver
to select the shift-point vehicle speed setting.
PWR (power mode) : Sets the shift points to a higher vehicle
speed to use engine power effectively.
ECO (economy mode) : Sets the shift points to a lower vehicle speed
for improved fuel economy.
14024
23-11
Hydraulic Control Devices
Valve Layout Diagram
Upper valve body
12 11 9 2 3 6 5
10 8 7
4
31513
Lower valve body
8 2 3 7 9
4
1 6 5
31514
23-12
23
Valve Functions
Upper valve body
No. Valve name Description of function
1 2-3 Shift valve Switches between 2nd and 3rd gears
When range selector is shifted to R range while vehicle is moving
2 Reverse inhibitor valve forward at moderate or high speed, this valve, operated by solenoid
output, prevents shifting to reverse.
Adjusts line pressure and supplies hydraulic pressure to lock-up signal
3 Modulator valve
valve and orifice control valve
Adjusts signal pressure (throttle pressure) that is used to provide
4 Throttle valve
optimum line pressure in accordance with operating conditions
Controls pressure of automatic transmission fluid supplied from primary
5 Secondary regulator valve
regulator valve to torque converter as well as lubricating oil pressure
6 Reducing valve Reduces line pressure and feeds to throttle valve
7 Lock-up signal valve Engages and disengages lock-up mechanism
Lowers accumulator back pressure when throttle opening becomes
8 Accumulator control valve smaller, and obtains accumulator control pressure from line pressure that
is used to reduce shift shock
Lowers line pressure to reduce shift shock when range selector is
9 Low coast modulator valve
shifted to L range
10 Orifice control valve Switches orifices to reduce shock
When range selector is shifted to L range at high vehicle speed, this
11 Low inhibitor valve
valve, operated by timing solenoid output, shifts to 3rd gear
12 Check valve Switches fluid passage to rear clutch (C2) in D range and R ranges
Lower valve body

No. Valve name Description of function
Switches fluid passage according to the position (P, R, N, D, 2, L) of range
1 Manual valve
selector lever
2 1-2 Shift valve Switches between 1st and 2nd gears
3 3-4 Shift valve Switches between 3rd and overdrive gears
4 Pressure relief valve Maintains pressure supplied to cooler at low level
5 Primary regulator valve Regulates hydraulic pressure (line pressure) to devices
6 Lock-up control valve Adjust flow rate of automatic transmission fluid to torque converter
7 C0 exhaust valve Reduces shock in 3rd-to-2nd shifting
Adjusts hydraulic pressure switching timing in 3rd-to-2nd shifting to reduce
8 2-3 Timing valve
shock
9 Cutback valve Applies cutback pressure to throttle valve to reduce line pressure
23-13
Shift Function
2 3 4 5 6 7 8 9 10 11 12
1
B1 B2
B0
C0
F1
C1 C2
F0
13 14 15 18 19 20 21 22 23 24
16 17
P 29810
1 Overdrive direct clutch (C0) 13 Overdrive input shaft

2 Overdrive brake (B0) 14 Overdrive one-way clutch (F0)
3 Overdrive planetary carrier 15 Overdrive planetary sun gear
4 Overdrive planetary ring gear 16 Input shaft
5 Overdrive planetary pinion gears 17 Rear clutch (C2)
6 Front clutch (C1) 18 Intermediate shaft
7 2nd brake (B1) 19 Front planetary carrier
8 1st and reverse brake (B2) 20 Front planetary sun gear
9 No. 2 one-way clutch (F1) 21 Front planetary pinion gears
10 Front planetary ring gear 22 Rear planetary carrier
11 Rear planetary ring gear 23 Rear planetary sun gear
12 Rear planetary pinion gears 24 Output shaft
Clutch and brake functions
Name Function
Overdrive direct clutch (C0) Interlocks overdrive sun gear and overdrive planetary carrier
Overdrive brake (B0) Prevents rotation of overdrive sun gear
Prevents overdrive planetary carrier from rotating in counterclockwise
Overdrive one-way clutch (F0)
direction relative to overdrive sun gear during driving
Front clutch (C1) Interlocks input shaft and intermediate shaft
Rear clutch (C2) Interlocks input shaft with front and rear planetary sun gears
2nd brake (B1) Prevents rotation of front and rear planetary sun gears
1st and reverse brake (B2) Prevents rotation of front planetary carrier
Prevents counterclockwise rotation of front planetary carrier and allows
No. 2 one-way clutch (F1)
only clockwise rotation
23-14
23
Clutch, Brake and Solenoid Operations
Shift position C0 C1 C2 B0 B1 B2 F0 F1 S1 S2 Remarks
P Parking Parking
R Reverse Reverse
N Neutral Neutral
1st Automatic shifting
2nd 1 2 3 4
D
3rd Overdrive OFF mode
Overdrive 1 2 3 4
1st
Automatic shifting
2 2nd
1 2 3
3rd
1st Locked in 1st gear
1 2 3 (3rd gear shifting
L 2nd occurs only when timing
3rd solenoid activates.)
S1 and S2 refer to shift solenoid 1 and shift solenoid 2, respectively : Activates : Activates only during driving
: Overrun preventive control
23-15
Overdrive Direct Clutch
1 22 3 4 5 6 7 9 10
3 1 12
13 11 14
P 29811
1 Overdrive direct clutch drum 7 Clutch plates 13 Overdrive input shaft

2 O-ring 8 Clutch discs 14 Input shaft
3 Overdrive direct clutch piston 9 Clutch flange
4 O-ring 10 Snap ring A : Operating pressure
5 Overdrive clutch return springs 11 Overdrive planetary sun gear
6 Snap ring 12 Overdrive planetary carrier
< Active condition >

The control valve supplies operating pressure A to overdrive direct clutch piston 3, coupling clutch discs 8 and
clutch plates 7. This interlocks overdrive planetary sun gear 11 with overdrive planetary carrier 12.
As a result, the entire overdrive planetary gear acts as a single unit to transmit the engines driving power from
overdrive input shaft 13 to input shaft 14.
< Inactivate condition >

Since operating pressure A is not supplied, the force of overdrive clutch return springs 5 presses against overdrive
direct clutch piston 3.
As a result, clutch plates 7 are separated from clutch discs 8, and the engine power is not transmitted.
23-16
23
Front Clutch (C1)
1 2 3 4 5 6 7 8
1 4 13
10 11 12 13 14
15 12 16
P 29812
1 Front clutch drum 7 Clutch cushion plate 13 Rear clutch hub

2 O-ring 8 Clutch plates 14 Snap ring
3 O-ring 9 Clutch discs 15 Input shaft
4 Front clutch piston 10 Thrust bearing lace 16 Intermediate shaft
5 Front clutch return springs 11 Thrust bearing
6 Snap ring 12 Front clutch hub A : Operating pressure

The control valve supplies operating pressure A to front clutch piston 4, which causes the coupling of clutch discs 9 and
clutch plates 8, thus transmitting the engines driving power from input shaft 15 to front clutch hub 12 and intermediate
shaft 16.

Since operating pressure A is not supplied, the force of front clutch return springs 5 presses against front clutch
piston 4.
23-17
Rear Clutch (C2)
1 2 3
5 6 7 8 9 10
11 13 10 7 12
P 29813
1 Snap ring 7 Rear clutch piston 13 Rear clutch hub

2 Clutch flange 8 O-ring
3 Clutch discs 9 O-ring A : Operating pressure
4 Clutch plates 10 Rear clutch drum
5 Snap ring 11 Input shaft
6 Rear clutch piston return 12 Front and rear planetary
springs sun gears

The control valve supplies operating pressure A to rear clutch piston 7, which causes the coupling of clutch discs 3 and
clutch plates 4, thus transmitting the engines driving power from input shaft 11 and rear clutch hub 13 to rear clutch
drum 10 and front and rear planetary sun gears 12.

Since operating pressure A is not supplied, the force of rear clutch piston return springs 6 presses against rear clutch
piston 7.
23-18
23
Overdrive Brake (B0)
1 2 3 5
4
8
7
6
11
10
9 12 8
11 A
13
P 29814
1 Snap ring 6 Snap ring 11 Overdrive case

2 Brake flange 7 Overdrive brake return springs 12 Overdrive direct clutch
3 Clutch discs 8 Overdrive brake piston 13 Overdrive planetary sun gear
4 Brake plates 9 O-ring
5 Brake plates 10 O-ring A : Operating pressure

The control valve supplies operating pressure A to overdrive brake piston 8, which causes the coupling of clutch discs
3 and brake plates 4, 5, thus interlocking overdrive direct clutch 12 with overdrive case 11. This sets overdrive
planetary sun gear 13 in locked condition.

Since operating pressure A is not supplied, the force of overdrive brake return springs 7 presses against overdrive
brake piston 8.
As a result, brake plates 4, 5 are separated from clutch discs 3, and the engine power is not transmitted.
23-19
2nd Brake (B1)
1 2 4
5 6
3
7 8 9 10
11 10 7
12
P 29815
1 Snap ring 6 2nd brake return springs 11 Rear clutch

2 Brake flange 7 Brake piston No. 1 12 Front and rear planetary sun
3 Clutch discs 8 O-ring gears
5 Snap ring 10 Center support A : Operating pressure

The control valve supplies operating pressure A to brake piston No.1 7, which causes the coupling of clutch discs 3 and
brake plates 4, thus interlocking rear clutch 11 with center support 10. This sets front and rear planetary sun gears 12 in
locked condition.

Since operating pressure A is not supplied, the force of 2nd brake return springs 6 presses against brake piston
No.1 7.
As a result, brake plates 4 are separated from clutch discs 3, and the engine power is not transmitted.
23-20
23
1st and Reverse Brake (B2)
1 2 3 4
8 9 10
5
13 11 12 8 A
6 7
P 29816
1 Snap ring 7 1st and reverse brake return 12 Transmission case

2 Brake flange springs 13 Front planetary carrier
3 Clutch discs 8 1st and reverse brake piston
4 Brake cushion plate 9 O-ring A : Operating pressure
6 Snap ring 11 1st and reverse brake hub

The control valve supplies operating pressure A to 1st and reverse brake piston 8, which causes the coupling of clutch
discs 3 and brake plates 5, thus interlocking 1st and reverse brake hub 11 with transmission case 12. This sets front
planetary carrier 13 in locked condition.

Since operating pressure A is not supplied, the force of 1st and reverse brake return springs 7 presses against 1st and
reverse brake piston 8.
As a result, brake plates 5 are separated from clutch discs 3, and the engine power is not transmitted.
23-21
Planetary Gears
Overdrive planetary gear
2
3
8
7
6
5 P 29866
Front and rear planetary gears

1 9
12
10
11
4
07468
16
13
15
14
P 29817
1 Pinion gear 7 Overdrive pinion gears 13 Rear sun gear

2 Ring gear 8 Overdrive ring gear 14 Rear planetary carrier
3 Sun gear 9 Front sun gear 15 Rear pinion gears
4 Planetary carrier 10 Front planetary carrier 16 Rear ring gear
5 Overdrive sun gear 11 Front pinion gears
6 Overdrive planetary carrier 12 Front ring gear
Three sets of Simpson-type planetary gears provide a total of five gear ratios: four forward speeds and one reverse
speed.
Each planetary gear set consists of a sun gear 3 at the center and pinion gears 1 that revolve around the sun gear
and on their axes. This set of gears are contained in a ring gear 2. The pinion gears are attached to a planetary
carrier 4, so that all pinion gears rotate in the same direction and at the same rate. Gear shifting occurs when these
four elements sun gear, pinion gears, ring gear and planetary carrier are provided with certain conditions.
Clutches and brakes provide operating conditions to the planetary gears in accordance with shifting.
Overdrive One-Way Clutch

1 Overdrive direct clutch drum and overdrive one-way clutch inner
race
2 Overdrive one-way clutch
3 Overdrive one-way clutch outer race
2
3
1
P 29818
During acceleration in the 1st, 2nd and 3rd gears, the overdrive one-way clutch 2 engages and becomes interlocked
with the overdrive sun gear and overdrive planetary carrier.
In the 4th gear, the overdrive one-way clutch 2 rotates freely.
23-22
23
No. 2 One-Way Clutch
1 Front planetary carrier and No. 2 one-way clutch inner race
1 2 No. 2 one-way clutch
3 3 No. 2 one-way clutch outer race
P 29819
During acceleration in the 1st gear, the No. 2 one-way clutch 2 engages and becomes interlocked with the front
planetary carrier.
In the 1st, 2nd and 3rd gears, the No. 2 one-way clutch 2 rotates freely.
23-23
Torque Transmission Process
2 3 4 5 6 7 8 9 10 11 12
1
13 14 15 18 19 20 21 22 23 24
16 17
P 29810
1 Overdrive direct clutch 13 Overdrive input shaft

2 Overdrive brake 14 Overdrive one-way clutch
3 Overdrive planetary carrier 15 Overdrive planetary sun gear
4 Overdrive planetary ring gear 16 Input shaft
5 Overdrive planetary pinion gears 17 Rear clutch
6 Front clutch 18 Intermediate shaft
7 2nd brake 19 Front planetary carrier
8 1st and reverse brake 20 Front planetary sun gear
9 No. 2 one-way clutch 21 Front planetary pinion gears
10 Front planetary ring gear 22 Rear planetary carrier
11 Rear planetary ring gear 23 Rear planetary sun gear
12 Rear planetary pinion gears 24 Output shaft
23-24
23
D, and 2 Ranges (1st Gear)
1 3 A 4 6 9 19 B 10 C 22 11
21 20 18 23 12 24
13 14 15 5 16
Planetary gear rotates as assembly Fixed in position by one-way clutch

Output Input
Output
Input
A B C
P 29820
Overdrive direct clutch 1, front clutch 6, overdrive one-way clutch 14 and No. 2 one-way clutch 9 activate to provide the
1st gear. At overdrive planetary gear A, overdrive direct clutch 1 operates to interlock overdrive planetary carrier 3
(overdrive input shaft 13) with overdrive planetary sun gear 15. This disables overdrive planetary pinion gears 5 from
rotating on their axes, and overdrive planetary carrier 3 becomes locked (direct coupling) in position with overdrive
planetary ring gear 4, thus transmitting driving force to input shaft 16. Clockwise rotation of overdrive planetary carrier 3
results in a force that attempts to turn overdrive pinion gears 5 in a counterclockwise direction, producing clockwise
rotating force for overdrive planetary sun gear 15. However, since overdrive planetary sun gear 15 rotates faster than
overdrive planetary carrier 3, overdrive one-way clutch 14 activates, interlocking overdrive planetary carrier 3 with
overdrive planetary sun gear 15. This disallows overdrive planetary pinion gears 5 from rotating on their axes, in the
same way as when overdrive direct clutch 1 activates. Therefore, overdrive planetary carrier 3 becomes locked (direct
coupling) in position with overdrive planetary ring gear 4, thus transmitting the driving force to input shaft 16.
These two power transmitting systems reduce the load on overdrive direct clutch 1.
The clockwise rotating force of input shaft 16 is transmitted to intermediate shaft 18 by the action of front clutch 6, then
turns rear planetary pinion gears 12 clockwise by means of rear planetary ring gear 11. In this process, rear planetary
carrier 22 is stationary due to vehicle weight. Therefore, rear planetary sun gear 23 receives counterclockwise rotating
force and transmits this force to front planetary pinion gears 21, exerting force to rotate front planetary carrier 19 in a
counterclockwise direction. However, since No. 2 one-way clutch 9 prevents front planetary carrier 19 from rotating in a
counterclockwise direction, pinion gears 12, 21 cause front planetary ring gear 10 and rear planetary carrier 22 to rotate in
a clockwise direction, thereby transmitting the rotating force to output shaft 24. (Rotational directions are described as
viewed from the torque converter side.)
23-25
Power transmitting process
Overdrive input shaft 13 Overdrive planetary carrier 3 Overdrive planetary pinion gears 5 Overdrive planetary
ring gear 4 Input shaft 16 Front clutch 6 Intermediate shaft 18 Rear planetary ring gear 11 Rear planetary
pinion gears 12 Rear planetary carrier 22 Output shaft 24
Front and rear planetary sun gears 20, 23 Front planetary pinion gears 21
Front planetary ring gear 10
23-26
23
D Range (2nd Gear)
3 4 A 6 7 B C 22 11
13 18 23 12 24
14 5 16
Front planetary sun gear Rear planetary sun gear
Planetary gear rotates as assembly locked in position locked in position
Input
Output
A B C
P 29821
Front clutch 6, 2nd brake 7 and overdrive one-way clutch 14 activate to provide the 2nd gear. In this gear, overdrive one-
way clutch 14 transmits the rotating force of input shaft 16 to rear planetary pinion gears 12 by means of intermediate
shaft 18 and rear planetary ring gear 11. Although rear planetary sun gear 23, which is meshed with pinion gears 12,
receives a counterclockwise rotating force, 2nd brake 7 prevents its rotation, disabling the transfer of the rotating force to
front planetary gear B. As a result, the rotating force transmits to rear planetary carrier 22 via rear planetary pinion gears
12, then to output shaft 24.

23-27
D, 2 and L Ranges (3rd Gear)
1 3 A 4 6 17 10 B C 22 11
18 21 20 23 12 24
13 14 5 16
Planetary gear Planetary gear Planetary gear
rotates as assembly rotates as assembly rotates as assembly
A B C
P 29822
Overdrive direct clutch 1, front clutch 6, rear clutch 17 and Overdrive one-way clutch 14 activate to provide the 3rd gear. In
this gear, front clutch 6 and rear clutch 17 cause intermediate shaft 18 and front and rear sun gears 20, 23 to rotate in the
same direction. Therefore, front and rear planetary pinion gears 12, 21 become locked in position, thus the entire
assemblies of planetary gears A, B, C rotate together to transmit the rotating force of input shaft 16 to output shaft 24
without reducing the rate of rotating speed.

ring gear 4 Input shaft 16 Front clutch 6 Intermediate shaft 18
Rear planetary ring gear 11 Rear planetary pinion gears 12
Rear clutch 17 Rear planetary carrier 22 Output shaft 24
Rear planetary sun gear 23 Rear planetary pinion gears 12

Front planetary sun gear 20 Front planetary pinion gears 21 Front planetary ring gear 10
23-28
23
D Range (4th Gear)
1 2 3 A 4 6 17 10 B C 22 11
13 5 15 16 18 21 20 23 12 24
Overdrive planetary sun gear 15
Planetary gear rotates as assembly Planetary gear rotates as assembly
Output
Input
A B C
P 29823
If the overdrive conditions (see the table below) are fulfilled when the transmission is in 3rd gear, overdrive direct clutch 1
disengages, and overdrive brake 2 activates at the same time to provide the overdrive gear ratio. In the overdrive gear,
overdrive brake 2 is in operation, thus locking overdrive planetary sun gear 15 in position. Therefore, the rotating force
transmitted from overdrive input shaft 13 to overdrive planetary carrier 3 causes overdrive planetary pinion gears 5 to revolve
around the sun gear and on their own axes, which results in an increased rotating speed of overdrive planetary ring gear 4
(input shaft 16). The rotating force of input shaft 16 is transmitted to output shaft 24, in the same way as in the 3rd gear.
Overdrive conditions
Shift position D
Overdrive OFF SW OFF
Temperature of oil in oil pan Approximately 0C
{32F} or higher
ring gear 4 Input shaft 16 Front clutch 6 Intermediate shaft 18
Rear planetary ring gear 11 Rear planetary pinion gears 12
Rear clutch 17 Rear planetary carrier 22 Output shaft 24
Rear planetary sun gear 23 Rear planetary pinion gears 12

Front planetary sun gear 20 Front planetary pinion gears 21 Front planetary ring gear 10
23-29
2 Range (2nd Gear)
1 3 A 4 6 B C 22 11
13 16 18 12 24
14 5 15
Planetary gear Rear planetary sun gear
Front planetary sun
rotates as assembly gear locked in position locked in position
Input
Output
A B C
P 29824
The rotating power is transmitted in the same way as in the previously described 2nd gear in the D range. However, when
engine brake is applied, overdrive direct clutch 1 activates and prevents overdrive planetary sun gear 15 from rotating
clockwise. In other words, when the transmission is in 2nd gear with the range selector in the D range, overdrive one-way
clutch 14 transmits the rotating power to input shaft 16. When the engine brake is applied, however, the counterclockwise
rotating force of overdrive planetary sun gear 15 inactivates overdrive one-way clutch 14 and causes overdrive planetary
sun gear 15 to spin freely. This disallows the transmission of the engine brake force. To properly transmit the engine brake
force in the 2 range, overdrive direct clutch 1 is activated to interlock overdrive planetary sun gear 15 with overdrive
planetary carrier 3.
ring gear 4 Input shaft16 Front clutch 6 Intermediate shaft 18 Rear planetary ring gear 11 Rear planetary
23-30
23
L Range (1st Gear)
3 A 4 6 8 9 19 B 10 C 22 11
13 5 16 18 21 20 23 12 24
Planetary gear Front planetary carrier
rotates as assembly fixed in position
Output Input
Output
Input
A B C
P 29825
The rotating power is transmitted in the same way as in the previously described 1st gear in the D and L ranges. However,
when the engine brake is applied, 1st and reverse brake 8 activates and prevents front planetary carrier 19 from rotating
clockwise. In other words, when the transmission is in 1st gear with the range selector in the D or 2 range, No. 2 one-way
clutch 9 prevents a counterclockwise rotation of front planetary carrier 19 and transmits the rotating power to output shaft
24. When the engine brake is applied, however, a rotating force in the reverse direction is generated, inactivating No. 2
one-way clutch 9 and allowing front planetary carrier 19 to spin freely. This disallows the transmission of the engine brake
force. To properly transmit the engine brake force in the L range, 1st and reverse brake 8 is activated to lock front
planetary carrier 19 in position.

Front and rear planetary sun gears 20, 23 Front planetary pinion gears 21
Front planetary ring gear 10
23-31
R Range
1 3 A 4 17 8 19 B 10 C
13 14 5 16 21 20 23 24
Planetary gear Front planetary carrier
rotates as assembly in fixed position
Output
Input
A B C
P 29826
In the R range, overdrive direct clutch 1, overdrive one-way clutch 14, rear clutch 17 and 1st and reverse brake 8 activate
to provide reverse gear. The rotating force of overdrive input shaft 13 is transmitted to input shaft 16 via direct coupling, in
the same way as in the 1st gear in the D and 2 ranges. Since rear clutch 17 in operation, the rotating force of input shaft 16
is transmitted to pinion gears 21 of front planetary gear B by means of the sun gear. However, because front planetary
carrier 19 is locked in position by 1st and reverse brake 8, the rotating force of front planetary sun gear 20 is transmitted to
the ring gear by means of front planetary pinion gears 21, thus providing a counterclockwise rotating force to output shaft
24.
ring gear 4 Input shaft 16 Rear clutch 17 Front planetary sun gear 20 Front planetary pinion gears 12
Front planetary ring gear 10 Output shaft 24
23-32
23
N Range
6 17
24
16
P 29827
N range
Since front clutch 6 and rear clutch 17 are disengaged, the driving force of input shaft 16 is not transmitted to output
shaft 24.
P Range
1 Parking lock gear
2 Output shaft
1 3 Transmission case
4 Parking lock pawl
2
P 29828
P range
In the same way as in the N range, the driving force of the input shaft is not transmitted to output shaft 2. Parking lock
pawl 4, which is linked with the range selector lever, meshes with parking lock gear 1 which is directly connected to
the output shaft, thus disallowing vehicle movement.
23-33
Torque Converter
1 Pump impeller
2 Turbine liner
3 Stator
4 Lock-up damper
5 One-way clutch
6 Front converter cover
1 7 Lock-up piston
2
The torque converter transfers engine torque to the
transmission. It transmits engine torque by means of
3
oil when it is not in a lock-up condition, and it transfers
power via the lock-up piston when it is in a lock-up
condition.
4
The torque converter is a 3-element, 1-stage, 2-phase
5 type.
1-stage indicates that the torque converter has one
turbine liner, which is an output element. 2-phase
6 means that it provides a torque converter function
when the turbine liner speed is relatively slow as
7 compared to the pump impeller speed, and acts as a
fluid coupler when the turbine liner speed is high.
P 29829
< Lock-up mechanism in inactive condition >

B
The lock-up control valve supplies the torque converter operating
pressure through oil passage A to the space between the front
converter cover and lock-up piston. This oil pressure separates the
clutch facing of the lock-up piston from the front converter cover. As
a result, the torque converter operating pressure supplied through oil
A
passage A is released from oil passage B, and enters the oil cooler.
07480
< Lock-up mechanism in active condition >

B The lock-up control valve switches the operating oil passage. The
torque converter operating pressure is supplied through oil passage
B to the pump impeller, turbine liner and stator.
As a result, the oil pressure applied to the lock-up piston causes the
clutch facing of the lock-up piston to engage with the front converter
C cover for improved power transmitting efficiency.
C : Drain
07481
23-34
23
Oil Pump
1 Driven gear
2 Crescent
1 3 Drive gear
4 Oil pump body
2 5 Outlet port
6 Inlet port
3
6
P 29830
Feature ...... The oil pump gears have a small number of gear teeth and features a special high-performance tooth
profile.
Operation ... The drive gear is fitted to the extension sleeve of the torque converter, and rotates in the same
direction (in the direction of the arrow) as the engine to compress and discharge the intake oil.
23-35
Operation Error Protection Device
5 3
1
13
12 7
15
16 11
14
10
8
13990
2
17
15
16 1
A
A
19
B
5
9 18
10
20
13
31559
23-36
23
1 Key interlock solenoid 10 Automatic transmission reverse 18 Key interlock electronic control
2 Starter switch buzzer unit
3 Automatic transmission knob 11 Shift lock link 19 Automatic transmission elec-
4 Shift button 12 Shift lock release knob tronic control unit
5 Overdrive OFF switch 13 P range switch 20 Backup lamp relay
6 Selector lever 14 Brake pedal
7 Pin 15 Stop lamp switch A : From inhibitor switch
8 Lever bracket 16 Fuse box B : To backup buzzer
9 Shift lock actuator 17 Meter cluster
Parking Shift Lock Device with Key Interlock

The key interlock device prevents the removal of the key unless selector lever 6 is in the P (Parking) range. The shift
lock device disallows the selector lever from moving from the P range position unless brake pedal 15 is pressed,
thereby preventing accidental vehicle movement caused by an unintended selector lever operation.
Key interlock device

4 < Lock condition >
Condition: When selector lever 6 is in a position other
than the P range or when shift button 4 is pressed with
the selector lever in the P range, pin 7 is not in contact
with P range switch 13 (switch is set free). Therefore,
the switch is ON.

An electric current flows from key interlock electronic

6 control unit 18 to key interlock solenoid 1 to activate the
13
key interlock solenoid.
7
Key interlock solenoid 1 turns ON to prevent starter
switch 2 from being turned to the LOCK position, thus
disabling the removal of the key.
< Unlock condition >
Condition: When selector lever 6 is in the P range and
shift button 4 is not pressed, pin 7 presses again P range
switch 13 (switch is activated). Therefore, the switch is
OFF.

13992
No electric current flows from key interlock electronic
control unit 18 to key interlock solenoid 1. Therefore, the
key interlock solenoid is OFF.

Key interlock solenoid 1 does not turn ON, thereby dis-
engaging starter switch 2 and allowing the switch to turn
to the LOCK position for the removal of the key.
23-37
P shift lock device
With selector lever 6 in the P range, when the elec-
tric current (see the table below) supplied to shift
4
lock actuator 9 sets the shift lock actuator in lock
position A, pin 7 is restrained by shift lock link 11 and
6 disallows pressing of shift button 4. Therefore, the
selector lever cannot be moved from the P range.
Power supply Switch Operation mode

IG +B Brake P range Unlock Lock

7

A
9

11
P 31523
With selector lever 6 in the P range, when the electric

current (see the above table) supplied to shift lock
actuator 9 sets the shift lock actuator in unlock posi-
4 tion B, shift lock link 11 is in the forward position to set
pin 7 free, thus allowing pressing of shift button 4.
Therefore, the selector lever can be moved from the P
6 range to another range position.
Should an electrical problem occur and hinder proper
operation, pulling of shift lock release knob 12 deacti-
vates the P shift lock.
7
B
12
9
11
P 31525
23-38
23
Selector lever reverse position warning device
When starter switch 2 is ON, moving selector lever 6 to
the R (reverse) range activates the reverse position
detecting switch (inhibitor switch: built into automatic
transmission) and turns on automatic transmission re-
verse buzzer 10 to warn the driver that the selector
lever is in the reverse position.
10
13995
23-39
TROUBLESHOOTING PROCEDURES
Automatic transmission problems can be caused by the following malfunctions.

Engine malfunction
Improperly adjusted parts
Faulty hydraulic system
Faulty mechanical functions
Faulty electrical system
When diagnosing the above abnormalities, be sure to inspect the following basic items.
Engine condition: ^ Engine Shop Manual 4D3
Accelerator control cable adjustment: ^ Engine Shop Manual 4D3 Gr 13
Automatic transmission fluid level and condition: P 23-56
Range selector cable adjustment
In addition to the inspection of the above items, use the self-diagnosis function to locate the cause of the problem and
take necessary measures.
After repair is complete, test-drive the vehicle to determine whether the problem is corrected or further inspection is
necessary.
If the cause of the problem cannot be located, or if repair work does not correct the problem, conduct a line pressure
test and a stall test. P 23-50, 52
It should be noted that special knowledge and tools are required to repair the automatic transmission unit or replace
parts. Therefore, conduct an inspection for the purpose of evaluating the operating condition of the transmission. For
maintenance or repair of the automatic transmission, contact your nearest authorized Mitsubishi dealer or distributor.
Use of the MUT-II allows efficient inspection of the automatic transmission system.
Self-diagnosis process Note 1 : The following abnormalities

Abnormality generation (Note 1)
significantly lower driving
performance. In the case that
these abnormalities generate
Delivery of vehicle during operation, the auto-
matic transmission warning
lamp lights.
Faulty operation of vehicle
Self-diagnosis procedure (Note 2)
speed sensors
Faulty operation of sole-
noid other than lock-up so-
lenoid
Correct problem or replace parts Test drive (Note 3) Faulty operation of accel-
erator sensor
Faulty operation of inhibitor
Test drive Self-diagnosis procedure (Note 4) switch
Faulty throttle position
PWM signal
Note 2 : Inspect for malfunctions that
Self-diagnosis Abnormality found in self-diagnosis?
Yes occurred during user opera-
No tion. Record inspection re-
sults.
Is there abnormality? Note 3 : Check abnormal conditions.
Yes Check for other abnormalities
In a test drive, operate the
No Inspection of individual symptoms
accelerator pedal in full
Inspection of transitory problems
End range (from the released
position to full throttle) with
a vehicle speed of up to
approximately 50 km/h
{31.1 mph}.
Note 4 : Inspect problems that gener-
ate during a test drive.
Record inspection results.
23-40
23
Types of Self-Diagnosis
The following two types of self-diagnosis function can be selected.
Self-diagnosis
Using diagnosis switch Using MUT-II
Disconnect the diagnosis switch

(plug connector) to indicate mal- Data list function
Flight recorder function
function codes.
Data of malfunctions stored in Connect the MUT-II to the automatic
the memory can be deleted with transmission electronic control unit
the memory clear switch. with a test harness to download and
display malfunction codes.
In addition to the self-diagnosis func-
tion, the MUT-II is equipped with a
data list function that indicates sensor
and switch values and a flight recorder
function that records those data for a
certain length of time before and after
the triggering. These functions are
useful in analyzing malfunctions.
(Refer to the MUT-II operation
manual.)
Features of the two self-diagnosis methods

Self-diagnosis method
Item Use of diagnosis switch Use of MUT-II
Convenience
Number of self-diagnosis items
Data reading ease
Data application range
: Good
: Fair
: Bad
23-41
TROUBLESHOOTING
Using diagnosis switch to recall diagnosis codes and using memory clear switch to delete diagnosis codes
The diagnosis switch is used for the analysis of malfunction, and the memory clear switch allows deletion of stored
diagnosis codes.
Recalling diagnosis code P23-42
Pull out the diagnosis switch to recall the diagnosis code of the current problem from the electronic control units
memory.
Pull out the diagnosis switch and memory clear switch to recall the diagnosis codes of the current and past problems
from the electronic control units memory.
Deleting diagnosis codes P23-43
Pull out and reinsert the memory clear switch to delete the diagnosis codes stored in the electronic control units
memory.
Procedure for recalling diagnosis codes

[Current diagnosis code]
Remove diagnosis switch A (plug connector). The warning lamp
begins flashing. The flashing pattern indicates a diagnosis code.
Check the code list to locate the problem location. P23-44
[Current and past diagnosis codes]

A B 31521
Remove diagnosis switch A (plug connector) and memory clear
switch B (1-pin connector). The warning lamp begins flashing
to indicate diagnosis codes.
The warning lamp indicates the diagnosis codes of past malfunc-
tions and the diagnosis code of the current problem, if any.
CAUTION
If diagnosis switch A is connected first, diagnosis codes in
the electronic control units memory are deleted, and a 01
(normal) code is indicated.
14025
23-42
23
Code 1-2 is indicated as follows Procedure for reading diagnosis codes
ON 2nd-time The automatic transmission electronic control units memory is
OFF indication stored with the data of all malfunctions that occurred after the
2.4 1.2 2.4 previous self-diagnosis operation.
0.6 0.6 The warning lamp turns off for 2.4 seconds after the self-diagnosis
0.4 0.4 operation starts, then indicates a code.
Code 2-4 is indicated as follows The tens digit is indicated by 1.2-second ON operation and 0.6-
ON second OFF operation.
OFF The ones digit is indicated by 0.4-second ON operation and
P 28223
0.6-second OFF operation.
The lamp remains OFF for 2.4 seconds between codes.
If there are two or more malfunction codes in the memory, they
are output in an order from the smallest code number. Each
malfunction code is indicated three times before the following
code is output.
After all malfunction codes in the memory are output, the indica-
tion process repeats from the beginning.
Procedure for deleting diagnosis codes
Keep diagnosis switch A (plug connector) connected.
Disconnect memory clear switch B (1-pin connector). After more
than one second, connect the memory clear switch. When the
memory clear switch remains connected for more than three
seconds, diagnosis codes in the electronic control unit are de-
leted.
A B 31521
23-43
TROUBLESHOOTING
Diagnosis Code Chart
Diagnosis
code
1 Normal
11 Power supply voltage Power supply voltage remains below 7.5 V
for 1 second or longer with range selector
in a position other than P or N range.
13 Oil temperature sensor When oil temperature of more than 135C Maximum oil temperature
{275F} or lower than -50C{-58F} is detected.
Note that MUT display is fixed at 40C
{104F} after fail-safe judgement result.
15 Engine speed sensor Engine speed sensor detects a value of less Prohibits 2-3 shift timing control.
than 300 rpm when range selector is in a
position other than P or N range and when
output shaft rotating speed is 1000 rpm or higher.
24 Accelerator sensor When accelerator sensor voltage is less than Shift-point is set at 0% throttle
0.4 V, or 4.6 V or higher opening.
Prohibits throttle learning function.
Prohibits 2-3 shift timing control.
Line pressure at maximum
Lock-up control change
25 Vehicle speed sensor 2 Vehicle speed sensor 2 indicates sudden Maintains the gear selected immediately
speed decrease. before malfunction detection.
Turns off shift solenoids 1, 2 when
engine speed sensor detects a value
of less than 1000 rpm.
while solenoid is receiving current. Turns off lock-up solenoid and timing
When solenoid output disconnection occurs solenoid.
while solenoid is not receiving current. Refer to the chart on P23-54 for gear
selection.
while solenoid is receiving current. Turns off lock-up solenoid and timing
When solenoid output disconnection occurs solenoid.
while solenoid is not receiving current. Refer to the chart on P23-54 for gear
selection.
34 Line pressure solenoid When wire breakage or short-circuit occurs. Turns off line pressure solenoid.
35 Lock-up solenoid When solenoid output short-circuit occurs Turns off lock-up solenoid.
43 Inhibitor switch No signal Operates as D range and prohibits
shifting to 4th gear.
Two or more signals Control function activates based on
priority order of L > R > 2 > D > N (P).
Refer to pages 23 through 54 for
actual vehicle operation conditions.
50 PTO solenoid When solenoid output short-circuit occurs Turns off PTO solenoid.
When solenoid output is cut off while
solenoid is not receiving current.
51 Timing solenoid When solenoid output short-circuit occurs Turns off timing solenoid.
23-44
23
Diagnosis
code
54 Exhaust brake cut-off Exhaust brake activates when exhaust brake Prohibits exhaust brake cut-off control
signal cut-off signal is generated. Allows lock-up only at high cruising
speed.
58 PWM signal Malfunction of engine electronic control unit Shift-point is set at 0% throttle opening.
(PWM signal fixed at 1 V or lower) Prohibits 2-3 shift timing control.
Line pressure at maximum
Prohibits throttle position learning function.
Wire breakage or short-circuit Prohibits throttle position learning function.
23-45
TROUBLESHOOTING
Procedure for servicing with MUT-II
0 Special tools
MUT-II PLUS MB991496-A
19492
MUT-II harness MK327601 System inspection
19141
ROM pack (MRT-E4) MK327927
19493

B
Turn the starter switch to the LOCK position.
Connect the 2 MUT Communication Harness to the 1 MUT-II,
and insert the 3 ROM Pack.
Fit connector C onto Mut connector B (16-pin) in the relay box.
A NOTE
C 3 Instructions for operation of the MUT-II are given in the separate
2 MUT-II Reference Manual.
1 31469
23-46
23
Inspection using MUT-II
The MUT-II indicates diagnosis codes that provide information of malfunctioning items (devices that require
inspection).
The MUT-II indicates sensor signal conditions with numerical values (service data). Comparison of the service data
with judgement criteria allows evaluation of the transmission operation. Diagnosis codes and service data codes can
be effectively used for troubleshooting.
1 2
Malfunctioning item Service
Diagno (devices that require data Signal name Service Judgement
Inspection condition
-sis code data criterion
inspection) code
11 POWER VOLTAGE
When engine is cold Equivalent to
outside air
temperature
13 OIL TEMPSNSR 13 A/T OIL TEMP .F When engine is in warm-up operation Gradual increase
Non-operating engine after warm-up Gradual decrease
operation
Idle after warm-up operation 725 rpm
.
15 ENG SPD SNSR 15 ENGINE SPEED RPM Corresponds with
Racing
tachometer
Full throttle 0%
17 ACCEL PERCENT .% Gradual pressing Increases continuously
Full throttle 100 %
Selector in P range ON
19 P POS. SW
Selector in position other than P range OFF
Selector in R range ON
20 R POS. SW
Selector in position other than R range OFF
Selector in N range ON
21 N POS. SW
Selector in position other than N range OFF
Selector in D range ON
22 D POS. SW
Selector in position other than D range OFF
Full throttle 0.850.1 V
24 ACCEL SNSR 24 ACCEL VOLT . V Gradual pressing Increases continuously
Full throttle 4.150.1 V
Vehicle stationary in position 0 mph
.
25 VEH SPD SNSR 25 VEH SPEED MPH Correspond with
Vehicle in operation
speedometer
Selector in 2 range ON
26 2 POS. SW
Selector in position other than 2 range OFF
Selector in L range ON
27 L POS. SW
Selector in position other than L range OFF
Overdrive OFF SW ON ON
28 OD-OFF SW
Overdrive OFF SW OFF OFF
In power mode ON
29 POWER S/W
In economy mode OFF
23-47
TROUBLESHOOTING
1 2
Diagno (devices that require data Signal name Service Inspection condition Judgement
inspection) code
Driving in 1st and 2nd gears ON
31 SHIFT VALVE 1 31 SHIFT VALVE 1 Driving in 3rd and 4th gears OFF
Driving in 2nd and 3rd gears ON

32 SHIFT VALVE 2 32 SHIFT VALVE 2 Driving in 1st and 4th gears OFF
34 LINE PRESS. V 34 LINE PRESS . Idle According to line

lbf/in2 Stall pressure chart
Turns ON according
Driving with consistent throttle to lock-up vehicle
35 LOCK UP VALVE 35 LOCK UP VALVE opening speed chart during
road test. P 23-54
Vehicle stationary in D range OFF
Abnormal oil temperature
ON
(ATF temperature lamp ON)
36 OIL TEMP SW
Normal oil temperature
OFF
(ATF temperature lamp OFF)
Brake pedal pressed ON
37 BRAKE SW
Brake not applied OFF
Exhaust brake activation during driving ON
38 EXH. BRAKE SW
Exhaust brake inactive OFF
43 INHIBIT SIG
ABS activation ON
47 ABS SW
ABS inactive OFF
Connector disconnected OPEN
48 M CLEAR SW
Connector in connection CLOSE
Plug connector disconnected OPEN
49 DIAGNOSIS SW
Plug connector in connection CLOSE
50 PTO VALVE 50 PTO VALVE PTO operation ON
PTO non-operation OFF
23 shifting when accelerator pedal
ON
51 TIMING VALVE 51 TIMING VALVE is released
Vehicle stationary in position OFF
System malfunction (warming lamp ON) ON
53 DIAG LAMP
System normal (warning lamp OFF) OFF
Exhaust brake activation during driving OFF
54 EXB CUT SIG 54 EXB CUT SIG
Stopping using exhaust brake OFF ON
Operate range selector from P to L Changes as follows:
55 SELECTOR POS. RANGE
in order. PRND2L
According to lock-up
1ST vehicle speed chart
Driving at constant speed during road test.
2ND
56 GEAR POS. 3RD Accelerating gradually from 0 km/h P 23-54 (1ST
4TH 2ND 3RD 4TH)
N Selector in N range N
REV Selector in R range REV
23-48
23
1 2
Diagno (devices that require data Signal name Service Inspection condition Judgement
inspection) code
. Closed throttle 0%
58 PWM SIG. 58 PWM PERCENT % Accelerator pedal pressed gradually Continuous increase
Accelerator pedal at full throttle 100% or more
PTO SW ON ON
59 PTO SW
PTO SW OFF OFF
23-49
23-50
Starter circuit
Line pressure
Inhibitor switch
Control linkage
Shift solenoid 2
Shift solenoid 1
Timing solenoid
Lock-up solenoid
Torque converter
Engine idle speed
Accelerator sensor
Engine speed sensor


Suspected problem factor
Symptoms and problems
Automatic transmission unit malfunction

TROUBLESHOOTING

Automatic transmission fluid level and condition

Malfunction
Vehicle runs in N range

Parking position is still engaged when
selector is moved from P range
Vehicle moves in P range
Vehicle does not move in any range
Abnormal
movement
Vehicle does not move in R range

Vehicle does not move in D, 2 or L range
Lock-up point extremely high or low
Does not lock up
No engine brake in 2 range
No engine brake in L range
Kick-down does not operate
Shift point extremely high or low
Engine revs up in 2-3 shift
Does not shift down from 2nd to 1st
Does not shift down from 3rd to 2nd
Does not shift down from 4th to 3rd
Abnormal shift operation
Does not shift up from 3rd to 4th

Does not shift up from 2nd to 3rd
Does not shift up from 1st to 2nd
Starter circuit
Line pressure
Inhibitor switch
Control linkage
Shift solenoid 2
Shift solenoid 1
Timing solenoid
Lock-up solenoid
Torque converter
Engine idle speed
Accelerator sensor
Engine speed sensor


Suspected problem factor
Automatic transmission unit malfunction

Automatic transmission fluid level and condition

Malfunction
During lock-up operation

When shifting from 3rd to 2nd
When shifting from 4th to 3rd
When shifting from 1st to 2nd, to 3rd, to 4th
When shifting from 3rd to 4th
When shifting from 2nd to 3rd
When shifting from 1st to 2nd
When shifting from N to D and from N to R
When shifting from N to D
Excess shock during shifting
When shifting from N to R

In 4th gear
In 3rd gear
In 2nd gear
In 1st gear
Slippage
In reverse gear
In forward and backward
Transmission overheat and oil blow-off from breather
Engine stalls when range selector is moved to R, D,
2 or L, or when vehicle is stationary
Engine starts with range selector in position other
Others
than N or P range
23
Engine cannot be started with range selector in N or

P range
23-51
Stall Test
Purpose
To check wearing of gears, slippage of one-way clutches, operation of
torque converter and overall performance of the engine.
Measuring procedure
Before the test, inspect the engine coolant, engine oil and automatic
transmission fluid. Run the engine until the engine coolant tempera-
ture reaches an appropriate level. Also conduct a warm-up operation
for the automatic transmission and bring the automatic transmission
fluid temperature to an appropriate level.
Place wheel chocks in front and back of all wheels, and apply the
parking brake. When operating the accelerator pedal, be sure to
press down firmly on the foot brake pedal.
Shift the range selector lever to the D range.
Press down on the accelerator pedal gradually to full throttle. When
the engine speed stabilizes, quickly read the engine rpm (stall
speed) and remove foot from the accelerator pedal.
CAUTION
Limit each measuring operation to five seconds. Extended
testing causes automatic transmission fluid degradation and
adverse effects to the internal parts.
If the engine speed does not stabilize but continues to in-
crease or suddenly jumps, stop the test immediately.
Shift the range selector lever to the N range, and let the engine run
at approximately 1200 rpm for one minute or longer for cooling.
Conduct tests in the same way with the range selector lever in each
of the 2, L and R ranges.
Stall speed
FE 639 1810150 rpm

FE 649 1890150 rpm
Diagnosis of test result

Measuring result Suspected abnormality
Insufficient engine output power
Lower than standard
value in all ranges Faulty operation of one-way clutch in torque
converter
Slippage of front clutch
Higher than standard
value in D range Faulty operation of No. 2 one-way clutch
Low line pressure
Slippage of rear clutch
Higher than standard
value in R range Slippage of 1st and reverse brake
Low line pressure
Low line pressure
Higher than standard Inappropriate automatic transmission fluid level
value in all range Slippage of overdrive direct clutch
Faulty operation of overdrive one-way clutch
23-52
23
Time Lag Test
Purpose
To check the conditions of overdrive direct clutch, front clutch, rear
clutch and 1st and reverse brake.
Measuring procedure
Bring the oil temperature to normal operating level of between 50
and 80C {122 and 176F}.
Start the engine and check the idle speed.
Shift the range selector lever from the N range to the D range and
use a stopwatch to measure the time it takes for shock to be felt.
In the same way, measure the time lag by shifting the range
selector lever from the N range to the R range.
Standard value
ND shifting 0.7 sec or less
NR shifting 1.2 sec or less

Low line pressure
Large time lag in
Slippage of front clutch
ND shift
Low line pressure
Large time lag in Slippage of rear clutch
NR shift Slippage of 1st and reverse brake
23-53
Line Pressure Test

Purpose
To check the oil pump capacity, control valve functions and leaks in
hydraulic circuit.
Measuring procedure
CAUTION
The line pressure test requires two persons. One person must
observe tire movement and wheel chocks from outside the
vehicle, while the other person conducts the test.
Apply the parking brake firmly.

Place wheel chocks.
Remove pressure detecting plug 1, and mount the oil pressure
gauge.
1 Start the engine, and operate it until the automatic transmission
fluid temperature reaches between 50 and 80C {122 and 176F}.
Then, check the idle speed.
While pressing the brake pedal firmly with the left foot, shift the
range selector lever to the D range and measure the oil pressure
while the engine is idling.
Press the accelerator pedal all the way, and quickly measure the oil
P 29841 pressure at stall speed.
CAUTION
If the engine RPMs do not reach stall speed and the rear
wheels start rotating, release the accelerator pedal and stop
the test.
Measure the oil pressure with the range selector lever in the R
range by following the above procedure.
After the measurement, re-install pressure detecting plug 1 and
tighten to the specified torque.
Pressure Bolt size 1/2-20UNF
detecting plug Tightening torque 7.5 Nm {5.5 lbf.ft, 0.76 kgfm}
Line pressure kPa {lbf/in2, kgf/cm2}

Idle oil FE639 D range 529 to 784 {77 to 115, 5.4 to 8.0}
pressure FE649 R range 755 to 1127 {110 to 165, 7.7 to 11.5}
Stall oil FE639 D range 990 to 1480 {145 to 215, 10.1 to 15.1}
pressure FE649 R range 1401 to 2107 {205 to 305, 14.3 to 21.5}
23-54
23

Faulty adjustment of throttle cable
Higher than standard Sticking of regulator valve
value in all ranges
Sticking of throttle valve
Faulty adjustment of throttle cable
Sticking of regulator valve
Lower than standard
value in all ranges Sticking of throttle valve
Excessive wear of oil pump
Faulty overdrive direct clutch
Lower than standard Oil leak in D range system
value only in D range Faulty front clutch
Oil leak in R range system
Lower than standard
value only in R range Faulty rear clutch
Faulty 1st and reverse brake
23-55
Road Test
Measuring procedure
Before the road test, check the level and condition of the auto-
matic transmission fluid. Also make sure that the range selector
cable and the accelerator control cable are properly adjusted.
Operate the automatic transmission in every range position dur-
ing the road test and check slippage and other operating condi-
tions during shifting of gears.
Check to see if the shift feels too tight or too loose.
Check the shift points of up-shifting and downshifting.
Check shift-point vehicle speeds under various driving conditions.
Shift-point vehicle speeds Unit : km/h {mph}

Throttle opening Shifting Economy mode Power mode
D1D2 8.63 to 11.1 {5.36 to 6.9} 9.37 to 11.84 {5.82 to 7.36}
Half throttle D2D3 19.73 to 22.2 {12.3 to13.8} 20.96 to 23.43 {13.0 to 14.6}
D3D4 48.83 to 51.3 {30.3 to 31.9} 38.72 to 41.19 {24.1 to 25.6}
D1D2 17.26 to 19.73 {10.7 to 12.3} 19.48 to 21.95 {12.1 to13.6}
Full throttle D2D3 34.53 to 36.99 {21.5 to 23.0} 41.93 to 44.39 {26.1 to 27.6}
D3D4 63.14 to 65.6 {39.2 to 40.8} 73.99 to 78.92 {46.0 to 49.0}
L2L1 22.94 to 25.4 {14.3 to 15.8} 22.94 to 25.4 {14.3 to 15.8}
Closed throttle
2322 51.79 to 54.26 {32.2 to 33.7} 51.79 to 54.26 {32.2 to 33.7}
23-56
23
Lock-up vehicle speeds Unit : km/h {mph}
Throttle opening Shifting Economy mode Power mode
3rd gear ON (Overdrive ON) 48.09 to 50.56 {29.9 to 31.4}
Half throttle
3rd gear ON (Overdrive OFF) 53.03 to 55.49 {33.0 to 34.5}
4th gear ON 56.38 to 58.85 {35.0 to 36.6}
3rd gear ON 53.03 to 55.49 {33.0 to 34.5}
Full throttle
4th gear ON 73.99 to 78.92 {46.0 to 49.0}
3rd gear OFF
Closed throttle 43.16 to 45.63 {26.8 to 28.4}
4th gear OFF

5.714 differential gear ratio, 0.374 m tire radius (215/85R16)
If the differential gear ratio and/or the tire radius are different from the above, proper standard values must be
calculated based on the ratios of the differences and the above figures.
23-57
Inspection of Automatic Transmission Fluid (ATF)

If the automatic transmission has insufficient ATF, the pump draws air together with ATF. Air bubbles mixed in the ATF
cause a sponge effect and lower the pressure. This can cause slipping of internal clutches.
On the other hand, if the ATF level is too high, excess air bubbles also result when rotating parts agitate the ATF, thus
causing the same effect as when the ATF level is low.
In both cases, excess air bubbles lead to overheat, oxidation of oil and varnish generation, thereby hindering proper
operation of the valves and clutches.
Excess air bubbles in the ATF also cause ATF to overflow from the vent hole and filler tube, which may be mistakenly
diagnosed as an ATF leak.
To prevent these problems, read the ATF level accurately by following the procedure described below.
(1) Inspection of ATF condition
If ATF has a burned odor and contains metal shavings or particles,
the automatic transmission needs an overhaul. Closely inspect the
ATF adhered on level gauge A.
If ATF is suspected to be in poor condition, take out a sample and
inspect closely.
(2) Inspection of ATF level

CAUTION
Inspection is conducted while the engine is running. Be
careful of moving parts and hot areas to prevent personal
injuries and burns.
Before inspection, check the idle speed.
Place the vehicle on level ground.
Bring the transmission to normal operating temperature (70
to 80C {158 to 176F}) before inspection.
Before pulling out level gauge A, clean the protective cap
and the upper part of the filler tube.
Apply the parking brake firmly, and place wheel chocks.

With the engine idling, press down on the brake pedal and shift the
range selector lever slowly from the P range to the L range, stop-
ping at each position in between. Then return the range selector
lever to the P range.
With the engine idling, pull out level gauge A. Wipe the ATF from
A
the level gauge and blow compressed air to remove lint and other
particles. Insert the level gauge, and pull it out. Check to make sure
that the ATF level is in the range marked HOT.
CAUTION
If the ATF temperature is low (20 to 30C {68 to 86F}), such
as after an ATF change, bring the ATF level to the area on
the level gauge marked COLD. Then, after the transmis-
sion temperature rises to normal operating level (70 to 80C
07500 {158 to 176F}), check to make sure that the ATF level is in
the area on the level gauge marked HOT.
If the markings on the front and back sides of the level
gauge show different level indications, use the line that
indicates the lower ATF level.
If the ATF level is low, add ATF from the filler tube to the specified
level on level gauge A.
23-58
23
Changing Automatic Transmission Fluid (ATF)

(1) Drain
Place an ATF receiving tray under the automatic transmission oil
pan. Remove the drain plug located at the back side of the pan to
drain ATF.
Tightening torque: 27 Nm {20 lbt.ft, 2.8 kgfm}
CAUTION
ATF is very hot immediately after the engine is turned off.
Wait until the ATF temperature lowers sufficiently.
For faster ATF drainage, warm up the engine.
P 29843
ATF in the hydraulic circuit, torque converter and oil cooler
cannot be drained in the above process.
Inspect the drained ATF for dirtiness and contamination
such as metal shavings and particles.
After the above process, approximately 1 L {1.1 qts} of ATF remains

in the oil pan. If you wish to drain this remaining ATF, remove the oil
pan. P23-76
Amount of drained ATF

ATF drained by removing oil pan : Approximately 4.5 L {4.8 qts}
ATF drained by removing drain plug : Approximately 3.5 L {3.7 qts}
(2) Adding ATF

Prepare new ATF.
Re-install the oil pan drain plug and gasket.
From filler tube A, add the same amount of ATF as drained.
CAUTION
Be careful not to let dust and other particles mix with ATF.
A
Start the engine and let it idle for at least two minutes.
07821
Shift the range selector lever into every position, then back to the P
range.
CAUTION
Do not rev up the engine in the above process.
Check the ATF level. P23-56
(3) ATF leaks

Torque converter housing of the automatic transmission unit
Check for leaking locations
Since the torque converter and the surrounding area can be soiled
with oil that leaks from the engine, inspect those areas carefully.
ATF is red, so that it can be easily distinguished from engine oil.
Before dismounting the automatic transmission, carefully examine
if ATF leaks from the torque converter or the automatic transmis-
sion unit (oil seal of oil pump housing or connection of oil pump
housing and case).
23-59
REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY
Preparation
Removal sequence
1 Exhaust pipe ^ Gr 15
2 Selector cable P23-72
2 3 Electrical harness
1 5 Parking brake ^ Gr 36
3 6 Oil cooler hose P23-63
7 Speedometer cable
CAUTION
After removing propeller shaft 5, suspend the shaft at
31515 the same height as the installation position by secur-
ing it to the frame with a rope.
5 CAUTION
If the automatic transmission unit is replaced due to a
malfunction and if the automatic transmission fluid
contains a large amount of impurities, conduct flush-
4 ing of the oil cooler system. P23-63
30821
30920
6
7
30822
23-60
23
Removal
Removal sequence
1 Bolt
- 2 Bolt
9 3 Dust cover
A
4 Bolt (8)
5 5 Bolt
7
8 6 Bolt
8 7 Bolt (4)
C 7 8 Drive plate
9 Automatic transmission assem-
B
bly
1
3 A : Torque converter
4 2 B : Flywheel
6 C : Pilot section

P 32107
CAUTION
Remove the automatic transmission assembly with drive plate 8 attached to torque converter A.

Bolt (Automatic transmission assembly mounting and dust
1 cover mounting) 47 {35, 4.8}
2 Bolt (Dust cover mounting) 13 {9.4, 1.3}

4 Bolt (Flywheel and drive plate coupling) 32 {24, 3.3}
5 Bolt (Rear mounting) 83 to 105 {61 to 80, 8.5 to 11}
82 {61, 8.4} M12
Bolt (Automatic transmission assembly mounting)
6 47 {35, 4.8} M10
Bolt (Bracket mounting) 40 {30, 4.1}
7 Bolt (Drive plate mounting) 7912 {598.7, 8.11.2}
- Lubricant
Pilot section C on torque converter A in automatic Molybdenum disultide grease
9 transmission assembly [NLGI No.2 (Li soap)] As required
23-61
9
Service procedure
Automatic transmission assembly
[Removal]
Remove dust cover 3.
3
07934
Turn the engine so that bolt 4 is positioned at service window D.

4 A 4 Remove eight bolts 4. Remove two bolts at each of the four loca-
tions by turning the engine and stopping at the proper position.
D 07936
Support automatic transmission assembly 9 with a jack, then re-

6 9 5 move automatic transmission assembly mounting bolts 5, 6.
Remove automatic transmission assembly 9 by pulling towards the
back of the vehicle.
CAUTION
Do not support the automatic transmission by the oil pan,
since it causes shape deformation of the oil pan and oil pan
gasket.
Since torque converter A can easily separate from the auto-
P 32108 matic transmission assembly, be careful not to drop the
torque converter.
Mounting bolts 6 are different in length. Record the length of
each bolt when removing, so that bolts can be re-installed in
the original locations.
[Installation]
Install drive plate 8 to torque converter A before installing the torque
converter into automatic transmission assembly 9.
Tighten bolts 7 to the specified torque.
8
9
07938
23-62
23
40 mm {1.57 in.} or more
Check to make sure that torque converter A is properly mounted in
B 8 9 automatic transmission assembly 9.
When the torque converter is properly installed, the distance between
the surface of drive plate 8 and the case mounting surface is as
A indicated in the diagram.
Apply grease on pilot sections C of flywheel B and torque converter A.
C
07939
Turn flywheel B so that one of bolt holes E on the flywheel is located at

the lowest position. Bolt holes are used to connect drive plate 8 to the
flywheel.
E 07940
Turn drive plate 8 so that one of bolt holes E is located at the lowest
position.
8
E 07941
Install automatic transmission assembly 9 into position slowly and

6
9 5 carefully while aligning pilot section C and the dowel pin of the rear
A plate.
Tighten several mounting bolts 6 on automatic transmission assembly
9 for temporary holding. Tighten bolts 5 to the specified torque to
C mount the automatic transmission assembly to the rear support.
CAUTION
Torque converter A can easily separate from the automatic
transmission assembly 9. To keep the torque converter in
P 32109 place, set the back side of automatic transmission assembly
slightly lower than the front part.
Before mounting the automatic transmission assembly 9, wipe
oil adhered on the internal wall of the torque converter hous-
ing.
23-63
Align the bolt holes of drive plate 8 and flywheel B by looking through
4 A 4 service hole D, and mount bolts 4.
Temporarily tighten all eight bolts, two bolts at each of the four loca-
tions, by turning the engine and stopping at the proper position. Then,
repeat the same process, and tighten the bolts to the specified torque.
B
8
D 07943
Tighten all automatic transmission assembly mounting bolts 6 to the

3
specified torque.
2 Tighten bolts 2 to the specified torque to secure dust cover 3 in place.
07944
23-64
OIL COOLER 23
20
21
23
22
21
24
3
6
7 4 3 4 1
2 1
3 3
4
4 5
1 5
2 1
6

-
1 8
-
16
6
14 19
18
11
13
17
31017
Removal sequence
1 Hose clamp 10 Automatic transmission fluid 18 Oil cooler front support
2 Rubber hose thermostat switch 19 Oil cooler rear support
3 Bolt 11 Plug 20 Bolt
4 Clamp 12 Thermostat valve 21 Clamp
5 Eye bolt 13 Bracket 22 Oil cooler pipe
6 Oil cooler tube 14 Connector 23 Oil cooler pipe
7 Bracket 15 Blower assembly 24 Bracket
8 Bracket 16 Oil cooler assembly
9 Plug 17 Oil cooler mount frame
23-65
OIL COOLER
10 Operating temper- When rising (OFFON) 973C {2075.4F} Replace
ature of automatic
transmission fluid When falling (ONOFF) 90C {194F} MIN
thermostat switch
12 Thermostat valve Starting operation 76.53C {1705.4F} Replace
temperature
Bypass opening 832C {1813.6F} Replace
temperature

3 Bolt (Clamp mounting) 3.0 to 4.4 {2.2 to 3.3, 0.3 to 0.45}
9 Plug 29 to 39 {22 to 29, 3 to 4}
10 Automatic transmission fluid thermostat switch 29 to 39 {22 to 29, 3 to 4}
11 Plug 147 to 186 {110 to 139, 15 to 19} Wet
22, 23 Oil cooler pipe 29 to 30 {22 to 29, 3 to 4}
- Sealant
9 Thread area of plug THREEBOND 1110B As required
10 Thread area of automatic transmission fluid thermostat switch THREEBOND 1110B As required
23-66
23
F
Service procedure
Inspection of automatic transmission fluid thermostat

973C {2075.4F} switch
ON
10 OFF Carry out the following inspection and replace automatic transmission
90C {194F} MIN
fluid thermostat switch 10 if there are any faults.
Check that there is no continuity between terminals 1 and 2 at
ambient temperature of 205C {689F}.
Place automatic transmission fluid thermostat switch 10 in a container
filled with automatic transmission fluid, and raise the temperature
07806 while stirring well.
Measure the temperature when continuity has been achieved be-
tween terminals 1 2
and , and check that the measured value con-
Lower and measure the temperature when continuity is lost between
terminals1 2
and , and check that the measured value conforms to
the standard value.
A H Inspection of thermostat valve

Carry out the following inspection. If any fault is found, replace thermo-
stat valve 12.
B 12 Place thermostat valve 12 in a container filled with automatic trans-
mission fluid and raise the fluid temperature while stirring the fluid.
Make sure that end A starts stroking at a temperature of 76.53C
{1705.4F}.
Raise the fluid temperature further and make sure that end A expands
13978
by 4.5 mm {1.18 in.} and dimension B in the illustration is 13.4 mm
{0.53 in.} at a temperature of 832C {1813.6F}.
K Inspection of blower assembly

Check blower assembly 15 and make sure it operates when battery
1 2
15
voltage is loaded between terminals and . If any fault is found,
replace the blower assembly.

07808
23-67
AUTOMATIC TRANSMISSION CONTROL
Range Selector Lever
3
-
4
27
6 28
15 -
38 -
14 -
-
29 - 37
33 36
16 35
34
-
25
30 32
9
-33
8
- - 42
- 42
31 45
10 43
44
39
18 46
24
-
19
47
23
48
17 1 41

*
49
31504
23-68
23
1 Nut 18 Indicator panel 34 Pin
2 Shift lock release knob 19 Bolt 35 Ball spring
3 Adapter 20 Shift lock actuator 36 Ball support
4 Screw 21 Automatic transmission 37 Steel ball
5 Screw reverse buzzer 38 Selector lever
6 Range selector lever cover 22 Ball joint 39 Screw
7 Connector 23 Lock nut 40 P-range switch
8 Screw 24 Grommet 41 Plate
9 Cover 25 Pin 42 Clevis pin
10 Screw 26 Sleeve 43 Shift lock link
11 Switch button 27 Rod 44 Shift lock link
12 Overdrive OFF switch 28 Spring 45 Clevis pin
13 Pin 29 Nut 46 Shift lock link
14 Spring 30 Bushing 47 Lever bracket
15 Shift button 31 Rod 48 Bolt
16 Automatic transmission knob 32 Pipe 49 Base plate
17 Screw 33 Bushing
* : Lever assembly P23-71
Assembly sequence

1 Nut (Lever assembly mounting) 17 to 22 {12 to 16, 1.7 to 2.2}
4 Screw (Range selector lever cover mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
8 Screw (Cover mounting) 2.0 {1.4, 0.2}
10 Screw (Automatic transmission knob mounting) 2.0 {1.4, 0.2}
17 Screw (Indicator panel mounting) 1 to 2 {0.7 to 1.4, 0.1 to 0.2}
19 Bolt (Lever bracket mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
23 Lock nut (Ball joint mounting) 16 to 24 {12 to 17, 1.6 to 2.4}
29 Nut (Lever mounting) 9.8 to 14.0 {7.2 to 10.0, 1.0 to 1.4}
39 Screw (P-range switch mounting) 0.2 to 0.3 {0.1 to 0.2, 0.02 to 0.03}
48 Bolt (Base plate mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
- Lubricant
14 Outside surface of spring Multipurpose grease [NLGI No.2 (Li soap)] As required
15 Sliding area of shift button Multipurpose grease [NLGI No.2 (Li soap)] As required
26 Sliding area of sleeve Wheel bearing grease [NLGI No.2 (Li soap)] As required
33 Interior of bushing Chassis grease [NLGI No.1 (Ca soap)] As required
36 Sliding area of ball support Chassis grease [NLGI No.1 (Ca soap)] As required
38 Sliding area of selector lever Wheel bearing grease [NLGI No.2 (Li soap)] As required
42, 45 Sliding area of clevis pin Chassis grease [NLGI No.1 (Ca soap)] As required
47 Sliding area of lever bracket Chassis grease [NLGI No.1 (Ca soap)] As required
23-69
12
B
7
Service procedure
Removal of connector
Using screwdriver A, pull out terminal B of overdrive OFF switch 12 from
the inside of connector 7 and remove the connector.
A
7
07625
GH
[Removal]
Switch button, overdrive OFF switch
11 Using screwdriver A, remove switch button 11 from overdrive OFF

12
switch 12.
12 Remove overdrive OFF switch 12 from automatic transmission knob
16 by pushing the switch out.
A
16
13980
[Inspection of overdrive OFF switch 12]

12
Free
1 : RW 2 : BW 3 : YW
Lock
2 : BW
1 : RW Free
Lock


Replace overdrive OFF switch 12 if it is faulty.
3 : YW 07488
16
15
I Removal of pin
While keeping shift button 15 and spring 14 pressed down, remove pin
13 towards the inside (arrow direction) of automatic transmission knob
16.
13 14
13981
23-70
23
Brake
switch
Other loads P Inspection of shift lock actuator
Power supply Switch Operating mode

20
P-range switch IG +B Brake P range Unlock Lock

Lock
Unlock 07489

Check to make sure that shift lock actuator 20 is in operating mode under
the above power supply and switch position.
Q
Replace the shift lock actuator if it is faulty.
Inspection of automatic transmission reverse buzzer

21 Check to make sure that the automatic transmission reverse buzzer
sounds when 12 volts DC is loaded between terminals 1
and . 2
Replace automatic transmission reverse buzzer 21 if it is faulty.
NOTE
Automatic transmission reverse buzzer 21 sounds continuously
when you apply voltage.
If you want to make automatic transmission reverse buzzer 21
07145 sound intermittently, use the automatic transmission reverse
R
buzzer and the back buzzer in combination.
23 Installation of ball joint

31
Using ball joint 22 adjust rod 31 so that its thread ridge conforms to the
16 mm {0.63 in.} dimensions as illustrated, then tighten with lock nut 23.
(at least 13 mm
{0.51 in.})
22
07628
V Installation of sleeve
Shift range selector lever 38 to the P range. Install sleeve 26 by rotating it
26 so that the dimension between the sleeve and the upper part of the lever
conforms to the value as illustrated.
15.2 to 15.9 mm
{0.60 to 0.63 in.}
38
07629
23-71
OFF
ON
d P-range switch
[Inspection]
1 2 3
40 321 ON
OFF
Replace P-range switch 40 if it is faulty.
07630
[Installation]
Install P-range switch 40 so that it is OFF when the range selector lever
is in the P range.
23-72
23
Lever Assembly
1 Nut
4
2 Clip
3 Nut
4 Nut
9 5 Spacer (for adjustment)
6 Bushing
7 Lever
8 Collar
3 1 9 Lever bracket
*a : Range selector lever P23-66

*b : Selector cable P23-72
6 *a
Assembly sequence
7 8
5 *b2
6 76 43
8 9 *a1
-
*b
2
13982

1 Nut (Range selector lever mounting) 17 to 22 {12 to 16, 1.7 to 2.2}
3 Nut (Bracket mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
4 Nut (Lever mounting) 17 to 22 {12 to 16, 1.7 to 2.2}
- Lubricant
8 Outside surface of collar Chassis grease [NLGI No.1 (Ca soap)] As required
4
5
Service procedure
Selection of spacer
Select the spacer so that when nut 4 is tightened at specified torque
the clearance between lever bracket 9 and spacer 5 conforms to the
dimensions as illustrated.
5 5
There are two spacer thicknesses available : 0.3, 0.5 mm {0.012,
9 0.020 in.}
0 to 0.3 mm {0 to 0.012 in.} 7 After installation make sure lever 7 can be operated smoothly.
07810
23-73
A 1
1 2
5
1
5
5
10 -
2
-
9
8 12

7
11
*b
13
*a
P 31143
23-74
23
Removal sequence
1 Clip 8 Nut A : To range selector lever
2 Nut 9 Bushing
3 Selector cable 10 Lever *a : Automatic transmission unit
4 Insulator 11 Nut *b : Transmission control shift lever
5 Bracket 12 Bracket P23-76
6 Nut 13 Bracket
7 Rod

2 Nut (Selector cable mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
3 Selector cable (For mounting on bracket) 60 to 85 {6.0 to 8.5}
6 Nut (Rod mounting) 9.8 to 15 {7.2 to 11, 1.0 to 1.5}
8 Nut (Lever mounting) 28 to 35.7 {2.8 to 3.5}
11 Nut (Bracket mounting) 38 to 54 {28 to 40, 3.9 to 5.5}
- Lubricant
Chassis grease
9 Inside bushings As required
[NLGI No.1 (Ca soap)]
13
3
Service procedure
Selector cable
Loosen nuts A on the selector cable 3 all the way to the ridges.
A
3
P 29850
Set automatic transmission lever knob B (located inside the cabin)

and transmission control lever *b to the D range position.
*b
D range
P 29851
23-75
Shake automatic transmission lever knob B back and forth.
P 29852
Check to make sure that automatic transmission lever knob B is in the

D range, and tighten nuts A on selector cable 3 to the specified torque.
3 A
B
P 29853
Make sure that starter key C can be removed with automatic transmis-
B sion lever knob B in the P range.
07774
[Adjustment]
Adjust nuts A on selector cable 3 so that transmission control lever *b
B moves smoothly in the entire range when automatic transmission
*b lever knob B is moved from the L range to P range.
CAUTION
If the adjustment of nuts A is improper, automatic transmis-
sion lever knob B produces resistance when it is moved to the
L or P range. In some cases, the starter key cannot be removed
3 A
with the automatic transmission lever knob in the P range.
P 29854
23-76
23
MEMO
23-77
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS

-
21 18

23 *b
22 -

- 2
17 -
15 16 24
7 28
27
8
-
27
30
- 31

12 11
6 10
*a
5
4
13

2
- 1

31516
Removal sequence
1 Drain plug 14 Inhibitor switch 27 Bolt

2 Bolt 15 Nut 28 Speedometer sleeve lock plate
3 Oil pan 16 Nut 29 Speedometer driven gear
4 Oil cleaner magnet 17 Transmission control shift lever 30 O-ring
5 Bolt 18 O-ring 31 Speedometer sleeve
6 Oil strainer 19 Oil temperature switch
7 Bolt 20 O-ring *a : Automatic transmission unit
8 O-ring 21 Elbow *b : Parking brake assembly
9 Speed sensor 22 O-ring ^ Gr 36
10 Nut 23 Elbow : Non-reusable parts
11 Lock washer 24 Breather cap
12 Gasket 25 Rear oil seal
13 Bolt 26 Torque converter
23-78
23
Service standards
9 Speed sensor resistance (at normal temperature) 560 to 680 Replace
Oil temperature switch OFFON 143 to 151C {289 to 304F}
19 Replace
activating temperature ONOFF Approximately 125C {257F}

1 Drain plug 27 {21,2.8} With magnets
2 Bolt (Oil pan mounting) 7 {5.1,0.7}
5 Bolt (Strainer mounting) 10 {7.2,1.0}
7 Bolt (Speed sensor mounting) 8 {5.8,0.8}
10 Nut (Inhibitor switch mounting) 7 {5.1,0.7}
13 Bolt (Inhibitor switch mounting) 12.5 {9.4,1.3}
15 Nut (Transmission control shift lever mounting) 12.5 {9.4,1.3}
16 Nut (Transmission control shift lever mounting) 12.5 {9.4,1.3}
19 Automatic transmission fluid temperature switch 24.5 {18,2.5}
21 Elbow 32 {24,3.3}
23 Elbow 32 {24,3.3}
27 Bolt (Speedometer sleeve lock plate mounting) 12.5 {9.4,1.3}

Location Parts of application Specified lubricant and/or sealant Quantity
O-rings Automatic transmission fluid As required
3 Mounting surfaces of oil pan and automatic transmission unit THREEBOND 1281B As required
25 Lip section of oil seal Wheel bearing grease As required
[NLGI NO.2 (Li soap)]
0 Special tools
3 Oil pan remover MD998727 Removal of oil pan
P 29856
23-79
0 Special tools
25 Oil seal installer MH063608 Installation of oil seal
P 29857
0 3
Service procedure
Oil pan
[Removal]
Remove bolts 2.
CAUTION
To prevent oil pan 3 from dropping when separating the
sealant from the oil pan, keep several bolts (not tightened)
mounted at intervals of three bolt holes.
3
2
P 29871
Insert 0 oil pan remover at a corner of oil pan 3, and separate the
oil pan from the automatic transmission unit.
CAUTION
Be careful not to deform the shape of oil pan 3 when insert-
ing 0 oil pan remover.
Do not tilt the oil pan during removal since the oil pan 3
contains oil.
[Installation]
3 Remove the sealant from the mounting surfaces of the automatic
transmission unit and oil pan 3.
Clean oil cleaner magnets 4, and mount them in the oil pan.
Apply sealant on oil pan 3, and mount the oil pan on the automatic
transmission unit.
4 Tighten bolts 2 to the specified torque.
CAUTION
Do not allow automatic transmission fluid on the contact
surfaces of oil pan 3 and the automatic transmission unit.
Apply sealant continuously with a diameter of 2 or 3 mm
{0.079 to 0.12 in.}, as shown in the diagram.
Install the oil pan within 10 minutes after the application of
the sealant.
Tighten bolts 2 evenly by conducting the tightening opera-
tion for each bolt several times.
P 29872
23-80
23
9 Inspection of speed sensor
Measure the resistance between the connector terminals shown in
the diagram. If the measured value deviates from the standard
value, the connector is defective.
Standard resistance between terminals: 560 to 680 (at normal
temperature)
J
P 29859
Inhibitor switch
[Installation]
14 Set control shaft A to the N position.
Mount inhibitor switch 14 on control shaft A.
Tighten two bolts 13.
Tighten nut 10.
13 10 A
P 29860
Loosen two bolts 13, and position inhibitor switch 14 so that refer-
ence line B on the inhibitor switch aligns with groove C.
While holding inhibitor switch 14 with one hand, tighten two bolts
B
13 to the specified torque with the other hand.
Bend the two lock tabs on the nut of inhibitor switch 14.
14
C
13
P 29861
[Inspection]
14
Check the electric conduction at wire connector D of inhibitor switch
14 using a tester.
< Connection chart >
B N C PL RL NL DL 2L LL
P
R
N
D P 29862 D
2
L
: Electric conduction between terminals
23-81
143 to 151C {289 to 304F}

OFF ON
O Oil temperature switch
Place oil temperature switch assembly 19 in a container filled with
Approximately 125C {257F} glycerin. Vary the temperature of the oil, and check to make sure that
the switch operates (ON and OFF) at the specified temperatures.
P 29869
23-82
23
25 0
U Installation of oil seal
CAUTION
After the oil seal 25 is removed, clean the surface of the
extension housing of automatic transmission unit *a to which
oil seal is mounted.
Apply grease on the lip section of oil seal 25.

*a Use 0 oil seal installer to insert oil seal 25 all the way into the
P 29870
extension housing of automatic transmission unit *a.
CAUTION
Insert oil seal 25 evenly.
Do not damage or deform the shape of oil seal 25.
26
V Installation of torque converter
Pour new automatic transmission fluid into torque converter 26
when the torque converter to be installed is new.
Automatic transmission fluid quantity : Approximately 2 L {2.1 qts}
Apply automatic transmission fluid on front oil seal A, and mount
torque converter 26 on the oil pump.
B CAUTION
Be careful not to damage oil seal A when mounting torque
converter 26.
Measure dimension B between the torque converter housing and

the set block of torque converter 26 to make sure that the torque
converter is inserted into the proper position.
Dimension B : 44 mm {1.73 in.} or more
A
P 29858
23-83
INSPECTION AND ADJUSTMENT OF OTHER DEVICES
1 Power mode switch
2 Starter switch
4
2 3 Accelerator sensor
4 Relay box
5 Engine speed sensor
1 8 6 Automatic transmission fluid cooler fan relay
8 Backup lamp relay
7 6
3
31524
5
07959
Service standards
6, 7, 8 Minimum relay operating voltage 16 V or lower Replace
23-84
23
1
Service procedure
Inspection of power mode switch
8 2 6
1234 LED
(activation
indication)
6 LED
(night time
illumination)
7
PWR
ECO
If an abnormality is found, replace power mode switch 1.
3 1 7 5 4
18622
23-85
2 Starter switch
[Removal and installation] ^ Electrical 210
[Inspection]
Conduct the following inspection. If an abnormality is found, replace
starter switch 2.
(1) Inspection of electric conduction
E AP2A AN6A
1 2 3 4 2 6 5
Without key
LOCK
With key
D
C (OFF)
ACC
ON
AN2A AP2A AN6A START
07057 B M A F/M S K1 K2
(2) Inspection of key interlock solenoid

AN2A
1 2 LOCK ACC ON START Remarks
Plunger C is engaged,
and key D cannot be
Turning range removed.
of key D Plunger C is
disengaged, and key
D can be removed.
: Terminals applied with battery voltage

E : Key interlock solenoid
23-86
23
3
(1)
Accelerator sensor
Initial voltage data storage
When accelerator sensor 3 is dismounted or replaced, it is neces-
sary to save the initial voltage value (full throttle) in the automatic
transmission electronic control unit memory.
A Check items
Idle adjustment knob is appropriate.
Accelerator sensor 3 are properly mounted. ^ 4D3 Gr 13
Idle adjustment knob A is fully pushed in.
D B
E
C
E P 29875
23-87
Initial full-throttle voltage data storage
Delete the data in the automatic transmission electronic control unit
memory by keeping the following conditions for five seconds.
Stop the vehicle (engine OFF).
Shift the range selector lever to the L range.
Turn off the overdrive OFF switch. (Overdrive OFF)
Disconnect diagnosis switch (plug connector) F.
Press on the brake pedal.
F 31526 Press on the accelerator pedal to full throttle.
When data deletion is complete, the warning lamp flashes.
Remove feet from the accelerator and brake pedals, and shift the
range selector lever to the P range and connect diagnosis switch F.
Hold the accelerator pedal at full throttle, and press down on the
brake pedal for more than three seconds.
During this process, the warning lamp lights for three seconds.
After the full throttle position data is stored in the electronic control
unit, the warning lamp turns off.
After confirming that the warning lamp has turned off, remove
feet from the brake and accelerator pedals. Then turn off the starter
14025 switch.
If the warning lamp does not light, repeat the procedure from the
beginning.
23-88
23
(2) Inspection of accelerator sensor
4
Apply a voltage of 5 V to terminal , and ground terminal . 1
A 3
Measure the output voltage that generates at terminal when lever
A is moved to each position.
C
If the measured values deviate from the standard value, replace the
accelerator sensor.
Regarding the removal and installation of the sensor, refer to
^ 4D3 Gr 13
B : Idle position
C : Maximum lever stroke position
Accelerator sensor output voltage at idle Connector terminals
B
(V) 3 1
0.850.1
+5V GND Accelerator sensor output voltage at full Connector terminal
4 3 2 1
throttle (V) 3 1
4.150.1
6
07969
6 Inspection of engine speed sensor

(1) Inspection of engine speed sensor mounting condition ^ Gr
11
(2) Inspection of engine speed sensor unit

Connector terminals
Standard value (k )
1 2
07190
1.40.2
789
engine speed sensor.
Inspection of relay (constant-open type, 4-pin)
1 2 3 4 Remarks
Electric current supplied
2
Electric current not Measure the voltage of
supplied electric current.

4 1 : Terminals applied with battery voltage
3 If an abnormality is found, replace the relay.
07142
23-89
Group 23
Automatic Transmission
Table of Contents
BACK
HOME
Pub No. TWSE9501-23

23
SPECIFICATIONS .................................................................................. 2
TROUBLESHOOTING PROCEDURE .................................................. 50
ELECTRIC CIRCUIT AND PARTS INSTALLATION POSITION .......... 62
INSPECTION BY INDIVIDUAL DIAGNOSIS CODE ............................ 65
INSPECTION BY SYMPTOM ............................................................... 92
INSPECTION OF TEMPORARY FAULT ............................................ 107
INSPECTION USING THE CHECK BOX (HARNESS CHECKER).... 108

Stall Test .......................................................................................................... 112
Line Pressure Test .......................................................................................... 113
Road Test ........................................................................................................ 115
Inspection of Automatic Transmission Fluid ............................................... 117
Replacement of Automatic Transmission Fluid .......................................... 118
WORK BEFORE REMOVAL AND INSTALLATION OF AUTOMATIC

TRANSMISSION ASSEMBLY ............................................................ 120
REMOVAL AND INSTALLATION OF AUTOMATIC

TRANSMISSION ASSEMBLY ............................................................ 121
OIL COOLER ...................................................................................... 126
AUTOMATIC TRANSMISSION CONTROL ........................................ 130
REPLACEMENT OF RELATIVE PARTS OF AUTOMATIC

TRANSMISSION BODY ..................................................................... 142
23-1
SPECIFICATIONS
Item Specifications
Manufacturer JATCO
Transmission model M030A4
Torque converter Type Symmetrical 3-element, 1-stage, 2-phase type
Stall torque ratio 2.0
Automatic Type Planetary gear type, 4 forward speeds, 1 reverse speed
transmission FE639 FE649
Gear ratio 1st 3.028 2.784
2nd 1.570 1.544
3rd 1.000 1.000
4th 0.724 0.694
Reverse 2.625 2.275
Range selection pattern P R N D2L
(Engine is started in N and P ranges only)
Automatic Recommended fluid Automatic transmission fluid DEXRON II type
transmission fluid Fluid quantity L {qts} 12 {12.7}
When fluid is Approximately 6.7 {7.1}
replaced L {qts}
23-2
Automatic Transmission Assembly
1 3 9
2 4 5 6 7
8 10
11
12
13
14
21 20 19 18
17 16 15
4
07427
1 Reverse clutch 8 Forward one-way clutch 15 Control valve

2 High clutch 9 Low one-way clutch 16 Magnet
3 Brake band 10 Transmission case 17 Oil pan
4 Front planetary gear 11 Extension housing 18 Oil pump
5 Rear planetary gear 12 Output shaft 19 Torque converter
6 Forward clutch 13 Parking gear 20 Converter housing
7 Overrunning clutch 14 Low and reverse brake 21 Input shaft
The automatic transmission consists of a torque converter with a lock-up system and a fully automatic 4-speed gear
system.
Torque converter
The transmission input system of the torque converter increases the torque transmitted from the engine to a maximum of
twice the input torque. The torque converter also acts as a fluid coupling which absorbs shock during engine start up and
gear shifting. Above a specified speed level, the lock-up system is activated to prevent slippage and to improve
transmission efficiency.
Transmission
The transmission has four forward speeds and one reverse speed. Transmission is accomplished by two sets of planetary
gears, and four sets of hydraulically operated, wet-type multiplate brakes and brake bands.
Hydraulic control
Precise gearshift control is achieved by the incorporation of various electronic controls that are handled by a microcom-
puter which has entire control of the system.
23-3
Control Mechanism
Control system
Torque converter
Multiplate clutch
Final drive gear

Multiplate brake
Propeller shaft
One-way clutch
Lock-up piston
Planetary gear
Output shaft
Drive shaft
Input shaft
Engine
Brake band
Tire
Oil pump Servo system
Driving power transmitting
route
Hydraulic control line
Oil temperature Vehicle speed
sensor Control valve
sensor
Mechanical signal
Electric signal
Shift Shift Overrun- Line
Lock-up
Accelerator sensor
ning pressure
solenoid solenoid solenoid clutch
A B solenoid solenoid
Dropping Sensor and

Automatic transmission resistor
electronic control unit various switches
07428
Power mode switch

ECO
(ECONOMY) Gearshift
control Solenoid
PWR output control
(POWER)
Shift solenoid A
Line
pressure
control Shift solenoid B
Exhaust brake signal

Overrunning clutch
Lock-up solenoid
control
Inhibiter switch
Lock-up solenoid
Accelerator sensor Overdrive

release
control Line pressure solenoid
Accelerator switch
Engine revolution signal
Overdrive switch
Fail-safe
Oil temperature sensor
control

Installed on automatic transmission
Abnormal point
Vehicle speed sensor 2 memory circuit Output control of
power mode switch Power mode indicator lamp
Halfway along speedometer indicator lamp
cable
(inside cab) Self-diagnosis Automatic transmission
control warning lamp
Self-diagnosis switch
07429
23-4
23
The control method basically consists of: gearshift control, line pressure control, lock-up control and overrunning clutch
control; and issues electronic commands for control, all of which are controlled by the electronic control unit depending on
the driving conditions of the vehicle.
Table of control item and input/output

Control item Line Gearshift Shift Lock-up Engine Fail-safe Self-
pressure control pattern control brake control diagnosis
control (includes selection control function
overdrive control
gearshift
Item control)
Power mode switch
Accelerator sensor (Note 3)
Vehicle speed Installed on
sensor 1 transmission (Note 3)
(power shaft
revolution sensor)
Vehicle speed Installed halfway
sensor 2 along speedometer (Note 1) (Note 1) (Note 1) (Note 1)
Input
cable (inside cab)

Inhibiter switch (Note 3) (Note 4)
Overdrive switch
Exhaust brake signal
Accelerator switch (Note 2) (Note 2) (Note 4)
Voltage signal from electronic control
unit power source
Diagnosis switch (Note 5)
Shift solenoid A (Note 3)
Output
Shift solenoid B (Note 3)

Line pressure solenoid (Note 3)
Lock-up solenoid (Note 3)
Overrunning clutch solenoid (Note 3)
Power mode indicator lamp
Automatic transmission warning lamp
Note 1 : Backup vehicle speed sensor 1 (installed on the transmission)

Note 2 : Backup accelerator sensor
Note 3 : When these input/output signals become abnormal, the automatic transmission electronic control unit activates
the fail-safe function.
Note 4 : This is used as a the basis for the start of self-diagnosis, and if self-diagnosis is not initiated, it judges that either
one is faulty.
Note 5 : Activates self-diagnosis function.
23-5
Line pressure control
Line pressure solenoid

A
1
2 Filter
2 3 Needle valve
3
4 Line pressure solenoid
OFF
A : Pilot pressure
B
B : Throttle pressure (to pressure modifier valve)
ON C : Drain
4
The accelerator sensor monitors the amount of the accelerator
C 07430
opening, and by controlling line pressure solenoid 4, pilot
pressure A from the oil pump is regulated, via the pressure
regulator valve, into the optimum hydraulic pressure (throttle
pressure B) for driving.
The line pressure solenoid is controlled by the ON-OFF opera-

Line pressure solenoid control signal
tion activated by signals transmitted from automatic transmis-
One cycle High
(0.02 seconds) sion electronic control unit 1.
Throttle pressure
The ON-OFF signals are transmitted to line pressure solenoid

ON
4 at 50 Hz (0.02 cycles per second). However, the ratio of ON
OFF and OFF signal time coming from the accelerator sensor, in
OFF-time ratio (%) : Small
One cycle conjunction with accelerator opening, is determined by auto-
matic transmission electronic control unit 1.
ON
When line pressure solenoid 4 is switched OFF, needle valve
OFF Low 3 closes the pilot pressure (*1) drain line. When the line
OFF
OFF-time ratio (%) : Large Small Line pressure Large pressure solenoid is switched ON, the drain line opens. Ac-
solenoid
ON (OFF-time ratio) cordingly, the larger the OFF-time ratio in the ON-OFF signals
at 50 Hz, the longer the closing time of the drain line, and the
OFF (Low Accelerator opening High)
OFF higher the throttle pressure B (*2).
07431
On the contrary, the smaller the OFF-time ratio, the shorter the
closing time of the drain line, and throttle pressure B does not
increase.
*1 : The pilot pressure is the pressure for use in the control
mechanism, obtained after the line pressure has been
adjusted by the pilot valve. In line pressure control, pilot
pressure is supplied as a signal pressure to the pressure
modifier valve and as a hydraulic pressure source.
*2 : The throttle pressure is the pressure obtained after pilot
pressure has been adjusted by the activation of the line
pressure solenoid.
23-6
23
Pressure modifier valve
1 1 Automatic transmission electronic control unit
3 Pressure modifier valve
B 4 Spring
5 Pressure regulator valve
2 6 Spring
C 7 Pressure regulator plug
3
8 Pressure regulator sleeve
A
D A: Pilot pressure
B: Throttle pressure
4 C: Drain
E E: Pressure reception area difference
F: Oil pump delivery pressure
5
F
The activation of line pressure solenoid 2 regulates throttle
pressure B. This regulated pressure in turn acts as an input
signal to convert pilot pressure A into a signal pressure that
activates pressure regulator valve 5.
As illustrated, the pilot pressure line and the throttle pressure
line are connected to pressure modifier valve 3.
6 By this design, the pilot pressure acts on chamber D and
pressure reception area difference E, and is regulated to equal-
7
8 ize with the repercussive force of spring 6 and the throttle
pressure.
When the pressure that has been adjusted by the pressure
07432
modifier valve is delivered to pressure modifier plug 7, it is
added to the repercussive force of the spring and adjusts the
line pressure. In this fashion, the line pressure is controlled by
signals from electronic control unit 1.
23-7
Gearshift control
Based on the signals it receives from the accelerator sensor
(corresponding to the accelerator opening), and from the vehi-
cle speed sensor (corresponding to the vehicle speed), the
automatic transmission electronic control unit sends signals to
solenoids A, B, installed on the control valve, to shift gears
automatically into the optimum gear position.
Gearshift control under normal conditions

The accelerator sensor evaluates the engine load, and the
vehicle speed sensor evaluates the vehicle speed. After evalu-
ating this data, the optimum converter gear position is
determined according to the gearshift diagram. At standstill in
the drive range, the gears are shifted into 2nd to reduce creep.
(When starting by depressing the accelerator pedal, down
shifting takes place immediately to shift the gears into 1st.)
Gearshift control under cold conditions

The design of the system is such that 4th gear cannot be
selected if the temperature of the automatic transmission fluid
is below the specified level, or the vehicle speed is below the
specified rate.
Operating conditions for overdrive (D4 position)
Overdrive switch ON
Range selector lever D range
Vehicle speed The specified minimum or more
Oil temperature sensor Approximately 10C {50F} or more
Solenoids A, B
A 1 Automatic transmission electronic control unit
1 2 Shift solenoids A, B
A : Pilot pressure
ON B : Shift valve operation pressure
OFF
C : Drain
B
Solenoids A 2, B 2 are ON-OFF solenoids controlled by sig-

C
2 nals received from automatic transmission electronic control
unit 1.
07433 The ON signal of solenoids A, B generates oil pressure by
closing the drain line, and this oil pressure acts on the gear
shifting valve, switching the valve operations.
Solenoid A controls the operation of shift valve A (shifting
valve)
Solenoid B controls the operation of shift valve B (shifting
valve)
When solenoids A, B are switched OFF, the drain line is
opened and no oil pressure acts on the valve, so it is inactive.
23-8
23
Shift valves A, B
A B
2 Shift solenoid
A : Inactive condition
B : Operating state
C : Pilot pressure
1 Shift valves A, B are gear shifting valves that change the

C C 1
operating pressure applied to the friction parts (clutch, brakes,
etc.) by making the oil pressure generated by solenoids A, B
act on the end surfaces of the valves.
Combining the ON and OFF states of shift valves A, B causes
the operating pressure to shift gears into 1st, 2nd, 3rd and 4th.
2 A solenoid ON signal, causes the oil pressure to act on the
This illustration shows the example of shift valve A end surfaces of the valves to overcome the repercussive force
07434
(spring force) coming from the reverse direction, opening the
valves.
When the solenoid is OFF, no operation occurs as no oil
pressure is applied to the end surfaces of the valves. If the
valves are operating, they are pushed back by the
repercussive force of the spring.
Lock-up control
The lock-up control improves the efficiency of the transmission
by eliminating slippage of the torque converter. Control of the
operation of the lock-up control valve is done by signals trans-
mitted from the automatic transmission electronic control unit
via the lock-up solenoid.
Lock-up control under normal conditions

The accelerator sensor monitors the engine load, and the
vehicle speed sensor monitors the vehicle speed. On the
basis of these monitored data, the lock-up ON-OFF operation
is controlled according to the specified gearshift diagram.
Lock-up control under cold conditions

The lock-up control improves the efficiency of heat-up by not
operating until the temperature of the automatic transmission
fluid reaches 40C {104F}. After the temperature reaches
40C {104F} or more, lock-up operation is possible until the
temperature drops below 20C {68F}, this prevents hunting.
23-9
Lock-up solenoid
A
1 2 Lock-up solenoid
4 3 Needle valve
3
4 Filter
OFF
A : Pilot pressure
B B : To lock-up control valve
ON C : Drain
2
Lock-up solenoid 2 is controlled by the ON-OFF operation
C according to the lock-up range established by automatic trans-
07435
mission electronic control unit 1.
The ON-OFF signals are transmitted to lock-up solenoid 2 at
50 Hz (0.02 cycles per second) and the time ratio of the ON
signal is determined by automatic transmission electronic con-
High
trol unit 1.
Pilot pressure
Lock-up
When lock-up solenoid 2 is switched OFF, needle valve 3
inactive state closes pilot pressure A (*1) drain line. When the lock-up sole-
Lock-up
operating state noid is switched ON, the drain line opens.
Accordingly, the larger the OFF-time ratio in the ON-OFF
signals at 50 Hz, the longer the closing time of the drain line,
Low which maintains the pilot pressure.
On the contrary, the smaller the OFF-time ratio, the longer the
Lock-up solenoid opening time of the drain line, which reduces the pilot pres-
Large Small
OFF-time ratio sure.
07436
(*1) : The pilot pressure is the pressure for use in the control
mechanism, obtained after the line pressure has been
adjusted by the pilot valve.
Lock-up control valve
B C 1 Automatic transmission electronic control unit
A D 2 Lock-up solenoid
3 Lock-up control valve
3
A: Converter pressure
1
B: Converter pressure (Lock-up piston operating side)
C: Converter pressure (Lock-up piston release side)
D: Pilot pressure
E
E: To oil cooler
2
07437
As illustrated, the converter pressure line is connected to lock-up control valve 3. Changeover of the lock-up control valve
is made by lock-up solenoid 2, based on signals received from automatic transmission electronic control unit 1. This
operation changes over the line of hydraulic oil to be supplied to the torque converter to either the lock-up piston release
side or the lock-up piston operating side.
23-10
23
< Lock-up inactive state >
5 6 4 1 Automatic transmission electronic control unit
B 2 Lock-up solenoid
A 3 Lock-up control valve
4 Oil pump
5 Torque converter
C
6 Lock-up clutch
C : Torque converter pressure

3 D
D : Pilot pressure
2
1 E : To oil cooler
E A
07438
When the lock-up is inactive, the OFF-time ratio of lock-up solenoid 2 is long and the closing time of the drain line is long,
which maintains pilot pressure D. Accordingly, the lock-up solenoid outlet pressure, combined with the repercussive force
of the spring, acts on lock-up control valve 3 end surface, pushing it to the left. This operation causes torque converter
pressure C to act on chamber A, and lock-up clutch 6 is not connected as the oil flows from chamber A into chamber B.
< Lock-up operating state >

6 4 1 Automatic transmission electronic control unit
5
B 2 Lock-up solenoid
3 Lock-up control valve
4 Oil pump
C 5 Torque converter
6 Lock-up clutch
7 Lock-up control plug
7 3 D
2 1 A: Drain
C: Torque converter pressure
D: Pilot pressure
E: To oil cooler
A
E
A
07439
When the lock-up is operating, the OFF-time ratio of lock-up solenoid 2 is short and the opening time of the drain line is
long, which reduces pilot pressure D. Accordingly, torque converter pressure C and the pilot pressure act on lock-up
control plug 7, pushing lock-up control valve 3 to the right. This operation causes the torque converter pressure to act on
chamber B, connecting lock-up clutch 6 directly.
23-11
Overrunning clutch control
The automatic transmission power train uses a forward one-
way clutch to buffer shocks from gear shifting which are likely
to occur when shifting down.
When the vehicle is coasting, and when the engine brake is
applied from D to 2nd, and D to L during range selection, the
forward one-way clutch freewheels so that no opposite driving
force is transmitted to the engine. To deal with this situation,
the operation of the overrunning clutch prevents freewheeling
of the forward one-way clutch, so that the engine brake takes
effect.
Overrunning clutch solenoid

2 Overrunning clutch solenoid
A 3 Shuttle shift valve S
1 4 Overrunning clutch control valve
A : Pilot pressure
OFF B : Overrunning clutch control valve operating pressure
ON C : Drain
B
Overrunning clutch solenoid 2 is controlled by the ON-OFF
C operation activated by signals transmitted from automatic
2 transmission electronic control unit 1. The ON signal is deter-
mined by the automatic transmission electronic control unit,
07440
based on data received from various sensors.
When the overrunning clutch solenoid is switched ON, the
needle valve closes the drain line. When the overrunning
A clutch solenoid is switched OFF, the drain line opens. Accord-
1
ingly, when the overrunning clutch solenoid is switched ON,
the hydraulic pressure generated by the operation of the
overrunning clutch solenoid acts on overrunning clutch control
valve 4 end surface, via shuttle shift valve S 3.
Shuttle shift valve S

Shuttle shift valve S 3 is a fixed valve that is part of the
3 2 hydraulic line and makes the pilot pressure, generated when
overrunning clutch solenoid 2 is switched ON, act on
overrunning clutch control valve 4.
4
Operating to make the line pressure ON/
OFF which acts on the overrunning clutch
reducing valve
07441
23-12
23
Overrunning clutch control
1
2 1 Automatic transmission electronic control unit
A
3 Shuttle shift valve S
A B 4 Overrunning clutch
7 5 Overrunning clutch reducing valve
E 6 Overrunning clutch control valve
7 Plug
3 A: Pilot pressure
C 4 B: Line pressure (D, 2, L range)
C: Line pressure (2, L range)
D: L range 1st reducing valve pressure
E: Drain
D
The line pressure is controlled by the ON-OFF operation of the
overrunning clutch control. The line pressure acts on
B overrunning clutch reducing valve 5 using the operation of
overrunning clutch solenoid 2.
6 07442
< Overrunning clutch solenoid ON >

Overrunning clutch control valve 6 comes into operation when the hydraulic pressure generated by the operation of
overrunning clutch solenoid 2 acts on the overrunning clutch control valve end surface via shuttle shift valve S 3. By this
operation, the line pressure does not act on overrunning clutch reducing valve 5.
< Overrunning clutch solenoid OFF >

Overrunning clutch control valve 6 becomes inactive due to the repercussive force of the spring. By this operation, the line
pressure reduced by overrunning clutch reducing valve 5 acts on overrunning clutch 4. In the L range, the overrunning
clutch control valve is fixed in its inactive state by 1st reducing valve pressure D.
Shift pattern selection control

Two kinds of driving mode can be selected: the economy
mode suitable for driving with a light load; or the power mode
suitable for driving with the maximum load, for climbing, and
for accelerating.
Accelerator opening
1 2 2 3 3 4
When the power mode is PWR, the power mode is fixed.
1 2' 2' 3' 3' 4' When the power mode is ECO, either the economy mode or
the power mode is automatically selected depending on the
driving conditions of the vehicle.
In the power mode, the vehicle speed at the time of gear
Power pattern shifting is set to a higher side than in the economy mode.
Economy pattern
The diagram on the left shows a model of gear shifting charac-
Vehicle speed teristics.
07443
23-13
Shift pattern shifting conditions
< Economy mode to power mode >
Range selector lever D range
Accelerator depression angle Higher than the standard value (Note)
Power mode switch ECO
Note : Sixteen ranges are established, as shown in the diagram on the
left, depending on the accelerator opening and the vehicle speed.
Each range determines the power mode shift and the accelerator
14024
opening rate.
Shift from the economy mode to the power mode occurs when the
Likely to shift to power mode accelerator opening exceeds a specified value.
Large The lower the vehicle speed and the larger the accelerator opening, the
more likely the shift to the power mode.
Likely to shift to
Accelerator
power mode
< Power mode to economy mode >

opening
Power mode switch ECO

Accelerator opening Low
Small Operating time lag Maximum of three seconds depending
Low Vehicle speed High 07445 on the vehicle speed
< Power mode fixed >

Power mode switch PWR
Warning lamp indication with key turned to ON
If an abnormality occurs sometime during the day-to-day operation of
the vehicle, the warning lamp within the meter cluster alerts the driver
by flashing for eight seconds at 2 Hz, as shown by B in the diagram,
when the key is turned to ON.
If no abnormality is found, the lamp lights for two seconds, and self-
checking is carried out to see if the bulb has burnt-out, as shown by A
in the diagram.
NOTE
14025
Abnormalities are notified only when they were detected during
the immediate preceding operation (duration of key ON to OFF
time).
Warning lamp lighting when an abnormality occurs while the
Lit
Normal conditions vehicle is being driven
2
seconds The warning lamp does not light when a minor abnormality occurs that
Light goes out
would have a slight affect on the driving performance.
Memorized data of A
Lit trouble that occurred When any of the troubles listed below occur that would greatly impair
the driving performance, the warning lamp lights to alert the driver to
2
seconds Light the trouble.
goes out
Both speed sensors 1, 2 faulty
2 Hz B
8 seconds Shift solenoid A faulty
07963 Shift solenoid B faulty
Line pressure solenoid faulty
Lock-up solenoid faulty
Overrunning clutch solenoid faulty
Accelerator sensor faulty
Inhibiter switch faulty
23-14
23
NOTE
Warning of an abnormality occurring is limited to such troubles
that would greatly impair the driving performance.
Indicator lamp lighting at self-diagnosis

To facilitate an easy search for causes of troubles that have a low
possibility of recurrence, the automatic transmission electronic control
unit memorizes the data on trouble while the vehicle is being driven.
By entering the signal for the start of self-diagnosis, the memorized
data are recalled and the automatic transmission warning lamp
flashes.
NOTE
The automatic transmission electronic control unit stores all the
data on the troubles that have occurred since the immediate
previous self-diagnosis.
Fail-safe function
The fail-safe function controls the operation of the vehicle in as safe a way as possible so that the operating performance
is not hindered when an abnormality occurs in the vehicle speed sensor, the accelerator sensor, the inhibiter switch or in
the control mechanism solenoids.
The vehicle speed sensor has two ways of sending signals: using the sensor installed on the transmission (output shaft
revolution sensor); and using the sensor installed halfway along the speedometer cable. Therefore, it is possible to
continue operating the vehicle even if one of them fails.
Accelerator sensor
If the accelerator sensor fails, the idling switch detects the accelerator opening and controls the line pressure in
accordance with the table below so that it is possible to continue operating the vehicle.
Idling switch Line pressure Vehicle speed at time of shift
OFF Pressure at maximum Throttle opening at 8/8 equivalent
ON Pressure at minimum Throttle opening at 0/8 equivalent
Inhibiter switch
If the inhibiter switch fails and multiple signals are input by the automatic transmission electronic control unit while the
vehicle is either travelling or at standstill, the selection position is set in the order: D > N > R > 2 > L, so it is possible to
continue operating the vehicle. However, depending on the range selection position, the hydraulic circuit line inside the
control valve is changed over by the manual valve, and the actual vehicle travelling state is as shown in the table below.
Range selector
lever position
P R N D 2 L
Item
Input signal from P and other R and other N and other D and other 2 and other 2 and L L and other L and 2
inhibiter switch selection selection selection selection selection range selection range
range range range range range signals range signals
signals signals signals signals signals signals
(except L (except 2
range range
signal) signal)
Vehicle travelling state P R N D1D2D3 212223 2122 L1L2L3 L1L2
23-15
Shift solenoids A, B
If one of the solenoids fails while the range is in D, 2 or L, the other solenoid is switched to OFF (in the gear position as
shown in the table) and it is possible to continue operating the vehicle. If both solenoids fail, the mechanically controlled
hydraulic circuit takes over.
Shift Normal Solenoid A faulty Solenoid B faulty Solenoids A, B faulty

position A B Gear A B Gear A B Gear A B Gear
D range 1st 3rd 3rd 3rd
2nd 3rd 3rd 3rd
3rd 3rd 3rd 3rd
4th 3rd 3rd 3rd
2 range 1st 3rd 3rd 3rd
2nd 3rd 3rd 3rd
3rd 3rd 3rd 3rd
4th 3rd 3rd 3rd
L range 1st 3rd 3rd 3rd
2nd 3rd 3rd 3rd
3rd 3rd 3rd 3rd
4th 3rd 3rd 3rd
: Continuity : No continuity : Faulty

If the line pressure solenoid fails, it is switched to OFF and the line pressure is maximized so it is possible to continue
operating the vehicle.
Lock-up solenoid
If the lock-up solenoid fails, it is switched to OFF and the lock-up is released.
If the overrunning clutch solenoid fails, it is switched to OFF and the overrunning clutch is engaged so that the engine
brake takes effect all the time the vehicle speed is reduced.
23-16
23
Electronic Control Mechanism
1 Automatic transmission electronic
control unit
3 Accelerator switch
4 Vehicle speed sensor 2
1 2 3
14026

The automatic transmission electronic control unit is installed at the
master vac area by the drivers seat and processes data to judge the
vehicle travelling state based on the signals received from the sensors,
and transmits its own signals to the solenoids to perform gear shifting
control, lock-up control, and the automatic transmission control needed
to keep the vehicle operating.
The automatic transmission electronic control unit also carries out self-
diagnosis of the major sensor solenoids.
Accelerator sensor
+0.2
4.0 0 The accelerator sensor is installed on the accelerator lever and converts
the accelerator opening data into voltage signals, then transmits them to
Output voltage (V)
the automatic transmission electronic control unit.

The electric signals of the accelerator sensor have the output character-
istics as shown in the diagram on the left and, using these output
0 features the accelerator sensor monitors the accelerator pedal angle and
1.0 0.1
the accelerator opening rate.
0 S F
(Idling position : 0/8) (Full position : 8/8)
Accelerator opening
07449
Accelerator switch
The accelerator switch is installed on the accelerator lever and detects
when the accelerator is fully closed, then transmits this signal to the
NOTE
The accelerator switch is also used for exhaust brake control.

Vehicle speed sensor 2 is installed halfway along the speedometer cable
(inside the cab) and converts the vehicle speed into pulse signals, then
transmits them to the automatic transmission electronic control unit.
23-17
A B
7
8
4
3
14027
1 Control valve 5 Shift solenoid B A : Lower body side

2 Vehicle speed sensor 1 6 Line pressure solenoid B : Upper body side
3 Oil temperature sensor 7 Lock-up solenoid
4 Shift solenoid A 8 Overrunning clutch solenoid

Vehicle speed sensor 1 is installed on the parking gear located at the
output shaft side, inside the transmission case, and converts the vehicle
speed into pulse signals, then transmits them to the automatic transmis-
sion electronic control unit.

The oil temperature sensor is installed in the control valve inside the
transmission case and converts data on the change in oil temperature
Resistance ()
into continuous electric signals, then transmits them to the automatic

transmission electronic control unit.
The electric signals of the oil temperature sensor have the output charac-
teristics as shown in the diagram on the left, and after receiving these
output signals, the automatic transmission electronic control unit exerts
Temperature control to prevent shifting up to D4 (overdrive), to prevent lock-up, and to
07451
make partial modification to the line pressure control, etc.
23-18
23
Shift solenoids A, B
Shift solenoids A, B are installed in the control valve. They control
shifting using the ON-OFF operation after receiving signals from the
Combining the ON and OFF states of the two solenoids, controls gear
shift positioning as shown in the table below.
Shift solenoid A ON OFF OFF ON

Shift solenoid B ON ON OFF OFF
Gear position 1st 2nd 3rd 4th
In the case of a duty ratio at 50% Line pressure solenoid and lock-up solenoid
0.01 second The line pressure and lock-up solenoids are installed in the control valve.
ON They maintain the specified pressure by opening or closing the drain line
by repeating the ON and OFF operation at 50 Hz (0.02 cycles per
second) corresponding to the signals received from the automatic trans-
mission electronic control unit.
OFF A duty cycle type solenoid is used which makes it possible to alter and
0.02 second control the ON-time and OFF-time ratios within one cycle from 0% to
50 cycles
per second 100%.
07452
At a duty ratio of 50%, the ON-time is 0.01 seconds and the OFF-time is
0.01 second within the cycle of 0.02 seconds.

The overrunning clutch solenoid is installed in the control valve and
receives signals from the automatic transmission electronic control unit
to carry out the ON and OFF operations by which the overrunning clutch
is either engaged or disengaged.

Signals from the engine revolution sensor for control of the engine
operation are first sent to the pre-stroke control unit, then they are
transmitted to the automatic transmission electronic control unit.
Engine revolution
sensor
13762
23-19
Dropping resistor
The dropping resistor is installed at the rear cab mount. Electric current
to the line pressure solenoid is re-routed through the dropping resistor
after activating the needle valve.
Dropping resistor
14029
At the time of needle valve

The line pressure solenoid draws a great amount of electric current when
activation the needle valve is activated and, for that reason, the current from the
automatic transmission electronic control unit is routed to the line pres-
sure solenoid, bypassing the dropping resistor.
After needle
valve However, once the needle valve of the line pressure solenoid has started
Current
(mA) activation operating, the ON-OFF operation can be maintained with a relatively
small amount of current and the current is routed through the dropping
resistor to the line pressure solenoid.
Operating time of line pressure 07455
solenoid (m sec.)
Overdrive switch
Overdrive switch
The overdrive switch, installed on the range selector lever, is operated by
the driver to shift from 3rd to 4th gear.
ON : Shifts up into 4th gear, increasing fuel consumption
OFF : Does not shift up into 4th, making the engine brake effective, and
improving climbing performance.
14030
Power mode switch

The power mode switch, installed on the instrument panel, is operated by
the driver to change the vehicle speed setting when shifting gears.
PWR (Power mode) : Fixes the power mode which increases the
vehicle speed when shifting gears.
ECO (Economy mode) : Automatically selects either the power
mode which increases the vehicle speed when
shifting gears, or the economy mode which
decreases vehicle speed when shifting gears
14024
depending on the travelling conditions of the
vehicle.
23-20
23
Hydraulic Control Mechanism
21 G
22
20
23 N
M P
C
16
D
4 13
11
5
E
7 17
8
3 19
24
2 10
1
15
F 14 18
B 6
12
K
H J L
9
07458
1 Pressure regulator valve 21 Lock-up control valve

2 Pressure regulator plug 22 Lock-up control plug
3 Pressure regulator sleeve 23 Lock-up control sleeve
4 Pressure modifier valve 24 Shuttle shift valve D
5 Modifier accumulator valve
6 Pilot valve A: Oil pump
7 Accumulator control valve B: Feed back accumulator piston
8 Accumulator control sleeve C: Oil cooler
9 Manual valve D: Front part lubrication
10 Shift valve A E: Rear part lubrication
11 Shift valve B F: Filter
12 Shuttle shift valve S G: Lock-up solenoid
13 Overrunning clutch control valve H: Line pressure solenoid
14 4 2 relay valve J: Shift solenoid A
15 4 2 sequence valve K: Shift solenoid B
16 Servo charger valve L: Overrunning clutch solenoid
17 3 2 timing valve M: 4th gear accumulator
18 1st reducing valve N: 3rd gear accumulator
19 Overrunning clutch reducing valve P: N D accumulator
20 Torque converter relief valve
23-21
Function of various valves
Name Function
1 Pressure regulator valve Adjusts the hydraulic pressure that is discharged from oil pump A to the optimum level
(line pressure) suitable for the travelling state of the vehicle
2 Pressure regulator plug
3 Pressure regulator sleeve
4 Pressure modifier valve Adjusts the signal pressure (pressure modifier pressure), using the auxiliary valve signal of
pressure regulator valve 1, to make the line pressure the optimum level suitable for the
driving conditions
5 Modifier accumulator valve Prevents line pressure vibration by evening out the pressure modifier pressure that has been
adjusted by pressure modifier valve 4
6 Pilot valve Generates pressure (pilot pressure) at a consistent level, by adjusting the line pressure,
which is needed for the operation of the line pressure, lock-up, overrunning clutch, and gear
shifting controls
7 Accumulator control valve Adjusts the accumulator back pressure to a suitable level to match the travelling state of
the vehicle
8 Accumulator control sleeve
9 Manual valve Delivers the line pressure to the various circuits corresponding to the selected position
Range/Line 1 2 3 4
Line pressure
P
PRND 2 1 4 2
R
N
D
1 3
2
07459
L
When the line pressure reaches a position where no delivery of the pressure is made, the pressure is
drained
10 Shift valve A Depending on the driving conditions of the vehicle such as speed and accelerator opening,
this shift valve controls the output pressure of shift solenoid A and the three hydraulic lines
for gear shifting simultaneously, and in combination with the operation of shift valve B,
causes automatic shifting into 1st
2nd3rd 4th gears
11 Shift valve B Depending on the driving conditions of the vehicle such as speed and accelerator opening,
this valve controls the output pressure of shift solenoid B and the three hydraulic lines for
gear shifting simultaneously, and in combination with the operation of shift valve A, causes
automatic shifting into 1st
2nd3rd 4th gears
12 Shuttle shift valve S This is a fixed valve that is part of the hydraulic line between overrunning clutch solenoid L
and overrunning clutch control valve 13
13 Overrunning clutch control Prevents the concurrent operation of the brake band in the 4th gear position and the
valve overrunning clutch. This valve changes over the lines for the 4th gear operating pressure and
the overrunning clutch operating pressure. (If the overrunning clutch were to operate while in
the 4th gear position in the D range, interlocking would result)
14 4 2 relay valve At shift-down from 4th gear to 2nd gear, while the 4th gear operation is being memorized,
the operation of 4 2 sequence valve 15, shift valve A 10 and shift valve B 11 prevent
shift-down from 4th gear to 2nd gear through 3rd gear
15 4 2 sequence valve This prevents draining of the band servo pressure that acts when shifting into 4th gear.
It continues operating until the clutch high-operating pressure and servo release pressure
(in the same hydraulic line) drain out at the time of shifting down from 4th gear to 2nd gear
16 Servo charger valve An accumulator and a one-way orifice are fitted to the hydraulic line of 2nd gear band servo
operating pressure to buffer the shifting shock caused at shift-up from 1st gear to 2nd gear.
Accordingly, to ensure a sufficient flow of oil at the time of shift-down from 4th gear to 2nd
gear, and 3rd gear to 2nd gear, servo charger valve 16 operates at 3rd gear and higher,
so that the 2nd gear band servo operating pressure is supplied without going through the
one-way orifice
23-22
23
Name Function
17 3 2 Timing valve This is a fixed valve that is part of the hydraulic line between shift valve B 11 and the band
servo release side
18 1st reducing valve To buffer the shock of engine brake caused at the time of shift-down from 2nd gear to 1st
gear in the L range, it reduces the operating pressure for the low and reverse brake
19 Overrunning clutch reducing To buffer the shock of the engine brake, this valve reduces the operating pressure to the
valve overrunning clutch. The hydraulic pressure that has been adjusted by the accumulator
control valve is applied to the valve, and regulated to equalize the overrunning clutch
operating pressure corresponding to the engine brake capacity
20 Torque converter relief valve This prevents the torque converter pressure from becoming excessive
21 Lock-up control valve Makes the lock-up operate or not operate.
By making the lock-up release operation transitional, the lock-up can be made smoothly
22 Lock-up control plug
23 Lock-up control sleeve
24 Shuttle shift valve D This changes over the hydraulic lines so that the output pressure of the lock-up solenoid acts
on the lock-up valve in 2nd, 3rd or 4th gear in the D range. (The lock-up operation is
prevented in 1st gear and in the P, R and N ranges)
* When no output pressure is generated from lock-up solenoid G by the signals received
from the automatic transmission electronic control unit, the lock-up control does not
operate even in 2nd, 3rd, or 4th gear in the D range
Gearshift function
8 9 5 1 2 10 11 3 4 8
12
21
13 14 15 16 17 18 19 6 20 7
07460
1 Reverse clutch 8 Low and reverse brake 15 Front pinion gear

2 High clutch 9 Oil pump 16 Front planetary gear carrier
3 Forward clutch 10 Front internal gear 17 Rear sun gear
4 Overrunning clutch 11 Rear internal gear 18 Rear pinion gear
5 Brake band 12 Parking pawl 19 Rear planetary gear carrier
6 Forward one-way clutch 13 Input shaft 20 Output shaft
7 Low one-way clutch 14 Front sun gear 21 Parking gear
23-23
Clutch and brake function
Name Function
1 Reverse clutch (Reverse/C) Connection of input shaft 13 and front sun gear 14
2 High clutch (HI/C) Connection of input shaft 13 and front planetary gear carrier 16
3 Forward clutch (FWD/C) Connection of front planetary gear carrier 16 and forward one-way clutch 6
4 Overrunning clutch (OVR/C) Connection of front planetary gear carrier 16 and rear internal gear 11
5 Brake band (B/B) Fixing of front sun gear 14
6 Forward one-way clutch Frees the forward rotation (same rotational direction as the torque converter) of rear internal
(FWD, O.W.C) gear 11, and fixes the reverse rotation compared to front planetary gear carrier 16 and low
one-way clutch 7 outer race
7 Low one-way clutch Fixes the reverse rotation of front planetary gear carrier 16, and frees the forward rotation
(Low, O.W.C) (same rotational direction as the torque converter)
8 Low and reverse brake Fixes front planetary gear carrier 16
(L & R/B)
Operating periods of clutch and brake
Band servo
Shift FWD, LOW,
Reverse/C HI/C FWD/C OVR/C 2nd gear 3rd gear 4th gear O.W.C. O.W.C. L&R/B Remarks
position
engaged released engaged
P Parking
R Reverse
N Neutral
D 1st Automatic
2nd shifting
1234
3rd *1
4th *2
2 1st Automatic
2nd shifting
1234
3rd *1
4th *2
L 1st 1st fixed
2nd 1234
3rd *1
4th *2
*1 : Hydraulic pressure acts on both sides of the band servo piston of the 2nd gear engaged position and the 3rd gear
released position. But as the pressure reception area at the release side is largest, the brake band does not bind up.
*2 : In the above *1 state, hydraulic pressure acts on the 4th gear engaged position and the brake band is engaged.
: Always engaged
: Engaged at vehicle speeds of 10 km/h {6.21 mph} or more
: Operates during acceleration
: Engaged but does not transmit power
23-24
23
Reverse Clutch (Multiplate type)
1
2
3
4
6 2
14
7 12
8 15
9 19
16
10
14 11 6 17
13 12
A
18
07461
1 Dish plate 8 Snap ring 15 Connecting shell

2 Driven plate 9 Spring retainer 16 High clutch drum
3 Spacer 10 Return spring 17 Front sun gear
4 Retaining plate 11 D-ring 18 Input shaft
5 Snap ring 12 Reverse clutch piston 19 Check ball
6 Driving plate 13 Oil seal
7 Spacer 14 Reverse clutch drum A : Clutch operating pressure
< When operating >

The hydraulic pressure from the control valve, that has been changed over by the manual valve, is delivered only during
reversing and pushes reverse clutch piston 12. This operation brings driving plate 6 and driven plate 2 into contact with
each other, so that the power transmitted from high clutch drum 16 is transmitted to front sun gear 17 via connecting shell
15.
< When not operating >

As no pressure is delivered except during reversing, reverse clutch piston 12 is pushed back by the repercussive force of
return spring 10. This operation separates driving plate 6 and driven plate 2 and no power transmission takes place.
Check ball 19, which is built into the reverse clutch piston, releases oil when reverse clutch drum 14 is freewheeling so
that the residual oil within the drum does not build up pressure and cause partial clutch operation. (The check ball is also
fitted to other multiplate type clutches.)
23-25
High Clutch (Multiplate type)
7
5 8
6 9
4
3
2
10 6
1 10
11
13
12 12
14
A
15
07462
1 High clutch drum 7 Spacer 13 High clutch hub

2 D-ring 8 Retaining plate 14 Front planetary gear carrier
3 D-ring 9 Snap ring 15 Input shaft
4 Spring retainer 10 Driving plate
5 Snap ring 11 Return spring A : Clutch operating pressure
6 Driven plate 12 High clutch piston
In the 3rd or 4th (overdrive) gear positions, the control valve (hydraulic control mechanism) makes hydraulic pressure act
on high clutch piston 12, so that the clutch plates (driving plate 10 and driven plate 6) come into contact with each other
and the power transmitted from input shaft 15 is transmitted to front planetary gear carrier 14 via high clutch hub 13.
23-26
23
Brake Band
1 Anchor end bolt
2 Return spring
1 3 Return spring
4 Overdrive servo piston
5 Servo piston retainer
6 Servo piston
9 7 Piston stem
8 Band strut
8 9 Brake band
2nd gear shift operating chamber

7
3rd gear shift operating chamber
4th gear shift operating chamber
2
4 3
07463
One end of brake band 9 is fixed to the transmission case by anchor end bolt 1.
The servo piston assembly has three chambers each of which corresponds to a certain gear position, to which hydraulic
pressure is supplied. Operating pressure is transmitted from the control valve to act on the piston for each gear shift
position, and piston stem 7 is pushed up to make the brake band fix the reverse clutch drum. This operation fixes the front
sun gear.
1st gear : As there is no delivery of hydraulic pressure to the servo piston assembly, the brake band does not act due to
the repercussive force of the return spring.
2nd gear : Hydraulic pressure is delivered to the 2nd gear shift operating chamber, pushing up the piston stem to make
the brake band fix the reverse clutch drum.
3rd gear : Hydraulic pressure is delivered to the 2nd gear shift operating chamber and the 3rd gear shift operating
chamber. The force acting on the pressure reception area difference of the piston with the repercussive force of
return spring 2, pushes the piston stem down to release the brake band.
4th gear : The pressure acting on the 2nd and 3rd gear shift operating chambers releases the piston. But pressure
delivered to the 4th gear shift operating chamber acts on drive servo piston 4 to push up the piston stem, and
this operation causes the brake band to fix the reverse clutch drum.
2nd gear shift 3rd gear shift 4th gear shift

operating chamber operating chamber operating chamber
1st gear
2nd gear
3rd gear
4th gear
: Pressure acting
23-27
Forward Clutch (Multiplate type) and Overrunning Clutch (Multiplate type)
1 6
7
2 8
9 10
3
4
5
11
A 13
14
17
12
19 16
18 15 07464
11 3 4 9 8 12
15
C
D
24
20 21 22 23
07465
23-28
23
1 Snap ring 17 Oil seal
2 Retaining plate 18 Spring retainer
3 Driving plate 19 Snap ring
4 Driven plate 20 Front planetary gear carrier
5 Dish plate 21 Rear internal gear and forward one-way clutch
6 Snap ring inner race
7 Retaining plate 22 Forward one-way clutch
8 Driving plate 23 Forward clutch hub and forward one-way clutch
9 Driven plate outer race
10 Dish plate 24 Overrunning clutch hub
11 Forward clutch drum
12 Forward clutch piston A: Forward clutch related parts
13 D-ring B: Overrunning clutch related parts
14 Oil seal C: Forward clutch operating pressure
15 Overrunning clutch piston D: Overrunning clutch operating pressure
16 D-ring
Forward clutch
In the 1st, 2nd, 3rd, or 4th (overdrive) gear positions of any of the forward ranges (D, 2, L), the control valve (hydraulic
control mechanism) makes hydraulic pressure act on forward clutch piston 12, so that the clutch plates (driving plate 3
and driven plate 4) come into contact with each other and connect forward clutch drum 11, front planetary gear carrier
20, and the forward one-way clutch outer race.
Overrunning clutch
In the case of the D range, overdrive switch OFF and 2, and the L ranges, the control valve (hydraulic control
mechanism) makes hydraulic pressure act on overrunning clutch piston 15 to operate the engine brake, so that the
clutch plates (driving plate 8 and driven plate 9) come into contact with each other and connect forward clutch drum 11,
front planetary gear carrier 20, and the rear internal gear without connecting with forward one-way clutch 22.
23-29
Low and Reverse Brake (Multiplate type)
11
10 12
9
8
7
1 6
2
4 5
13
15
14
16 07466
16
17
4 18
10
19
07467
23-30
23
1 Snap ring 11 D-ring
2 Retaining plate 12 Oil seal
3 Spacer 13 Return spring
4 Driven plate 14 Bolt
5 Seal ring 15 Dish plate
6 Needle bearing 16 Driving plate
7 Low one-way clutch inner race 17 Forward clutch drum
8 O-ring 18 Transmission case
9 Spring retainer 19 Front planetary gear carrier
10 Low and reverse brake piston
In the 1st gear position in the L range and in the R range, the control valve (hydraulic control mechanism) makes hydraulic
pressure act on low and reverse brake piston 10, so that the clutch plates (driving plate 16 and driven plate 4) come into
contact with each other and fix transmission case 18 and forward clutch drum 17, fixing front planetary gear carrier 19.
23-31
Planetary Gear
1 Pinion gear
2 Internal gear
5 7 3 Sun gear
2 6 4 Front sun gear
4 5 Front planetary carrier
3 6 Rear sun gear
7 Rear internal gear
8 Front internal gear and
rear planetary carrier
9 Planetary carrier
1
9
8
07468 07469
Two sets of Simpson type planetary gears are used so that five gear ratios, four forward speeds and one reverse speed
are possible.
The planetary gear is constructed so that sun gear 3 is in the center and pinion gears 1 revolve within internal gear 2,
enclosing them. The pinion gears are supported by planetary gear carrier 9 so that all the pinion gears make identical
rotations, in the same direction, simultaneously. Thus, the planetary gear consists of four elements: the sun gear, the
pinion gear, the internal gear, and the planetary gear carrier. If the necessary conditions are met by any two of the
following: the sun gear, the internal gear or the planetary gear carrier; gear ratio is changed. The clutch and the brake
give conditions to the planetary gear in conjunction with gear shifting.
Forward one-way clutch

1 Rear internal gear and forward one-way clutch inner
2
race
1 3 2 Forward one-way clutch
3 Forward clutch hub and forward one-way clutch outer
race
07470
The forward one-way clutch, being fixed on the accelerating side of the 1st, 2nd, and 3rd gears, contributes to the power
transmission. In the 4th gear, however, although the forward one-way clutch is making the forward clutch operate, it does
not transmit power to forward one-way clutch 2 because the forward clutch remains free. (Inner race revolution > outer
race revolution)
Accordingly, at shift-down from 4th gear to 3rd gear, and 4th gear to 2nd gear positions, gear shifting is possible by
controlling only one set of friction elements so that the shift timing is maintained correctly with the shifting shock buffered.
Friction elements Forward clutch High clutch Brake band : Friction element set is connected
: Friction element set is connected
but not transmitting power
N
D1
D2
D3
D4 (Overdrive)
23-32
23
Low one-way clutch
1 Forward clutch drum and low one-way clutch outer
3
1 race
2 2 Low one-way clutch
3 Low one-way clutch inner race
The low one-way clutch fixes the rear internal gear via the
forward clutch and the forward one-way clutch on the acceler-
ating side in the 1st gear position of the D, 2 ranges. In the
2nd, 3rd or 4th gears it freewheels.
07471
Torque transmitting route

N range, P range
1 4
: Input : Fixed (in P range)
07472
1 Input shaft
2 Parking pawl
3 Parking gear
4 Output shaft
< N range >

None of the control systems work. The power of input shaft 1 is not transmitted to output shaft 4 because the clutch is not
engaged.
< P range >

The control systems are in the same state as in the N range. Parking pawl 2, which is linked to the range selector lever, is
engaged with parking gear 3 and output shaft 4 is fixed mechanically. (The area encircled in a dotted line, as illustrated.)
23-33
R range
1 2
3
B
Operating force AB
(Does not contribute to
transmission)
9
10
11 8 6 5
: Input : Fixed : Output : Pinion
07473
1 Front planetary gear 7 Rear planetary carrier

2 Rear planetary gear 8 Front sun gear
3 Forward one-way clutch 9 Front internal gear
4 Low and reverse brake 10 Reverse clutch
5 Output shaft 11 Input shaft
6 Front pinion gear
Reverse clutch 10 is engaged and power is transmitted from input shaft 11 to front sun gear 8 via the reverse clutch drum.
Also low and reverse brake 4 engages to fix the front planetary carrier. By this operation, the clockwise rotation of front
sun gear 8 makes front internal gear 9 (connected to output shaft 5) rotate counterclockwise at a reduced rate.
(Direction of rotation is as seen from the torque converter side.)
Conditions
Reverse clutch 10 engaged
Low and reverse brake 4 engaged
Power transmitting route

Input shaft 11 Reverse clutch 10 Front sun gear 8 Front pinion gear 6
Front internal gear 9 Output shaft 5
23-34
23
D and 2 Ranges (1st gear)
1 2
Only counterclockwise rotation is fixed
3 4
B B
C
A
Transmission of Transmission of
power A B power B C
6
7
5
3
4
12 9 11 10 8
07474
1 Front planetary gear 7 Overrunning clutch

2 Rear planetary gear 8 Output shaft
3 Forward one-way clutch 9 Rear pinion gear
4 Low one-way clutch 10 Rear planetary carrier
5 Rear internal gear 11 Rear sun gear
6 Forward clutch 12 Input shaft
Forward clutch 6 engages, and forward one-way clutch 3 and low one-way clutch 4 operate to prevent rear internal gear 5
from rotating counterclockwise.
Power is transmitted from input shaft 12 to rear sun gear 11 causing it to rotate clockwise. When this happens, rear pinion
gear 9 rotates counterclockwise, and tries to force rear internal gear 5 to rotate in the same direction. However,
counterclockwise rotation of the rear internal gear is prevented, therefore rear planetary carrier 10 (engaged with output
shaft 8) rotates at a reduced speed clockwise. When the vehicle is coasting, the rear internal gear rotates clockwise so the
forward one-way clutch freewheels. When this happens, the engine brake is not effective because low one-way clutch 4 is
freewheeling, and opposite driving power is not transmitted to the engine even if overrunning clutch 7 is engaged.
Conditions
Forward clutch 6 engaged
Forward one-way clutch 3 operating Overrunning clutch 7 engaged
Low one-way clutch 4 operating D : Vehicle speeds of 10 km/h {6.21 mph} or more
2 : Accelerator opening for the entire range

Input shaft 12 Rear sun gear 11 Rear pinion gear 9 Rear planetary carrier 10 Output shaft 8
23-35
D, 2 and L Ranges (2nd gear)
1 2
3 4
B
Transmission
of power B A
6 8
7
15 5
14 3
13
9
16 12 11 10
: Input : Fixed : Output : Component force : Pinion
(speed increase)
07475
1 Front planetary gear 12 Front sun gear

2 Rear planetary gear 13 Front pinion gear
3 Forward one-way clutch 14 Front planetary carrier
4 Low one-way clutch 15 Brake band
5 Front internal gear 16 Input shaft
6 Forward clutch
8 Overrunning clutch
9 Rear pinion gear
10 Output shaft
11 Rear sun gear
23-36
23
Forward clutch 6 engages, and front planetary carrier 14 and rear internal gear 7 are connected by forward one-way
clutch 3, causing brake band 15 to fix front sun gear 12. Power is transmitted from input shaft 16 to rear sun gear 11,
making the rear planetary carrier rotate clockwise together with front internal gear 5, which rotates in the same direction
and at the same speed because it is connected to the rear planetary carrier. When this happens, with the front sun gear
fixed by the operation of the brake band, the front planetary carrier, the forward clutch, and the forward one-way clutch
causes the rear internal gear to rotate clockwise. Therefore, the speed becomes faster, in proportion to the rate of rotation
of the rear internal gear, than in 1st gear position. When the vehicle is coasting, the rear internal gear rotates clockwise
and the forward one-way clutch freewheels so opposite power is not transmitted to the engine. (No engine braking takes
place.) For this reason, overrunning clutch 8 (the area enclosed in a dotted line, as illustrated) is engaged to prevent the
forward one-way clutch from freewheeling so that the opposite driving power is transmitted to the engine, making engine
braking effective.
Conditions
Forward one-way clutch 3 operating
Brake band 16 engaged
Overrunning clutch 8 engaged
D : Vehicle speeds of 10 km/h {6.21 mph} or more
L : Accelerator opening for the entire range

Rear internal gear 7 Forward one-way clutch 3

Input shaft 16 Rear sun gear 11 Rear pinion gear 9 Rear planetary carrier
F o r w a r d

clutch 6
Output
shaft 10
Front internal gear 5 Front pinion gear 13 Front planetary carrier 14
23-37
D, 2 and L Ranges (3rd gear)
1 2
3 4
B
Transmission
of power B A
6 7
5
11
3
12 10 9
07476
1 Front planetary gear 10 Front planetary carrier

2 Rear planetary gear 11 High clutch
3 Forward one-way clutch 12 Input shaft
4 Low one-way clutch
6 Forward clutch
7 Overrunning clutch
8 Rear planetary carrier
9 Output shaft
23-38
23
High clutch 11 engages to connect input shaft 12 and front planetary carrier 10. Also, forward clutch 6 engages and
forward one-way clutch 3 operates to connect the front planetary carrier and rear internal gear 5. Power is transmitted
from the input shaft to the rear sun gear, as well as to the rear internal gear by the operation of the high clutch. This
transmission of power causes the rear sun gear and the rear internal gear to rotate clockwise simultaneously. This makes
rear planetary carrier 8 (connected to output shaft 9) rotate together with the rear sun gear and the rear internal gear as
one set. When the vehicle is coasting, the rear internal gear is rotating clockwise so that the forward one-way clutch is
allowed to freewheel, therefore, opposite driving power is not transmitted to the engine (no engine brake taking effect).
For this reason, overrunning clutch 7 (the area enclosed in a dotted line, as illustrated) is engaged, preventing forward
one-way clutch 3 from freewheeling, so the opposite driving power is transmitted to the engine to make engine braking
effective.
Conditions
High clutch 11 engaged
Forward one-way clutch 3 operating
D : Vehicle speeds of 10 km/h {6.21 mph} or more
L : Accelerator opening for the entire range

Input shaft 12

High clutch 11 Rear sun gear
Front planetary carrier 10 Forward clutch 6 Rear pinion gear

Forward one-way clutch 3 Rear internal gear 5

Rear planetary carrier 8 Output shaft 9
23-39
D, 2 and L Ranges (4th gear)
1 2
3 4
B
Constant freewheeling
speed A>B
7
5
6
12 10
11 9
07477
1 Front planetary gear 7 Front internal gear

2 Rear planetary gear 8 Rear planetary carrier
3 Forward one-way clutch 9 Output shaft
4 Low one-way clutch 10 Front planetary carrier
5 Brake band 11 Front sun gear
6 High clutch 12 Input shaft
High clutch 6 engages to connect input shaft 12 and front planetary carrier 10.
Also, brake band 5 operates to fix front sun gear 11. The operation of high clutch 6 transmits power from the input shaft to
the front planetary carrier, making the front planetary carrier rotate clockwise. This makes front internal gear 7 (connected
to output shaft 9) rotate clockwise at an increased speed as the front sun gear is fixed by the brake band. When the
vehicle is coasting, opposite driving power is transmitted to the engine making engine braking effective. In operation in the
4th gear position in the D range, because forward one-way clutch 4 freewheels, driving power is not transmitted although
the forward clutch is engaged.
Conditions
High clutch 6 engaged
Brake band 5 engaged
Forward clutch engaged (not transmitting power)

Input shaft 12 High clutch 6 Front planetary carrier 10 Front pinion gear
Front internal gear 7 Rear planetary carrier 8 Output shaft 9
23-40
23
L Range (1st gear)
1 2
5 6
4
3
11 10 9 8
07478
1 Front planetary gear 7 Forward one-way clutch

2 Rear planetary gear 8 Output shaft
3 Rear internal gear 9 Rear planetary carrier
4 Forward clutch 10 Rear sun gear
5 Overrunning clutch 11 Input shaft
6 Low and reverse brake
Forward clutch 4 and overrunning clutch 5 engage to connect the front planetary carrier and rear internal gear 3. Also, low
and reverse brake 6 engages to fix the front planetary carrier and the rear internal gear. In contrast to the operation in 1st
gear position in the D, 2 ranges, in 1st gear position in the L range, forward one-way clutch 7 is fixed by overrunning clutch
5, and the rear internal gear is fixed by the low and reverse brake instead of by the low one-way clutch. This operation
prevents freewheeling of the forward one-way clutch and the low one-way clutch when the vehicle is coasting or when
shifting down from 2nd to 1st gear in the L range, so that opposite driving power is transmitted to the engine to make
engine braking effective.
Conditions
Forward one-way clutch 7 operating (when accelerating)
Low and reverse brake engaged

Input shaft 11 Rear sun gear 10 Rear pinion gear Rear planetary carrier 9 Output shaft 8
23-41
Torque Converter (with lock-up clutch)
1 Turbine runner
1
2 Pump impeller
3 Stator
2 4 One-way clutch
7 5 Torsional damper
6 Converter cover
3
6 7 Lock-up piston
5 4 The torque converter transmits the engine torque to the transmission.

When the lock-up clutch is not operating, power is transmitted by oil, and
when the lock-up clutch is operating, power is transmitted by lock-up
piston 7. The torque converter is a symmetrical 3-element, 1-stage,
2-phase type. Symmetrical 3-element means that the three elements:
pump impeller 2, turbine runner 1 and stator 3; are arranged symmetri-
cally. 1-stage means that there is only one turbine runner (output ele-
ment). 2-phase means that when the speed of the turbine is relatively low
compared to that of the pump impeller, the torque converter operates as
a torque converter, and while at high speed, it acts as a fluid coupling.
07479
< When lock-up is not operating >

B The torque converter operating pressure is delivered from the lock-up
valve and supplied to the space between converter cover 6 and lock-up
piston 7 through oil passage A, and separates the clutch facing of the
lock-up piston from the converter cover. By this operation, the torque
converter operating pressure fed through oil passage A is released
A through oil passage B to the oil cooler.
07480
< When lock-up is operating >

B The pressure line is changed over by the lock-up valve to feed the torque
converter operating pressure to pump impeller 2, turbine runner 1, and
stator 3 side through oil passage B.
By this operation, the lock-up piston receives hydraulic pressure to make
the facing of lock-up piston 7 make contact with converter cover 6 so that
C
the efficiency of the power transmission is improved.
C : Drain
07481
23-42
23
MEMO
23-43
Oil Pump (Variable displacement vane pump)
1 2
3
A
4 B
7
6 11 12
9
8 07482
10 13
D
14 E
5
F
15 18
19
16
15
17 G
H
20
J
07483
1 Automatic transmission elec- 11 Transmission system A: Electric signal

tronic control unit 12 Tire B: Flow of oil
2 Control valve 13 Oil pan C: Power transmission
3 Pressure regulator valve 14 Feedback accumulator piston D: Line pressure
4 Accumulator piston 15 Pivot pin E: Feedback pressure
5 Control piston 16 Cam ring F: Torque converter operating pressure
6 Oil pump 17 Return spring G: Pressure modifier pressure (D, 2, L
7 Accelerator sensor 18 Vane and R ranges)
8 Engine 19 Rotor H : Line pressure (R range)
9 Torque converter 20 Vane ring J : Line pressure (operating oil and
10 Oil cooler lubricant for other devices)
23-44
23
A A : Gear pump
B : Unnecessary flow
B C : Variable displacement vane pump
Discharge
This pump makes it possible to control the oil pump discharge to the
C minimum necessary throughout the operation from low revolution to high
revolution. It suppresses the increase in the driving torque in comparison
to the gear pump that discharges an excessive amount of oil at high
Pump revolution
revolutions. Also, in comparison to the gear pump: it has less variation in
07484 discharge pressure, less pressure loss due to friction, less noise, etc.
D: When control piston is not operating

<D> E: When control piston is operating
F: Engagement part of the torque converter drive sleeve
H G
(1) The rotor is fitted to the drive sleeve of the torque converter, and
rotates in the same direction as the engine (in the arrow direction),
and the oil sucked into chamber G is discharged at H. (Direction of
rotation when seen from the rear side of the oil pump is
F
counterclockwise.)
07485
<E> (2) The discharged oil functions as the operating pressure and lubricant
for the torque converter, the control valve, the clutch, and the brake.
(3) The discharge increases in accordance with the increase in the rate
of revolution of the oil pump.
J
(4) Feedback pressure from the control valve works in area J and
adjusts the cam ring position (amount of eccentricity) relative to the
center axis of revolution of the rotor by the movement of the control
07486 piston (in the arrow direction). This operation increases or decreases
the intake volume of area G to control the pump discharge.
23-45
Fail-safe system
4
2
1 3 5
6
13
12 7
15
11
14
10
8
9
13990
OFF
2 ACC
ON
17
15
16 OD 1
OFF P R
A A
19
18
10
9 NC
NO 13
13991
23-46
23
1 Key interlock solenoid 10 Automatic transmission 18 Key interlock electronic control
2 Starter switch reverse buzzer unit
3 Overdrive OFF switch 11 Shift lock link 19 Automatic transmission electronic
4 Shift button 12 Shift lock release knob control unit
5 Automatic transmission knob 13 Parking range switch
6 Selector lever 14 Brake pedal A : To inhibiter switch
7 Pin 15 Stop lamp switch B : To back buzzer
8 Lever bracket 16 Fuse box
9 Shift lock actuator 17 Meter cluster
Parking shift locking with key interlocking system

The key interlocking device is a system that makes it impossible for the key to be pulled out when selector lever 6 is in any
position other than the P (parking) range. The shift locking safety device is a system that makes it impossible for the
vehicle to move when the selector lever is locked in the P range unless brake pedal 14 is depressed.
Key interlocking system

4 < When locked >
Conditions : When selector lever 6 is in any position other than
in the P range, or in the P range but shift button 4 is de-
pressed, pin 7 moves away from P range switch 13 (so the
switch is free from any contact), therefore the switch is ON.

6 Current flows from key interlock electronic control unit 18 to
13 key interlock solenoid 1, switching the key interlock solenoid

7 ON.
Activation of key interlock solenoid 1 means starter switch 2

cannot be turned to the LOCK position, therefore the key
cannot be pulled out.
< When not locked >

Conditions : When selector lever 6 is in the P range and shift
button 4 is not depressed, pin 7 presses down P range switch

13992 13 (the switch is operating), therefore the switch is OFF.
No current flows from key interlock electronic control unit 18 to

key interlock solenoid 1, switching the key interlock solenoid

OFF.
Key interlock solenoid 1 is not operating and starter switch 2 is

released so that the starter switch is turned to the LOCK
position, and the key can be pulled out.
23-47
Parking shift locking system
4 When selector lever 6 is in the P range and shift lock
actuator 9 is locked (state A) depending on the state of the
power supply (refer to the table below) to the shift lock
6 actuator, pin 7 is restrained by shift lock link 11 and cannot
push shift button 4, and the selector lever cannot be shifted
to any position other than the P range.

IG +B Brake P range Unlock Lock

11

7

A
9
13993
When selector lever 6 is in the P range and shift lock

actuator 9 is unlocked (state B) depending on the state of
4
the power supply (refer to the table above) to the shift lock
actuator, shift lock link 11 falls forward freeing pin 7 so that
shift button 4 is pressed down, allowing the selector lever to
6 move to positions other than the P range.
In the event of any electrical troubles, P shift locking can be

released by pulling shift lock release knob 12.
11
12
7
13994
23-48
23
Warning system for selector lever reverse position
When starter switch 2 is ON, if selector lever 6 is put into the R
(reverse) range, the reverse position detector switch (inhibiter
switch built into the automatic transmission) operates to turn
automatic transmission reverse buzzer 10 ON, and alerts the
driver that the lever is in the reverse position.
10
13995
23-49
TROUBLESHOOTING PROCEDURE
Possible causes for automatic transmission troubles are as follows:
Engine performance faulty
Incorrect adjustment of components
Hydraulic system faulty
Mechanical function faulty
Electrical system faulty
In carrying out a diagnosis of the above items, elementary inspections must be made on the following matters.
Condition of the engine ^ Gr 13
Adjustment of accelerator control cable ^ Gr 13
Automatic transmission fluid quantity and deterioration P23-117
Adjustment of selector cable P23-136
At the same time, use the self-diagnosis function to search for and study the causes of the troubles and take proper
measures to deal with the cause.
After this is done, carry out a road test to see if the trouble has been solved and to judge if any further diagnosis is
required.
When causes cannot be located or the trouble cannot be solved even after repair, carry out a stall test and a line pressure
test. P23-112, 113
Repair and replacement of parts inside the automatic transmission body cannot be carried out yourself. Therefore, after
evaluating the condition in the service works, if there is trouble inside the automatic transmission body, or any of the
interior parts need to be inspected, replace the automatic transmission body as a unit.
For inspection of the automatic transmission system, it is recommended that you use the multi-use tester for more efficient
testing.
System inspections are classified into the following categories according to symptoms and recognition of the diagnosis
codes.
Inspection by individual diagnosis code memorized by the electronic control unit
Inspection by symptoms
Inspection of temporary troubles
Self-diagnosis Procedure
Lighting of automatic transmission warning lamp Note 1 : If a trouble was detected during the
Trouble occurs (Note 1) last trip (i. e. sometime between
Normal condition
Lights up the key being turned ON and OFF),

the automatic transmission warn-

2
seconds ing lamp will flash when the starter
Light goes out User brings in the vehicle for service switch is turned ON, as illustrated
in the diagram on the left.

Lights up When trouble detected

Also if any of the troubles listed

2 below occur while driving that
seconds Light Self-diagnosis conducted (Note 2)
goes out would reduce the driving perform-
ance considerably, the automatic

2 Hz 8 seconds transmission warning lamp will light

07963 up.
Both vehicle speed sensors 1, 2
Repair or replacement of faulty part
Road test (Note 3) faulty
Any solenoid faulty

Accelerator sensor faulty


Road test Self-diagnosis conducted (Note 4) Note 2 : Troubles that occurred during vehi-
cle use are inspected and re-

corded.
Note 3 : Detecting the fault.
Self-diagnosis Any trouble found by self-diagnosis?
Yes You must carry out a road test at

a speed lower than 50 km/h

No

{31.1 mph} and operate the ac-

Any fault found? celerator from fully closed to fully
Yes opened.
Check if any other fault exists

Note 4 : Troubles that occurred during the

No

Inspection by symptoms
road test are inspected and re-
Inspection of temporary troubles
Diagnosis is finished corded.
23-50
23
Self-diagnosis methods
You can select a self-diagnosis method from the three alternatives below.
Self-diagnosis
Use of diagnosis switch Input of signal for start of Use of multi-use tester
self-diagnosis
Removing the diagnosis
By operating the power
switch (plug-in connector), Data listing function
mode switch, the range se-
displays the trouble codes. Flight recorder function
lector lever, and the accel-
The records of the troubles
erator switch in the specified Trouble codes are read and
are deleted by removing the
sequence, self-diagnosis is displayed from the automatic
memory clearing fuse.
started and trouble codes transmission electronic con-
are displayed. trol unit by connecting it to
The records of the troubles the test harness.
are deleted by setting the In addition to the self-diag-
starter switch OFF after the nosis function, the multi-use
self-diagnosis has been tester has a data listing func-
completed. tion to display the various
values of sensors and
switches, and a flight re-
corder function to record
such values and data for a
certain period before and af-
ter the trigger point. These
functions also help trouble
diagnosis. (Refer to the
Multi-use Tester Operation
Manual, published sepa-
rately.)
Characteristic features of each method
Self-diagnosis method Input of signal for start

Item Use of diagnosis switch of self-diagnosis Use of multi-use tester
Convenient
Items to be self-diagnosed
Ease of reading
Scope of application
: Excellent
: Good
: Fair
: Bad
23-51
Reading of diagnosis codes
< When Using Diagnosis Switch >
Reading of the diagnosis codes using the diagnosis switch is to be carried out in accordance with the following flow chart:
Self-diagnosis
Turn the starter switch ON
Automatic transmission NG
Inspection and repair of the automatic
warning lamp lights for 2 transmission warning lamp
Flashes for another 8 seconds at
seconds Bulb burnt-out
2 Hz when the fault was detected
in the previous trip Wiring breakage, short circuit
OK Contact faulty
Automatic transmission electronic
Remove diagnosis switch control unit faulty
Automatic
transmission warning lamp
lights
Diagnosis
codes are displayed Repeats flashing at 4 Hz
Self-diagnosis impossible
Self-diagnosis is possible
(memory of trouble not normal)
NG
Diagnosis code is 01 Battery has been removed for a long period
Battery performance has deteriorated
OK Battery connection incorrect
No self-diagnosis has been made since
Records trouble code and Judged as normal removal of the battery or removal of the
locates faulty part automatic transmission electronic control unit
Memory has been cleared using the memory
clearing fuse
Self-diagnosis is finished Turn the starter switch OFF
Turn the starter switch OFF

Remove the memory clearing fuse (for 10 seconds or longer)
Replace and reconnect the memory clearing fuse and diagnosis
switch in turn
Turn the starter switch ON again

Remove diagnosis switch and make sure that the automatic
transmission warning lamp flashes at 4 Hz
Finish
23-52
23
Diagnosis switch
When carrying out a self-diagnosis, turn the starter switch ON and let the
power mode indicator flash by removing diagnosis switch A (plug-in
connector).
This flashing pattern denotes the trouble codes.
A
14032
Memory clearing fuse

In normal cases, the trouble codes recorded in the automatic transmis-
sion electronic control unit are not deleted automatically. You must
delete them yourself after reading the codes or after repairs have been
completed.
To delete the memories, turn the starter switch OFF and remove memory
clearing fuse A for longer than 10 seconds.
A 14033
Indication of automatic transmission warning lamp

Indication at the time the trouble occurs while driving
It lights up when a trouble occurs that would reduce driving perform-
ance considerably.
Both vehicle speed sensors 1, 2 faulty
Shift solenoid A develops a fault
Shift solenoid B develops a fault
Line pressure solenoid develops a fault
Lock-up solenoid develops a fault
14025 Overrunning clutch solenoid develops a fault
Accelerator sensor develops a fault
Inhibiter switch develops a fault
Automatic transmission warning lamp lighting Indication at the time starter switch was turned ON
If any trouble has occurred during operation by the user, the indica-
Lights up In normal condition
tor lamp within the meter cluster flashes for 8 seconds at 2 Hz to
2
seconds alert the user of the fault, when the key is turned ON as shown in B.
Light goes out
When there is no trouble the lamp lights for 2 seconds, as shown in
Lights up When trouble detected A, to tell the user that things are normal. This also indicates that the
2
bulb has not burnt-out.
seconds Light
goes out NOTE
2 Hz 8 seconds
The indicator lamp flashes only when a trouble occurred in the
07963 previous trip. Any trouble that happened prior to that will not
cause the indicator lamp to flash.
23-53
Indication when self-diagnosis is impossible
The indicator lamp flashes constantly at 4 Hz when self-diagnosis
Diagram B cannot function, even when the starter switch is turned ON and the
Lights up diagnosis switch is removed.
Light
goes out
1 second
07831
Trouble codes indication

The automatic transmission electronic control unit records the data
Indication of code 1-2 of all the troubles that have occurred since the last self-diagnosis.
Lights up
The When trouble diagnosis is started, the light goes out for 2.4 seconds
Light second
goes indication then the code indication starts.
out 2.8 starts The tens digit is indicated by the number of flashes of 1.2
2.4 1.2 1.2
0.4 0.4 0.4
(Seconds)
seconds duration, followed by 1.2 seconds unlit
Indication of code 1-2 The ones digit is indicated by the number of flashes of 0.4
Lights up
seconds duration, followed by 0.4 seconds unlit
Light Interval between codes is indicated by 2.8 seconds unlit
goes out
02738 When several codes are to be output, the output order is by time of
occurrence, and each trouble code is output three times, then the
automatic transmission electronic control unit moves on to the next
data output.
After all the trouble codes have been output, the output is repeated
from the first code.
Any fault newly detected while a current trouble code is being
output will not be reflected in the on-going indication.
Items to be self-diagnosed
Diagnosis Trouble point Pattern of flashing of automatic transmission warning lamp

code
01 (Normal) Light goes out
Lights up
11 Voltage at power supply Light goes out

13 Oil temperature sensor
15 Engine revolution signal
31 Shift solenoid A
32 Shift solenoid B
35 Lock-up solenoid
43 Inhibiter switch
12071
23-54
23
< When Using Multi-use Tester >
Connection of multi-use tester and electronic control unit
Turn the starter switch to LOCK.
2 Connect the ends of 1 multi-use tester harness to multi-use tester
3 connector 2 of cab harness 1 and cigarette lighter socket 3 respec-
tively.
NOTE
Multi-use tester connector 2 is fastened to cab harness 1 with
adhesive tape.
Connect 3 ROM pack to 2 multi-use tester sub-assembly.

1 Carry out trouble diagnosis using diagnosis codes and service data
using the multi-use tester.
NOTE
Refer to the Multi-use Tester Operation Manual, published sepa-
1 2 3 rately, for details regarding the operation of the multi-use tester.
13813
0 Special tools
Multi-use tester harness MB991231
02804
Multi-use tester sub-assembly MC858999 Inspection of system
02803
ROM pack MC885250
02805
23-55
Inspection with Multi-use Tester
1 The multi-use tester indicates diagnosis codes and faulty items, identifying the devices to be inspected.
2 Information signals from various sensors are indicated in certain values (service data). The multi-use tester compares
the values with the judgement standards to make sure of the conditions of the sensors. Service data codes are also
indicated as well as diagnosis codes.
1 2
Indication on MUT Inspection Indication on MUT Inspection procedure
procedure
No. Item name No. Item name Unit Conditions at inspection Judgement
standard
11 POWER VOLTAGE Carry out
an
12 VEH SPD SNSR1 inspection 12 VEH SPEED1 . At standstill 0 mph
according MPH Travelling Synchronized
to the to
inspection speedometer
procedure
13 OIL TEMP SNSR specified 13 A/T OIL TEMP . Engine cold Equivalent to
F ambient
in the temperature
individual
diagnosis Engine warmed-up Gradual
code increase
Engine stop after Gradual
warming-up decrease
15 NE SNSR 15 ENGINE SPEED . Idling after warming-up 750 rpm
RPM Racing Synchronized
to tachometer
16 PATTERN SW Power mode selected POWER
Economy mode selected ECONOMY
17 OD-OFF SW ON OD OFF
OFF OD
18 N POS.SW Selector N ON
Selector other than N OFF
19 D POS.SW Selector D ON
Selector other than D OFF
20 2 POS.SW Selector 2 ON
Selector other than 2 OFF
21 1 POS.SW Selector L ON
Selector other than L OFF
22 ACCEL SW Accelerator fully closed ON
Gradual depressing ONOFF
23 EXH BRK CTRL Starter switch ON ON
24 ACCEL SNSR 24 ACCEL VOLT . Accelerator fully closed 1.0 V
V Gradual depressing Continuous
increase
Accelerator fully opened 4.0 to 4.2 V
25 VEH SPD SNSR2 25 VEH SPEED2 . At standstill 0 mph
MPH While travelling Synchronized
to
speedometer
23-56
23
1 2
Indication on MUT Inspection Indication on MUT Inspection procedure
procedure
No. Item name No. Item name Unit Conditions at inspection Judgement
standard
26 POWER LAMP Power mode selected PWR
Economy mode selected ECO
27 EXH CUT RELAY Exhaust brake ON OFF
while travelling
Stopping with exhaust OFFON
brake ON
28 R POS.SW Selector R ON
Selector other than R OFF
29 VALVE POS. At standstill in the D 2nd gear
range position
Acceleration from Changes as
080 km/h {49.7 mph} follows:
with accelerator at half 2nd1st
throttle 2nd3rd
4th
30 SELECTOR POS. Shift selector from P to Changes as
L in sequence follows:
NRN
D2L
31 SHIFT VALVE A 31 SHIFT VALVE A Travel in 1st and 4th gear ON
Travel in 2nd and 3rd gear OFF
32 SHIFT VALVE B 32 SHIFT VALVE B Travel in 1st and 2nd gear ON
Travel in 3rd and 4th gear OFF
34 LINE PRESS. V 34 LINE PRESS. V
35 LOCKUP VALVE 35 LOCKUP VALVE Oil temperature warmed OFF
up to 40C {104F} at
standstill in D range
position
Acceleration at half FE639 51 to 57 km/h
throttle and OD-OFF {31.69 to 35.42 mph}
FE649 53 to 59 km/h
{32.93 to 36.66 mph}
Turns ON at the
above vehicle
speeds
Speed reduction with FE639, FE649
accelerator fully closed 35 to 42 km/h
{22.75 to 26.10 mph}
Turns ON at the
above vehicle
speeds
41 OVERRUN VALVE 41 OVERRUN VALVE
43 INHIBIT SIG.
23-57
< When Using the Signal Input for Start of Self-diagnosis >
The trouble diagnosis is started under the conditions determined using the accelerator switch. Therefore, all the switches
that function with the idling up system, such as the air-conditioner switch, must be turned OFF. After fully warming up the
engine, input start signal of self-diagnosis in accordance with the following flow chart.
Diagram A [Example] The shift solenoid B is faulty Start of diagnosis Note 1 : Flashing as shown in diagram A
takes place in sequence as shown in
Shift solenoid B Overrunning clutch solenoid the table below. Make sure of the
Shift solenoid A
Lock-up solenoid sequence of flashing so that no mis-
Stop the vehicle
Accelerator sensor Oil temperature sensor or take is made in reading the code.
power supply voltage signal However, when vehicle speed sen-
Vehicle speed sensor 2 of automatic transmission
(installed halfway along the electronic control unit sors 1, 2 are both faulty at the same
speedometer cable inside Turn the starter switch to ON
the cab) Engine revolution time, both will show normal flashing.
signal
(installed on the Line pressure Therefore, if troubles such as gear
automatic solenoid
t1 : 2 No does not shift occur, measure the
Lights up transmission) seconds
Does the automatic transmission voltage between the terminals of the
t2 : 2.5 warning lamp light up for 2 seconds?
a
seconds
automatic transmission electronic
Light
t3 : 1 Yes control unit.
second
goes out t1 t2 t3 t3 t3 t3 t3 t3 t3 t3 t3 t3 t1 t2
Turn the starter switch to OFF Sequence Inspection point
Repetition
1 Vehicle speed sensor 1 (Installed on
Self-diagnosis start signal automatic transmission)
(Note 1)
Shift the range selector lever into D 2 Vehicle speed sensor 2 (Installed on meter)
while depressing the brake pedal 3 Accelerator sensor
Enlarged diagram of section a 4 Shift solenoid A
5 Shift solenoid B
Lights Lights
Close the accelerator fully. Turn the 6 Overrunning clutch solenoid
power mode switch to ON 7 Lock-up solenoid
Light Light (Note 2)
goes out goes 8 Oil temperature sensor, power supply
0.1 0.9 out 0.6 0.4 voltage signal of automatic transmission
t3 t3 electronic control unit
Normal condition Abnormal condition 07890 Turn the starter switch to ON 9 Engine revolution signal
Shift the range selector lever into Wiring breakage, bulb burnt-out or automatic
2 and turn the power mode switch transmission electronic control unit faulty
to OFF
Note 2 : Turn idling switch ON
Note 3 : Turn idling switch OFF
Note 4 : Refer to diagram A to read the
Shift the range selector lever into L self-diagnosis code.
and turn the power mode switch to
ON by depressing the accelerator
If the key is turned OFF after
pedal lightly (Note 3) indication of self-diagnosis is
started, the self-diagnosis fin-
ishes. As turning the key OFF
Normal also deletes the troubles stored
Self-diagnosis is finished Does the automatic transmission
warning lamp flash normally? (Note 4) in memory, be sure to record the
troubles before turning OFF.
Abnormal
Abnormal flashing repeats Flashing at 4 Hz repeats Lamp does not flash
Self-diagnosis is possible Self-diagnosis is impossible Self-diagnosis is impossible

(Trouble memory is not correct)
Abnormality at place denoted by flashing Battery has been removed for a long period
(Note 6) Inhibiter switch, idling switch and wiring,
Battery performance has deteriorated or automatic transmission electronic
Battery connection incorrect control unit faulty
No self-diagnosis has been made since
removal of battery or removal of
automatic transmission electronic control
unit.
Memory has been cleared by removing
the memory clearing fuse
Note 6 : When abnormal flashing occurs for signal 8 (in Note 1), inspect the output voltage of the automatic transmission electronic control unit at
terminals 12 (+) and 15 (-) (oil temperature sensor circuit). Measure the output voltage when the oil temperature is 40C {104F}. If the voltage
is approximately 1.1 volts, it is normal; if approximately 2.4 volts, it is faulty.
Also, inspect the output voltage of the automatic transmission electronic control unit at terminals 29 (+) and 31 (-) (power supply voltage signal).
Measure during travelling at a speed of 15 km/h {9.32 mph}. If the voltage is within 12 to 13 volts, it is normal; if less than 12 volts, it is faulty.
23-58
23
Trouble Diagnosis Item
Trouble
Sequence Pattern of flashing of automatic transmission warning lamp Trouble point
code
1 Vehicle speed sensor 1 12
2 Vehicle speed sensor 2 25
3 Accelerator sensor 24
4 Shift solenoid A 31
5 Shift solenoid B 32
6 Overrunning clutch solenoid 41
7 Lock-up solenoid 35
Oil temperature sensor, automatic

13
8 transmission electronic control
11
unit power supply voltage signal
9 Engine revolution signal 15
10 Line pressure solenoid 34
12072
23-59
Measures to be taken when self-diagnosis does not work
Carry out an inspection in the following sequence when self-diagnosis does not function after the input of a self-diagnosis
start signal.
Note : When automatic transmission warning

Stop the vehicle
lamp is normal.

Turn the starter switch to ON (Engine is not operating)

Is D range input signal to the automatic transmission electronic Abnormal

Inhibiter switch or wiring is faulty
control unit terminal 20 normal?

Normal (12 to 13 volts in D range)
Is 2 range input signal to the automatic transmission electronic Abnormal


Normal (12 to 13 volts at 2 range)
Is L range input signal to the automatic transmission electronic Abnormal


Normal (12 to 13 volts in L range)
Is power mode switch input signal both in PWR and ECO

Abnormal
conditions to the automatic transmission electronic control unit Power mode switch or wiring is faulty
terminal 9 normal?

Normal (With power mode switch

ECO, 4.5 to 5.5 volts, with ON, 1 volt
or less)
Abnormal
Is idling switch input signal in ON condition to the automatic Accelerator switch or wiring is faulty
transmission electronic control unit terminal 4 normal?

Normal (At idling, 12 to 13 volts)

Automatic transmission electronic control unit is faulty

1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
14035
23-60
ELECTRIC CIRCUIT AND PARTS INSTALLATION POSITION
13972
23-62
23
1 Key interlock solenoid
(Built in starter SW)
2 Starter SW
3 Exhaust brake cut relay
4 Thermostat relay
5 Thermostat SW
6 Intake shutter 3-way M/V
7 Exhaust brake 3-way M/V
3 8 Back buzzer
2
10 Battery
1 11 ATF cooler fan motor
12 ATF thermostat SW
13 ATF temperature SW
14 Dropping resistor
15 Idle up 3-way M/V
b c 16 Vehicle speed sensor (A/T side)
37 38 d 6 8
4 7 17 Inhibitor SW
5
18 Terminal SW
19 Diode
36
20 Intake shutter connector
35 21 MUT connector
22 Diagnosis SW
34 23 Fuse box
19 a 24 Shift lock actuator
e 25 A/T reverse buzzer
33 20 26 P range SW
28 27 O/D OFF SW
32 f 15 28 ATF cooler fan relay
31 30 29 22 21
29 Accelerator SW
F18 F20 F23 F24 F27 30 Accelerator sensor
9 31 Stop lamp SW
14 10 32 A/T ECU
13 12
11 33 Vehicle speed sensor (Cab side)
27 23 34 Key interlock ECU
35 Power mode SW
36 Warming up SW
37 Meter cluster
F5 F13
26 F3 F6 F7 F10 38 ATF temperature resistor

ATF : Automatic transmission fluid
ECU : Electronic control unit
25 M/V : Magnetic valve
MUT : Multi-use tester
24 MUTIC : Multipurpose timing control unit
O/D : Overdrive
18 17 16 SW : Switch
14941
23-63
TB
INSPECTION BY INDIVIDUAL DIAGNOSIS CODE 23
List of diagnosis codes
Diagnosis Countermeasures for troubles

code Trouble point Judgement standard using A/T ECU (Backup mode)
11 Power supply voltage 10 volts or less (At vehicle speed of None
10 km/h {6.21 mph} or more)
12 Vehicle speed sensor 1 (Note) Control in accordance with vehicle speed
sensor 2
13 Oil temperature sensor Indication of 20C {4F} or less None (Oil temperature : Judged as
(At vehicle speed of 10 km/h {6.21 mph} extremely low temperature)
or more)
15 Engine revolution sensor Indication of 500 rpm or less None
(At vehicle speed of 10 km/h {6.21 mph}
or more)
24 Accelerator sensor Accelerator sensor voltage 0.1 volt or less, Set accelerator opening using accelerator
or 4.7 volts or more switch and control shifting and line pressure
25 Vehicle speed sensor 2 (Note) Control in accordance with vehicle speed
sensor 1
31 Shift solenoid A Wiring breakage or short circuit for 30 ms Shift solenoids A, B OFF (3rd gear fixed)
or more
32 Shift solenoid B Wiring breakage or short circuit for 30 ms
or more
34 Line pressure solenoid Wiring breakage or short circuit for 140 ms Line pressure solenoid OFF
or more
35 Lock-up solenoid Wiring breakage or short circuit for 140 ms Lock-up solenoid OFF
or more
41 Overrunning clutch Wiring breakage or short circuit for 30 ms Overrunning clutch solenoid OFF and line
solenoid or more pressure maximum at 4th gear
43 Inhibiter switch No signal or duplicate signals Put in the D range and do not shift to 4th
gear
Select the range following the priority
order and do not shift to 4th gear. Priority
order D>N>R>2>1
A/T ECU : Automatic transmission electronic control unit

(Note) Detection of faulty vehicle speed sensors 1, 2
Compare the indications of vehicle speed sensors 1, 2. When either one of them shows 20 km/h {12.4 mph} or
more while the other remains at 0, the one that shows 0 is faulty.
When travelling at vehicle speeds of 20 km/h {12.4 mph} or more and either sensor indicates an unusually drastic
fall (10 km/h {6.21 mph} per 0.1 second), the sensor is faulty.
23-65
INSPECTION BY INDIVIDUAL DIAGNOSIS CODE
11. Abnormal voltage at power supply

NG
Inspection of fuse Fuse blown Replace
OK

Inspection of voltage at power supply OK Automatic transmission electronic control unit

faulty
terminals 29 and 30 of automatic transmission Replace
electronic control unit

NG

Continuity inspection of harness between NG Repair or

fuse and automatic transmission electronic Wiring breakage, short circuit of harness, replace
control unit connector incorrectly connected
OK
Electric system faulty Repair
Automatic
transmission Fuse box
electronic
control unit
07895
23-66
23
14037
1 Fuse box
1
Service procedure
A:
Inspection of fuse
Automatic transmission fuse
2
14038
A Inspection of voltage at power supply terminals of automatic

transmission electronic control unit
With the starter switch ON, inspect to see that battery voltage is applied
to terminals 29 and 30 respectively.
Terminals 31 and 32 are ground terminals.
A : Twist wire
29 30 31 32
14039
23-67
12. Vehicle speed sensor 1 signal faulty

NG
Inspection of installation condition of vehicle
Vehicle speed sensor 1 installation faulty Repair
speed sensor 1

OK

NG
Vehicle speed sensor 1 body faulty
Inspection of vehicle speed sensor 1 body Replace

OK

Continuity inspection of harness between NG Wiring breakage, short circuit of harness, Repair or
vehicle speed sensor 1 and automatic connector incorrectly connected replace

OK

Replace
NG automatic
Inspection of parking gear (sensor plate) Parking gear (sensor plate) faulty
transmission
body
OK
Automatic transmission electronic control unit Replace

faulty
Automatic Cab Chassis

Vehicle speed
transmission sensor 1
electronic
control unit
14040
23-68
23
1
a
14041

Service standards
2 Resistance of vehicle speed sensor 1 1-2 500 to 650 Replace
(At connector)
1 3 2-3
2 14042
1-3
2
Service procedure
Inspection of vehicle speed sensor 1
Connector terminals
Standard value
1 : Output 2 : GND 3 : Shield
500 to 650
1 3

2 07896
vehicle speed sensor 1 2.
23-69
13. Oil temperature sensor signal faulty

Replace
NG automatic
Inspection of oil temperature sensor body Oil temperature sensor body faulty transmission

body
OK

Continuity inspection of harness between oil NG Wiring breakage, short circuit of harness, Repair or
temperature sensor and automatic connector incorrectly connected replace
OK

faulty Replace
Automatic
transmission Cab Chassis
Oil temperature
electronic Terminal switch sensor
control unit
Inside of automatic
transmission
14043
23-70
23
1
a
14044

2 Oil temperature sensor
3 Terminal switch
Service standards
2 Resistance of oil temperature sensor 20C {68F} Approximately 2.5 k Replace
(At terminal switch connector) 40C {104F} Approximately 1.2 k
60C {140F} Approximately 0.6 k
80C {176F} Approximately 0.3 k
2
Service procedure
Inspection of oil temperature sensor body
Connector terminal
Standard value Oil temperature
8 9
Approximately 2.5 k 20C {68F}

8 9 Approximately 0.3 k 80C {176F}

14045
When the measured value deviates extremely from the standard
value or when the resistance value does not change in spite of the
change in the fluid temperature, replace the oil temperature sen-
sor body.
23-71
15. Engine revolution sensor signal faulty

NG Repair or
Inspection of engine revolution sensor ^ Gr Engine revolution sensor faulty or installation
13

faulty replace
OK

Continuity inspection between pre-stroke NG

control unit to engine revolution sensor Wiring breakage, short circuit of harness, Repair or
connector incorrectly connected replace
^ Gr 13

OK

Continuity inspection between pre-stroke NG Repair or

Wiring breakage, short circuit of harness,
control unit and automatic transmission connector incorrectly connected replace
electronic control unit side harness
OK

faulty Replace
3
Automatic 1
transmission
electronic Pre-stroke
control unit control unit
14046
23-72
23
a
3
14047
1 Pre-stroke control unit ^ Gr 13

2 Engine revolution sensor ^ Gr 13
23-73
24. Accelerator sensor signal faulty

Inspection of power supply voltage of Repair or
Power supply system faulty
accelerator sensor at automatic transmission replace
electronic control unit terminal

Inspection of input voltage at automatic OK Automatic transmission electronic control unit

faulty Replace
transmission electronic control unit terminal

NG

Inspection of voltage at connector of NG

Inspection of accelerator sensor

accelerator sensor NG

OK

OK

Accelerator sensor faulty Replace

faulty Replace
connector incorrectly connected
accelerator sensor and automatic transmission replace
Automatic
transmission
electronic Accelerator sensor
control unit
14048
23-74
23
14049
Service standards
1 Output voltage of accelerator sensor Idling Replace
0
position 1.0 0.1 V
4 3 2 1
Accelerator
1
3 : Ground 14050 at full
throttle
4 +0.2
0 V
4 :: Input
Output
(5 volts)
2 Input/output voltage of connector of Power supply Repair

automatic transmission electronic voltage of 4.5 to 5.5 V or replace
control unit (With starter switch ON) accelerator
sensor
10 15
Output
0
voltage of 1.0 0.1 V
accelerator
sensor
(At idling)
11 15
Output
voltage of 4 +0.2
0 V
accelerator
1 2 3 4 5 6 7 8 9 10 21 22 23 2425 26 28
11 12 13 14 15 16 17 18 19 20 29 30 31 32 33 34 35 36 sensor (With
accelerator
at full
throttle)
14051 11 15
23-75
A
1
Service procedure
Inspection of accelerator sensor
4
Load 5 volts to terminal , and ground terminal .1
C Measure output voltage from terminal 3 at each position of lever A.
If the measured value deviates from the standard value, replace accel-
erator sensor 1.
Removal and installation of sensor : ^ Gr 13
B : Idling position
C : Maximum stroke position of lever
Output voltage of accelerator sensor Connector terminal
B
at idling 3 1
0
1.00.1 V
+5V GND Output voltage of accelerator sensor with Connector terminal

4 3 2 1 accelerator at full throttle 3 1
4 +0.2
0 V
07969
23-76
23
A 2 Inspection of voltage of automatic transmission electronic
control unit terminals
[Inspection of power supply voltage of accelerator sensor]
Loosen the accelerator control button as much as possible.
With the key turned ON, measure power supply voltage between
terminals 10 (+) and 15 () of the automatic transmission electronic
control unit and check if the measured value conforms to the standard
1 2 3 4 5 6 7 8 9 10 21 22 23 24 25 26 28
11 12 13 14 1516 17 18 19 20 29 30 31 32 33 34 35 36
value.
14039 A : Twist wire.
Power supply voltage of Connector terminal

accelerator sensor 10 15
4.5 to 5.5 V
[Inspection of output voltage of accelerator sensor]

With the key turned ON and at idling (accelerator pedal released),
measure output voltage of the accelerator sensor between terminals
11 (+) and 15 () of the automatic transmission electronic control unit,
and check if the measured value conforms to the standard value.
Output voltage of accelerator Connector terminal

sensor at idling 11 15
1.00.1 V
With the key turned ON and the accelerator at full throttle (accelerator
pedal depressed fully), measure output voltage of the accelerator
sensor between terminals 11 (+) and 15 () of the automatic transmis-
sion electronic control unit, and check if the measured value conforms
to the standard value.

with accelerator at full throttle 11 15
4 +0.2
0
V
With the key turned ON and while depressing the accelerator pedal
slowly and smoothly from idling to full throttle, measure output voltage
of the accelerator sensor between terminals 11 (+) and 15 () of the
automatic transmission electronic control unit, and check to see if the
measured value conforms to the standard value.

at pedal depression 11 15
To change continuously in accordance with the
movement of the accelerator pedal
23-77
25. Vehicle speed sensor 2 faulty

NG
Inspection of speedometer cable Speedometer cable installation faulty, wiring Repair

breakage
OK

NG
Vehicle speed sensor 2 body faulty
Inspection of vehicle speed sensor 2 body Replace

OK

vehicle speed sensor 2 and automatic connector incorrectly connected replace

OK

Continuity inspection between vehicle speed NG

Ground faulty Repair
sensor 2 and body ground
OK

faulty Replace
Automatic
transmission
electronic Vehicle speed sensor 2
control unit
14052
23-78
23
14053

2 Speedometer cable
1
Service procedure
Inspection of vehicle speed sensor 2 body
Inspect continuity between terminals while manually rotating the revolv-
ing shaft of vehicle speed sensor 2 1. When continuity is found and lost
alternately four times in one rotation of the revolving shaft, the vehicle
speed sensor 2 is normal. If any fault is found, replace the vehicle speed
sensor 2.
2
07907
Inspection of speedometer cable

Inspect speedometer cable 2 for any fracture of the cable and check the
way it rotates, also inspect the mounting area of vehicle speed sensor 2
3. If any fault is found, repair or replace the speedometer cable.
2
14054
23-79
31. Shift solenoid A faulty

NG Replace automatic
Inspection of shift solenoid A Shift solenoid A faulty transmission body
OK

automatic transmission terminal and connector incorrectly connected replace
automatic transmission electronic control unit
OK

faulty
Inside of automatic
transmission
Terminal
switch
Automatic
transmission Shift
Cab Chassis solenoid A
electronic
control unit
14055
23-80
23
a
1
14057

2 Terminal switch
3 Shift solenoid A
Service standards
3 Resistance of shift solenoid A 25.0
(At fluid temperature 20C {68F})
Measure the resistance between terminal 3 of the
connector of the terminal switch side and the
automatic transmission case
14056
3
Service procedure
Inspection of shift solenoid A
Measure the resistance between terminal 3 of the connector of automatic
transmission terminal switch 2 side and the automatic transmission case
(near the automatic transmission terminal).
Connector terminal
Standard value Fluid temperature
3 Automatic transmission case
3
25.0 20C {68F}
14058 If the measured value deviates from the standard value, replace shift
solenoid A 3.
23-81
32. Shift solenoid B faulty

Inspection of shift solenoid B Shift solenoid B faulty

transmission body
OK

connector incorrectly connected
automatic transmission terminal and automatic
replace
OK

faulty
Inside of automatic
transmission
Terminal
switch
Automatic Shift
transmission Cab Chassis solenoid B
electronic
control unit
14059
23-82
23
a
1
14061

2 Terminal switch
3 Shift solenoid B
Service standards
3 Resistance of shift solenoid B 25.0
Measure resistance between terminal 2 of the
14056
3
Service procedure
Inspection of shift solenoid B
(near the automatic transmission terminal).
Connector terminal
2
25.0 20C {68F}
14058 If the measured value deviates from the standard value, replace shift
solenoid B 3.
23-83
34. Line pressure solenoid faulty

Inspection of line pressure solenoid Line pressure solenoid faulty

transmission body
OK

OK

faulty
Inside of automatic
transmission
Terminal
switch
Automatic
transmission Line pressure
Cab Chassis solenoid
electronic
control unit
14063
23-84
23
a
1
14065

2 Terminal switch
Service standards
3 Resistance of line pressure solenoid 3.2
6
14056
3
Service procedure
Inspection of line pressure solenoid
(near automatic transmission terminal).
Connector terminal
6 3.2 20C {68F}
14058
If the measured value deviates from the standard value, replace line
pressure solenoid 3.
23-85
35. Lock-up solenoid faulty

Inspection of lock-up solenoid Lock-up solenoid faulty

transmission body

OK

OK

faulty
Inside of automatic
transmission
Terminal
switch
Automatic Lock-up
transmission Cab Chassis solenoid
electronic
control unit
14067
23-86
23
a
1
14069

2 Terminal switch
3 Lock-up solenoid
Service standards
3 Resistance of lock-up solenoid 13.4
7
14056
3
Service procedure
Inspection of lock-up solenoid
Connector terminal
7
13.4 20C {68F}
14058
If the measured value deviates from the standard value, replace lock-up
solenoid 3.
23-87
41. Overrunning clutch solenoid faulty

Inspection of overrunning clutch solenoid Overrunning clutch solenoid faulty transmission body
OK

Continuity inspection of harness between NG Repair or

Wiring breakage, short circuit of harness,
OK

faulty
Inside of automatic
transmission
Terminal
switch
Automatic
transmission Overrunning
Cab Chassis clutch solenoid
electronic
control unit
14071
23-88
23
1
a
14073

2 Terminal switch
Service standards
3 Resistance of overrunning clutch solenoid 25.0
4
14056
3
Service procedure
Inspection of overrunning clutch solenoid
Connector terminal
4
25.0 20C {68F}
14058
overrunning clutch solenoid 3.
23-89
43. Inhibiter signal faulty

NG
Inspection and adjustment of inhibiter switch Replace
OK

NG NG
Power supply inspection of inhibiter switch
Inspection of fuse

power supply terminal (terminal 3)

OK

OK

NG Continuity inspection of harness between

inhibiter switch and automatic transmission Fuse blown Replace

OK

NG
Automatic transmission electronic control unit Continuity inspection of harness between

faulty inhibiter switch and fuse
OK
Replace
Wiring breakage, short circuit of harness, Wiring breakage, short circuit of harness, Repair or
connector incorrectly connected connector incorrectly connected replace

Repair or replace
Power supply system faulty Repair
Inhibiter switch
Fuse box
To starter
Diode relay
Automatic
transmission Cab Chassis
electronic
control unit
14075
23-90
23
1
a
14076

2 Inhibiter switch P23-136
3 Fuse box
3
Service procedure
A:
Inspection of fuse
Fuse for automatic transmission
14038
23-91
INSPECTION BY SYMPTOM
Shift Control Faulty
Note 1 : Make sure you carry out the inspection in strict
Gear shift is possible when in the D range but cannot shift accordance with the self-diagnosis procedures on
down when accelerator pedal is depressed vehicles that are brought in for service on account
of troubles. P23-50
Inspect for accelerator sensor faults.
Keep written records on note pads of faulty points.
Stop the vehicle
Inspect faulty point using self-diagnosis function

(Note 1)
Stop the engine leaving the starter switch ON
Is power supply output voltage signal of Abnormal Automatic transmission electronic control unit
accelerator sensor from terminal 10 of automatic Replace
faulty
transmission electronic control unit normal?
Normal (4.5 to 5.5 volts) Automatic transmission electronic

control unit
Is accelerator sensor input signal, throughout the

Abnormal
entire range from fully closed to fully opened, to
terminal 11 of automatic transmission electronic 1 2 3 4 5 6 7 8 9 10
control unit normal?
11 12 13 14 15 16 17 18 19 20
Normal (Approximately
1.0 volt when fully opened 14035
to approximately 4.0 volts
when fully closed)
Is accelerator sensor connecting circuit from Repair or

terminals 10, 15 of automatic transmission Accelerator sensor or wiring faulty
replace
electronic control unit normal? Abnormal
Normal
Replace automatic transmission electronic control

unit
Road test
No
Is shift-down possible when accelerator pedal
Inspect automatic transmission body
is depressed?
Yes
The automatic transmission electronic control unit

that was used before replacement was faulty
23-92
23
Does not shift up when accelerator pedal is depressed slowly while travelling in the D range. (Does not shift up from D1 to D2, from D2
to D3, or from D3 to D4)

Stop the vehicle accordance with the self-diagnosis procedures on
vehicles that are brought in for service on account
of troubles. P23-50
Inspect for faults in vehicle speed sensor and the
Inspect faulty point using self-diagnosis function (Note 1) various solenoids (except lock-up solenoid).
Note 2 : When the fluid temperature is 40C {104F} or more,
output voltage of terminal 12 of automatic transmis-
Warm up the engine and raise the fluid temperature to 40C sion electronic control unit becomes 1.1 volts or less.
{104F} or more (Note 2) Note 3 : If the connector of the vehicle speed sensor is al-
most disconnected, self-diagnosis might misjudge
the situation as normal because the connector will
be disconnected while the vehicle is travelling and
connected while it is standing still. Therefore, make
Stop the engine leaving the key ON. sure that the connector is securely connected.
Put the range selector lever into the D range.
Set the overdrive switch to ON
Abnormal Repair or
Is input signal to terminal 6 of automatic transmission Overdrive switch or wiring faulty
electronic control unit with overdrive switch ON normal? replace
Normal (4.5 to 5.5 volts with

overdrive switch ON)
Is input signal to terminals 20, 19, 1, 2 of automatic Abnormal

Repair or
transmission electronic control unit when inhibiter switch in Inhibiter switch or wiring faulty
replace
the respective range normal?
Normal (In the respective

range: 12 to 13 volts)
Abnormal
Is oil temperature sensor input signal to terminal 12 of Oil temperature sensor or wiring Repair or
automatic transmission electronic control unit normal? faulty replace
Normal (1.1 volts or less)
Is vehicle speed sensor 2 (built into meter) input signal to Abnormal

terminal 24 of automatic transmission electronic control unit Vehicle speed sensor 2 (built into meter) Repair or
normal? (Note 3) or wiring faulty replace
Normal (Intermittent at 1 volt or Automatic transmission electronic

less and at 4 volts or more) control unit
Turn starter switch OFF and raise the vehicle

1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A 14035
23-93
Note 4 : Take precautions to prevent the vehicle from moving
A of its own accord.
Start the engine and inspect in conditions of simulated vehicle

travel (Note 4)
Does AC voltage between terminals 16 (+) and 13 () of

automatic transmission electronic control unit satisfy the It does not
Vehicle speed sensor 1 (installed on Repair or
following standards?
automatic transmission) connector replace
At standstill : 0 volt AC
or wiring faulty
At vehicle speed of 30 km/h {18.4 mph} : 1 volt AC or more
As speed increases, voltage increases continuously
Yes < Inspection 1 >
Is output signal of terminals 35, 36 of automatic transmission Automatic transmission electronic

electronic control unit when shift solenoids A, B are ON or Replace
control unit faulty
OFF normal?
Normal (At ON, 12 to 13 volts.

At OFF, 1 volt or less)
< Inspection 2 >
Turn starter switch OFF and lower the vehicle to the Abnormal
Connectors of shift solenoids A, B Repair or
ground. Is continuity between connectors and cables of replace
or wiring faulty
shift solenoids A, B normal? (Note 5)
Note 5 : Except lock-up solenoid
Normal
control unit
Replace the automatic transmission electronic control unit
21 22 23 24 25 26 28
29 30 31 32 33 34 35 36
Road test 14077
Abnormal
Is shift control normal? Inspect automatic transmission body
The automatic transmission electronic control unit that was used

before replacement was faulty
23-94
23
< Inspection 1 >
Inspection of output voltage to various solenoids
Inspect and see if the ON and OFF operation of the various solenoids
are normal while increasing vehicle speed.
Gear position
Automatic D1 D2 D3 D4
transmission
electronic
control unit terminal Solenoid
35 Shift solenoid A ON OFF OFF ON
36 Shift solenoid B ON ON OFF OFF
< Inspection 2 >

Inspection of various solenoids, connectors and wiring
Remove the connector of the automatic transmission electronic con-
trol unit. Then inspect and see if the resistance between the terminals
of the solenoids (terminals to be connected to 35 and 36) and the
vehicle ground conforms to the standard value.
Resistance between Connector terminals
terminals 35 36 Vehicle ground

20 to 40

23-95
Shift pattern selection control faulty
With power mode switch OFF and while travelling in the D range, there is
no shift to power mode when accelerator pedal is depressed quickly
Inspect faulty point using self-diagnosis function

(Note 1)
Inspect voltage variations corresponding to accelerator

opening of accelerator sensor with starter switch ON and the
engine stopped (Note 2)
Road test (Note 2)
Check and see if the gears shift from D3 to D4 while No

travelling in the D range at 5/8 accelerator opening, power
mode switch OFF and overdrive switch ON (Note 3)
Yes
Replace the automatic transmission
Abnormal
Is the vehicle speed at the time of shifting as indicated in the
table below (Note 5)?
Condition remains
Normal abnormal even after
replacement of automatic
transmission electronic
At the time the accelerator pedal is depressed all the way control unit
Abnormal
down quickly and shifting down to D3, and when shifting up to
D4 again, is the vehicle speed as indicated in the table below
(Note 5)?
Normal
Normal Replace automatic transmission body

(Note 6)

accordance with the self-diagnosis procedures on
of troubles. P23-50
Inspect abnormality of accelerator sensor, vehicle
speed sensors and overdrive switch.
Note 2 : Mount check box, and check voltage at time of 5/8
accelerator opening. When road testing, depress the
accelerator pedal and use a tester to see if the
voltage conforms to the voltage at time of 5/8 accel-
erator opening. P23-108
Voltage at 5/8 accelerator opening

Approximately 2.8 to 2.9 V
23-96
23
Note 3 : Shift point can be detected using the light-emitting diode, in-
stalled in the check box, which reflects the operation of shift
solenoids A, B.
D3 position Neither shift solenoids A, B are lit

D4 position Shift solenoid A is lit. B is not lit
Note 4 :
FE639 Approximately 32 Km/h {19.88 mph}
The vehicle speed at the time of shifting must be within the specified
range approximately 5 km/h {3.1 mph}.
Note 5 :
The vehicle speed at the time of shifting must be within the specified
range approximately 5 km/h {3.1 mph}.
Note 6 : When any fault is found by reinspection after replacement of

23-97
Lock-up control faulty
In the following conditions, lock-up does not operate
accordance with the self-diagnosis procedures on
In D3 or D4 positions
When travelling at the lock-up standard speed
of troubles. P23-50
< Inspection 2 >
Inspect for faults in accelerator sensor, vehicle
speed sensors, lock-up solenoid and engine revo-
lution.
Stop the vehicle When the engine revolution signal is not input
correctly, the lock-up function operates for a while
after starting travelling but stops functioning within
a certain period.
Inspect faulty point using self-diagnosis function Note 2 : When the fluid temperature is 40C {104F} or more,
(Note 1) output voltage of terminal 12 of automatic transmis-
sion electronic control unit becomes 1.1 volts or less.

control unit
Warm up the engine and raise the fluid
temperature to 40C {104F} or more (Note 2)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
Stop the engine leaving the starter switch ON. 14035

Put selector lever into the D range. Turn
overdrive switch ON
Is input signal to terminal 6 of automatic Abnormal

Repair or
transmission electronic control unit with overdrive Overdrive switch or wiring faulty
replace
switch ON normal?
Normal (4.5 to 5.5 volts

with overdrive switch ON)
Is oil temperature sensor input signal to terminal Abnormal

Oil temperature sensor or wiring faulty Repair or
12 of automatic transmission electronic control replace
unit normal?
Normal (1.1 volts or less)
Is vehicle speed sensor 2 (built into meter) Abnormal

input signal to terminal 24 of automatic Vehicle speed sensor 2 (built into meter) or Repair or
transmission electronic control unit normal? wiring faulty replace
(Note 3)
Note 3 : If the connector of the vehicle speed sensor is al-
Normal (No continuity at 1 volt
or less and 4 volts or more) most disconnected, self-diagnosis might misjudge
the situation as normal because the connector will
Turn starter switch ON (The engine is stopped) be disconnected while the vehicle is travelling and
connected while it is standing still. Therefore, make
sure that the connector is securely connected.
B
23-98
23
B
Is input signal of accelerator switch to terminal 4 Abnormal

Repair or
of automatic transmission electronic control unit Accelerator switch or wiring faulty
replace
normal?
Normal (12 to 13 volts
at idling)
Turn starter switch OFF and raise the vehicle
Start the engine and inspect in conditions of

simulated vehicle travel
Does AC voltage between terminals 16 (+) and

13 () of automatic transmission electronic
control unit satisfy the following standard?
At standstill : 0 volt AC No Repair or
Vehicle speed sensor 1 (installed on automatic
At vehicle speed of 30 km/h {18.4 mph} : replace
transmission) connector or wiring faulty
1 volt AC or more
As speed increases, voltage increases
continuously
Yes < Inspection 1 >
Turn starter switch OFF and lower the vehicle Abnormal

to the ground. Is continuity of lock-up solenoid, Repair or
Lock-up solenoid, connector or wiring faulty
connector and wiring normal? replace
Normal
< Inspection 2 >
Start the engine. Is output signal of terminal 22

Abnormal
of automatic transmission electronic control unit Automatic transmission electronic control unit
Replace
in conditions of simulated vehicle travel with faulty
lock-up solenoid ON normal?
control unit
Normal (12 to 13 volts with
the lock-up engaged)
Road test 21 22 23 24 25 26 28
29 30 31 32 33 34 35 36
Normal 14077
Abnormal Replace automatic
Is vehicle speed with lock-up engaged normal? Automatic transmission body faulty
transmission body
Normal
The automatic transmission electronic control unit

that was used before replacement was faulty
23-99
< Inspection 1 >
Inspection of lock-up solenoid, connector and wiring
Remove the connector of the automatic transmission electronic con-
trol unit. Then inspect and see if voltage between terminal 22 and the
vehicle ground conforms to the standard value.
Standard value
Resistance between Connector terminal
terminals 22 Ground
10 to 20
<Inspection 2>
Inspection of vehicle speed with lock-up engaged
Inspect and see if the vehicle speed at the time when the output signal
to the lock-up solenoid is changed over from OFF to ON with 4/8
accelerator opening conforms to the standard value.
Standard value
Shift gear Vehicle
position model Vehicle speed with lock-up engaged
D3 FE639 51 to 57 Km/h {31.69 to 35.42 mph}

FE649 53 to 59 Km/h {32.93 to 36.66 mph}
D4 FE639 70 to 76 Km/h {43.50 to 47.23 mph}
FE649 74 to 80 Km/h {45.98 to 49.71 mph}
23-100
Others
Line pressure
Inhibiter switch
Control linkage
Shift solenoid B
Shift solenoid A
Overdrive switch
Lock-up solenoid
2 - 3 accumulator
1 - 2 accumulator
N - D accumulator
Accelerator sensor
Possible causes

Control valve assembly
Engine idling revolution
Engine revolution sensor
3 - 4 (N - R) accumulator
Starter switch and starter

Automatic transmission fluid condition and level
Symptoms
1
2
3
Starter does not turn when in N or P ranges
2
Starter turns when in other than N or P ranges
2
5
3
4
Engine idling noise excessive when vehicle at standstill
Vehicle moves even when in P range or parking gear remains
1
engaged even in other than P range
2
Vehicle moves even when in N range
Vehicle does not move when in R range (moves when in D,

1
3
4
2
2 and L ranges), slips, acceleration extremely slow
Numbers in the chart indicate the order of priority in which relevant locations are to be inspected.
1
4
5
3
2
Brakes engage suddenly when R range selected
5
8
4
6
7
3
2
1
Excessive shock when changing from N to D range

Vehicle does not move when in D range (moves when in 2,
1
L and R ranges)
Vehicle does not move when in D or 2 ranges (moves when in L
23
5
3
4
2
and R ranges), slips, acceleration extremely slow
23-101
Symptoms
Excessive shock when changing from 2nd to 3rd gear

Excessive shock when changing from 1st to 2nd gear
Excessive shock when changing from 3rd to 4th gear

Engine stops when R, D, 2 or L ranges selected
Slippage tends to occur at engine start-up
Does not change from 2nd to 3rd gear

Does not change from 1st to 2nd gear
Does not change from 3rd to 4th gear
Gear change shift point too high
Slips from 1st to 3rd gear

Excessive creep
No creep at all
Possible causes
Automatic transmission fluid condition and level 1 1 1
Control linkage 2 2 2 3
Engine idling revolution 1 1
Inhibiter switch 1 1 1
Accelerator sensor 3 1 1 1 1
Vehicle speed sensor 5 5 5 2
Overdrive switch 2
Line pressure 4 2 3 2 2 2
Control valve assembly 6 3 4 4 4 3 4 4 4
Shift solenoid A 3 4
Shift solenoid B 3
Line pressure solenoid 5
Lock-up solenoid 2
N - D accumulator 7
1 - 2 accumulator 2 3
2 - 3 accumulator 3
3 - 4 (N - R) accumulator 8 3
Oil temperature sensor 6 5
23-102
Line pressure
Inhibiter switch
Control linkage
Shift solenoid B
Shift solenoid A
Overdrive switch
Lock-up solenoid
2 - 3 accumulator
1 - 2 accumulator
N - D accumulator
Accelerator sensor
Possible causes

Control valve assembly

Automatic transmission fluid condition and level
Symptoms
4
5
3
2
Slippage when changing from 1st to 2nd gear
4
5
3
2
Slippage when changing from 2nd to 3rd gear
5
3
2
4
Slippage when changing from 3rd to 4th gear
1
Brakes engage when changing from 1st to 2nd gear
1
Brakes engage when changing from 2nd to 3rd gear

1
Brakes engage when changing from 3rd to 4th gear

1
4
3
2
Maximum speed point too low, acceleration too slow

1
3
5
6
4
2
Does not change from 4th to 3rd gear
1
4
3
2
Does not change from 4th to 2nd or from 3rd to 2nd gear
1
4
3
2
Does not change from 3rd to 1st or from 2nd to 1st gear
Shock from gear change felt when accelerator released
3
4
2
1
and speed decreases

High shift point when changing from 4th to 3rd, from 3rd
23
2
1
to 2nd, and from 2nd to 1st gear
23-103
Symptoms
Down-shift or engine overrunning when operating from
Engine races, slips when changing from 3rd to 2nd gear

Engine races, slips when changing from 4th to 2nd gear
Engine races, slips when changing from 4th to 3rd gear
No down-shift when operating from 4th gear (when
Engine races, slips when changing from 4th or 3rd to

4th gear (when vehicle speed over kick-down limit)
vehicle speed within kick-down limit)
Vehicle does not move in any range

1st gear
Possible causes
Automatic transmission fluid condition and level 1 1 1 1 1
Control linkage 2
Inhibiter switch
Accelerator sensor 1 2 2 2 2 2
Vehicle speed sensor 2 1
Overdrive switch
Line pressure 3 3 3 3 3
Control valve assembly 5 6 5 5
Shift solenoid A 3 3 5
Shift solenoid B 4 4
Line pressure solenoid 4 4 4 4 4
Lock-up solenoid
N - D accumulator
1 - 2 accumulator
2 - 3 accumulator
23-104
23
Symptoms
Abnormal smell from automatic transmission fluid filler pipe

Excessive shock when changing from 2nd to 1st gear
Does not change from 2nd to 1st gear while in L range
Automatic transmission fluid ejected through air

Changes from 2nd to 3rd gear while in 2 range
Changes from 1st to 2nd gear while in L range
Lock-up point extremely high or extremely low

Excessive noise when in D, 2, L, or R ranges
Engine brake not effective while in L range
Overheating of automatic transmission
breathers while cruising
Lock-up piston slips

Does not lock up
while in L range
Engine stalls
Possible causes
Automatic transmission fluid condition
1 1 1 1 1 1
and level
Control linkage 2
Engine idling revolution 2
Inhibiter switch 1 1 1 1 3
Accelerator sensor 3 3 1 2 1
Vehicle speed sensor 4 2 2 2
Engine revolution sensor 4
Overdrive switch
Line pressure 4 6 3
Control valve assembly 6 4 1 6 8 6 4
Shift solenoid A 5 3
Shift solenoid B
Line pressure solenoid 5 5
Lock-up solenoid 7 4 3
Overrunning clutch solenoid 7
N - D accumulator
1 - 2 accumulator
2 - 3 accumulator
Oil temperature sensor 5
23-105
Range selector lever cannot be shifted from P range even when brake
Symptoms
Range selector lever can be shifted from P range even when brake
Starter switch cannot be turned to LOCK position (Key cannot be
Starter switch turns to LOCK position even when range selector
pedal depressed (when starter switch in ACC to START position)
pedal not depressed (when starter switch in LOCK position)

pulled out even when range selector lever in P range)
Shift lock cannot be released using shift lock lever
Back buzzer does not sound

lever in other than P range
Possible causes
Wiring faulty, breakage
P range switch faulty
Shift lock actuator faulty
Range selector
Overdrive OFF switch faulty
lever
Automatic transmission reverse buzzer faulty
Mechanical fault of range selector lever
Key interlock solenoid faulty
Stop lamp switch faulty or adjusted incorrectly
Electronic Automatic transmission electronic control unit abnormal
control unit Key interlock electronic control unit abnormal
Starter switch faulty
23-106
INSPECTION OF TEMPORARY FAULT 23
Temporary Faults
02597
illustrated.
as illustrated.
suspensions.
02598
02599
23-107
INSPECTION USING THE CHECK BOX (HARNESS CHECKER)
A simple method for checking the electrical system is to use the harness checker and the check box.
NOTE
In this method, to connect the check harness, the connection between the cab harness and the automatic
transmission electronic control unit is cut off. This erases the trouble related signals recorded in the automatic
transmission electronic control unit. Therefore, if you carry out both this method and self-diagnosis for a
trouble, you must carry out self-diagnosis and keep written records of the diagnosis preceding this method.
G A
F
E 2
C 1
D 07828
Preparatory work before inspection

Turn the starter switch to ACC and cut off the power.
Disconnect automatic transmission electronic control unit 1 and cab harness 2.
Connect 1 check harness (MC134298) and 2 check box (MC134299) between cab harness 2 and automatic
electronic control unit 1.
A: Voltmeter changeover switch between 5 and 30 volts

B: Light-emitting diode
C: Right channel
D: Center channel 8 to 17
E: Left channel 1 to 7, or 8 to 17 (changeover)
F: Output terminal for external voltmeter (tester) or oscilloscope
G: Voltmeter
Inspection of sensor, harness and switch

Inspection is performed by operating channels C, D and E of 2 check box. For the changeover of channels from 1
to 7 use left channel E. To change over from 8 onward turn the left channel from 8 to 17, then use center channel D in
the proper order.
CAUTION
Turn the voltmeter changeover switch to OFF, before changing over channels.
23-108
23
No. Name Key switch channel channel Normal condition
1 Accelerator switch ON 1 4 12 to 13 volts when the accelerator pedal
(Engine stopped) is released, 1 volt or less when the
accelerator pedal is lightly depressed
2 Overdrive switch 2 12 to 13 volts when the switch is ON,
1 volt or less when the switch is OFF
3 Power mode switch 3 10.5 to 11.5 volts when the switch is ECO,
1 volt or less when the switch is PWR
4 Automatic transmission fluid 4 2 1.8 volts when the automatic transmission
temperature sensor fluid temperature is 10C {50F},
1.1 volts when the automatic transmission
fluid temperature is 40C {104F}
5 Ground ACC 5 Resistance between check box
terminal and metal parts of the vehicle
is 100 or less
6 6
7 VBATT ACC or ON 7 4 12 to 13 volts
(Power supply from battery) (Engine stopped)
8 VIG ON 8
(Power supply from starter (Engine stopped)
switch)
9 9
10 VOUT 10 2 4.5 to 5.5 volts
(Accelerator sensor power)
11 Accelerator sensor 11 0.9 to 1.0 volt when the accelerator is
fully closed, 4.0 to 4.2 volts when the
accelerator is fully opened
12 Exhaust brake 12 4 11.5 to 12.5 volts when the exhaust brake
is operating, 1 volt or less when the
exhaust brake is not operating
For the inspection of items 13, 14 and 15 below, use an external voltmeter (tester) or oscilloscope
13 Vehicle speed sensor 1 ON 13 1 0 volt when the vehicle is stopped,
(While travelling) 1 volt or more when the vehicle is
cruising at 30 km/h {18.6 mph}
14 Vehicle speed sensor 2 14 4 6374 pulses/km square wave
VL : 1 volt or less, VH : 4.5 to 5.5 volts
15 Engine revolution signal ON 15 3 4 pulses/Rev
(Engine revolving) 0 V5 V square wave
23-109
INSPECTION USING THE CHECK BOX (HARNESS CHECKER)
Inspection of Automatic Transmission Electronic Control Unit
Connect the vehicle to a chassis dynamo, etc.
Inspect the various parts by monitoring whether 2 check box light-emitting diode B lights up.
No. Name Light-emitting diode Normal Condition

1 Overrunning clutch solenoid 1 Lights up in 1st and 4th gear shift ranges
(Overrunning clutch OFF)
2 Lock-up solenoid 2 Lights up when the lock-up mechanism is operating
3 Line pressure solenoid 3 Brightest when the accelerator is fully closed, the more the
accelerator is opened the dimmer it gets
4 Shift solenoid A 4 Lights up in the 1st and 4th gear shift ranges
5 Shift solenoid B 5 Lights up in the 1st and 2nd gear shift ranges
NOTE
Gear shift range refers to the range into which each gear is shifted.
Work after inspection

Turn the starter switch to LOCK and cut off the power.
Disconnect 1 check harness from between the automatic transmission electronic control unit and the cab harness.
Connect the automatic transmission electronic control unit and the cab harness.
23-110
23
MEMO
23-111
Stall Test
Aim
The stall test is carried out to check the friction-prone elements inside the
automatic transmission, the sliding of the one-way clutch, the operation
of the torque converter and the overall performance of the engine.
Measurement procedure
Be sure to inspect the engine coolant, engine oil and the automatic
transmission fluid, before the test. Warm up the engine and the auto-
matic transmission to raise the temperatures of the coolant and the
automatic transmission fluid to an appropriate level.
Also make sure, in advance, that the accelerator sensor voltage is within
the specified limit. Replace the accelerator sensor if it is faulty.
CAUTION
Performing the stall test when the accelerator sensor voltage is
low might damage the transmission.
Chock the front and rear wheels, and apply the parking brake. Be sure
to keep the foot brake fully depressed while operating the accelerator
pedal.
Shift the range selector lever into the D range.
Slowly depress the accelerator pedal until it is fully depressed. When
the engine has reached a point at which it revolves at a steady rate
(stall revolution), write down the number of revolutions quickly and
release the accelerator pedal.
CAUTION
Each measurement should be completed within 10 seconds. If
continued for a longer time it might cause the deterioration of the
automatic transmission fluid or have an adverse effect on inter-
nal parts.
Stop the test immediately if the engine revolution does not stabi-
lize and keeps increasing gradually or if it suddenly increases as
if the engine were racing.
Shift the range selector lever into the N range, and cool the engine by
stabilizing its revolution at approximately 1200 rpm for one minute or
more.
Repeat the test for selector lever ranges 2, L and R.
Stall revolution
FE639 1720150 rpm
FE649 1820150 rpm
Diagnosis of results
Measurement results Possible faults
High at any selector lever range Line pressure is low
High when in the D range Forward clutch or forward one-way clutch is weakened *
High when in the D and 2 ranges Low one-way clutch slips *
High when in the R range Reverse clutch or low and reverse brake slips *
Within the limits One-way clutch stuck inside torque converter, or a fault in the high clutch or the brake band.
Other parts are normal *
Lower than the standard value Engine fault or one-way clutch inside torque converter slips *
* : To determine the cause precisely, carry out a road test.
23-112
23
Line Pressure Test

1 Pressure detector plug 4.9 to 9.8 {3.6 to 7.2, 0.5 to 1.0}
Aim
The line pressure test is carried out to check the oil pump performance,
the control valve functions and to check the hydraulic circuit for leakage.
Remove pressure detector plug 1 and install the pressure gauge in the
bottom front part of the automatic transmission case.
Measurement procedure is the same as for the stall test. Measure as
you gradually open the accelerator from engine idling.
Read the line pressure.
After measurement is completed, tighten pressure detector plug 1 at
specified torque.
NOTE
Since pressure detector plug 1 has sealant on its threads it
A
14131 cannot be reused.
Measure line pressure when the engine idling revolution is the
standard value.
Thread size for pressure detector plug 1
Automatic transmission case Plug, pressure gauge fitting

female screw (parallel pipe thread) male screw (taper pipe thread)
PS 1/8 PT 1/8
Line pressure Unit : kPa {lbf/in2, kgf/cm2}

R 470 to 745 {68 to 108, 4.8 to 7.6}
FE639
Oil pressure when engine is idling
FE649 D, 2, L 295 to 470 {43 to 68, 3.0 to 4.8}
R 1225 to 1520 {178 to 220, 12.5 to 15.5}
Oil pressure when engine is stalled FE639
FE649 D, 2, L 920 to 1100 {134 to 159, 9.4 to 11.2}
23-113
Diagnosis of results
Measurement results Possible faults

Measured value is low in all shift Abnormality might exist in the pressure supply system or output from the oil pump
ranges (P, R, N, D, 2, and L) is low. For example:
Oil pump worn
Control piston abnormal
Pressure regulator valve or plug stuck, spring fatigued
Hydraulic pressure leaks along the hydraulic line via the oil strainer oil pump
When engine is idling
pressure regulator valve

Engine idling revolution low
Measured value is low at particular Hydraulic pressure delivered from manual valve might be leaking from the related
selector lever range devices or lines. For example:
When there are hydraulic pressure leaks in the low and reverse brake systems,
line pressure will decrease in shift ranges R and L but will stay normal in ranges P,
N, D and 2
Measured value is high Abnormality might exist in sensors or in pressure adjustment functions. For example:
Accelerator sensor adjusted incorrectly
Oil temperature sensor broken
Line pressure solenoid malfunction (stuck in OFF, filter clogged, disconnection)
Pressure modifier valve stuck
Pressure regulator valve or plug stuck
Hydraulic pressure does not rise from Abnormality might exist in sensors or in pressure adjustment functions.
engine idling level For example:
Automatic transmission electronic control unit broken
Line pressure solenoid malfunction (stuck in ON)
Pilot valve stuck or pilot filter clogged
Pressure rises but does not reach Abnormality might exist in sensors or in pressure adjustment functions.
standard value For example:
Control piston abnormal
Line pressure solenoid malfunction (stuck, filter clogged)
Pilot valve stuck or pilot filter clogged
23-114
23
Road Test
Check, before the test, the level and state of the automatic transmission
fluid, and make sure that the range selector and accelerator control
cables are adjusted correctly.
During the road test, shift gears into every range to check for slippage
and other abnormalities.
Check if the lever is easy or hard to shift.
Check the shift points for both shift-up and shift-down.
Under various driving conditions, check the vehicle speeds at shifting.
Vehicle speeds at shifting Unit : km/h {mph}
Power mode switch OFF ON

Item (Economy mode) (Power mode)
D1D2 6 to 10 {3.73 to 6.21} 7 to 11 {4.35 to 6.84}
FE639 D2D3 14 to 20 {8.70 to 12.43} 16 to 22 {9.94 to 13.67}
Half throttle D3D4 22 to 28 {13.67 to 17.40} 29 to 35 {18.02 to 21.75}

Accelerator opening : 4/8 D1D2 5 to 9 {3.11 to 5.59} 5 to 9 {3.11 to 5.59}
FE649 D2D3 14 to 20 {8.70 to 12.43} 17 to 23 {10.56 to 14.29}
D3D4 24 to 30 {14.91 to 18.64} 29 to 35 {18.02 to 21.75}
D1D2 15 to 21 {9.32 to 13.05} 21 to 27 {13.05 to 16.78}
FE639 D2D3 36 to 42 {22.37 to 26.10} 43 to 49 {26.72 to 30.45}
Full throttle
D3D4 63 to 69 {39.15 to 42.88} 77 to 83 {47.85 to 51.58}
Accelerator opening : 8/8
(kickdown range) D1D2 15 to 21 {9.32 to 13.05} 19 to 25 {11.81 to 15.54}
FE649 D2D3 32 to 38 {19.88 to 23.61} 40 to 46 {24.86 to 28.58}
D3D4 56 to 62 {34.80 to 38.53} 76 to 82 {47.23 to 50.95}
23-115
Unit : km/h {mph}
Power mode switch OFF ON

Item (Economy mode) (Power mode)
L2L1 22 to 28 {13.67 to 17.40}
FE639 2322 50 to 56 {31.07 to 34.80}
2423 81 to 87 {50.33 to 54.06}
Accelerator fully closed : 0/8
L2L1 24 to 30 {14.91 to 18.64}
FE649 2322 51 to 57 {31.69 to 35.42}
2423 81 to 87 {50.33 to 54.06}
Unit : km/h {mph}
FE639
Overdrive switch ONOFF D4D3 81 to 87 {50.33 to 54.06}
FE649
Unit : km/h {mph}

2nd gear OFF 35 to 42 {21.75 to 26.10}
(in the 2 range only)
FE639 3rd gear ON 51 to 57 {31.69 to 35.42}
Half throttle 4th gear ON 70 to 76 {43.50 to 47.23}
Accelerator opening : 4/8 2nd gear ON 35 to 41 {21.75 to 25.48}
(in the 2 range only)
Lock-up speed FE649 3rd gear ON 53 to 59 {32.93 to 36.66}
4th gear ON 74 to 80 {45.98 to 49.71}
2nd gear ON 34 to 40 {21.13 to 24.86}
Accelerator opening FE639 (in the 2 range only)
Fully closed : 0/8 FE649 3rd gear OFF 35 to 42 {21.75 to 26.10}
4th gear OFF 35 to 42 {21.75 to 26.10}
When the automatic transmission fluid level is too low, air is sucked in along with the fluid from the pump. The air bubbles
turn the fluid spongy and can lead to a decline in pressure and slippage of the internal clutch.
If, on the other hand, the fluid level is too high due to an incorrect top up, the fluid is whipped up by the revolving parts and
the air bubbles thus created can lead to the same adverse conditions as when the level is too low.
In both cases the presence of air bubbles will lead to overheating, oxidation of the fluid or creation of varnish and will
prevent the valves and clutches from operating correctly.
Furthermore, the presence of air bubbles will cause the fluid to be discharged through the automatic transmission vents or
filler tubes, and can be mistaken for fluid leakage.
To prevent these from happening use the following procedure to correctly inspect the fluid level.
23-116
23
Inspection of Automatic Transmission Fluid
(1) Inspection of characteristics
If the automatic transmission fluid smells burnt or if it contains metal
particles or sludge as a result of internal friction and wear of metal or
other material, the transmission assembly must be completely over-
hauled. Make sure you carefully examine the fluid on dipstick 1. If you
find the quality questionable, take a sample and examine it more
closely.
(2) Inspection of automatic transmission fluid level

1 Park the vehicle on level ground, make sure that the parking brake
is fully activated and chock the wheels to keep them from rolling.
2 Start the engine and let it idle. To fill the hydraulic circuit with
automatic transmission fluid, slowly shift the range selector lever
once through the P to L ranges and finally shift into the N range.
While the engine is still idling, pull out dipstick 1 and wipe off the
C D fluid sticking to it. Reinsert the dipstick, then pull it out again and
check the fluid level.
07500 fluid temperature is still low (4015C {10427F}) the level should
be within area C marked COLD on dipstick 1 as illustrated in A.
If the fluid level is inspected after the vehicle has been driven and
the fluid temperature is high (6515C {14927F}) the level should
be within area D marked HOT on dipstick 1 as illustrated in B.
WARNING
Take care during the inspection because the engine will be
running. Take sufficient care to avoid burns or injuries result-
ing from contact with moving parts.
CAUTION
NOTE
engine is idling when you are checking the fluid level. When
the engine is at standstill, the fluid level appears higher than it
actually is.
actual drive.

23-117
Replacement of Automatic Transmission Fluid
(1) Draining
Place a container under the oil pan, remove drain plug 1 in the front
of the oil pan and drain the fluid.
WARNING
Take care because the automatic transmission fluid tempera-
ture immediately after the engine has stopped is very high. To
1 avoid scalds, wait until a safe temperature has been reached
before draining the fluid.
07820 NOTE
The fluid will drain faster if the engine is first run to raise the
fluid temperature.
The fluid cannot be drained from the hydraulic circuit, the
torque converter or the oil cooler.
Check the drained fluid for dirt, metal particles and metal
fragments.
(2) Supply
Add approximately 6.7 L {7.1 qts} of automatic transmission fluid
(DEXRON II type) through filler tube 2.
CAUTION
Make sure that dirt and foreign particles do not become mixed
in with the fluid when it is added.
2
Shift the range selector lever into the N range, start the engine and
07821 let it idle for at least two minutes.
After shifting the lever through all ranges once, shift it back into N.
CAUTION
To prevent burning out the interior of the automatic transmis-
sion assembly, make sure that the engine is not allowed to
race when you do the above.
Supply fluid until the fluid level is at the lower limit of the specified
area on dipstick 1. Next, check the fluid level to make sure it is
within the specified limit.
NOTE
Determining the fluid level immediately after supplying the
fluid might be difficult due to the fluid stuck in the inside of the
filler tube. Therefore, check the fluid level a few times between
intervals.
If the fluid is oversupplied, it will overflow and can be mistaken
for leakage.
23-118
23
(3) Fluid leakage
Automatic transmission converter housing area
Checking for the source of leakage
When checking for leaks keep in mind that leaks in the converter
and the surrounding areas can be the result of oil leaking from the
engine.
The color of the fluid is red and can be distinguished from engine oil.
Carry out the following inspection before removing the automatic
transmission.
Check carefully to find out whether the leaking is from the torque
converter or from the automatic transmission side (the oil seal area
of the oil pump housing or the area where the oil pump housing is
engaging with the case).
23-119
WORK BEFORE REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY
1
3
14096

2 Disconnect negative battery cable. ^ Gr 54
3 Jack up the front axle on a garage jack.
WARNING
racks.
CAUTION
Keep the automatic transmission in neutral throughout the operation.

23-120
REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY 23
Preparatory Work
Removal sequence
1 1 Oil cooler hose P23-126
2 Harness (ground)
3 Speedometer cable
4 Chassis harness
6 Selector cable P23-136
5 7 Propeller shaft ^ Gr 25
2
7 NOTE
After removing propeller shaft 7, tie it to
the frame at the height of installation as-
4 3 sembly using a piece of rope, etc.
14078
07931
23-121

Removal sequence
1 Bolt
2 Bolt
- 3 Dust cover
A 4 Bolt (8)
5 Bolt
7 5 6 Bolt
8 7 Bolt (4)
C 8 8 Driving plate
7
9 Automatic transmission assembly
B
1
A : Torque converter
3
B : Flywheel
4 2
6 C : Pilot area
07932
NOTE
Remove the automatic transmission assembly with driving plate 8 attached to torque converter A.

1 Bolt (Automatic transmission assembly and dust 47 {35, 4.8}
cover, common mounting)
2 Bolt (Dust cover mounting) 13 {9.4, 1.3}
4 Bolt (Flywheel and driving plate connecting) 32 {24, 3.3}
5 Bolt (Rear mounting) 83 to 105 {61 to 80, 8.5 to 11}
6 Bolt (Automatic transmission assembly mounting) 82 {61, 8.4} M12
47 {35, 4.8} M10
Bolt (Bracket mounting) 40 {30, 4.1}
7 Bolt (Driving plate mounting) 7912 {598.7, 8.11.2}
- Lubricant
9 Pilot area C of torque converter A inside the automatic Molybdenum disulfide grease As required
transmission assembly [NLGI No.2 (Li soap)]
23-122
23
9 Cranking handle MH061289 Cranking of engine
36 {1.42}
05999
9
Service procedure
Automatic transmission assembly
[Removal]
Remove dust cover 3.
3
07934
Put 0 cranking handle on the engine crankshaft pulley mounting nut,

and crank until bolt 4 can be reached through working hole D.
Continue cranking and remove eight bolts 4, two each at four points,
one by one.
0
07935
4 4
D 07936
23-123
6 Use a jack to support automatic transmission assembly 9 and remove

5 automatic transmission installation bolts 5, 6.
9
Remove automatic transmission assembly 9 by pulling it backward.
CAUTION
Be careful not to apply force to any part of the oil pan.
Since as a single unit torque converter A can come loose easily,
be careful not to drop it.
07937 NOTE
Installation bolts 6 differ in length, write down the location of
each before removing.
[Installation]
Install in advance driving plate 8 to torque converter A of automatic
transmission assembly 9.
Tighten bolts 7 at specified torque.
9
07938
Make sure that torque converter A is installed onto automatic trans-

B 8 9
39 mm mission assembly 9 correctly.
{1.54 in.} When the torque converter is correctly installed, the distance between
or more
the surface of driving plate 8 and the mounting surface of the case
A conforms to the dimension as illustrated.
C Apply grease to pilot area C.
07939
One of bolt holes E of flywheel B, for connection with driving plate 8,

should be at the bottom.
E 07940
One of bolt holes E, of driving plate 8, should be at the bottom.
8
E 07941
23-124
23
While aligning pilot area C with the dwell pin of the rear plate, slowly
6 insert automatic transmission assembly 9.
5
9 After temporarily tightening several installation bolts 6 of automatic
A
transmission assembly 9, tighten installation bolt 5 into the rear sup-
port at specified torque.
C NOTE
Since as a single unit torque converter A can come loose easily,
make sure that it is correctly positioned by slightly lowering the
rear part of automatic transmission assembly 9.
07942 Before connecting the parts together remove the oil sticking to
the interior walls of the torque converter housing.
Through working hole D align the connecting holes on driving plate 8

and flywheel B and temporarily tighten bolts 4.
Use 0 cranking handle to crank the engine and temporarily tighten
the eight bolts, two each at four points. Then, tighten all the bolts in the
same order, at specified torque.
0
07935
4 4
B
8
D 07943

While simultaneously tightening ground strap G and dust cover 3, tighten
F
all of the automatic transmission installation bolts 6 at specified torque.

3 : M101.25-40
: M101.25-60

2 G

: M121.75-60
: M101.5-20 (bracket F installation)

: M101.25-50+flange nut
: Starter installation bolt, nut

Tighten bolts 2 at specified torque and fix dust cover 3.

14028
23-125
OIL COOLER
21
24
20 23
22
3
6 25
7 4 3 4
1
2 1
3
3 4
4 5
1 5
1
2
8
1 -
-
16
6
14 19
18
11
13
17
13977
Removal sequence
1 Hose clamp 10 Automatic transmission fluid 19 Oil cooler rear support
2 Rubber hose thermostat switch 20 Eye bolt
3 Bolt 11 Plug 21 Oil cooler pipe
4 Clamp 12 Thermostat valve 22 Eye bolt
5 Eye bolt 13 Bracket 23 Oil cooler pipe
6 Oil cooler tube 14 Connector 24 Bracket
7 Bracket 15 Blower assembly 25 Vinyl tube
8 Bracket 16 Oil cooler assembly
9 Automatic transmission fluid 17 Oil cooler mount frame
temperature switch 18 Oil cooler front support
Follow the removal sequence in reverse
23-126
23
ature of automatic
temperature switch
ature of automatic
thermostat switch
12 Thermostat valve Starting operation 76.53C {1705.4F} Replace

temperature
Bypass opening 832C {1813.6F} Replace
temperature

9 Automatic transmission fluid temperature switch 29 to 39 {22 to 29, 3 to 4}
10 Automatic transmission fluid thermostat switch 29 to 39 {22 to 29, 3 to 4}
20 Eye bolt 25 to 34 {18 to 25, 2.5 to 3.5}
22 Eye bolt 25 to 34 {18 to 25, 2.5 to 3.5}
- Sealant
9 Thread area of automatic transmission fluid temperature switch THREEBOND 1110B As required
10 Thread area of automatic transmission fluid thermostat switch THREEBOND 1110B As required
1403C {2845.4F}
9
Service procedure
Inspection of automatic transmission fluid temperature
switch
ON
OFF Carry out the following inspection and replace automatic transmission
9 133C {271F} MIN fluid temperature switch 9 if there are any faults.
Check that there is no continuity between terminals and 1 at 2
ambient temperature of 205C {689F}.
2 1 Place automatic transmission fluid temperature switch 9 in a container
tween terminals 1 2
terminals1 2
the standard value.
23-127
OIL COOLER
973C {2075.4F}
ON
F Inspection of automatic transmission fluid thermostat
switch
10 OFF Carry out the following inspection and replace automatic transmission
90C {194F} MIN
fluid thermostat switch 10 if there are any faults.
Check that there is no continuity between terminals 1and 2at am-
bient temperature of 205C {689F}.
Place automatic transmission fluid thermostat switch 10 in a container
tween terminals 1 2
terminals1 2
the standard value.
A H Inspection of thermostat valve

Carry out the following inspection. If any fault is found, replace thermo-
stat valve 12.
B 12 Place thermostat valve 12 in a container filled with automatic trans-
mission fluid and raise the fluid temperature while stirring the fluid.
Make sure that end A starts stroking at a temperature of 76.53C
{1705.4F}.
Raise the fluid temperature further and make sure that end A expands
13978
by 4.5 mm {1.18 in.} and dimension B in the illustration is 13.4 mm
{0.53 in.} at a temperature of 832C {1813.6F}.
15
K Inspection of blower assembly
Check blower assembly 15 and make sure it operates when battery
voltage is loaded between terminals 1 2
and . If any fault is found,
replace the blower assembly.

07808
23-128
23
MEMO
23-129
Range Selector Lever
3
-
4
5
27
28
15 -
34 -
14 - 29 -
33
25
16
33 -
32
30
9
8 - - 38
31 - 38
41 39
10 40
35 42
18
24
2
- 19
23 43
44 37
1
17
*
45
13979
23-130
23
1 Nut 17 Screw 32 Pipe
2 Shift lock release knob 18 Indicator panel 33 Bushing
3 Adapter 19 Bolt 34 Selector lever
4 Screw 20 Shift lock actuator 35 Screw
5 Screw 21 Automatic transmission 36 P-range switch
6 Range selector lever cover reverse buzzer 37 Plate
7 Connector 22 Ball joint 38 Clevis pin
8 Screw 23 Lock nut 39 Shift lock link
9 Cover 24 Grommet 40 Shift lock link
10 Screw 25 Pin 41 Clevis pin
11 Switch button 26 Sleeve 42 Shift lock link
12 Overdrive OFF switch 27 Rod 43 Lever bracket
13 Pin 28 Spring 44 Bolt
14 Spring 29 Nut 45 Base plate
15 Shift button 30 Bushing
16 Automatic transmission knob 31 Rod * : Lever assembly P23-135
Assembly sequence

1 Nut (Lever assembly mounting) 17 to 22 {12 to 16, 1.7 to 2.2}
8 Screw (Cover mounting) 2.0 {1.4, 0.2}
10 Screw (Automatic transmission knob mounting) 2.0 {1.4, 0.2}
17 Screw (Indicator panel mounting) 0.98 to 1.96 {0.72 to 1.45, 0.1 to 0.2}
19 Bolt (Lever bracket mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
23 Lock nut (Ball joint mounting) 16 to 24 {12 to 17, 1.6 to 2.4}
29 Nut (Lever mounting) 9.8 to 14.0 {7.2 to 10.0, 1.0 to 1.4}
35 Screw (P-range switch mounting) 0.2 to 0.3 {0.14 to 0.22, 0.02 to 0.03}
44 Bolt (Base plate mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
- Lubricant
14 Periphery of spring Multipurpose grease [NLGI No.2 (Li soap)] As required
15 Sliding area of shift button Multipurpose grease [NLGI No.2 (Li soap)] As required
26 Sliding area of sleeve Wheel bearing grease [NLGI No.2 (Li soap)] As required
33 Interior of bushing Chassis grease [NLGI No.1 (Ca soap)] As required
34 Sliding area of selector lever Wheel bearing grease [NLGI No.2 (Li soap)] As required
38, 41 Sliding area of clevis pin Chassis grease [NLGI No.1 (Ca soap)] As required
43 Sliding area of lever bracket Chassis grease [NLGI No.1 (Ca soap)] As required
23-131
12
B
7
Service procedure
Removal of connector
Using screwdriver A, pull out terminal B of overdrive OFF switch 12 from
the inside of connector 7 and remove the connector.
A
7
07625
GH
[Removal]
Switch button, overdrive OFF switch
11 Using screwdriver A, remove switch button 11 from overdrive OFF

12
switch 12.
12 Remove overdrive OFF switch 12 from automatic transmission knob
16 by pushing the switch out.
A
16
13980
[Inspection of overdrive OFF switch 12]

12
Free
1 : RW 2 : BW 3 : YW
Lock
2 : BW
1 : RW Free
Lock


Replace overdrive OFF switch 12 if it is faulty.
3 : YW 07488
16
15
I Removal of pin
While keeping shift button 15 and spring 14 pressed down, remove pin
13 towards the inside (arrow direction) of automatic transmission knob
16.
13 14
13981
23-132
23
Brake
switch
Other loads P Inspection of shift lock actuator

20
P-range switch IG +B Brake P range Unlock Lock

Lock
Unlock 07489

Check to make sure that shift lock actuator 20 is in operating mode under
the above power supply and switch position.
Q
Replace the shift lock actuator if it is faulty.
Inspection of automatic transmission reverse buzzer

21 Check to make sure that the automatic transmission reverse buzzer
sounds when 12 volts DC is loaded between terminals 1
and . 2
Replace automatic transmission reverse buzzer 21 if it is faulty.
NOTE
Automatic transmission reverse buzzer 21 sounds continuously
when you apply voltage.
If you want to make automatic transmission reverse buzzer 21
07145 sound intermittently, use the automatic transmission reverse
R
buzzer and the back buzzer in combination.
23 Installation of ball joint

31
Using ball joint 22 adjust rod 31 so that its thread ridge conforms to the
16 mm {0.63 in.} dimensions as illustrated, then tighten with lock nut 23.
(at least 13 mm
{0.51 in.})
22
07628
V Installation of sleeve
Shift range selector lever 34 to the P range. Install sleeve 26 by rotating it
26 so that the dimension between the sleeve and the upper part of the lever
conforms to the value as illustrated.
15.2 to 15.9 mm
{0.60 to 0.63 in.}
34
07629
23-133
OFF
ON
` P-range switch
[Inspection]
1 2 3
36 321 ON
OFF
Replace P-range switch 36 if it is faulty.
07630
[Installation]
Install P-range switch 36 so that it is OFF when the range selector lever
is in the P range.
23-134
23
Lever Assembly
1 Nut
4
2 Clip
3 Nut
4 Nut
9 5 Spacer (for adjustment)
6 Bushing
7 Lever
8 Collar
3 1 9 Lever bracket
*1 : Range selector lever P23-130

*2 : Selector cable P23-136
6 *1
Assembly sequence
7 8
5 *22
6 76 43
8 9 *11
-
*2
2
13982

1 Nut (Range selector lever mounting) 17 to 22 {12 to 16, 1.7 to 2.2}
3 Nut (Bracket mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
- Lubricant
8 Periphery of collar Chassis grease [NLGI No.1 (Ca soap)] As required
4
5
Service procedure
Selection of spacer
Select the spacer so that when nut 4 is tightened at specified torque
the clearance between lever bracket 9 and spacer 5 conforms to the
dimensions as illustrated.
5 5
There are two spacer thicknesses available : 0.3, 0.5 mm {0.012,
9 0.020 in.}
0 to 0.3 mm {0 to 0.012 in.} 7 After installation make sure lever 7 can be operated smoothly.
07810
23-135
-
18 21
23
22 -

11 20
19 -
14 - 19 24 25
12

9 10 26
27
8 28
4
13
32
31
3 30
7
5
*1
*2
13983
Removal sequence
1 Nut 11 Bolt 21 Nut 30 Bolt
2 Nut 12 Nut 22 Bushing 31 Power take-off cover
3 Nut 13 Insulator 23 Lever 32 Gasket
4 Nut 14 Nut 24 Bolt
5 Bolt 15 Bracket 25 Bracket *1 : To lever assembly
6 Bracket 16 Selector cable 26 Nut P23-135
7 Bolt 17 Adjuster 27 Lever *2 : Automatic transmission
8 Clip 18 Bushing 28 Bolt body
9 Nut 19 Bushing 29 Inhibiter switch : Non-reusable parts
10 Clip 20 Rod

1, 2 Nut (Selector cable mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
3, 9, Nut (Bracket and clip mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
12, 14
4 Nut (Bracket mounting) 59 to 78 {43 to 58, 6.0 to 8.0}
7, 11 Bolt (Clip and insulator mounting) 9.8 to 15.0 {7.2 to 11.0, 1.0 to 1.5}
16 Selector cable (Installed on bracket) 59 to 83 {43 to 61, 6.0 to 8.5}
24 Bolt (Bracket mounting) 69 to 93 {51 to 69, 7.0 to 9.5}
26 Nut (Lever mounting) 43 {32, 4.4}
28 Bolt (Inhibiter switch mounting) 1.96 to 2.55 {1.45 to 1.88, 0.20 to 0.26}
30 Bolt (Power take-off cover mounting) 32 to 42 {24 to 31, 3.3 to 4.3}
23-136
23
- Lubricant
18, 19, 22 Interior of bushing Chassis grease [NLGI No.1 (Ca soap)] As required

29 Inhibiter switch set pin MH062063 Adjustment of inhibiter switch
4 {0.16}
03727
2 1
126K M
Service procedure
to Nut, bracket, selector cable and
adjuster
[Installation]
Loosen nuts 1, 2 all the way to the two ends of the screw as illustrated.
16
17 07770
Put in-cab automatic transmission lever knob A and automatic trans-

mission lever 27 into the N range.
N D 2
A R L
P
27
13984
Jiggle in-cab automatic transmission lever knob A back and forth.
13985
23-137
After making sure that in-cab automatic transmission lever knob A is
2 1 in the N range, tighten nuts 1, 2 at specified torque.
A CAUTION
When tightening nuts 1, 2 make sure that adjuster 17 does not
move from its position.
16
17
13986
Make sure that starter key B can be pulled out when in-cab automatic
A transmission lever knob A is in the N range.
13987
Install brackets 6, 15 to marking area C of selector cable 16 as

illustrated. Install clips 8, 10 and insulator 13 in that order.
6
16 C 8 16
15
10 16 13 16 13988
[Adjustment]
D 2
While shifting the in-cab automatic transmission lever knob A through all
A R
N L
P
the ranges from L to P, use nuts 1, 2 to adjust selector cable 16 so that
automatic transmission lever 27 can move smoothly through ranges L to
27 P.
CAUTION
1 If nuts 1, 2 are adjusted incorrectly, in-cab automatic transmis-
2
sion lever knob A will not move smoothly around ranges L or P.
Incorrect adjustment can also prevent the starter key from being
pulled out when the range selector lever is in the P range.
16
13989
23-138
23
28 Y Inhibiter switch
[Removal]
28 After moving manual shaft A to the L range as illustrated, loosen bolt 28
29
and remove inhibiter switch 29.
28
A 07795
[Installation]
Move manual shaft A to the L range as illustrated and install inhibiter
29 switch 29 temporarily.
A 07796
Move manual shaft A to the N range as illustrated.
A
07797
29 28 C Insert 0 inhibiter switch set pin or a 4 mm pin through positioning

28
holes C of inhibiter switch 29 and range selector lever B at right
angles, tighten bolt 28 at specified torque and pull out the pin.
B
0
28 07798
[Inspection]
Check to make sure that when lever 27 is moved to the R range, the
N D 2 L
R back lamp lights and the back buzzers (inside and outside the cab)
P
sound. Also check to see that the starter operates when the lever is in
the N and P ranges.
27
07799
23-139
Use a tester and check wiring connector D leading out from inhibiter
1 2 3 4 5
9 8 7 6 switch 29 for continuity.
< Connection chart >
D 1 2 3 4 5 6 7 8 9
P
R
29 N
07800 D
2
L
Check to make sure that when lever 27 is in the N range and is rotated
29
in both directions from a fixed position, continuity exists within (almost)
N D 2
the same range in both other directions. (Continuity within approxi-
L
R
mately 1.5 from the fixed position in each of the other two directions is
P
considered normal.)
27 Adjust inhibiter switch 29 as required, depending on whether there is
continuity and whether continuity is in the correct range.
07801
28 [Adjustment]
28 Loosen bolts 28 and move range selector lever B into the N range as
illustrated.
28
07802
29 28 C Insert 0 inhibiter switch set pin or a 4 mm pin through positioning

28
holes C of inhibiter switch 29 and range selector lever B at right
angles, tighten bolt 28 at specified torque and pull out the pin.
B
0
28 07798
Repeat the inspection procedure mentioned above and replace

inhibiter switch 29 if it is faulty.
23-140
23
MEMO
23-141
REPLACEMENT OF RELATIVE PARTS OF AUTOMATIC TRANSMISSION BODY
-
*1
*2
-
-
2 10

6 5
-
14

-8
9
7

13
12
07859
1 Torque converter 11 Rear oil seal
2 O-ring 12 Drain plug
3 Front oil seal 13 Bolt
4 Oil seal 14 Gasket
5 Speedometer gear bushing 15 Oil pan
6 Speedometer gear
7 Bolt *1 : Automatic transmission body
8 O-ring *2 : Parking brake assembly ^ Gr 36
9 Vehicle speed sensor 1 : Non-reusable parts
10 Speedometer gear bushing
Assembly sequence
23-142
23
5 Speedometer gear bushing 78 to 88 {58 to 65, 8 to 9}
7 Bolt (Vehicle speed sensor 1 mounting) 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7}
13 Bolt (Oil pan mounting) 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
- Sealant
2 O-ring Automatic transmission fluid As required
(DEXRON II type)
3 Outer periphery of front oil seal Automatic transmission fluid As required
(DEXRON II type)
Lip area of front oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
4 Lip and packing areas of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
8 O-ring Automatic transmission fluid As required
(DEXRON II type)
11 Outer periphery of rear oil seal Automatic transmission fluid As required
(DEXRON II type)
Lip area of rear oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
*1 Installation surface of front and rear oil seals Automatic transmission fluid As required
(DEXRON II type)

3 Oil seal installer MH062061 Installation of front oil seal

46 {1.81}
07809
11 Oil seal installer MH062062 Installation of rear oil seal
45 {1.77}
07860
23-143
1
1
Service procedure
Installation of torque converter
After applying automatic transmission fluid (DEXRON II type) to O-ring
3 2 and front oil seal 3, assemble torque converter 1 by rotating and
pushing it in.
A : Input shaft
CAUTION
2 A Be careful not to damage front oil seal 3
07861
When torque converter 1 is correctly assembled, the distance be-

43 mm {1.69 in.} tween the lug and case surfaces conforms to the dimension as
or more
illustrated.
07862
*1
3 3 Front oil seal
[Removal]
Using screwdriver A or a similar instrument as a lever, remove front oil
seal 3 from automatic transmission body *1.
After removing front oil seal 3, be sure to clean the area on automatic
transmission body *1 where it was installed.
A
07863
C
Apply grease to packing area A and lip area B of oil seal 4.
Using a round bar C of approximately 15 mm {0.59 in.}, drive in oil
seal 4 evenly in the direction as illustrated.
B A
4
04771
23-144
23
B C [Installation]
Apply automatic transmission fluid (DEXRON II type) to periphery B of
front oil seal 3 and to oil seal installation surface C on automatic
transmission body *1.
Apply grease to lip area D of front oil seal 3, and use 0 oil seal
3 D installer to press-fit the oil seal into automatic transmission body *1.
*1
0 07864
11
G Rear oil seal
[Removal]
*1 Using screwdriver A or a similar instrument as a lever, remove rear oil
seal 11 from automatic transmission body *1.
After removing rear oil seal 11, be sure to clean the area on automatic
transmission body *1 where it was installed.
A
07865
C [Installation]
D Apply automatic transmission fluid (DEXRON II type) to periphery C of
rear oil seal 11 and to oil seal installation surface D on automatic
E *1 Apply grease to lip area E of rear oil seal 11, and use 0 oil seal
11 installer to press-fit the oil seal into automatic transmission body *1.
0 07866
K Installation of oil pan

Be sure to wipe off sealant sticking to the thread area on automatic
Be sure to clean the area on automatic transmission body *1 where
gasket 14 is to be installed.
A Install magnet A as illustrated, when using new oil pan 15 or when the
magnet has been removed.
B : Front of the vehicle
B
15
07867
23-145
After installing a new gasket 14 in oil pan 15, align illustrated holes C
with automatic transmission body *1 and install the oil pan.
When installing gasket 14, be sure to clean the surface on oil pan 15
C where the gasket is to be installed.
14
*1
15
C
07868
15 Install bolts 13 to oil pan 15 and tighten at specified torque in the

8 13
6 11 numbered order as illustrated.
2
4 17 B : Front of the vehicle
10
15
9
18 3
12 1
14 5
16
B 7
13
07869
23-146
Group 24
Transfer
' 98 Minor Change

Table of Contents
BACK HOME

24
GROUP 24 TRANSFER < FG >
SPECIFICATIONS ........................................................................... 24- 2
STRUCTURE AND OPERATION .................................................... 24- 2
TROUBLESHOOTING ..................................................................... 24- 4
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY ..... 24- 6
FRONT DRIVE ................................................................................. 24- 10
IDLER GEAR AND REAR DRIVE ................................................... 24- 16
TRANSFER CONTROL ................................................................... 24- 22
24-1
SPECIFICATIONS
Item Specifications
Model TF3
Gear ratio HIGH 1.090
LOW 1.987
Gear oil Oil quantity L {qts.} 3.0 {3.2}
Dry mass (including transmission body) kg {lb} Approximately 190 {420}
Control Front drive and HIGH-LOW switching floor change remote control

Transfer Body
1 Transmission main shaft
1 2
2 Drive shaft gear
3 Transfer idler gear
4 Transfer idler shaft
5 Output shaft
6 Output shaft LOW gear
7 Output shaft HIGH gear
3 8 Front drive hub and sleeve
9 Front drive shaft
8
7 6 27272
1 2 The transfer functions as both the distributer for four-wheel

drive and as the sub-transmission with a reduction device.
This transfer is a three-shaft constant-mesh type.
3 HIGH/LOW changeover and front drive ON/OFF are control-
7
4 led by a transfer control lever in the cab.
8 6
9
5
To front axle To rear axle
ON OFF
HIGH LOW
Front drive 06389
HIGH/LOW switching
24-2
24
Transfer Control
2
3
4
27273
1 Transfer control lever 3 Transfer

2 2H/4H control cable 4 HIGH/LOW control cable
Move the transfer control lever 1 from left to right to change-over between two-wheel drive and four-wheel drive. Forward
and backward movement changes between HIGH and LOW.
Transfer Control Electric Circuit

1 Fuse box
1 2 2 Meter cluster
3 Transfer four-wheel drive indicator
3 4 lamp
4 Transfer LOW indicator lamp
5 Transfer LOW switch
6 Transfer four-wheel drive switch
Shift transfer control lever to 4L and transfer

LOW switch 5 comes ON and transfer LOW
indicator lamp 4 in the meter cluster 2 lights
up. Shift transfer control lever to 4H and trans-
fer four-wheel drive switch 6 comes ON and
transfer four-wheel drive indicator lamp 3 lights
up.
6 5
27274
24-3
TROUBLESHOOTING
Symptoms
Gears fail to disengage on HIGH/LOW changeover

Gears fail to disengage on front drive changeover
Gears fail to engage at HIGH/LOW changeover
Gears fail to engage at front drive changeover
Front drive is engaged, but indicator is not lit
Front drive is not engaged, but indicator is lit

Gears slip out while cruising in front drive
LOW is selected, but indicator is not lit
LOW is not selected, but indicator is lit

Gears slip out while cruising
Possible causes
Front drive shaft and constant sleeve splines worn
Hub and HIGH/LOW constant sleeve splines worn
Idler shaft bearing worn or damaged
Output shaft bearing worn or damaged
Drive shaft needle bearing worn or damaged
Transfer Gears damaged
body faulty Output shaft LOW gear and HIGH gear
backlash excessive
Gear oil viscosity unsuitable
Constant sleeve and dog clutch cracked
HIGH/LOW constant sleeve and hub cracked
Shift rail bent
Shift rail friction movement poor
Control mechanism Shift fork bent
faulty Shift fork claw worn
Steel ball and shift rail poppet groove worn
Poppet spring fatigued or cracked
Transfer control Control cable faulty
system faulty LOW switch faulty
Transfer four-wheel drive switch faulty
Wiring broken or connection poor
24-4
24
MEMO
24-5

9
A
- 1
- 4
14 12 - -

* 6
8 7
13
11
27275
1 Bolt 10 Oil seal
2 Air breather 11 Transfer assembly P24-10, 16
3 Needle bearing 12 Distance pipe
4 Transfer input rear cover 13 Bolt
5 Lock nut 14 Extension spacer
6 O-ring
7 Drive shaft gear A : Positioning pin
8 Bolt * : Transmission assembly
9 Bolt : Non-reusable parts
NOTE
For removal from vehicle, see ^ Gr 10.
Check backlash of drive shaft gear 7 before disassembly.
Do not remove needle bearing 3 from transfer input rear cover 4 unless it is faulty.
Assembly sequence
NOTE
Check backlash when assembling parts.
24-6
24
7, 11 Drive shaft gear and transfer idler gear backlash 0.08 to 0.22 {0.0031 to 0.0087} 0.50 {0.020}

1 Bolt (Transfer input rear cover mounting) 44 {33, 4.5}
5 Lock nut tightening torque 49049 {36036, 505}
13 Bolt (Extension spacer mounting) 44 {33, 4.5}

* Mounting surface of extension spacer transmission assembly THREEBOND 1215 As required
4 Mounting surface of transfer assembly transfer input rear cover THREEBOND 1215 As required
10 Lip area of oil seal and transfer assembly Wheel bearing grease As required
[NLGI No.2 (Li soap)]
14 Mounting surface of transfer assembly extension spacer THREEBOND 1215 As required

25 {0.98}
32.5
{1.28}
3 Needle roller bearing MH061926 Installation of input rear cover needle

installer bearing
50
4 {0.16}
{1.97}
06396
50
{1.97}
5 Socket wrench 44490-44101 Removal and installation of transmission
main shaft lock nut
00069
184
55.5 {7.24}
{2.19}
10 Oil seal installer MH061924 Installation of oil seal
85
{3.35}
06398
24-7
0
3
Service procedure
Installation of needle bearing
3 4
5
06399
Removal and installation of lock nut

0 : Socket wrench
7
0
5
06400
11 F Installation of oil seal

10
A 0
06401
24-8
24
MEMO
24-9
FRONT DRIVE
3

-4
13
40

33
11
31
30
28
27
- 26 36
35
20 8
14 *
9 38 1
37 -
22 * 3
7
34
6 29
-5 19 39
20 -
16 17 21
15 24
27 -
18

- -

27276
1 Bolt 14 Interlock ball 29 Synchronizer sleeve
2 Shift rail cover 15 Lock nut 30 Front drive shift fork
3 Bolt 16 O-ring 31 Snap ring
4 Transfer case side cover 17 Companion flange 32 Front drive shift rail
5 Screw plug 18 Bolt 33 Shift rail stopper
6 Poppet spring 19 Front drive shaft 34 Snap ring
7 Steel ball 20 Snap ring 35 Front drive hub
8 Transfer LOW switch 21 Bearing 36 Snap ring
^ Gr54 22 Dust cap 37 Bolt
9 Transfer four-wheel drive 23 Oil seal 38 Front drive case
switch ^ Gr54 24 Front drive case cover 39 Oil seal
10 Screw plug 25 Set bolt 40 Transfer assembly
11 Set bolt 26 Snap ring
12 HIGH/LOW shift rail 27 Retainer * : Dowel pin
13 HIGH/LOW shift fork 28 Spring : Non-reusable parts
24-10
24
NOTE
HIGH and LOW shift rail 12 cannot be disassembled unless front drive shift rail 32 is set to front drive ON.
Assembly sequence
4039383736353433
25
323130282726
29 181716151410
131211
242322212019 987654321

12 Deflection of HIGH/LOW shift rail 0.02 {0.00079} or less 0.03 Correct
{0.0012} or replace
12, 40 Clearance between HIGH/LOW shift rail [16 {0.63}] 0.05 to 0.09 0.2 Replace
and transfer assembly rail hole {0.0020 to 0.0035} {0.0079} faulty parts
13 Tilt of claw against HIGH/LOW shift fork hole 0.1 {0.0039} or less 0.2 {0.0079} Replace
13, 29 Clearance between HIGH/LOW shift fork 0.3 to 0.5 1.0 Replace
and synchronizer sleeve {0.012 to 0.020} {0.039} faulty parts
29, 30 Clearance between front drive shift fork 0.3 to 0.5 1.0 Replace
and synchronizer sleeve {0.012 to 0.020} {0.039} faulty parts
30 Tilt of claw against front drive shift fork hole 0.1 {0.0039} or less 0.2 Replace
{0.0079} faulty parts
32 Front drive shift rail deflection 0.02 {0.00079} or less 0.03 Correct
{0.0012} or replace
32, 40 Clearance between front drive shift rail [16 {0.63}] 0.05 to 0.09 0.2 Replace
and transfer assembly rail hole {0.0020 to 0.0035} {0.0079} faulty parts

1 Bolt (Shift rail cover mounting) 44 {33,4.5}
3 Bolt (Transfer case side cover mounting) 24 {17, 2.4}
8 Transfer LOW switch tightening 344.9 {253.6, 3.50.5}
9 Transfer four-wheel drive switch tightening 344.9 {253.6, 3.50.5}

11 Set bolt (Shift fork mounting) 29 {22, 3} Caulk at
three points
after
tightening
15 Lock nut tightening 29549 {21536, 305}
18 Bolt (Front drive case cover mounting) 44 {33, 4.5}
37 Bolt (Front drive case mounting) 44 {33, 4.5}
24-11
FRONT DRIVE
4 Mounting surface of transfer assembly transfer case side cover THREEBOND 1215 As required
24 Mounting surface of front drive case front drive case cover THREEBOND 1215 As required
38 Mounting surface of transfer assembly front drive case THREEBOND 1215 As required

20, 26, 34 Snap ring expander MH061268 Removal and installation of snap ring
01137
42
{1.65}
Bearing installer MB999104
52
23 {2.05} 05661 Installation of front drive case cover oil seal
Differential bearing inner MB999105

race installer adapter 88
{3.46} 50
{1.97} 05667
15.5 {0.61}
39 Oil seal installer MH061923 Installation of shift rail oil seal
35
{1.38} 19 {0.75} 06404
24-12
24
GU
Service procedure
Removal and installation of set bolt

Tighten shift fork mounting set bolt 11, 25 at specified torque, and stake
the thread area at three points using a punch.
H\
06405
Inspection of shift rail

12, 32 12, 32.
NOTE
To measure the deflection of shift rails 12, 32, turn them one full
H\d
01127
Clearance between shift rail and transfer assembly

rail hole
40 Measure the outer diameter of shift rail 12, 32 and the inner diameter of
12, 32 transfer assembly hole 40. If the clearance is higher than the limit,
replace faulty parts.
IYZ
06406
Clearance between shift fork and synchronizer

sleeve
29
13, 30
06407
24-13
FRONT DRIVE
1
S Installation of oil seal
2 : Differential bearing inner race installer adapter
2
23
c
06409

Apply grease to lip area A of oil seal 39 and press-fit it into transfer
40
A assembly 40.
39 0
06410
24-14
24
MEMO
24-15
32 28 27 -
29
25-
31 30
34
32 29
26
9- 7-

10 11 1
12
13
4
-
21
-

33

-
33

-
19
-
17
16
27278
1 Bolt 19 Rear drive shaft HIGH gear
2 Spring pin 20 Needle bearing
3 Speedometer gear 21 Synchronizer sleeve
4 O-ring 22 Needle bearing
5 Oil seal 23 Rear drive shaft LOW gear
6 Speedometer gear bushing 24 Needle bearing
7 Bolt 25 Bolt
8 Oil seal 26 Plate
9 Output rear cover 27 Idler rear cover
10 Speedometer worm 28 Shim
11 Key 29 O-ring
12 Snap ring 30 Transfer idler shaft
13 Bearing 31 Transfer idler gear
14 Thrust washer 32 Bearing
15 Rear drive shaft 33 Drain plug, inspection plug
16 Snap ring 34 Transfer case
17 Bearing
18 Thrust washer : Non-reusable parts
24-16
24
NOTE
Check backlash and end play of gears before disassembly.
Do not remove needle bearing 22 from rear drive shaft 15 unless it is faulty.
Assembly sequence
3132
3433 28272625
3029 1716111022
15212423141312201918 7
65432
1
98
NOTE
Check backlash and end play when assembling parts.
Check friction and rotation movements when assembling rotating parts.

Standard value
Starting torque of transfer idler gear 0 to 2 {0 to 1.45, 0 to 0.2} Adjust shim

3, 6 Clearance between speedometer gear and [12] 0.04 to 0.09 0.15 Replace
speedometer gear bushing {[0.47] 0.0016 to 0.0035} {0.0059}
15, 19, 20 Play of rear drive shaft HIGH gear in diameter 0.02 to 0.06 0.12 Replace
15, 23, 24 Play of rear drive shaft LOW gear in diameter 0.02 to 0.06 0.12 Replace
19 End play of rear drive shaft HIGH gear 0.25 to 0.40 0.60 Replace
{0.0098 to 0.0016} {0.024} thrust washer
or gear
19, 31 Backlash between rear drive shaft HIGH gear 0.08 to 0.22 0.50 Replace
and transfer idler gear {0.0031 to 0.0087} {0.020}
21 Clearance between synchronizer sleeve groove 0.3 to 0.5 1.0 Replace
and HIGH/LOW shift fork {0.012 to 0.020} {0.039} faulty parts
23 End play of rear drive shaft LOW gear 0.25 to 0.40 0.60 Replace
{0.0098 to 0.016} {0.024} thrust washer
or gear
23, 31 Backlash between rear drive shaft LOW gear 0.08 to 0.24 0.50 Replace
and transfer idler gear {0.0031 to 0.0094} {0.020}

7 Bolt (Output rear cover mounting) 44 {33, 4.5}
25 Bolt (Plate and idler rear cover mounting) 44 {33, 4.5}
33 Drain plug and inspection plug tightening 6915 {5111, 7.01.5}
24-17
- Lublicant and/or sealant
Location Points of application Specified lublicant and/or sealant Quantity
3 Friction surfaces between speedometer gear and speedometer Molybdenum disulfide grease As required
gear bushing
9 Mounting surface of transfer case output rear cover THREEBOND 1215 As required
27 Mounting surface of transfer case idler rear cover THREEBOND 1215 As required
33 Thread area of drain plug and inspection plug THREEBOND 1105D As required

16.5
{0.65}
8 Oil seal installer MH062691 Installation of output rear cover oil seal
06252
12 Snap ring expander MH061268 Removal and installation of snap rings
01137
40
{1.57}
22 Needle roller bearing MH061927 Installation of rear drive shaft needle

installer bearing
13
18.5 {0.51} 28 {1.10}
{0.73} 15 {0.59} 06413
24-18
24
Service procedure
Inspection before service
Starting torque of transfer idler gear
28 31
Disassemble parts, and measure the torque with push gauge A
A
leaving only transfer idler gear 31 in transfer case.
If the value deviates from the standard value, adjust it using shim
28.
On assembly, also check that starting torque is within the standard
value range using the same method.
Shim 28 is available in four thicknesses : 0.01 mm {0.00039 in.},
0.02 mm {0.00079 in.}, 0.03 mm {0.0012 in.}, 0.06 mm {0.0024 in.}.
2
07633
2 Driving-in spring pin

the opposite direction to speedometer gear 3.
3
6
36
03576
Clearance between speedometer gear and speedometer

gear bushing
3
5
03577

B Apply grease to lip area A of the inner rim of the oil seal, and press-fit oil
seal evenly into speedometer gear bushing 6 in the direction as illus-
trated using bar B (approximately 15 mm {0.59 in.}).
A 5
6
03578
24-19
6 Installation of speedometer gear bushing
Due to its eccentric center arrangement, speedometer gear bushing 6
6 allows replacement of speedometer gear 3 with gears having a different
number of teeth by changing only the installation direction, the worm
gear does not have to be changed.
M
When installing the bushing, align the stamped number, identical to the
number of speedometer gear teeth, with alignment mark M of output rear
cover 9.
The number of speedometer gear teeth can be identified by the identifi-
cation marks stamped on N or P.
3 P N Identification mark and number of speedometer gear teeth
Identification
mark A B C D L E F G H I J K
Number of
teeth 15 16 17 18 19 20 21 22 23 24 25 26
Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.2
8
06416

Apply grease to lip area A of oil seal 8 and press-fit it into output rear
cover 9.
0 8
JN
06419
Installation of thrust washer

Install thrust washer 14, 18 with oil groove A facing gear side.
A 14, 18
06418
24-20
24
KNPST Play of rear drive shaft gear in diameter
direction after assembly
NOTE
When replacing needle bearing 20, 24, use bearings from the
same color package.
R
01149
Installation of needle bearing

0 22
06420
24-21
TRANSFER CONTROL
Control Cable < Removal from the transfer side >
Work before removal
*b P24-22

1 3 Removal sequence
2
1 Bolt
4
2 Nut
3 Nut
4 HIGH/LOW control cable
5 2H/4H control cable
6 Shift rail cover
*a : Transfer body
*b : HIGH/LOW shift rail
*c : Front drive shift rail
*a *c 1 3
6 2 5 Installation sequence

27279

1 Bolt (Shift rail cover mounting) 44 {33, 4.5}
2, 3 Nut (HIGH/LOW and 2H/4H control cable mounting) 44 to 59 {33 to 43, 4.5 to 6.0}
Service procedure
Work before removal
A When removing, move shift lever knob A of the transfer control bar to
the position 4H.
27280
24-22
24
1
45
[Removal]
HIGH/LOW, 2H/4H Control Cable
Remove bolt 1 securing shift rail cover 6.
6
1
27281
Remove shift rail cover 6, and then remove inner cable A of HIGH/
*b, *c LOW and 2H/4H control cables 4 and 5, from HIGH/LOW shift rail *b,
*b, *c 3 2 A 3 2
and front drive shift rail *c. Loosen nuts 2 and 3 to their end of their
threads.
A 6 4, 5 6 4, 5
27282
Remove HIGH/LOW and 2H/4H control cables 4 and 5 from shift rail
cover 6.
4
5
6 27283
B [Installation]
*b Position HIGH/LOW shift rail *b and front drive shift rail *c as shown.
15 mm {0.59 in.} B : Transfer end face
8 mm {0.31 in.}
*c 27284
Adjust nuts 2 and 3 to the end of the thread to align the end of HIGH/
3 2
LOW and 2H/4H control cables 4 and 5 as shown.
82 mm
{0.310.079 in.}
4, 5
27285
24-23
TRANSFER CONTROL
Screw nut 3 into shift rail cover 6 and tighten it to the specified torque.
2 mm
{0.079 in.}
3
C CAUTION
Ensure that the HIGH/LOW and four-wheel / two-wheel drive
control cables are not positioned incorrectly.
The cable with the white line C is for HIGH/LOW.
After installation, the end of nut 3 should be located 2
mm{0.079 in.} from the front face of shift rail cover 6.
6 3
27286
2 mm Tighten the nut with its specified torque and lock it with nut 3. Then
*b, *c {0.079 in.} *b, *c slide the shift rail cover 6 and install the inner cable A to HIGH/LOW
shift rail *b and front drive shift rail *c.
6 2 A 6 2
A
27287
1 Tighten shift rail cover 6 installation bolt 1 at the specified torque.

102 mm
{0.390.079 in.}
102 mm
6 {0.390.079 in.}
1 27288
24-24
24
MEMO
24-25
TRANSFER CONTROL
Control cable < Removal from the transfer control cable side >
Removal Sequence
1 Nut
2 Bolt
3 Lock pin
4 Nut
5 HIGH/LOW control cable
6 Nut
7 2H/4H control cable

1
3
4
7
27289

1 Nut (HIGH/LOW control cable mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
2 Bolt (2H/4H control cable mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
4, 6 Nut (HIGH/LOW control cable and 2H/4H control 44 to 59 {33 to 43, 4.5 to 6.0}
cable mounting)
24-26
24
Service procedure
A Position shift lever A on position 4H.
27280
Adjust the distance between the center of the steering wheel and
245 mm {9.65 in.}
center of the shift lever knob A using the nut 6.
27290
Adjust nut 4 until the distance between shift lever A and the front face
6.5 mm of inner panel B is equal to distance illustrated.
{0.26 in.}
A
27291
24-27
TRANSFER CONTROL
Transfer Control Level
17
22
18
21
1
2 5
-8
6-
7
- 13
14
9 15
16
19 - 14
14
20 -
14 12
-
11
10
27292
1 Pin 9 Spring 17 Shift lever knob
2 Nut 10 Bolt 18 Change lever assembly
3 Support holder 11 Conical spring 19 Bracket
4 Spring 12 Nut 20 Bracket
5 Ball supporter 13 Collar 21 Stopper
6 Steel ball 14 Bushing 22 Lever bracket
7 Bolt 15 Cross sleeve
8 Detent plate 16 Conical spring
CAUTION
When removing pin 1, be careful that spring 4 does not fly out.
When removing support holder 3, ensure that steel ball 6 is not dropped.
24-28
24
Assembly sequence
15141311

22212019 101287654321

1817169

9 Spring load (installation 133 {5.24}) 46 N {10 lbf, 4.7 kgf} 41 N Replace
{9 lbf,4.2 kgf}

2 Nut (Support holder mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
7 Bolt (Detent plate mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
10 Bolt (Cross sleeve mounting) 8.8 to 13.7 {6.5 to 10.0, 0.9 to 1.4}
12 Nut (Change lever assembly mounting) 8.8 to 13.7 {6.5 to 10.1, 0.9 to 1.4}
17 Shift lever knob mounting 5.91.5 {4.31.08, 0.60.15}
- Lubricant
6 Apply grease all over the steel ball Multipurpose type grease [NLGI No.2 (Li soap)] As required
8 Apply grease all over detent plate Multipurpose type grease [NLGI No.2 (Li soap)] As required
14 Grease inside surface of bushing Multipurpose type grease [NLGI No.2 (Li soap)] As required
24-29
Group 25 - Propeller Shaft
Group 25 - Propeller Shaft

1998 Minor Change
BACK HOME
Group 25
Propeller Shaft
' 98 Minor Change

Table of Contents
BACK HOME

25
GROUP 25 PROPELLER SHAFT

< P2: FG (FRONT AXLE TO TRANSFER) >
SPECIFICATIONS ........................................................................... 25- 2
REMOVAL AND INSTALLATION OF PROPELLER SHAFT .......... 25- 4
REAR PROPELLER SHAFT ........................................................... 25- 6
BALANCING PROPELLER SHAFT ................................................ 25-10
25-1
SPECIFICATIONS
Vehicle model
FG639
Item
Propeller shaft Model P2
Pipe Outer diameterWall thickness mm {in.} 63.52.6 {2.500.10}
Universal joint Spider outer diameter mm {in.} 19 {0.75}
Needle bearing Outer diameter mm {in.} 2.5 {0.098}
Length of needle roller mm {in.} 13 {0.51}
Quantity of needle rollers 27
Slip yoke joint Spline diameter mm {in.} 39 {1.54}

Swing of Propeller Shaft
A : Lateral swing
< Universal joint > B : Longitudinal swing
A C : Fore-and-aft movement
Relative positions of transmission and rear axle vary

B depending on the fluctuation of the road surface and
load carried when operating the vehicle.
The universal joint and the slip yoke joint are provided
to absorb these influences.
< Slip yoke joint >
00815
25-2
STRUCTURE AND OPERATION/TROUBLESHOOTING 25
Configuration of Propeller Shaft Connection
1 Transmission
2 Transfer
1 3 Parking brake drum
4 Center bearing
3
7 7 5 Front axle
6 Rear axle
7 Rear propeller shaft
8 Front propeller shaft
1
2
5 6 A : Single-shaft connection at rear
3 7
7 8 B : Twin-shaft connection at rear
5 2
4 6
26466
TROUBLESHOOTING
Symptoms Propeller shaft Noise from propeller
vibrating shaft
Vibration at high speed
Noise when starting or

Vibration at low speed

while coasting
Clicking noise
Possible causes
Flange yoke assembly direction incorrect
Companion flange tightening torque excessive
Lubrication insufficient
Slip yoke joint
Spline play excessive
Clearance in spider axial direction excessive
Universal joint Needle bearing lubricated insufficiently
Needle bearing worn
Mounting bolt loose
Propeller shaft Bent
Dynamic balance adjusted incorrectly
Transmission gear selection too high
25-3
REMOVAL AND INSTALLATION OF PROPELLER SHAFT
*a
*b 05399
Work before removal

P25-4
Removal sequence
1 Nut *a : Front axle
2 Nut *b : Transfer
P25-6 : Non-reusable parts

1 Nut (Transfer side propeller shaft mounting) 59 to 74 {43 to 54, 6.0 to 7.5}
2 Nut (Front axle side propeller shaft mounting) 59 to 74 {43 to 54, 6.0 to 7.5}
Service procedure
Work before removal
WARNING
Since the propeller shaft will be removed, the parking brake
cannot be used. Therefore, you must chock the wheels securely
so the vehicle does not move.
3
A Remember to make alignment marks A before removal.
05211
25-4
25
MEMO
25-5
REAR PROPELLER SHAFT
-
3

4 -
-
05185

P25-7
1 Snap ring 5 Spider 9 Rear propeller shaft
2 Needle bearing 6 Slip yoke joint
3 Flange yoke 7 Sealed packing : Non-reusable parts
4 Grease nipple 8 Grease nipple
Assembly sequence
Repair kit : Universal joint spider kit
Standard value
1 to 5 Clearance of spider in axial direction 0 to 0.06 {0 to 0.0024} Adjust

2, 5 Clearance between needle bearing and spider [19] 0.02 to 0.05 0.1 Replace
{[0.75] 0.00079 to 0.0020} {0.0039}
6, 9 End play of slip yoke joint and rear In rotation 0.01 to 0.09 0.3 Replace
propeller shaft splines direction {0.00039 to 0.0035} {0.012}
In diameter 0.02 to 0.16 0.3 Replace
direction {0.00079 to 0.0063} {0.012}
9 Deflection of rear propeller shaft (Center) 0.4 Correct
{0.016} or replace
- Lubricant
4 Supply via grease nipple Wheel bearing grease [NLGI No.2 (Li soap)] Pack until
grease
overflows
from needle
bearing
oil seal
6 Friction surface of slip yoke joint sealed packing Wheel bearing grease [NLGI No.2 (Li soap)]
grease
overflows
from dust
plug
9 Spline of rear propeller shaft Wheel bearing grease [NLGI No.2 (Li soap)]
25-6
25
A
Universal joint tool set
MB999024
2 A : Yoke assembly C A : MB999025 Removal and installation of needle bearing
B : Push rod B : MB999026
C : Guide C : MB999010
29 29
27.7 B
{1.14} {1.14} {1.09} 02823
Service procedure
3, 6, 9 Clearance in axial direction for spider
2
Press needle bearing 2 downward firmly, and measure clearance A
between snap ring 1 and flange yoke 3, slip yoke joint 6, and rear
propeller shaft 9. If the measured value is higher than the limit, adjust it
1 2 3, 6, 9
by changing the thickness of the snap ring.
< Available snap ring thicknesses and their combination : Combination
A indicated by solid line is preferred >
Part name Thickness Color Combination Thickness Color
1 03215 identification identification
mark mark
Snap ring 1.5 mm None 1.5 mm None
{0.059 in.} {0.059 in.}
Snap ring 1.55 mm Yellow 1.55 mm Yellow
{0.061 in.} {0.061 in.}
Snap ring 1.6 mm Blue 1.6 mm Blue
{0.063 in.} {0.063 in.}
Snap ring 1.65 mm Purple 1.65 mm Purple
{0.065 in.} {0.065 in.}
NOTE
For snap ring 1, it is recommend that you use rings with the same
thickness on both ends.
1
[Removal]
Snap ring
A : Flat-blade screwdriver
03216
25-7
[Installation]
B : Drift
2
03217
Needle bearing
0 [Removal]
Put alignment marks on needle bearing 2 and spider 5.
Put alignment marks on flange yoke 3 and slip yoke joint 6.
2 0 : Universal joint tool set
6
5
3 03207
[Press-fitting]
0 : Universal joint tool set
0
2
6 5
25
03208
Clearance between needle bearing and spider

Measure the play towards the diameter direction between needle bear-
ing 2 and spider 5. If the measured value is higher than the limit, replace
2 with universal joint spider kit.
69
00231
Play between slip yoke joint and rear propeller shaft

spline
B
Measure play A in the rotation direction between slip yoke joint 6 and
rear propeller shaft 9 at the spline area. If the measured value is
6 higher than the limit, replace the faulty parts.
A 9
Measure play B in the diameter direction between slip yoke joint 6 and
higher than the limit, replace the faulty parts.
06720
25-8
25
7
9 7 Installation of sealed packing
Install sealed packing 7 onto propeller shaft 9 in the direction illustrated
until it is flush with the propeller shaft.
8
02691
Supply of grease via grease nipple

8
Pack grease via grease nipple 8 until grease starts overflowing from dust
plug A of slip yoke joint 6.
9
A 02692
Deflection of rear propeller shaft

Measure the deflection of rear propeller shaft 9 at the center. If the
measured value is higher than the limit, correct or replace it.
CAUTION
Be sure to check for cracks at the welded area after straightening
has been done by means of a press.
9
05186 NOTE
To measure the deflection of rear propeller shaft 9, turn it one full
25-9
BALANCING PROPELLER SHAFT
(1) After correcting propeller shaft deflection or replacing the flange yoke, universal joint, or related parts, measure the
balance of the completed propeller shaft assembly on a balancing machine and attach balance weights as required
to correct amount of imbalance to within the permissible range.
(2) Use the polar coordination method to correct dynamic balance.
(3) Permissible amount of imbalance for propeller shaft circumference

10 g {0.35 oz} or less/3,000 rpm
(4) Correction procedure
Balance weight attachment point
< Rear propeller shaft >

A : Balance weight attachment point
B : Alignment marks
80 mm
{3.15 in.}
B B A
05197
Available balance weights

Mass (g {oz}) Radius (mm {in.})
30 mm 45 mm
{1.18 in.} {1.77 in.} 2 {0.071} 31 {1.22}
or less or less
4 {0.14} 31 {1.22}
31 mm {1.22 in.} 33 mm {1.30 in.}
in radius in radius 6 {0.21} 31 {1.22}
8 {0.28} 31 {1.22}
10 {0.35} 31 {1.22}
02828 30 {1.06} 33 {1.30}
35 {1.23} 33 {1.30}
40 {1.41} 33 {1.30}
45 {1.59} 33 {1.30}
50 {1.76} 33 {1.30}
NOTE
Maximum balance weight allowed for one point is 100 g
{3.53 oz}.
Use a combination that keeps number of balance weights to
the minimum.
25-10
Group 25
Propeller Shaft
Table of Contents
BACK
HOME
Pub No. TWSE9501-25

25
GROUP 25 PROPELLER SHAFT
SPECIFICATIONS .................................................................................. 2
REMOVAL AND INSTALLATION OF PROPELLER SHAFT ................. 4
REAR PROPELLER SHAFT .................................................................. 6
FRONT PROPELLER SHAFT .............................................................. 10
BALANCING PROPELLER SHAFT ..................................................... 14
25-1
SPECIFICATIONS
Vehicle model FE639E FE639C, F
Item FE649E FE649C, F
Propeller shaft Model P3
Pipe Outer diameterWall thickness mm {in.} 63.53.5 {2.500.14} *82.62.3 {3.250.091}
Universal joint Spider outer diameter mm {in.} 21 {0.83}
Needle bearing Outer diameter mm {in.} 3 {0.12}
Length of needle roller mm {in.} 15.3 {0.60}
Quantity of needle rollers 25
Slip yoke joint Spline diameter mm {in.} 39 {1.54}
Center bearing Model No. 83A910CC3
Inner diameterOuter diameter mm {in.} 4072 {1.572.83}
* Swage type
Straight type Swage type

(Normal type)
03278

Swing of Propeller Shaft
A : Lateral swing
< Universal joint > B : Longitudinal swing
A C : Fore-and-aft movement
Relative positions of transmission and rear axle vary

B depending on the fluctuation of the road surface and
load carried when operating the vehicle.
The universal joint and the slip yoke joint are pro-
vided to absorb these influences.
< Slip yoke joint >
00815
25-2
TROUBLESHOOTING 25
Configuration of Propeller Shaft Connection
1 Parking brake drum
4 2 Center bearing
3 Rear axle
A 5 Front propeller shaft
A : Single-shaft connection
B : Twin-shaft connection
1 3
5 4
2 3
1
11085
TROUBLESHOOTING
Symptoms Propeller shaft Noise from propeller
vibrating shaft
Vibration at high speed
Noise when starting or

Vibration at low speed

while coasting
Clicking noise
Possible causes
Flange yoke assembly direction incorrect
Companion flange tightening torque excessive
Slip yoke joint
Spline play excessive
Clearance in spider axial direction excessive
Universal joint Needle bearing lubricated insufficiently
Needle bearing worn
Center bearing
Seized, worn, or rotation faulty
< Twin-shaft
connection > Cushion rubber deteriorating or deformed
Hanger mounting bolt loose
Mounting bolt loose
Propeller shaft Bent
Dynamic balance adjusted incorrectly
Transmission gear selection too high
25-3
REMOVAL AND INSTALLATION OF PROPELLER SHAFT
4
5
6
2

3
1
05199
Work before removal

P25-4
Removal sequence
1 Nut 5 Nut
2 Nut 6 Front propeller shaft
3 Rear propeller shaft P25-10
P25-6
4 Nut : Non-reusable parts

1 Nut (Rear axle side propeller shaft mounting) 98 to 120 {72 to 87, 10 to 12}
2 Nut (Center bearing side propeller shaft mounting) 98 to 120 {72 to 87, 10 to 12}
4 Nut (Front propeller shaft hanger mounting) 47 to 65 {35 to 48, 4.8 to 6.6}
5 Nut (Transmission side propeller shaft mounting) 98 to 120 {72 to 87, 10 to 12}
Service procedure
Work before removal
WARNING
Since the propeller shaft will be removed, the parking brake
cannot be used. Therefore, you must chock the wheels securely
A so the vehicle does not move.
Remember to make alignment marks A before removal.

A
05200
25-4
25
MEMO
25-5
1 -
2
-

5
-
4 05321

P25-7
1 Snap ring 5 Grease nipple 9 Grease nipple
2 Shim 6 Spider 10 Slip yoke joint
3 Needle bearing 7 Retainer packing 11 Rear propeller shaft
4 Flange yoke 8 Sealed packing
Assembly sequence : Non-reusable parts

3, 6 Clearance between needle bearing and spider [21] 0.01 to 0.06 0.1 {0.0039} Replace
{[0.83] 0.00039 to 0.0024}
10, 11 End play of slip yoke joint and rear In rotation 0.01 to 0.09 {0.00039 to 0.0035} 0.3 {0.012} Replace
propeller shaft splines direction
In diameter 0.02 to 0.16 {0.00079 to 0.0063} 0.3 {0.012} Replace
direction
11 Deflection of rear propeller shaft (Center) 0.4 {0.016} Correct
or replace
- Lubricant
grease
overflows
from needle
bearing
oil seal
8 Sealed packing lip Wheel bearing grease [NLGI No.2 (Li soap)] As required
grease
overflows
from dust
plug
11 Spline of rear propeller shaft Wheel bearing grease [NLGI No.2 (Li soap)] As required
25-6
25
A
MB999024
29 {1.14} 29
{1.14} 27.7 B
{1.09} 02823
Service procedure
3 Inspection before disassembly
1 Clearance in axial direction for spider
between snap ring 1 and shim 2. If the measured value is higher than the
standard value, adjust it by changing the thickness of the shim.
1 Available shim thicknesses :
0.1 to 0.7 mm {0.0039 to 0.028 in.} (7 thicknesses available in 0.1 mm
A
{0.0039 in.} increments)
3 NOTE
2 05777 For shim 2, it is recommended that you use shims with the same
3
thickness on both ends to ensure balanced revolution.
Needle bearing
[Removal]
0
Put alignment marks on flange yoke 4, slip yoke joint 10 and rear
3 propeller shaft 11.
10, 11 6
4 03207
[Press-fitting]
0
10, 11 6
03208
25-7
36 Clearance between needle bearing and spider
00231
78 Installation of retainer packing and sealed packing

Apply grease to inner periphery A of sealed packing 8 and install it as
illustrated.
Press retainer packing 7 onto slip yoke joint 10, and caulk claw B at
eight points.
A
7
8
B
10 7 8 03135
10 9 Supply of grease via grease nipple

Pack grease via grease nipple 9 until grease starts overflowing from dust
plug A of slip yoke joint 10.
9
A 03136
25-8
25
11
FG Play between slip yoke joint and rear propeller shaft
spline
B Measure play A in the rotation direction between slip yoke joint 10 and
10 higher than the limit, replace the faulty parts.
A
Measure play B in the diameter direction between slip yoke joint 10
and rear propeller shaft 11 at the spline area. If the measured value is
higher than the limit, replace the faulty parts.
03138
G Deflection of rear propeller shaft

Measure the deflection of rear propeller shaft 11 at the center. If the
CAUTION
11
NOTE
03137 To measure the deflection of rear propeller shaft 11, turn it one
25-9
FRONT PROPELLER SHAFT
10

1
2
-
5
-
4 03039

P25-11
1 Snap ring 7 Nut 13 Center bearing assembly
2 Shim 8 Disc spring 14 Front propeller shaft
3 Needle bearing 9 Companion flange
4 Flange yoke 10 Holder : Non-reusable parts
5 Grease nipple 11 Hanger
6 Spider 12 Cushion rubber
Assembly sequence

Standard value

3, 6 Clearance between needle bearing and spider [21] 0.01 to 0.06 0.1 {0.0039} Replace
{[0.83] 0.00039 to 0.0024}
14 Deflection of front propeller shaft (Center) 0.4 {0.016} Correct
or replace

7 Nut (Companion flange mounting) 290 to 390 {215 to 290, 30 to 40}
25-10
25
- Lubricant
5 Supply via grease nipple Wheel bearing grease [NLGI No.2 (Li soap)]Pack until
grease
overflows
from needle
bearing
oil seal
13 Pack interior of center bearing assembly Bearing grease [NLGI No.3 (Li soap)] 70 to 100%
of capacity
(20 to 29 g)
{0.71 to
1.02 oz}
Center bearing assembly seal lip area Bearing grease [NLGI No.3 (Li soap)] As required

A
MB999024
29 {1.14} 29
{1.14} 27.7 B
{1.09} 02823
Service procedure
3
1 Clearance in the axial direction for spider
between snap ring 1 and shim 2. If the measured value is higher than the
standard value, adjust it by changing the thickness of the shim.
1
Available shim thicknesses :
A 0.1 to 0.7 mm {0.0039 to 0.028 in.} (7 thicknesses available in 0.1 mm
{0.0039 in.} increments)
3 NOTE
2 05777 For shim 2, it is recommended that you use shims with the same
3
thickness on both ends to ensure balanced revolution.
Needle bearing
0 [Removal]
Put alignment marks on flange yoke 4 and front propeller shaft 14.
3
14 6
4 03207
25-11
FRONT PROPELLER SHAFT
[Press-fitting]
0
3
14 6
36
03208
Clearance between needle bearing and spider

8
00231
Installation of disc spring

8
Install disc spring 8 with its convex side facing nut A.
9
A 02822
Installation of companion flange

4
When installing, position concave side A of companion flange 9 and
convex side B of flange yoke 4 as illustrated.
9 B
GH
02700
Hanger and cushion rubber

[Removal]
Make alignment marks A before removal.
12
B [Installation]
Install hanger 11 and cushion rubber 12 aligning alignment marks A.
The relative position to the front of vehicle B is as illustrated.
A
11
B 03218
25-12
25
13 A
I Greasing center bearing assembly
Inspect the center bearing assembly for leaking grease every
50000 km {31000 miles} or at regular safety inspection. If a substantial
grease leak is found, pack grease into housing A.
Apply grease to seal lip area B.
NOTE
Bearing does not require greasing because it is sealed.
J
B 02800
Deflection of front propeller shaft

Measure the deflection of front propeller shaft 14 at the center. If the
CAUTION
14
NOTE
02821 To measure the deflection of front propeller shaft 14, turn it one
25-13
BALANCING PROPELLER SHAFT
(1) After correcting propeller shaft deflection or replacing the flange yoke, universal joint, or related parts, measure the
balance of the completed propeller shaft assembly on a balancing machine and attach balance weights as required
to correct amount of imbalance to within the permissible range.
(2) Use the polar coordination method to correct dynamic balance.
(3) Permissible amount of imbalance for propeller shaft circumference

10 g {0.35 oz} or less/3000 rpm < Rear propeller shaft >
5 g {0.18 oz} or less/3000 rpm < Front propeller shaft >
(4) Correction procedure
Balance weight attachment point
< Rear propeller shaft >
65 mm 65 mm
B B {2.56 in.} {2.56 in.} B
A
03240
< Front propeller shaft >

A : Balance weight attachment point
B : Alignment marks
B
A B
105 mm 65 mm
{4.13 in.} {2.56 in.}
03239
Available balance weights

Mass (g {oz}) Radius (mm {in.})
30 mm 30 mm
{1.18 in.} {1.18 in.} 2 {0.071} 31 {1.22}
or less or less
4 {0.14} 31 {1.22}
31 mm {1.22 in.} 33 mm {1.3 in.}
in radius in radius 6 {0.21} 31 {1.22}
8 {0.28} 31 {1.22}
10 {0.35} 31 {1.22}
02828 12 {0.42} 31 {1.22}
16 {0.56} 31 {1.22}
24 {0.85} 33 {1.30}
NOTE
Maximum balance weight allowed for one point is 100 g
{3.53 oz}.
Use a combination that keeps number of balance weights to
the minimum.
25-14
Group 26 - Front Axle
Group 26B - Front Axle

1998 Minor Change
BACK HOME
Group 26
Front Axle
Table of Contents
BACK
HOME
Pub No. TWSE9501-26

26
GROUP 26 FRONT AXLE
SPECIFICATIONS .................................................................................. 2

Adjustment of Wheel Alignment ....................................................................... 4
Adjustment of Steering Angle ........................................................................... 7
Measurement of Side Slip .................................................................................. 7
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE . 8
WHEEL HUB AND ROTOR .................................................................. 10
FRONT AXLE, KNUCKLE AND KINGPIN ........................................... 16
26-1
SPECIFICATIONS
Vehicle model
FE639 FE649
Item
Front axle Model F020T F035T
Type I section, reverse Elliot type
Kingpin Outer diameter Length mm {in.} 28180 {1.107.09}
Tread mm {in.} 1665 {65.6}
Mass kg {lb} Approximately 125 {275} Approximately 155 {340}

Front Axle, Knuckle and Kingpin
2
3
7 6 5
8 4
9
10
14
12 13
11
12107
1 Tie rod arm 6 Dust cap 11 Front axle

2 Tie rod assembly 7 Kingpin 12 Plug
3 Knuckle arm 8 Dust seal 13 Kingpin bushing
4 Knuckle 9 Kingpin shim 14 Thrust bearing
5 Bushing 10 Lock pin
26-2
26
Wheel Hub and Rotor
3 4
2
1 3
5
13
12
11
10 7 3
9 8
12108
1 Hub bolt 6 Adapter 11 Lock nut

2 Wheel hub 7 Spacer 12 Hub cap
3 Disc brake assembly 8 Inner bearing 13 Outer bearing
4 Oil seal 9 Rotor
5 Mud shield 10 Washer
26-3

Caster 230'100'
Kingpin inclination angle 8 810'

NOTE
level.
Before adjusting the wheel alignment, check for the following faults:
Incorrect power steering booster backlash

A Point the front wheels exactly forward.
Put mark A on the left and right front tires at the height of front
05851

A the front tires. Measure the distance C between the marks at the
A front of the vehicle.
C
B
00888
26-4
26
standard value.
D
00889
wrench.
1
12109
4 Move the vehicle forward and turn tie rod 2 towards the front, with
the tires pointed forward (F as illustrated). Make sure when adjust-
ing toe-in to the standard value, that both left and right tie rod ends
2
3 are in contact with ball stud 4 (G as illustrated) at the same time.
G
After adjustment, tighten clamp bolt 1 to secure the tie rod.
3 1
F
06116

Remove the hub caps.
Wipe off grease from the knuckle end, and attach camber/caster/
kingpin gauge H to the knuckle.
J While keeping the bubble in level J centered, measure the camber
K camber scale K. Follow this procedure to measure the camber
H
06039

Align turning radius gauges L. Prepare a platform M having the
Keep turning radius gauges L locked.
radius gauge L meet at their respective centers.
N
L M WARNING
05612
After jacking up the vehicle, chock the rear wheels securely with
chocks N.
Do not remove chocks N until the entire operation is completed.
26-5
Unlock turning radius gauge L, and set the scale to 0.
kingpin gauge H tightly to the front wheel hub and keep the bubble
centered.
slowly from the 0 point on the scale of turning radius gauge L, until
P direction changes 20 to the left for the left front wheel and 20 to
the right for the right front wheel.
Q L
H NOTE
rotate slightly.
At the 20 point, align the bubbles in caster scale P and kingpin

scale Q to 0 by turning the adjuster.
NOTE
Kingpin scale Q has scales for left and right; use the left scale
direction 20 to the left, past the 0 point of turning radius gauge L
on caster scale P and kingpin scale Q. The scale marks indicate the
26-6
26
Adjustment of Steering Angle
Service standards
Steering angle Inside (Outside : reference) 42 (33) Adjust

2 Lock nut (Knuckle stopper bolt fastening) 46.57 {345.4, 4.750.75}
NOTE
Be sure that wheel alignment is adjusted perfectly before adjust-
ing the steering angle.
To adjust the steering angle, set the turning radius gauges and plat-
form in the same way as for caster and kingpin inclination angle
measurement.
Turn the steering wheel to the left or right completely, and from the
position where the turning radius gauge is aligned to 0, adjust knuckle
2 stopper bolt 1. Adjust so that the steering angle is within the standard
inside steering angle value, to the left for the left front wheel, and to
the right for the right front wheel. Then, tighten lock nut 2 at specified
1
torque.
06073 NOTE
Be sure when working on the vehicle, to adjust both stopper
bolts 1 at the front and back of the knuckle arm side.
Measurement of Side Slip

NOTE
Be sure that wheel alignment is adjusted fully before measuring
side slip.

Maintain this position and slowly move vehicle forward, over side slip
tester A, as slowly as possible.
NOTE
Make sure, when measuring side slip, that the wheels point
exactly forward when the vehicle passes over side slip tester A.
Do not allow the wheels to veer from side-to-side.
A The side slip is indicated by side slip tester A after the vehicle has
05615 passed through the tester. Readjust wheel alignment if slippage is
3 mm {0.12 in.} or more per meter {3.28 ft.}.
26-7
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE
1
3
14096

3 Jack up the front axle with a garage jack.
WARNING
racks.

26-8
26
MEMO
26-9
WHEEL HUB AND ROTOR
26 < FE639 > 19

* 24
31 5 4
2 21
5
4 - 23 -
8 -
25 30

28
1 27
6
7
14
6 < FE639 >

29
< FE649 >
30
27
- 12
-
20 < FE649 >
- -
14
21
23 -
12110
1 Brake pipe 13 Outer bearing inner race 25 Bracket
2 Clip 14 Wheel hub and rotor assembly 26 Bolt
3 Brake hose 15 Oil seal 27 Adapter
4 Bolt 16 Inner bearing inner race 28 Bolt < FE639 >
5 Clip 17 Inner bearing outer race 29 Dust cover < FE639 >
6 Eye bolt 18 Outer bearing outer race 30 Mud shield
7 Brake hose 19 Nut < FE639 > 31 Spacer
8 Bolt 20 Bolt < FE649 >
9 Disc brake assembly ^ Gr 35 21 Disc rotor ^ Gr 35 * : Knuckle P26-16
10 Hub cap 22 Hub bolt : Non-reusable parts
11 Lock nut 23 Wheel hub
12 Lock washer 24 Bolt
WARNING
When you work, take care not to burn yourself because disc brake assembly 9 and disc rotor 21 are hot
immediately after the vehicle has been driven.
CAUTION
Be sure to protect brake hoses 3, 7 from dust by fitting blanking plugs after removal.
NOTE
Do not disassemble disc rotor 21 and wheel hub 23 except for replacement.
26-10
26
Assembly sequence
Follow the disassembly sequence inreverse.
WARNING
CAUTION
Be careful not to damage oil seal 15 when installing wheel hub and rotor assembly 14 onto knuckle *.
Service standards
13, Starting torque of wheel hub bearing FE639 1.5 Nm {1.08 lbf.ft, 0.15 kgfm} Tangential
16 to 18 force at hub
bolt: 14 N
{3.1 lbf,
1.4 kgf}
FE649 2 Nm {1.45 lbf.ft, 0.2 kgfm} Tangential
force at hub
bolt: 18 N
{4.0 lbf,
1.8 kgf}

3 Brake hose tightening (Axle side) 13 to 17 {9.4 to 12, 1.3 to 1.7}
4, 24 Bolt (Clip and bracket mounting) 12.32.5 {91.8, 1.250.25}
6 Eye bolt (Brake hose mounting) 222 {161.8, 2.250.25}
8 Disc brake mounting FE639 95.612 {719, 9.751.25}
FE649 15225 {11018, 15.52.5}
11 Lock nut Primary 11315 {8311, 11.51.5} Slackening off
tightening angle:
Approximately
Secondary 59 {43, 6} 45 (one eighth
tightening, of a turn)
after slacke-
ning
19 Nut (Disc rotor and wheel FE639 95.612 {719, 9.751.25}
hub mounting)
20 Bolt (Disc rotor and wheel FE649 85.812 {639, 8.751.25}
hub mounting)
26 Bolt (Adapter and mud shield mounting) 11820 {8714, 122}
28 Bolt (Dust cover mounting) FE639 12.32.5 {91.8, 1.250.25}
26-11
WHEEL HUB AND ROTOR
- Lubricant
10 Pack wheel hub cap FE639 Wheel bearing grease [NLGI No.2 (Li soap)] 6510 g
{2.290.35 oz}
FE649 Wheel bearing grease [NLGI No.2 (Li soap)] 9010 g
{3.170.35 oz}
13, 16 Pack the space between rollers of outer bearing inner race Wheel bearing grease [NLGI No.2 (Li soap)] As required
and inner bearing inner race
23 Pack interior space of wheel hub FE639 Wheel bearing grease [NLGI No.2 (Li soap)] 21020 g
{7.410.71 oz}
FE649 Wheel bearing grease [NLGI No.2 (Li soap)] 13010 g
{4.590.35 oz}

0.5 {0.020}
78
10 Hub cap wrench MB999108 Removal of hub cap
06046
70 {2.76}
Oil seal installer MB999097
84 {3.31}
05619
15 Press-fitting of oil seal (Use in combination)
Bearing installer
B
Model Part No. A B C
MB999099
EF 639 MB999099 88.5 71 51
{3.48} {2.80} {2.01} C MB999069
A
EF 649 MB999069 94.5 92.5 60
{3.72} {3.64} {2.36}
05621
57 {2.24}
70 {2.76}
05668
13, 16 Press-fitting of inner and outer bearing
Bearing installer outer races (Use in combination)
Model Part No. A B C
EF 639 MB999099 88.5 71 51 B
{3.48} {2.80} {2.01} MB999099
EF 649 MB999069 94.5 92.5 60 MB999069
(Inner side) {3.72} {3.64} {2.36} C
A
EF 649 MB999099 88.5 71 51
(Outer side) {3.48} {2.80} {2.01}
05621
26-12
26
Service procedure
17 16
14 11 13 18 [Adjustment]
Tighten lock nut 11 at specified torque (primary tightening) while
turning wheel hub and rotor assembly 14. Then, slacken off.
Turn wheel hub and rotor assembly 14 several times to smooth
operation of outer bearings 13 and 18, and inner bearings 16 and
17, and retighten lock nut 11 at specified torque (secondary
tightening).
Approximately 45 Slacken off lock nut 11 by approximately 45 (one eighth of a turn),
(one eighth of a turn)
12111 and lock it with a split pin. If the split pin and the pin hole do not
align, slacken off the lock nut slightly, making sure that there is no
play in the axial direction.
[Measurement]
Fasten spring balance A to hub bolt 22 and measure the tangential
force.
A If the measured tangential force is the standard value, the starting
Make sure that the starting torque is smaller than the tangential
force.
If the tangential force deviates from the specified value, adjust the
22 starting torque again.
12112 If the measured value deviates from the standard value, adjust the
described above.
If any fault is found after adjustment, replace outer and inner bear-
ings 13, 16 to 18.
NOTE
Measure the starting torque when oil seal 15 has been in-
3
stalled.
Removal and installation of brake hose

3 First remove brake hose 3 from bracket A (on the frame), then remove
the brake hose from wheel brake B. For installation, follow this procedure
B in reverse.
A
CAUTION
Make sure that brake hose 3 is not twisted when you install it.
9
12113
Installation of brake pad wear indicator harness of disc

5 brake assembly
5
Fix the taping position for brake pad wear indicator harness A on disc
5 brake assembly 9 using clip 5.
9
12114
26-13
WHEEL HUB AND ROTOR
F Removal of hub cap
10
0
G
12116

Refer to adjustment of the starting torque of the wheel hub bearing.
P26-13
IL
12117
Packing grease in outer bearing inner race and inner

13, 16 bearing inner race
B
B : Between rollers
K
01000

1
A
M
12118

[Removal]
Drive out inner bearing outer race 17 from the two indented parts A in
B
wheel hub 23.
B : Pin-punch
17 23
12119
26-14
26
[Installation]
17
23
N
12120
Outer bearing outer race

[Removal]
Drive out outer bearing outer race 18 from the two indented parts A in
B
wheel hub 23.
23 B : Pin-punch
A
18
12121
[Installation]
1
18
2
23 12122
22
R Installation of hub bolt
Hub bolt 22 is marked with L (left) or R (right) to indicate the side it is
to be installed on. Check this symbol before installing the bolt.
L, R 05490
26-15
FRONT AXLE, KNUCKLE AND KINGPIN

3
12 11
4
-
14
19
9
20
*1
- 10
- *2
11 - 30 13

17 31
6
7
-
27 21
-18 -
-
-
27 16 8
- 12123
1 Split pin 14 Key 27 Grease nipple
2 End plug 15 Knuckle arm 28 Dust seal
3 Ball seat 16 Nut 29 Kingpin bushing
4 Drag link ^ Gr 37 17 Key 30 Knuckle stopper bolt
5 Nut 18 Tie rod arm 31 Lock nut
6 Eye washer 19 Dust plug 32 Knuckle
7 Washer 20 Dust cap 33 Stud bolt
8 U-bolt nut 21 Nut 34 Front axle
9 U-bolt 22 Lock pin
10 Front axle bumper 23 Kingpin *1 : Shock absorber ^ Gr 33
11 Nut 24 Kingpin shim *2 : Leaf spring ^ Gr 33
12 Tie rod assembly ^ Gr 37 25 Thrust bearing : Non-reusable parts
13 Nut 26 Plug
Assembly sequence
31 30 32 29 28 27 26 19 17 14

23 22 21 20 18 16 15 13 12
34 33 25 24
11 10 9 8 7 6 5 4
321
Repair kit : Kingpin kit
26-16
26
23 Kingpin outer diameter 0.020 27.9 {1.098} Replace
[28]
0.053

[1.102]
0.00079

0.0021
29 Inner diameter of kingpin bushing +0.033 Replace
[28]
(After press-fitting into knuckle) 0
+0.0013

[1.102]
0
Clearance between kingpin and kingpin bushing 0.020 to 0.086 {0.00079 to 0.0034} 0.15 {0.0059}
32, 34 Vertical clearance between knuckle and front axle 0.02 to 0.10 {0.00079 to 0.0039} 0.20 {0.0079} Adjust using
kingpin shim
34 Bend in front axle, longitudinal direction 2 {0.079} or less 2 {0.079} Replace
Bend in front axle, vertical direction 2 {0.079} or less 2 {0.079}
Front axle kingpin inclination angle 8 810'

8 U-bolt nut (U-bolt mounting) 16215 {12011, 16.51.5}
11 Nut (Tie rod mounting) 9325 {6918, 9.52.5}
13 Nut (Knuckle arm mounting) 24549 {18036, 255}
16 Nut (Tie rod mounting) 24549 {18036, 255}
21 Nut (Lock pin mounting) 335 {253.6, 3.40.5}
31 Lock nut (Knuckle stopper bolt fastening) 46.57 {345.4, 4.750.75}
33 Stud bolt Inserting 88 {65, 9}
Removing 137 {100, 14}

15, 18 Thread areas of knuckle arm and tie rod arm Chassis grease [NLGI No. 1 (Ca soap)] As required
when reused
24 Both surfaces of kingpin shim Chassis grease [NLGI No. 1 (Ca soap)] As required
25 Upper surface of thrust bearing Chassis grease [NLGI No. 1 (Ca soap)] As required
27 Supply via grease nipple Chassis grease [NLGI No. 1 (Ca soap)] Pack until
grease
overflows
from dust
plug
28 Lip area of dust seal Chassis grease [NLGI No. 1 (Ca soap)] As required
29 Inner surface of kingpin bushing Chassis grease [NLGI No. 1 (Ca soap)] As required
33 Thread area of stud bolt LOCTITE 271 As required
26-17
Kingpin puller MB999013
A : Pipe D A: MB999014
23 C Removal of kingpin
B : Bolt B: MB999015
A
C : Cap C: MB999016
47 {1.85}
D : Nut B 06102 D: MB999017
Bushing installer 30
A {1.18}
32.8 MB999066
A : Bushing installer A {1.29}
29 B : Bushing installer B Removal and installation of kingpin bushing
A: MB999067
25 {0.98} B: MB999068
28 {1.10} 25 B
{0.98} 06103
12
Service procedure
Mounting of split pin and end plug
Tighten end plug 2 fully and slacken off by one half of a turn, then turn
the plug so that the head of split pin 1 faces the outside of the body.
Caulk the head of split pin 1 until it is approximately 4 mm {0.16 in.}
thick.
2
Approximately
1 4 mm {0.16 in.} 08010
*1 5 Mounting of nut
Mount and tighten nut 5 so that the dimensions of rubber bushing A of
shock absorber *1 are as illustrated.
32 mm
A {1.26 in.}
05763
A
K\ Installation of knuckle arm and knuckle
(1) Reassembly of existing knuckle arm 15 and/or knuckle 32

Polish taper surfaces A of knuckle arm 15 and knuckle 32 with
emery paper (120 grit or finer) uniformly, until abrasion traces left by
32
15 B the emery paper are only just visible. For new parts, polishing is not
required.
Clean taper surfaces A of knuckle arm 15 and knuckle 32, and
A thread area B of the knuckle arm. (Use a cleaning solvent for
08011 acetone color checking or other solvent.)
26-18
26
Install knuckle arm 15 after applying grease to thread area B. (Do
C not grease the taper surface of knuckle arm and knuckle 32.)
Tighten new nut 13 at specified torque. Without loosening the nut,
15 insert split pin C into the pin hole to lock the nut.
(2) Installation of new knuckle arm 15 and new knuckle 32

13 Clean taper surfaces A, or thread area B, of knuckle arm 15 and
knuckle 32, and install them without greasing.
32 Tighten new nut 13 at specified torque. Without loosening the nut,
06109
insert split pin C into the pin hole to lock the nut.
R Removal of lock pin

Remove nut 21, spring washer A, and washer B. Screw the nut into
lock pin 22 again until they are almost level with each other. Then, tap
the nut lightly to loosen the lock pin.
22
BA
21 06105
Remove nut 21. While holding drift C against lock pin 22, tap the lock
pin lightly to extract it.
22 C
06106
A B
S Removal of kingpin
Screw bolt A of the 0 kingpin puller into the thread area of kingpin 23.
Fasten bolt A with nut B, and remove kingpin 23.
0
23
06107
26-19
32
23
T\^
[Inspection]
Kingpin shim, knuckle, and front axle
Assemble kingpin 23 and thrust bearing 25 temporarily, and turn

34 knuckle 32 a couple of times to smooth its operation.
Measure the clearance between the upper surface of front axle 34 and
the lower part of knuckle 32.
If the measured value is higher than the limit, adjust the clearance.
25
06108
[Adjustment]
32 Adjusting kingpin shim 24 is available in four thickness: 0.10 mm
{0.0039 in.}, 0.15mm {0.0059 in.} 0.20 mm {0.0079 in.} and 0.30 mm
24
{0.012 in.}
Be sure to minimize the clearance by selecting appropriate kingpin
shim 24.
Make sure that knuckle 32 turns smoothly after assembly.
00952
U Installation of thrust bearing

Install thrust bearing 25 with case A facing upwards.
25
06110
A
V Mounting of plug
Drift in plug 26, and caulk it securely at three equidistant points around
the circumference.
A : When caulked
26
06111
26-20
26
1
XY
[Removal]
Dust seal and kingpin bushing
2 When removing the upper part of kingpin bushing 29, remove dust seal
29 28 at the same time.
28
28 12124
[Installation]
Press-fit kingpin bushing 29 so that gap A between kingpin bushing 29
1 and knuckle 32 is within 0 to 1 mm {0 to 0.039 in.}.
Oil hole of kingpin bushing 29 and tapped hole of knuckle 32 should
2 not deviate from each other by more than 5 mm {0.20 in.}.
Apply grease to lip area C of dust seal 28 and press-fit in the direction
as illustrated in the upper figure.
29 0 to 1 mm
{0 to 0.0039 in.}
29
32
0 to 1 mm
{0 to 0.0039 in.}
5 mm
{0.20 in.}
29
12125
34 ]^ Stud bolt and front axle

Coat thread area A of stud bolt 33 in front axle 34 with lock paint.
A
Mount stud bolt 33 maintaining a mounting dimension within 51 +0.5
1.0 mm
{2.01 +0.020
0.039 in.}.
51 +0.5
1.0 mm 33
{2.01 +0.020
0.039 in.}
06114
26-21
< Longitudinal >
D
^ Inspection of front axle
(1) Measurement of bend in front axle in longitudinal and vertical

directions
A
C Pass a piece of thread A through the kingpin hole of front axle 34
and hang weights B on both ends.
Use square C to find the degree of bend in both the longitudinal
direction D and the vertical direction E.
A If the measured value is higher than the limit, replace front axle 34.
C 34
< Vertical >

C A
B 34
E
00954
(2) Measurement of kingpin inclination angle

34
Mount kingpin 23 in front axle 34 as illustrated, and measure the
23
kingpin inclination angle. If the measured value is higher the limit,
replace the front axle.
F : Block gauge
G G : Bevel square
F 00955
26-22
Group 26B
Front Axle
' 98 Minor Change

Table of Contents
BACK HOME
Pub No. TWSE9501-226B

26B
GROUP 26B FRONT AXLE < FG >
SPECIFICATIONS .........................................................................26B- 2
STRUCTURE AND OPERATION ..................................................26B- 2
TROUBLESHOOTING ...................................................................26B- 5

Adjustment of Wheel Alignment ............................................................ 26B- 7
Adjustment of Steering Angle ................................................................ 26B- 10
Measurement of Side Slip ....................................................................... 26B- 11

FRONT AXLE ................................................................................26B- 12
WHEEL HUB AND BRAKE DRUM ...............................................26B- 14
KNUCKLE AND DRIVE SHAFT ....................................................26B- 22
AXLE HOUSING ............................................................................26B- 28
REDUCTION AND DIFFERENTIAL ..............................................26B- 30
26B-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Vehicle model FG639

Item
Front axle Model F020TW
Type Full floating type with birfield joint
Tread mm {in.} 1665 {65.6}
Model D1H modified
Type Single-reduction gear
Reduction
Tooth shape Hypoid gear
Speed reduction ratio 5.714
Differential Tooth shape Straight bevel gear
Grade * Normal : Maximum air temperature during operation below 40C {104F}
Gear oil
API GL-5
SAE 90
Hot area : Maximum air temperature during operation above 40C {104F}
API GL-5
SAE 140
Oil volume L {qts.} 3.0 {3.2}
Mass (reference) kg {lb} Approximately 230 {505}
* When used under heavily-loaded, severe conditions such as continuous driving on uphill grades, it is recommended that you use gear oil with a
SAE viscosity grade of 140. However, the air temperature must be above 10C {50F}.

Wheel Hub and Brake Drum
1 Lock washer
2 Lock nut
4
3 3 Outer bearing
4 Brake drum
5
2 5 Brake assembly
6 Wheel hub
7 Oil seal
1 8 Inner bearing
9 Hub bolt
6
10 Drive flange
12
11 Hub cap
* 12 Snap ring
11
* : Drive shaft
10 7
8
9
08165
26B-2
26B
Axle, Knuckle, and Drive Shaft
2
1
18 4 5
6
17 7
16
15
8
14 13 9
12 10
11
26614
1 Tie rod arm 7 Oil seal 13 Trunnion bearing

2 Tie rod assembly 8 Boot band 14 Spacer
3 Knuckle arm 9 Dust boot 15 Needle bearing
4 Kingpin, upper 10 Retainer 16 Drive shaft assembly
5 Conical spring 11 Dust seal 17 Knuckle spindle
6 Spacer 12 Kingpin, lower 18 Trunnion bearing
Drive shaft assembly 16 should transmit power in response to

the variations in rotation speed that occur due to variations in
steering angle, etc. when steering the vehicle.
16 To support this function, Birfield joint assembly area A in drive
A shaft assembly 16 uses a constant speed joint that transmits
power evenly, eliminating variations in rotation speed between
the driving shaft and the driven shaft.
05606
26B-3
Reduction and Differential
2
1
3
22
4
5
21
6
7
20
19
18 9
17 10
16
11
12
15 13
14
05607
1 Companion flange assembly 12 Differential pinion

2 Lock nut 13 Pinion shaft
3 Oil seal 14 Final drive gear
4 Front bearing 15 Bearing cap
5 Front bearing shim 16 Lock plate
6 Pinion spacer 17 Side bearing nut
7 Oil stopper 18 Side bearing
8 Rear bearing 19 Lock pin
9 Differential gear 20 Rear bearing shim
10 Differential gear spacer 21 Final drive pinion
11 Differential case 22 Differential carrier
26B-4
TROUBLESHOOTING 26B
Symptoms Power transmission
incorrect
Oil leaking from differential carrier and front axle housing
Propeller shaft turns but front wheels do not turn
Noise when starting and when changing gear

Oil leaking from companion flange assembly
Oil leaking from drive shaft assembly
Tires drag while steering into a bend

Noise while steering into a bend
Continuous noise while cruising
Intermittent noise while cruising

(at bench test)
Possible causes
Front axle housing bent
Drive shaft assembly bent
Drive shaft assembly damaged
Drive shaft assembly disengaged from differential gear spline
Wheel hub, knuckle Birfield joint in drive shaft assembly faulty
and drive shaft, and Kingpin bearing loose
axle housing Knuckle bearing worn
Oil seal faulty
Wheel hub bearing seized, worn, or rotation faulty
Wheel hub bearing damaged
Gear oil excessive
Oil seal faulty
Vent plug clogged
Sealant faulty
Side bearing seized, worn, or rotation faulty
Reduction and Side bearing broken
differential Side bearing preload adjusted incorrectly
Reduction and differential assembly mounting nut loose
Differential carrier cracked or damaged
Final drive gear and differential case tightening bolt loose
Final drive gear or final drive pinion broken
Final drive gear or final drive pinion worn
Final drive gear or final drive pinion damaged
26B-5
TROUBLESHOOTING

incorrect
Oil leaking from differential carrier and front axle housing
Propeller shaft turns but front wheels do not turn

Oil leaking from drive shaft assembly
Tires drag while steering into a bend

Noise while steering into a bend

(at bench test)
Possible causes
Final drive gear backlash excessive
Final drive gear backlash or tooth contact adjusted incorrectly
Final drive pinion starting torque adjusted incorrectly
Lock nut loose
Differential gear backlash excessive
Reduction and Front or rear bearing seized
differential Front or rear bearing worn
Front or rear bearing broken
Differential gear or differential pinion broken
Differential gear or differential pinion seized
Differential gear or differential pinion worn
Spacer worn or damaged
Differential gear spline worn
26B-6
ON-VEHICLE INSPECTION AND ADJUSTMENT 26B

Caster 030'100'
Kingpin inclination angle 930' 930'30'

NOTE
level.
Before adjusting the wheel alignment, check for the following faults :
Incorrect steering gear backlash

A Put mark A on the left and right front tires at the height of front
00887
26B-7
the front tires. Measure the distance C between the marks at the
A A front of the vehicle.
C
B 00888
standard value.
D
02897
2
wrench.
1
05609
Move the vehicle forward and turn tie rod 2 towards the front, with the
4
tires pointed forward (F as illustated). Make sure when adjusting toe-in
1 to the standard value, that both left and right tie rod ends 3 are in
contact with ball stud 4 (G as illustrated) at the same time.
G After adjustment, tighten clamp bolt 1 to secure the tie rod.
In order to keep the end of clamp bolts 1 away from the vehicle, mount
2 tie rod 2 so that clamp center H is placed in the range as illustrated.
3
F
06712
Approxi-
mately 180
H
Approxi-
mately 35 2
63.5
mm 1
{2.5 in.}
06713
26B-8
26B
J Point the front wheels exactly forward.
Remove hub cap 5, and attach camber caster kingpin gauge J.
5
26615
While keeping the bubble in level K centered, measure the camber

camber scale L. Follow this procedure to measure the camber
L K
J
05611

Align turning radius gauges M. Prepare a platform N having the
Keep turning radius gauges M locked.
radius gauges M meet at their respective centers.
P
N WARNING
M 05612
After jacking up the vehicle, chock the rear wheels securely
with chocks P.
Do not remove chocks P until the entire operation is com-
pleted.
Unlock turning radius gauges M, and set the scale at 0.

kingpin gauge J tightly to the front wheel hub and keep the bubble
centered.
slowly from the 0 point on the scale of turning radius gauges M,
Q until direction changes 20 to the left for the left front wheel and 20
R to the right for the right front wheel.
J M NOTE
rotate slightly.
26B-9
At the 20 point, align the bubbles in caster scale Q and kingpin
scale R to 0 by turning the adjuster.
NOTE
Kingpin scale R has scales for left and right; use the left scale
direction 20 to the left, past the 0 point of turning radius gauge M
on caster scale Q and kingpin scale R. The scale marks indicate the
Adjustment of Steering Angle

Service standards
Steering angle Inside (Outside : reference) 30 (29) Adjust

2 Lock nut (Knuckle stopper bolt tightening) 9612 {719, 9.751.25}
NOTE
Be sure that wheel alignment is adjusted perfectly before adjust-
ing the steering angle.
To adjust the steering angle, set the turning radius gauges and plat-
form in the same way as for caster and kingpin inclination angle
measurement.
Turn the steering wheel to the left or right completely, and from the
position where the turning radius gauge is aligned to 0, adjust knuckle
2 stopper bolt 1. Adjust so that the steering angle is within the standard
inside steering angle value, to the left for the left front wheel, and to
1 the right for the right front wheel. Then, tighten lock nut 2 at specified
torque.
26616 NOTE
Be sure when working on the vehicle, to adjust both stoper bolts
1 at the front and back of the knouckle arm side.
26B-10
26B
Measurement of Side Slip
NOTE
Be sure that wheel alignment is adjusted perfectly before meas-
uring side slip.

Maintain this position and slowly move vehicle forward, over side slip
tester A, as slowly as possible.
NOTE
Make sure, when measuring side slip, that the wheels point
exactly forward when the vehicle passes over side slip tester A.
Do not allow the wheels to veer from side-to-side.
The side slip is indicated by side slip tester A after the vehicle has
A passed through the tester. Readjust wheel alignment if slippage is
05615 3 mm {0.12 in.} or more per meter {3.28 ft.}.
26B-11
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE
1
3
14096

WARNING
racks.

26B-12
26B
MEMO
26B-13
1

19
-
-

-
21 18

7
20
-
5
-
4 -
-
8
26617
1 Clip 10 Outer bearing inner race 18 Wheel hub
2 Brake hose 11 Wheel hub and brake drum 19 Brake drum
3 Hub cap assembly 20 Bolt
4 Snap ring 12 Oil seal 21 Brake assembly ^ Gr 35
5 Bolt 13 Inner bearing inner race
6 Drive flange 14 Inner bearing outer race * : Knuckle and drive shaft
7 Bolt 15 Outer bearing outer race P26B-22
8 Lock washer 16 Nut : Non-reusable parts
9 Lock nut 17 Hub bolt
CAUTION
Be sure to protect brake hose 2 from dust by fitting plugs after removal.
NOTE
Do not disassemble wheel hub 18 and brake drum 19 except for replacement.
26B-14
26B
Assembly sequence
*21201110987 654321
11 : 1918171615141312
WARNING
CAUTION
Be careful not to damage oil seal 12, press-fitted into the top of wheel hub 18, when installing wheel hub and
brake drum assembly 11 into the knuckle and drive shaft.
Service standards
10, 12, Starting torque of wheel hub bearing 31 Nm Tangential
13, 15 {2.20.7 lbf.ft, 0.30.1 kgfm} force at hub
bolt 18 to
34 N {4.0 to
7.7 lbf., 1.8
to 3.5 kgf}

2 Brake hose tightening 13 to 17 {9.4 to 12, 1.3 to 1.7}
5 Bolt (Drive flange mounting) 68.64.9 {513.6, 70.5}
7 Bolt (Lock washer mounting) 92 {6.51.4, 0.90.2}
9 Lock nut (Wheel hub bearing Primary tightening 11315 {8311, 11.51.5}
mounting : wheel hub After primary tighten- 255 {183.6, 2.50.5}
bearing pre-pressure ing, carry-out
adjusting) secondary tightening
20 Bolt (Brake assembly mounting) 1235 {903.6, 12.50.5}

3 Contact surfaces of hub cap and wheel hub THREEBOND 1104 As required
6 Contact surfaces of drive flange and wheel hub THREEBOND 1104 As required
9 Thread area of lock nut Wheel bearing grease [NLGI No.2 (Li soap)] As required
10, 13 Pack the space between rollers of outer and inner bearing inner races Wheel bearing grease [NLGI No.2 (Li soap)] As required
18 Pack interior space of wheel hub Wheel bearing grease [NLGI No.2 (Li soap)] 6510 g
{2.30.3oz}
26B-15
0.5 {0.02}
78
3 Hub cap wrench MB999108 Removal of hub cap
08159
12.7
{0.50}
9 Lock nut adjustment tool MB999151 Removal and installation of lock nut
70
{2.76}
05617
A B C
Hub puller MB999070
11 A : Hub puller body A : MB999071 Removal of wheel hub and brake drum
B : Attachment 50 B : MB999072 assembly
C : Bolt {1.97} C : MB999073
165 {6.50} 05618
70 {2.76} Press-fitting of oil seal (Use in combination
with *1)
12, 14, Bearing installer MB999097 Press-fitting of inner bearing outer race
15 (T90ST30) (Use in combination with *2)
84 Press-fitting of outer bearing outer race
{3.31} 05619 (Use in combination with *3)
84 {3.31}
12 *1 Oil seal installer MB999153 Press-fitting of oil seal (Use in combination)

105 71
{4.13} {2.80}
05620
92.5
60 {2.36}
{3.64}
14 *2 Bearing installer MB999069 Press-fitting of inner bearing outer race

(Use in combination)
94.5
{3.72}
05621
71
51 {2.01} {2.80}
15 *3 Bearing installer MB999099 Press-fitting of outer bearing outer race

(T90ST26) (Use in combination)
88.5
{3.48}
05621
26B-16
26B
Service procedure
11 [Adjustment]
9 15 13 Tighten lock nut 9 at specified torque (primary tightening) while turning
10 14 wheel hub and brake drum assembly 11, then slacken off.
operation of outer bearings 10, 15, and inner bearings 13, 14 and
retighten lock nut 9 at specified torque (secondary tightening).
After adjustment, make sure that there is no play in the axial direction.
0 0 : Lock nut adjustment tool
26758
B Insert lock washer 8 so that flat area A fits onto notch B of the knuckle
spindle. Mount two bolts 7 (diagonally opposite each other) to lock nut
9, and tighten them at specified torque.
8 If lock nut 9 and the hole of lock washer 8 do not align, slacken off the
lock nut slightly.
A 7
26759
[Measurement]
Fasten spring balance C to hub bolt 17 and measure the tangential
force.
If the measured tangential force is the standard value, the starting
described above.
C 17
If any fault is found after adjustment, replace outer bearings 10, 15, or
26760 inner bearings 13, 14.
NOTE
Make sure that there is no drag in the brake lining and brake
drum 19 before you measure the tangential force.
Make sure that you install oil seal 12.
Do not install drive flange 6.
B
2 Removal and installation of brake hose
First remove brake hose 2 from bracket A (on the frame), then remove
the brake hose from wheel brake B. For installation, follow this procedure
2 in reverse.
CAUTION
A
26618
26B-17
3 Removal of hub cap
0 : Hub cap wrench
0
6
26761
Removal of drive flange
5 Remove snap ring 4, and insert bolts 5 (to the same depth) into two
A
tapped holes A provided for disassembly. Then, remove drive flange 6.
4
9
26762
Removal and installation of lock nut

When mounting lock nut 9 see P26B-17 : adjustment procedure for
starting torque of the wheel hub bearing.
0 : Lock nut adjustment tool
FI
9 26763

B
B : Between roller
01000
26B-18
26B
11 G Wheel hub and brake drum assembly
[Removal]
0 : hub puller
0
26764
B If wheel hub and brake drum assembly 11 cannot be removed be-

cause of stepped wear A in brake drum 19, remove the backing plate
C cover. Turn adjuster B in the opposite direction to the arrow on the
backing plate to increase the clearance between the brake drum and
19
brake shoe assembly C. Then, remove the wheel hub and brake drum
assembly.
[Installation]
After installing wheel hub and brake drum assembly 11, adjust the
A 08265 clearance between brake drum 19 and brake shoe assembly C.
H
^ Gr 35

A 2 : Oil seal installer
2
J
26768

[Removal]
A Drive out inner bearing outer race 14 evenly from three indented parts B
18 in wheel hub 18.
14 A : Pin-punch
B
26769
[Press-fitting]
1
14 2
18 26770
26B-19
K Outer bearing outer race
[Removal]
Drive out outer bearing outer race 15 evenly from three indented parts B
A in wheel hub 18.
A : Pin-punch
15
18 26771
[Press-fitting]
18
15
2
26772
17 LM Installation of nut and hub bolt

Hub bolt 17 is marked with L (left) or R (right) to indicate the side
L, R it is to be mounted on. Check this symbol before mounting the bolt.
17
Screw nut 16 onto hub bolt 17 and tighten at specified torque. Then,
stake the hub bolt to keep it from turning.
16
05634
26B-20
26B
MEMO
26B-21
KNUCKLE AND DRIVE SHAFT
7-
1
12 -
11
- -
-
19
20

10 15 -
-
-7 -
1
14 5-
- 13
-
-
27
-
-
17
2
16
- 26619
1 Nut 11 Kingpin, upper 21 Steering knuckle
2 Tie rod assembly ^ Gr 37 12 Knuckle arm 22 Boot band
3 Spacer 13 Tie rod arm 23 Dust boot
4 Needle bearing 14 Bolt 24 Trunnion bearing inner race
5 Knuckle spindle 15 Kingpin, lower 25 Trunnion bearing outer race
6 Drive shaft assembly 16 Bolt 26 Oil seal
7 Bolt 17 Retainer 27 Axle housing P26B-28
8 Spacer 18 Dust seal
9 Conical spring 19 Knuckle stopper bolt : Non-reusable parts
10 Lock nut 20 Lock nut
NOTE
Do not disassemble drive shaft assembly 6.
Assembly sequence
20 19

27 26 23 18 25 24 21 17 16 8 9 11 12 13 7 10 6 2 1 22

15 14 543
26B-22
26B
6 Deflection in drive shaft assembly (Inner shaft) 0.75 {0.030} or less 1.5 {0.059} Replace
Play in axial direction of drive shaft assembly 0.4 {0.016} or less Replace
Birfield joint
21 Starting torque of steering knuckle 4.81.3 Nm Adjust end of
{3.570.98lbf.ft, 49.413.6 kgfcm} arm at tie rod
side with a
spacer to
tangential
strength} of
287.8N {6.4
1.8 lbf.
2.90.8 kgf}

1 Nut (Tie rod assembly mounting) 93.224.5 {6918, 9.52.5}
7 Bolt (Tie rod arm and knuckle arm mounting) 16215 {11911, 16.51.5}
10 Lock nut 33339 {24629, 344}
14 Bolt (Kingpin, lower mounting) 16215 {11911, 16.51.5}
16 Bolt (Retainer and dust boot mounting) 41 {2.90.7,0.40.1}
20 Lock nut (Knuckle stopper bolt tightening) 9612 {719, 9.751.25}

3 Chamfered side of spacer inner rim Wheel bearing grease [NLGI No.2 (Li soap)] As required
4 Pack the space between rollers of needle bearing Wheel bearing grease [NLGI No.2 (Li soap)] As required
5 Mounting surface of steering knuckle spindle THREEBOND 1104 As required
6 Pack the interior of Birfield joint of drive shaft assembly Wheel bearing grease [NLGI No.2 (Li soap)] 9010 g
{3.170.35 oz}
7, 14 Thread area of bolt THREEBOND 1104 As required
12 Mounting surface of steering knuckle knuckle arm THREEBOND 1104 As required
13 Mounting surface of steering tie rod arm THREEBOND 1104 As required
15 Mounting surface of steering knuckle kingpin, lower THREEBOND 1104 As required
18 Lip area of dust seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
21 Pack the interior of steering knuckle Wheel bearing grease [NLGI No.2 (Li soap)] 40030 g
{14.11.06 oz}
23 Mounting surface of steering knuckle dust boot THREEBOND 1104 As required
24 Pack the space between rollers of trunnion bearing inner race Wheel bearing grease [NLGI No.2 (Li soap)] As required
27 Trunnion bearing mounting surface of axle housing ball yoke Wheel bearing grease [NLGI No.2 (Li soap)] As required
and outside surface of ball
26B-23
70
{2.76}

(T90ST30)
84
{3.31}
05619
25 Press-fitting of trunnion bearing outer race
41 61 (Use in combination)
{1.61} {2.40}
(T90ST25)
78.5
{3.09}
05621
34
{1.34}
26 Oil seal installer MB999152 Press-fitting of oil seal
55
{2.17} 05636
5 4
34
Service procedure
Installation of spacer and needle bearing
Pack the space between rollers of needle bearing 4 with grease and
A press-fit the needle bearing until it is level with the end of knuckle
spindle 5.
3 Install spacer 3 on knuckle spindle 5 as illustrated.
After installing spacer 3, coat the chamfered side A of the inner
diameter of the spacer with grease.
CAUTION
Take care not to use too much force when installing needle
05637
bearing 4.
6 Drive shaft assembly

[Inspection]
6 A Measure deflection A of drive shaft assembly 6 at the center of the inner
shaft. If the measured value is higher than the limit, replace the drive
shaft assembly.
NOTE
To measure the deflection of drive shaft assembly 6, turn it one
05638 one half of the indicated value.
26B-24
26B
[Installation]
C 26 Insert drive shaft assembly 6 into steering knuckle 21 with flat part C of
the Birfield joint facing upwards.
6 CAUTION
Be careful not to damage oil seal 26, when installing drive shaft
assembly 6.
21
26620
7 89 Spacer and conical spring

[Adjustment of pre-pressure in trunnion bearing]
Assemble conical spring 9 and spacer 8 (thickness=3.2 mm {0.13 in.})
and temporarily tighten kingpin, upper 11 with assembly bolt 7 as illus-
11
trated.
9 9
8
05640
Install kingpin, lower 15 into steering knuckle 21. Screw bolt 14 into
spring washer A, and tighten sufficiently but without applying tension
24, 25 21 to the spring washer.
Offer up kingpin, lower 15 until it fits snugly into trunnion bearings 24,
25 in the lower part.
Measure clearance B between steering knuckle 21 and kingpin, lower
B
A 15. Select spacer 8 based on the measured clearance.
15
Clearance B Thickness of spacer
14 0.6 mm {0.024 in.} 3.2 mm
05641
or more {0.13 in.}
Less than 3.6 mm
0.6 mm {0.024 in.} {0.14 in.}
If clearance B is 0.6 mm {0.024 in.} or more, tighten bolt 14 at

specified torque.
If clearance B is less than 0.6 mm {0.024 in.}, replace with spacer 8
(thickness=3.6 mm {0.14 in.}) and remeasure the clearance.
[Starting torque of steering knuckle]

Fasten spring balancer C to steering knuckle 21 and measure whether
the starting torque of the steering knuckle conforms to the standard
C value.
21 starting torque of the steering knuckle according to the procedure
described above. If any fault is found after adjustment, replace trun-
nion bearings 24, 25.
NOTE
08152 Be sure to measure the starting torque before installing dust seal
18 and dust boot 23.
26B-25
27
18 NS Installation of dust seal and dust boot
Install dust boot 23 on kingpin ball yoke area A in axle housing 27. Then,
mount dust seal 18 while widening its end part.
CAUTION
Do not widen dust seal 18 too much.
A
23 A
Q
05643
A Assembly of steering knuckle

27 Install kingpin, lower 15 into steering knuckle 21.
While turning the steering knuckle, install it into kingpin ball yoke area A
in axle housing 27.
21 15
R
05644
22 Tightening of boot band

Install boot band 22 at an angle within 20 as illustrated. Then, tighten
and caulk it.
10 A : Front of the vehicle
20 CAUTION
B Be careful not to overtighten dust boot 23, and make sure that
23 the rubber does not protrude too much from the joint surface.
22
A
05645
B 24
T Packing grease in trunnion bearing inner race
A : Grease pump nozzle
A
B : Between rollers
05646
26B-26
26B
U Trunnion bearing outer race
[Removal]
A : Pin-punch
27
A
25 05647
[Press-fitting]
2
25
27
05648
27 A
26
V Press-fitting of oil seal
Apply grease to lip area B of oil seal 26.
B Press-fit oil seal 26 in the direction as illustrated so that the oil seal is
0 level with the end of kingpin ball yoke A of axle housing 27.
05649
26B-27
AXLE HOUSING
1 Inspection plug
2 Drain plug
8
3 Nut
9 4 Nut
5 Reduction and differential assembly
P26B-30
6 Nut
7 U-bolt nut
8 U-bolt
9 Front spring pad
10 Vent plug
11 Axle housing
* : Propeller shaft ^ Gr 25
4
*
Assembly sequence
reverse.
NOTE
Do not remove axle housing 11 unless it
3 is faulty.
- 10
6
1
2 7
27680

11 Deflection in axle housing within 1.6 {0.063} 5 {0.2}

1 Inspection plug 98 to 115 {72 to 87, 10 to 12}}
3 Nut (Propeller shaft mounting) 59 to 74 {43 to 54, 6.0 to 7.5}
4 Nut (Reduction and differential assembly mounting) 34 to 44 {25 to 33, 3.5 to 4.5}
6 Nut (Lower part of shock absorber mounting) 33 to 49 {25 to 36, 3.4 to 5.0}
7 U-bolt nut (U-bolt mounting) 1057.8 {785.8, 10.80.8}
26B-28
26B
- Sealant
11 Reduction and differential assembly mounting surface of THREEBOND 1215 As required
axle housing
Service procedure
Service operations before removal and after installation
11
(1) Before removing any part, remove inspection plug 1 and drain plug
2 and drain the gear oil from axle housing 11.
(2) After installing all parts, fill axle housing 11 with the specified
amount of gear oil.
(3) Tighten drain plug 2 and inspection plug 1 at specified torque.

1
2
5
08154
Removal of reduction and differential assembly
5 Tighten M101.25 mm bolts evenly into two screw holes A provided for
removing reduction and differential assembly 5.
A A
G
05652
Axle housing
11
A [Inspection for deflection]
Support both ends of kingpin ball yoke part A of axle housing 11
horizontally and measure axle housing height B.
Turn axle housing 11 through 180 to measure height B.
If the height difference is higher than the limit, replace axle housing
11.
B
08156
[Applying sealant]
C Apply sealant to reduction and differential assembly 5 mounting sur-
3 to 4 mm
{0.12 to 0.16 in.}
face of axle housing 11.
Apply sealant linearly for part C and for the position that is symmetrical
to an imaginary center line.
D
CAUTION
Make sure that sealant does not ooze from the mating surface
D DD after installing reduction and differential assembly 5.
11
05654
26B-29
REDUCTION AND DIFFERENTIAL

12 13
-
- 9
16
18

-

29
8
6
2 3
4 1 05655
Work before disassembly P26B-33

Inspection before disassembly P26B-33
1 Bolt 12 Pinion shaft 22 Rear bearing shim
2 Lock plate 13 Differential pinion 23 Final drive pinion
3 Side bearing nut 14 Differential gear 24 Oil seal
4 Bolt 15 Spacer 25 Front bearing inner race
5 Bearing cap 16 Differential case 26 Front bearing outer race
6 Side bearing outer race 17 Lock nut 27 Rear bearing outer race
7 Side bearing inner race 18 Companion flange 28 Oil stopper
8 Differential assembly assembly 29 Differential carrier
9 Bolt 19 Front bearing shim
10 Final drive gear 20 Pinion spacer : Non-reusable parts
11 Lock pin 21 Rear bearing inner race
Assembly sequence
Inspection and adjustment after assembly P26B-34
CAUTION
Be sure when replacing any of the following parts, to replace both it and its associated parts as a set :
For bolt 4, bearing cap 5 or differential carrier 29, replace the carrier assembly.
For final drive gear 10 or final drive pinion 23, replace the gear set.
Make sure you keep left and right side bearings 6, 7 separate after remove, and be careful not to mix then up
when installing them.
NOTE
Write down the thickness of front bearing shim 19, pinion spacer 20 and rear bearing shim 22 when disassem-
bling to use it as reference when assembly.
26B-30
26B
10 Deflection of rear of final drive gear within 0.05 {0.0020}
10, 23 Backlash between final drive gear and final 0.15 to 0.20 Adjust or
drive pinion {0.0059 to 0.0078} replace
along with
the gear set
13, 14 Backlash between differential pinion and 0.15 to 0.20 Adjust using
differential gear {0.0059 to 0.0078} the spacer
or replace
14 Play in the rotating direction between drive shaft 0.07 to 0.16 Replace
and differential gear spline part {0.0028 to 0.0063}
23 Starting torque of final drive pinion 1 to 2 {0.7 to 1.4, 0.1 to 0.2} Adjust

1 Bolt (Lock plate mounting) 19.6 to 26.5 {14 to 20, 2.0 to 2.7}
4 Bolt (Bearing cap mounting) 68.6 to 78.4 {51 to 58, 7 to 8}
9 Bolt (Final drive gear mounting) 137.2 to 166.6 {101 to 122, 14 to 17}
17 Lock nut (Companion flange assembly installation) 313.6 to 411.6 {231 to 303, 32 to 42}

10 Thread area of final drive gear LOCTITE 271 As required
24 Lip area of oil seal Wheel bearing grease [NLGI No. 2 (Li soap)] As required

Radius 134.5 13 {0.51}
Differential working 30 A MB999034
base assembly C Maintenance work bench for reduction
A : Attachment A : MB999074 and differential
B : Holder B
11 {0.43}
B : MB999036
D
C : Holder C : MB999037 Flange stopper is used for installation
D : Working base D : MB999035 and removal of the companion flange
E : Flange stopper E E : MB999096 assembly
40 {1.57}
11 {0.43} 20 {0.79} 05656
83.5
{3.29}
3 Differential side bearing MB999012 Tightening of side bearing nut

adjustment tool
05657
53
{2.09}
7 Adapter MB999077 Removal of side bearing inner race (Use in
combination with available bearing puller)
44
{1.73}
05658
26B-31
Unit : mm {in.}
56
{2.20}
7 Bearing installer MB999079 Press-fitting of side bearing inner race
46
{1.81} 05659
25.5
21 Pinion rear bearing {1.00} MB999045 Removal of rear bearing inner race
remover 0.5
{0.02}
02956
42 Press-fitting of rear bearing inner race (Use

{1.65} MB999104 in combination with *1)
21, 24, Bearing installer (T90ST13) Press-fitting of oil seal (Use in combination
25 with *2)
52 Press-fitting of front bearing inner race
{2.05} 05661
46 {1.81}
21 *1 bearing installer MB999044 Press-fitting of rear bearing inner race (Use

in combination)
57
{2.24}
05662
05663
B
73
Drive pinion setting 34.8 MB999084
gauge set {1.37} Adjustment of starting torque and pinion
height of final drive pinion
A : Tool box 254.5 A : MB990824
39.9 {10.02}
B : Pinion gauge B : MB999086
{1.57} 05664
23 C : Cylinder gauge C C : MB999087
100 Cube ring

{3.94} 184
{7.24} 05665
12.55 to 12.7
{0.49 to 0.50}
Socket MB999054 Measurement of starting torque of final

drive pinion
6.43 to 6.6
{0.25 to 0.26} 05666
26B-32
26B
Unit : mm {in.}
24 *2 Bearing installer adapter MB999105 Press-fitting of oil seal (Use in combination)

88 (T90ST07)
{3.46} 50
{1.97} 05667
57
{2.24}

70 (T90ST31)
{2.76}
05668
26, 27 Press-fitting of front and rear bearing outer
79 race (Press-fit in combination)
{3.11}

89
{3.50}
05669

3
29 Mount differential carrier 29 on 0 differential working base assembly.
1 1 : Attachment
2
4
2 : Holder
3 : Holder
4 : Working base
1
05670
(1) Deflection of rear surface of final drive gear

Measure at the point of maximum diameter of final drive gear 10.
05671
10 (2) Backlash between final drive gear and final drive pinion
Measure at three points on the circumference of final drive gear 10.
05672
26B-33
14 (3) Backlash between differential pinion and differential gear
13
Measure backlash between differential pinion 13 and differential gear
14.
15
05673
(4) Tooth contact of final drive gear

10 Apply red lead primer to the surfaces of three or four teeth of final drive
A
gear 10, examine tooth contact by turning the gears a few times.
A : Examine tooth contact using paper.
05674
10 Inspection and adjustment after assembly

9 (1) Deflection of rear surface of final drive gear
Measure at the point of maximum diameter of final drive gear 10.
If the measured value deviates from the standard value, check
tightening torque of bolt 9 or replace along with the gear set.
05675
(2) Backlash of final drive gear

[Adjustment]
4
Before adjusting, tighten bolt 4 temporarily. Then, tighten side bearing
nut 3 using 0 differential side bearing adjustment tool until just before
3 pre-pressure is exerted on side bearings 6, 7.
6, 7
0 05676
26B-34
26B
[Measurement]
10
Measure final drive gear 10 backlash at three points on the circumfer-
ence of the final drive gear.
3
06710
< When backlash is too small > If backlash deviates from the standard value, rotate left and right side
10 bearing nuts 3 and move final drive gear 10 as illustrated using 0
side bearing adjusting tool to adjust backlash.
< When backlash is too small >
Adjust in order of A to B.
3 3 A : Loosen
B : Tighten
A B
< When backlash is too great >
Adjust in order of C to D.
09557 C : Loosen
< When backlash is too large >
D : Tighten
10
CAUTION
Be sure, when side bearing nut 3 on one side is loosened, to
tighten the other side by the same amount.
3 3
D C
09558
Tighten right and left side bearing nuts 3, by half the pitch between the
3
centers of adjacent holes, using 0 differential side bearing adjust-
4 ment tool to add pre-pressure to side bearings 6, 7.
Tighten bolt 4 at specified torque.
3
6, 7
0
06711
(3) Backlash between differential pinion and differential gear

14 13
Measure backlash between differential pinion 13 and differential gear
14. If the measured value deviates from the standard value, adjust
15 with spacer 15.
CAUTION
Make sure that the thickness of right spacer 15 is identical to that
of the left spacer.
05673
Spacer thicknesses :
1.4 to 1.6 mm {0.055 to 0.063 in.} (three thicknesses available in 0.1
mm {0.0039 in.} increments)
26B-35
(4) Tooth contact of final drive gear
10 [Inspection]
E Apply red lead primer to the surfaces of three or four teeth of final drive
gear 10, examine tooth contact by turning the gears a few times.
E : Examine tooth contact using paper.
[Adjustment]
If tooth contact deviates excessively from the standard value, adjust by
increasing or decreasing backlash and rear bearing shim 22.
05674
CAUTION
Be sure when replacing the gear because of abnormally worn
teeth to replace the gear set of final drive gear 10 and final drive
pinion 23 together.
Normal tooth contact at no load

< Leading edge > F
< Final drive gear >
H G F : Heel
J
G : Toe
K
H : Face
J : Flank
< Trailing edge > K : Clearance
01046
< Leading edge > < Final drive pinion >

F G
F : Heel
G : Toe
H H : Face
J
K J : Flank
K : Clearance
< Trailing edge >
01047
26B-36
26B
Maintenance item Assembly standards
Tooth contact position Lengthwise di- From center towards edge
rection of tooth
At no load
Vertical direction From center towards top of tooth for final drive gear and center for final drive pinion
Tooth contact shape Length Approximately 50 to 70% of tooth width
Width Approximately 50 to 70% of tooth depth
Degree of tooth contact It becomes weaker as it nears tooth root or tooth tip
NOTE
When tooth contact is near the toe at no load it becomes middle area contact at load.
Adjustment of tooth contact
Method of adjustment Moving direction

Advance final drive pinion to final drive gear Tooth contact moves towards
(Shims are added) tooth root
Adjustment by adding or reducing shims
Leading
Trailing
edge
edge
Retard final drive pinion from final drive gear Tooth contact moves towards
(Shims are reduced) tooth tip
Advance final drive gear to final drive pinion center Tooth contact moves in lengthwise
(Less backlash) direction of tooth
Leading edge: Nearer to toe and
slightly nearer to root of tooth
Adjustment using side bearing nut
Trailing edge: Nearer to heel and

slightly nearer to top of tooth
Retard final drive gear from final drive pinion center Tooth contact moves in lengthwise
(More backlash) direction of tooth
Leading edge: Nearer to heel and
Trailing edge: Nearer to toe and
01048
26B-37
5
Service procedure
Removal of bearing cap
Put alignment marks A on bearing cap 5 to distinguish left and right.
5
05678
7 Side bearing inner race

[Removal]
0 0 : Adapter
05679
[Press-fitting]
0
7
16
05680
F Final drive gear

[Removal]
Put alignment marks A on final drive gear 10 and differential case 16.
10
05681
[Installation]
9 Apply LOCTITE to thread area of all bolt holes B of final drive gear 10
and tighten bolts 9 at specified torque.
CAUTION
Be sure to let bolts 9 harden for at least an hour, after installation,
B before driving.
Furthermore, be sure to let bolts 9 harden for at least four hours
10 before running at full torque.
05682
26B-38
26B
G Lock pin
[Removal]
A : Punch
11
05683
B [Press-fitting]
After press-fitting lock pin 11, stake part B at two points.
11
A
05684
J Play between differential gear and drive shaft spline in

the rotating direction
B If the measured value is higher than the limit, replace faulty parts.
A : Rear axle shaft
B : Play
14
15
01065
K Installation of spacer
Install spacer 15 with oil grooves A side facing the differential gear.
A
05685
M Removal and installation of lock nut

0 : Flange stopper
0 17
05686
26B-39
29
2 A O SU X
to to Final drive pinion assembly
[Selection of rear bearing shim]
Install 1 pinion gauge temporarily in differential carrier 29 together
with the parts illustrated.
21
27 Tighten lock nut 17 using 2 socket to adjust starting torque A of the
1 28
pinion gauge to the standard value.
26
25 CAUTION
Do not assemble parts other than those illustrated.
18
17 05687
Set 3 cylinder gauge to standard starting torque to measure gap B

as illustrated.
3 Select rear bearing shim 22 using the calculation given below.
< Calculation of rear bearing shim thickness C >
B
C=B1.5 mm {0.059 in.}
Rear bearing shim thicknesses :
0.3 mm {0.012 in.} and 1.38 to 1.65 mm {0.054 to 0.065 in.}
(10 thicknesses available in 0.03 {0.0012 in.} mm increments)
CAUTION
05688 Be sure to keep the number of rear bearing shims 22 to the
minimum and keep them as close to the standard value as possi-
ble.
[Installation of rear bearing shim]

Install selected rear bearing shim 22 onto final drive pinion 23 and press-
fit rear bearing inner race 21 using 12 bearing installer.
1 CAUTION
23
Be sure, when installing rear bearing shim 22 comprised of a 0.3
mm {0.012 in.} shim and another shim, that the 0.3 mm {0.012 in.}
2
21 shim is installed next to the bearing.
22 05689
[Press-fitting of front bearing inner race]

Assemble pinion spacer 20 and front bearing shim 19 for press-fitting of
20 19 25 front bearing inner race 25 using 0 bearing installer.
0
05690
26B-40
26B
[Measurement of starting torque]
0 A After installing companion flange assembly 18, tighten lock nut 17 at
specified torque.
Measure starting torque A of final drive pinion 23 using 0 socket.
23
If the measured value deviates from the standard value, select pinion
spacer 20 and front bearing shim 19 to adjust the starting torque to the
20 standard value.
19
CAUTION
18 Do not install the oil seal before measuring the starting torque.
17 05691 Be sure to keep the number of shims to the minimum when
selecting pinion spacers 20.
Pinion spacer heights:

64.07 mm {2.52 in.} and 64.40 mm {2.54 in.} (Painted white)
Front bearing shim thicknesses:
0.30 mm {0.012 in.} and 2.00 to 2.33 mm {0.079 to 0.092 in.}, (12
Q
thicknesses available in 0.03 mm {0.0012 in.} increments)
Rear bearing inner race

[Removal]
0 0 : Pinion rear bearing remover
21 [Press-fitting]
P26B-40
S
05692
Removal of final drive pinion
CAUTION
23 Be sure to use a plastic mallet when driving out final drive pinion
23, and prevent it from dropping to the ground by holding it.
29
T
05693
1 Press-fitting of oil seal

A 24
Apply grease to lip area A of oil seal 24 and press-fit the oil seal into
differential carrier 29.
29 2 : Bearing installer adapter
05694
26B-41
V Front bearing outer race
[Removal]
B
Drive out front bearing outer race 26 evenly from three indented parts A
of differential carrier 29.
B : Pin-punch
26
29
A
05695
[Press-fitting]
2
26
29
WX
05696
Rear bearing outer race and oil stopper

B [Removal]
29 Drive out rear bearing outer race 27 and oil stopper 28 evenly from three
indented parts A of differential carrier 29.
B : Pin-punch
27 28
A
05697
[Press-fitting]
1
2 Insert oil stopper 28 in the direction of the arrow as illustrated.
29
05698
26B-42
Group 27
Rear Axle
Table of Contents
BACK
HOME
Pub No. TWSE9501-27

27
GROUP 27 REAR AXLE
SPECIFICATIONS .................................................................................. 2
WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE .... 7
WHEEL HUB AND BRAKE DRUM < FE639 > ....................................... 8
WHEEL HUB AND ROTOR < FE649 > ................................................ 16
AXLE HOUSING ................................................................................... 24
REDUCTION AND DIFFERENTIAL ..................................................... 28
27-1
SPECIFICATIONS
Vehicle model FE639 FE649
Item
Rear axle Model R033T
Type Full floating shaft tube system
Model D033H
Type Single-reduction gear
Reduction
Tooth shape Hypoid gear
Speed reduction ratio 5.714
Differential Tooth shape Straight bevel gear
Grade * Normal : Maximum air temperature during operation below 40C {104F}
Gear oil
API GL-5
SAE 90
Hot area : Maximum air temperature during operation above 40C {104F}
API GL-5
SAE 140
Oil volume L {qts.} 4.5 {4.8}
Mass (reference) kg {lb} Approximately 210 {460} Approximately 230 {505}
* When used under heavily-loaded, severe conditions such as continuous driving on uphill grades, it is recommended that you use gear oil with a
SAE viscosity grade of 140. However, the air temperature must be above 10C {50F}.
27-2
Wheel Hub and Brake Drum < FE639 >
1 Hub bolt
1 2 3 2 Wheel hub
3 Inner bearing
4 Inner oil seal
5 Brake assembly
4 6 Brake drum
7 Axle housing
8 Outer bearing
13
9 Lock nut
10 Lock washer
12 11 Outer oil seal
12 Axle shaft
13 Lock bolt
11
10 9 8
6 5
12041
Wheel Hub and Rotor < FE649 >

1 Hub bolt
2 3 2 Wheel hub
3 Inner bearing
1
4 Inner oil seal
5 Disc brake assembly
6 Disc rotor
4 7 Axle housing
8 Outer bearing
9 Lock nut
13 10 Lock washer
11 Outer oil seal
12 12 Axle shaft
13 Lock bolt
11
10 9
7
5
6
12042
27-3
Reduction and Differential
1 2
3
25
4
24
5
6
23
22 7
21 8
9
20
10
19 11
18
12
17
16 13
15
14
08326
1 Companion flange 14 Final drive gear

2 Lock nut 15 Differential case, LH
3 Dust cover 16 Bearing cap
4 Oil seal 17 Lock plate
5 Front bearing 18 Adjusting screw
6 Collar 19 Side bearing
7 Rear bearing 20 Differential pinion
8 Final drive pinion 21 Differential pinion washer
9 Pinion pilot bearing 22 Pinion spider
10 Lock ring 23 Differential carrier
11 Differential gear 24 Shim
12 Differential gear washer 25 Bearing retainer
13 Differential case, RH
27-4
TROUBLESHOOTING 27
insufficient
Oil leaking from differential carrier and axle housing
Propeller shaft turns but vehicle does not move


Oil leaking from axle shaft
Tires drag while cornering

Noise while cornering
Possible causes
Axle shaft mounting bolt loose
Axle shaft fractured
Axle shaft slips out of engagement
Oil seal faulty
Air breather clogged
Wheel hub, Wheel hub bearing seized
brake drum, Wheel hub bearing worn
disc rotor,
or axle housing Wheel hub bearing rotation faulty
Wheel hub bearing broken
Gear oil excessive
Sealant faulty
Inspection plug and drain plug loose
Side bearing seized
Side bearing worn
Side bearing rotation faulty
Side bearing broken
Side bearing preload adjusted incorrectly
Reduction and differential assembly mounting bolt and nut loose
Reduction Differential carrier cracked or damaged
and differential Final drive gear and differential case tightening bolts loose
Final drive gear or final drive pinion broken
Final drive gear or final drive pinion worn
Final drive gear or final drive pinion damaged
Final drive gear backlash excessive
Final drive gear backlash or tooth contact faulty
Final drive pinion starting torque faulty
Lock nut loose
27-5
TROUBLESHOOTING

insufficient
Oil leaking from differential carrier and axle housing
Propeller shaft turns but vehicle does not move


Oil leaking from axle shaft
Tires drag while cornering

Noise while cornering
Possible causes
Front and rear bearings seized
Front and rear bearings worn
Front and rear bearings broken
Pinion pilot bearing worn
Pinion pilot bearing seized or broken
Reduction Pinion spider broken
and differential Differential gear or differential pinion broken
Differential gear or differential pinion seized
Differential gear or differential pinion worn
Differential gear washer worn or damaged
Differential gear spline worn
27-6
WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE 27
4
1 3
14177

2 Disconnect the negative terminal of the battery cable. ^ Gr 54
3 Jack up the rear axle using a garage jack.
4 Support the rear frame on rigid racks.
WARNING
racks.

27-7
WHEEL HUB AND BRAKE DRUM < FE639 >

15
1
-
17

-
19
-
*
18 -
6
-
-
2
12043
1 Brake pipe 12 Inner bearing outer race
2 Bolt 13 Outer bearing outer race
3 Axle shaft 14 Nut
4 Outer oil seal 15 Brake drum
5 Bolt 16 Hub bolt
6 Lock washer 17 Wheel hub
7 Lock nut 18 Nut
8 Outer bearing inner race 19 Brake assembly ^ Gr 35
9 Wheel hub and brake drum assembly
10 Inner oil seal * : Axle housing P27-24
11 Inner bearing inner race : Non-reusable parts
CAUTION
Be sure to protect brake pipe 1 from dust by fitting blanking plugs after removal.
NOTE
Do not disassemble brake drum 15 and wheel hub 17 unless they are faulty.
Assembly sequence
WARNING
You must bleed air from the brake system after assembly, failure to do so would cause the brake to
malfunction. ^ Gr 35
CAUTION
Be careful not to damage inner oil seal 10, when installing wheel hub and brake drum assembly 9 into axle
housing *.
27-8
27
3 Axle shaft Bend of shaft center 1 {0.039} or less 2 {0.079} Replace
Wobble of flange face 0.03 {0.0012} or less 0.05 {0.0020}
Starting torque of wheel hub bearing 2.0 to 3.9 Nm Tangential
{1.4 to 2.9 lbf.ft, 0.20 to 0.40 kgfm} force at the
hub bolt :
20 to 38 N
{4.4 to
8.6 lbf, 2.0
to 3.9 kgf}

2 Bolt (Axle shaft mounting) 98 to 115 {72 to 87, 10 to 12}
5 Bolt (Lock washer mounting) 6.9 to 11 {5.1 to 8.0, 0.7 to 1.1}
7 Lock nut (Wheel hub Primary tightening 98 to 125 {72 to 94, 10 to 13}
bearing mounting : wheel After slackening off 29 to 39 {22 to 29, 3 to 4}
hub bearing preload completely, carry out
adjustment) secondary tightening
18 Nut (Brake assembly mounting) 98 to 135 {72 to 100, 10 to 14}
- Lubricant
4, 10 Lip area of outer and inner oil seals Wheel bearing grease [NLGI No. 2 (Li soap)] As required
7 Thread area of lock nut Wheel bearing grease [NLGI No. 2 (Li soap)] As required
8, 11 Pack the space between rollers of outer and inner Wheel bearing grease [NLGI No. 2 (Li soap)] As required
bearing inner races
17 Pack interior of wheel hub Wheel bearing grease [NLGI No. 2 (Li soap)] 37035 g
{13.11.23 oz}
27-9
7 Lock nut adjustment tool 12.7 MB999150 Removal and installation of lock nut
70 {2.76} {0.50}
05617
A C B
Hub puller components MB999070

A : Hub puller body A : MB999071 Removal of wheel hub and brake drum
9 B : Bolt B : MB999072 assembly
C : Attachment 50 {1.97}
C : MB999073
165 {6.50}
05618
70 {2.76}

(T90ST30)
84 {3.31}
10 05619 Press-fitting of inner oil seal: Use in
84 {3.31} combination
Oil seal installer MH062607

117 {4.61}
20 {0.79}
M101.25 06596
70 {2.76}

(T90ST30)
84 {3.31}
12 05619 Press-fitting of outer bearing outer race:
Use in combination
99
77 {3.03} {3.90}

(T90ST05)
109 {4.29}
05621
70 {2.76}

(T90ST30)
84 {3.31}
13 05619 Press-fitting of inner bearing outer race:
Use in combination
77 {3.03} 99 {3.90}
(T90ST05)
109 {4.29}
05621
27-10
27
Service procedure
9
[Adjustment]
Tighten lock nut 7 at specified torque for primary tightening, while
turning wheel hub and brake drum assembly 9.
Slacken off lock nut 7 completely.
operation of outer bearings 8, 13 and inner bearings 11, 12.
Retighten lock nut 7 at specified torque for secondary tightening.
0
7 06601
Align flat area A with notch B to install lock washer 6.

B
Make sure that the mounting holes of lock washer 6 and lock nut 7
align. If they do not, slacken off the lock nut and align them.
A
Install bolts 5 at the position as illustrated, aligning lock nut 7.
6
CAUTION
After adjustment, make sure that there is no play in the axial
direction of wheel hub and brake drum assembly 9.
5
7 06602
[Measurement]
Install spring balance C on hub bolt 16.
Measure the tangential force.
If the measured tangential force is within the specified value, the
starting torque conforms to the standard value.
Do not allow the starting torque to become higher than the tangential
C
16 force.
If the measured value deviates from the specified value, readjust.
If any fault is found after readjustment, replace outer bearings 8, 13
06603 and inner bearings 11, 12.
NOTE
Measure the starting torque with inner oil seal 10 installed.
Measure the starting torque with rear axle shaft 3 and outer oil
seal 4 removed.
Make sure that there is no drag in brake lining and brake drum 15
3
before you measure the tangential force.
Axle shaft
[Removal]
Insert two mounting bolts 2 of axle shaft 3 into two screw holes A,
provided for disassembly, of the flange. Then, remove the rear shaft.
2
3
A
A 06612
27-11
[Inspection]
B : Bend at the shaft center
B NOTE
C To measure the bend of axle shaft 3, turn it one full revolution
and read the dial gauge indicator. The bend is one half of the
indicated value.
3 C: Bend of flange surface
06613
[Installation]
Knock pin hole E of axle shaft 3 is the second hole clockwise from
disassembly screw hole A.
D E To mount axle shaft 3, align knock pin D with knock pin hole E.
E
A
3
A
E 06614
4
A 4 Outer oil seal
[Removal]
To remove outer oil seal 4, use a pair of pliers and pull protrusion A of the
outer oil seal circumference evenly.
06615
[Installation]
Apply grease to lip area B of outer oil seal 4 and press-fit the outer oil
B
seal in the direction as illustrated.
4
06616
27-12
27
Adjust and measure the starting torque of wheel hub bearing during
installation. P27-11
0
7 06783
B 8, 11
8G Packing grease in outer bearing inner race and inner
bearing inner race
A
A: Grease pump nozzle
B: Space between rollers
01000
9 9 Wheel hub and brake drum assembly

[Removal]
Remove wheel hub and brake drum assembly 9 using mounting bolt 2
of axle shaft 3.
CAUTION
Make sure you remove wheel hub and brake drum assembly 9 in
a straight line to prevent damage to oil seal 10.
0
2 06617
D If wheel hub and brake drum assembly 9 cannot be removed because

B of stepped wear A in brake drum 15, do the following:
E Remove the backing plate cover.
C Lift lever B.
15
C : Wire approximately 2 mm {0.079 in.}
Turn adjuster D in the opposite direction to the arrow on the backing
plate to retract brake shoe assembly E.
Remove wheel hub and brake drum assembly 9.
A
06630 CAUTION
[Installation]
After installing wheel hub and brake drum assembly 9, adjust the brake
shoe clearance. ^ Gr 35
27-13
1
F Installation of inner oil seal
Press-fit inner oil seal 10 until it is flush with the end of wheel hub 17.
17
2 10
06723
H Inner bearing outer race

[Removal]
Drive out inner bearing outer race 12 evenly from three indented parts A
B in wheel hub 17.
B : Pin-punch
12 17
A
06622
[Installation]
1
2
12
17
06623
I Outer bearing outer race

[Removal]
Drive out outer bearing outer race 13 evenly from three indented parts A
B in wheel hub 17.
B : Pin-punch
A
13 17
06624
27-14
27
1 [Installation]
13
17
06625
A
J Installation of nut
Tighten nut 14 at specified torque, then caulk the nut to keep it from
turning.
A : Punch
14
13924
16
L Installation of hub bolt
Hub bolt 16 is marked with L (left) or R (right) to indicate the side it is to
be mounted on. Check this symbol before press-fitting the bolt.
L, R
06653
27-15
WHEEL HUB AND ROTOR < FE649 >
-
-
1
26
28
*1 - 27
16
10 3
6
15
-

-
8 11 -
4
9
7
12
8 *2
6
5
9
11
12039
1 Brake pipe 12 Bolt 23 Outer bearing outer race
2 Clip 13 Axle shaft 24 Nut
3 Brake hose 14 Outer oil seal 25 Hub bolt
4 Clip 15 Bolt 26 Bolt
5 Bolt 16 Lock washer 27 Wheel hub
6 Eye bolt 17 Lock nut 28 Disc rotor
7 Brake hose 18 Outer bearing inner race
8 Bolt 19 Wheel hub and rotor assembly *1 : Axle housing P27-24
9 Dust shield 20 Inner oil seal *2 : Brake pad wear indicator
10 Bolt 21 Inner bearing inner race ^ Gr 54
11 Disc brake assembly 22 Inner bearing outer race : Non-reusable parts
^ Gr 35
WARNING
Disc brake assembly 11 and disc rotor 28 are hot immediately after the vehicle has stopped, so take care not to
burn yourself.
CAUTION
Be sure to protect brake pipe 1 and brake hoses 3, 7 from dust by fitting blanking plugs after removal.
NOTE
Do not disassemble wheel hub 27 and disc rotor 28 unless they are faulty.
27-16
27
Assembly sequence
WARNING
You must bleed air from the brake system after assembly, failure to do so would cause the brake to
malfunction. ^ Gr 35
CAUTION
Be careful not to damage inner oil seal 20 when installing wheel hub and rotor assembly 19 in axle housing *1.

13 Rear axle Bend of shaft center 1 {0.039} or less 2 {0.079} Replace
shaft
Wobble of flange face 0.03 {0.0012} or less 0.05 {0.0020} Replace
Starting torque of wheel hub bearing 2.0 to 3.9 Nm {1.4 to 2.9 lbf.ft, Tangential
0.20 to 0.40 kgfm} force at
hub bolt :
18 to 35 N
{4.0 to
7.9 lbf, 1.8
to 3.6 kgf}

5 Bolt (Clip mounting) 4 to 6 {2.9 to 4.3, 0.4 to 0.6}
6 Eye bolt (Brake hose mounting) 19.6 to 24.6 {14 to 18, 2 to 2.5}
8 Bolt (Dust shield mounting) 39 to 58 {28 to 43, 3.9 to 6.0}
10 Bolt (Disc brake assembly mounting) 125 to 175 {94 to 130, 13 to 18}
12 Bolt (Axle shaft mounting) 98 to 120 {72 to 87, 10 to 12}
15 Bolt (Lock washer mounting) 6.9 to 11 {5.1 to 8.0, 0.7 to 1.1}
17 Lock nut (Wheel hub Primary tightening 98 to 130 {72 to 125, 10 to 13}
bearing mounting : wheel After slacking off 30 to 40 {22 to 29, 3 to 4}
hub bearing preload completely, carry out
adjustment) secondary tightening
24 Nut (Hub bolt mounting) 34040 {25529, 354}
26 Bolt (Wheel nub and disc rotor mounting) 34 to 54 {25 to 40, 3.5 to 5.5}
- Lubricant
14, 20 Lip area of outer and inner oil seals Wheel bearing grease [NLGI No. 2 (Li soap)] As required
17 Thread area of lock nut Wheel bearing grease [NLGI No. 2 (Li soap)] As required
18, 21 Pack the space between rollers of outer and inner Wheel bearing grease [NLGI No. 2 (Li soap)] As required
bearing inner races
27 Pack interior space of wheel hub Wheel bearing grease [NLGI No. 2 (Li soap)] 37037 g
{13.11.31 oz}
27-17
17 Lock nut adjustment tool 12.7 M B999150 Removal and installation of lock nut
70 {2.76} {0.50}
05617
A C B
Hub puller components M B999070

19 A : Hub puller body A : MB999071 Removal of wheel hub and rotor assembly
B : Bolt B : MB999072
50 {1.97}
C : Attachment C : MB999073
165 {6.50}
05618
70 {2.76}

(T90ST30)
84 {3.31}
20 05619 Press-fitting of inner oil seal : Use in
84 {3.31} combination
Oil seal installer MH062607

117 {4.61}
20 {0.79}
M101.25 06596
70 {2.76}

(T90ST30)
84 {3.31}
22 05619 Press-fitting of inner bearing outer race :
Use in combination
99
77 {3.03} {3.90}

(T90ST05)
109 {4.29}
05621
70 {2.76}

(T90ST30)
84 {3.31}
23 05619 Press-fitting of outer bearing outer race :
99 Use in combination
77 {3.03} {3.90}

109 {4.29} (T90ST05)
05621
27-18
27
Service procedure
19
[Adjustment]
Tighten lock nut 17 at specified torque for primary tightening, while
turning wheel hub and rotor assembly 19.
Slacken off lock nut 17 completely.
Turn wheel hub and rotor assembly 19 several times to smooth
operation of outer bearings 18, 23 and inner bearings 21, 22.
Tighten lock nut 17 at specified torque for secondary tightening.
0
17 06632 Insert lock washer 16 so that flat area A fits onto notch B.
Make sure that the mounting holes of lock washer 16 and lock nut 17
align. If they do not, slacken off the lock nut and align them.
B Install bolts 15 at the positions as illustrated, aligning lock nut 17.
A 16 CAUTION
After adjustment, make sure that there is no play in the axial
direction of wheel hub and rotor assembly 19.
15
17
06633
[Measurement]
Install spring balance C on hub bolt 25.
Do not allow the starting torque to become higher than the tangential
C force.
If the measured value deviates from the specified value, readjust.
25 If any fault is found after readjustment, replace outer bearings 18, 23
and inner bearings 21, 22.
06634 NOTE
Measure the starting torque with inner oil seal 20 installed.
Measure the starting torque with disc brake assembly 11, outer
oil seal 14 and axle shaft 13 removed.
27-19
I Axle shaft
[Removal]
Insert bolts 12 into screw holes A of axle shaft 13. Then, remove the axle
shaft.
12
13
A
A 06612
[Inspection]
B : Bend of shaft center
B C NOTE
To measure the bend of axle shaft 13, turn it one full revolution
and read the dial gauge indicator. The bend is one half of the
indicated value.
13 C: Wobble of flange face
06613
[Installation]
Knock pin hole E of axle shaft 13 is the second hole clockwise from
D E disassembly screw hole A.
To mount axle shaft 13, align knock pin D with knock pin hole E.
E
A
13
A
J
E 12154
A Outer oil seal

14 [Removal]
To remove outer oil seal 14, use pliers and pull protrusion A of the outer
oil seal circumference evenly.
06641
[Installation]
B Apply grease to lip area B of outer oil seal 14.
Press-fit outer oil seal 14 in the direction as illustrated.
14
06642
27-20
27
M Removal and installation of lock nut
Adjust starting torque of wheel hub bearing during installation.
P27-19
NQ
17
06784

B
A A: Grease pump nozzle
B: Space between rollers
O
01000
Removal of wheel hub and rotor assembly

Remove wheel hub and rotor assembly 19 using mounting bolt 12 of axle
shaft 13.
CAUTION
Make sure you remove wheel hub and rotor assembly 19 in a
straight line to prevent damage to inner oil seal 20.
19 0
12
P
06643
Installation of inner oil seal

Press-fit inner oil seal 20 so that it is flush with the end of wheel hub 27.
1
2
20
27
R
06647

[Removal]
Drive out inner bearing outer race 22 evenly from three indented parts A
in wheel hub 27.
B
B : Pin-punch
27
A
22
06648
27-21
[Installation]
1
2
22
27
S
06649
Outer bearing outer race

[Removal]
Drive out outer bearing outer race 23 evenly from three indented parts A
B in wheel hub 27.
B : Pin-punch
27
A
23 06650
[Installation]
1
2
23
27
TU
06651
Installation of nut, hub bolt

25 Hub bolt 25 is marked with L (left) or R (right) to indicate the side it is to
be mounted on. Check this symbol before press-fitting the bolt.
L , R
06677
Tighten nut 24 at specified torque.

24
Drive nut 24 in using a punch to lock the nut.
06652
27-22
27
*2 Installation of brake pad wear indicator
4 4
Wire brake pad wear indicator *2 from disc brake assembly 11 in the
direction as illustrated and install using clips 4.
4
4 Wire brake pad wear indicator *2 from axle housing *1 to the frame in
4 4 4 4 the direction as illustrated and install using clips 4.
*2 *2 A : Tie-wrap
B : Connector
B 06663 CAUTION
Make sure that brake pad wear indicator *2 is not twisted or
4
unnecessarily slack when you install it.
*1 A
07389
27-23
AXLE HOUSING
12
13
- *1
6
1
*3
2
8
*2
5

11
9

7 3
12155

P27-26
1 Inspection plug 8 Nut 14 Axle housing
2 Drain plug 9 Bolt
3 Clip 10 Reduction and differential *1 : Shock absorber ^ Gr 34
4 Brake hose assembly P27-28 *2 : Propeller shaft ^ Gr 25
5 Packing 11 U-bolt nut *3 : Stabilizer ^ Gr 34
6 Nut 12 U-bolt
7 Nut 13 Spring pad : Non-reusable parts
CAUTION
Be sure to protect brake hose 4 from dust by fitting blanking plugs after removal.
NOTE
Do not remove axle housing 14 unless it is faulty.
Assembly sequence
CAUTION
Work after assembly

P27-26
27-24
27
14 Axle housing Runout of outer bearing mating area 0.5 {0.020} or less 1 {0.039} Replace
Difference of center area before and 1 {0.039} or less 5 {0.20} Replace
after turning

4 Brake hose mounting (on the axle housing) 13 to 17 {9.4 to 12, 1.3 to 1.7}
6 Nut (Shock absorber mounting) 26.4 to 33.3 {20 to 25, 2.7 to 3.4}
7 Nut (Propeller shaft mounting) 98 to 120 {72 to 87, 10 to 12}
8 Nut (Reduction and differential assembly mounting) 69 to 93 {51 to 69, 7.0 to 9.5}
9 Bolt (Reduction and differential assembly mounting) 83 to 108 {61 to 80, 8.5 to 11.0}
11 U-bolt nut (U-bolt mounting) 33924.5 {25018, 34.62.5}
- Sealant
14 Reduction and differential assembly mounting surfaces of axle THREEBOND 1215 As required
housing

10 Differential carrier base MB999102 Removal and installation of reduction and

differential assembly
28 {1.10} 06679
27-25
AXLE HOUSING
Service procedure
Remove inspection plug 1 and drain plug 2, then drain the gear oil
from axle housing 14.
WARNING
1
14
2 Work after assembly
06680
Fill axle housing 14 with the specified amount of gear oil via inspection
4
plug 1.
Removal and installation of brake hose

Remove brake hose 4 from bracket A (on the frame) first, then remove
the brake hose from axle housing 14. To assemble the brake hose follow
the disassembly sequence in reverse.
A 3
14
4
5 06681
10
F Removal and installation of reduction and differential
assembly
Remove the lift pad from garage jack A and mount 0 differential
carrier base, after turning pin B to the dimensions as illustrated insert
C 40mm
it and secure it with the bolt which secured the lift pad.
{1.57 in.}
Tighten two bolts in screw holes C used for removing reduction and
5 mm {0.20 in.}
B 33 mm {1.30 in.} differential assembly 10 evenly, and remove the reduction and differ-
0 10 mm {0.39 in.} ential assembly.
15 mm {0.59 in.}
20 mm Bolt size : M121.25 mm
A {0.79 in.}
NOTE
26 mm
{1.02 in.} 06682 Be sure to completely remove adhered sealant from the mount-
ing surface of the axle housing and carrier.
A A
J Axle housing
[Inspection]
Support the inner bearing mating parts at both ends of the housing
spindle of axle housing 14 horizontally.
B1, B2
06683 Set the dial gauge against outer bearing mating part A and turn it 360
14 to measure bend.
Set axle housing 14 vertical using square C. After measuring B1, turn
C
the axle housing 180 and measure B2 to find the difference.
If the measured value is higher than the limit, replace axle housing 14.
06684
27-26
27
D [Application of sealant]
14 G F Apply sealant to reduction and differential assembly 10 mounting
surface of axle housing 14.
F G E Apply sealant around the periphery of indented area E for part D.
Apply sealant linearly to part F.
NOTE
E F Make sure that sealant does not ooze from the mounting surface
F after installing reduction and differential assembly 10.
D
12156
3 to 4 mm
{0.12 to 0.16 in.}
GG
12157
27-27
28
24
- 33
8
2322
21 4
19
6 2 1
3
35 -
34
16
-
11
14
- 18
9 -
06749
Work before disassembly P27-32

Inspection before disassembly P27-32
1 Bolt 14 Differential gear washer 26 Pinion pilot bearing
2 Lock plate 15 Differential gear 27 Rear bearing inner race
3 Adjusting screw 16 Differential pinion washer 28 Final drive pinion
4 Bolt 17 Differential pinion 29 Oil seal
5 Bearing cap 18 Pinion spider 30 Front bearing inner race
6 Side bearing outer race 19 Bolt 31 Front bearing outer race
7 Side bearing inner race 20 Pinion assembly 32 Rear bearing outer race
8 Differential assembly 21 Lock nut 33 Bearing retainer
9 Bolt 22 Dust cover 34 Shim
10 Final drive gear 23 Companion flange 35 Differential carrier
11 Bolt 24 Collar
12 Differential case, LH 25 Lock ring : Non-reusable parts
13 Differential case, RH
Assembly sequence
Inspection and adjustment after assembly P27-33
CAUTION
Be sure when replacing any of the following parts to replace both it and its associated parts as a set :
For bolt 4, bearing cap 5 or differential carrier 35, replace the differential carrier set.
For final drive gear 10 or final drive pinion 28, replace the reduction gear set.
For differential case RH 13 and differential case LH 12, replace the differential case set.
Make sure you keep left and right side bearings 6, 7 separate after removal, and be careful not to mix them up
when installing them.
NOTE
Write down the thickness of shim 34 and collar 24 when disassembling to use it as reference when assembly.
27-28
27

6, 7 Starting torque of side bearing 1.96 to 2.94 Nm Adjust using
adjusting
{1.4 to 2.2 lbf.ft, 0.20 to 0.30 kgfm} screw
Tangential
force at
152 mm
{5.98 in.} point
around outer
periphery of
differential
case:
25.5 to 38.2 N
{5.7 to 8.6 lbf,
2.6 to 3.9 kgf}
10 Wobble of rear surface of final drive gear 0.1 {0.0039} or less Adjust or
replace along
with the gear
set
Measure the
wobble at a
point 132 mm
{5.20 in.} (on
the radius)
away from the
center of the
final drive gear
10, 28 Backlash between final drive gear and final drive pinion 0.20 to 0.28 {0.0079 to 0.011} 0.50 {0.020} Adjust or
replace along
with the gear set
15 Play in the rotating direction between axle shaft 0.05 to 0.15 {0.0020 to 0.0059} 0.50 {0.020} Replace
and differential gear spline
15, 17 Backlash between differential gear and differential pinion 0.15 to 0.20 {0.0059 to 0.0079} 0.50 {0.020} Replace
17, 18 Clearance between differential pinion and pinion spider [22] 0.17 to 0.27 0.50 {0.020} Replace
{[0.87] 0.0067 to 0.011} Adjust using
collar
20 Starting torque of pinion bearing New parts 1.96 to 2.94 Nm Tangential
{1.4 to 2.2 lbf.ft, 0.20 to 0.30 kgfm} force at
114 mm
{4.49 in.} point
around outer
periphery of
bearing
retainer:
34.3 to 51.9 N
{7.7 to 12 lbf,
3.5 to 5.3 kgf}
Adjust using
collar
Reused 1.6 to 2.4 Nm Tangential
parts {1.2 to 1.7 lbf.ft, 0.16 to 0.24 kgfm} force at
114 mm
{4.49 in.} point
around outer
periphery of
bearing
retainer:
27 to 41 N
{6.2 to 9.3 lbf,
2.8 to 4.2 kgf}

1 Bolt (Lock plate mounting) 19.6 to 26.5 {14 to 20, 2.0 to 2.7}
4 Bolt (Bearing cap mounting) 201.00 {150, 20.50}
9 Bolt (Final drive gear and differential case LH 166.6 to 225.4 {120 to 165, 17 to 23}
mounting)
11 Bolt (Differential case RH and differential case LH 83.3 to 112.7 {61 to 83, 8.5 to 11.5}
mounting)
19 Bolt (Pinion assembly mounting) 66.6 to 90.2 {49 to 67, 6.8 to 9.2}
21 Lock nut (Companion flange mounting) 372.4 to 470.4 {275 to 345, 38 to 48}
27-29
9, 11 Entire surface of bolt Rust preventive As required
10 Thread area of final drive gear LOCTITE 271 As required
11 Thread area of bolt LOCTITE 271 As required
29 Lip area of oil seal Wheel bearing grease [NLG1 No.2 (Li soap)]As required
35 Pinion pilot bearing mounting surface of differential carrier LOCTITE 601 As required

Differential working base assembly MB999034 Maintenance work bench for reduction
A : Attachment G A : MB999040 and differential assembly
A
RA F G RA
F C
R158 30 13
{6.22} {0.51} B
11 {0.43} D
B : Holder B : MB999036
C : Holder E C : MB999037
D : Working base 11 {0.43} 40 {1.57} D : MB999035
E : Flange stopper 20 {0.79} E : MB999096 Flange stopper is used for installation
05656 and removal of the companion flange
59
{2.32}
Removal of side bearing inner race: Use in
Adaptor MB999076 combination with available gear puller
(General tool)
45 {1.77}
05658
7
70 {2.76}
Bearing installer MH061748 Press-fitting of side bearing inner race
80 {3.15}
01039
85 12
{3.35} {0.47}
20 Bearing retainer MH061745 Installation of pinion assembly: Use two

guide pin 18 {0.71}
M121.25 01041
39.2 {1.54}
26 Pinion pilot bearing MH061976 Press-fitting of pinion pilot bearing

installer
45.2 {1.78}
01081
27-30
27
Unit : mm {in.}
Pinion rear
bearing 25.5 MB999045 Removal of rear bearing inner race
remover {1.00}
0.5
{0.020}
27 02956
52 {2.05}
Pinion bearing installer MH061005 Press-fitting of rear bearing inner race

125
62 {2.44} {4.92}
01077
88 {3.46}
29 Oil seal installer MH061750 Press-fitting of oil seal
112 {4.41}
01039
52 {2.05}
30 Pinion bearing installer MH061005 Press-fitting of front bearing inner race

125
62 {2.44} {4.92}
01077
78 {3.07}
31 Pinion bearing installer MH061977 Press-fitting of front bearing outer race
89 {3.50}
01078
88 {3.46}
32 Pinion bearing installer MH061264 Press-fitting of rear bearing outer race
99 {3.90}
01078
27-31
Service procedure
35
3
1 Mount differential carrier 35 on 0 differential working base assembly.
4
0
06750

Inspect for faulty parts before disassembly.
(1) Wobble of rear face of final drive gear
Measure wobble at a point 132 mm {5.20 in.} (on the radius) from the
center of final drive gear 10.
02945
10 (2) Backlash of final drive gear and final drive pinion

Measure at three points on the circumference of final drive gear 10.
06595
(3) Starting torque of side bearing

Install spring balance A at 152 mm {5.98 in.} outer periphery point of
differential case LH 12.
NOTE
A Measure the starting torque within final drive gear 10 and final
12
drive pinion 28 backlash range.
14333
27-32
27
10 (4) Tooth contact of final drive gear
B
Apply red lead to three or four teeth of final drive gear 10, examine
tooth contact by turning the gears a few times.
B : Examine tooth contact using paper.
01045
10 Inspection and adjustment after assembly
(1) Inspection of wobble of back face of final drive gear

Measure wobble at a point 132 mm {5.20 in.} (on the radius) from the
center of final drive gear 10.
02945
10 (2) Backlash of final drive gear and final drive pinion

[Adjustment]
Adjust backlash using left and right adjusting screws 3 with the
adjusted starting torques of side bearings 6, 7 unchanged.
3
Measure backlash at three points around the circumference of final
drive gear 10.
CAUTION
6, 7 Make sure when you loosen one adjusting screw 3 that you
tighten the other adjusting screw by the same amount, be-
06771
cause the starting torque of the side bearings 6, 7 changes.
(3) Starting torque of side bearing

10
[Inspection]
Install spring balance A at 152 mm {5.98 in.} outer periphery point
of differential case LH 12.
3
If the measured value deviates from the specified value, adjust.
12 A
14334 [Adjustment]
If the measured value deviates from the specified value, adjust it using
left and right adjusting screws 3.
CAUTION
Be sure to tighten left and right adjusting screws 3 by the same
amount of pitch.
NOTE
Adjust the backlash to within the standard backlash of final
drive gear 10 and final drive pinion 28.
27-33
10 (4) Tooth contact of final drive gear
B
[Inspection]
Apply red lead to three or four teeth of final drive gear 10, examine
tooth contact by turning the gears a few times.
B : Examine tooth contact using paper.
[Adjustment]
If tooth contact has deteriorated, adjust by increasing or decreasing
backlash and shim 34.
01045
CAUTION
Be sure when replacing the gear because of abnormally worn
teeth to replace the reduction gear set of final drive gear 10
and final drive pinion 28.
< Leading edge > Normal tooth contact at no load

C
E < Final drive gear >
D C : Heel
F
D : Toe
G E : Face
< Trailing edge > F : Flank
G : Clearance
01046
< Leading edge > D < Final drive pinion >

C
C : Heel
E D : Toe
F E : Face
F : Flank
G
G : Clearance
< Trailing edge >
01047
Maintenance item Assembly standards

Tooth contact position Lengthwise di- From center towards edge
rection of tooth
At no load
Vertical direction From center towards top of tooth for final drive gear and center for final drive
pinion
Tooth contact shape Length Approximately 50 to 70% of tooth width
Width Approximately 50 to 70% of tooth depth
Degree of tooth contact It becomes weaker as it nears tooth root or tooth tip
NOTE
When tooth contact is near the toe at no load it becomes middle area contact at load.
27-34
27
Adjustment of tooth contact
Method of adjustment Moving direction

Advance final drive pinion to final drive gear Tooth contact moves towards
Adjustment by adding or reducing shims
(Shims are reduced) tooth root
< Leading
edge > < Trailing
edge >
Retard final drive pinion from final drive gear Tooth contact moves towards
(Shims are added) tooth tip
Advance final drive gear to final drive pinion center Tooth contact moves in lengthwise
(Less backlash) direction of tooth
Leading edge : Nearer to toe and
Adjustment using adjusting screw

Trailing edge : Nearer to heel and
Retard final drive gear from final drive pinion center Tooth contact moves in lengthwise
(More backlash) direction of tooth
Leading edge : Nearer to heel and
Trailing edge : Nearer to toe and
01048
5 Removal of bearing cap

Put alignment marks A on bearing cap 5 and differential carrier 35 to
distinguish left and right.
5
35 A
13916
27-35
7 Side bearing inner race
[Removal]
A : Gear puller (General tool)
A
NOTE
Make sure you keep left and right side bearings 6, 7 separate
after removal, and be careful not to mix them up when installing
them.
0 7 06752
[Installation]
7
06753
12
FH
[Removal]
Final drive gear and differential case LH
10 Put alignment marks A on final drive gear 10 and differential case LH 12.
06724
9 [Installation]
Apply rust preventive to the entire surface of bolts 9.
12
Apply lock paint to the threads of all bolt holes B of final drive gear 10.
B Tighten bolts 9 at specified torque.
CAUTION
Be sure to apply rust preventive because of the need to tighten
bolt 9 at specified torque.
Be sure not to operate the vehicle for at least one hour after
installation in order to let the lock paint harden.
10 06754 Be sure not to operate the vehicle at full torque for at least four
hours after installation in order to let the lock paint harden.
27-36
27
13 HI Installation of differential case RH and differential case
LH
Apply rust preventive to the entire surface of bolts 11.
Apply lock paint to thread area A of bolts 11.
12
CAUTION
A Be sure to apply rust preventive because of the need to tighten
bolts 11 at specified torque.
11
12958 Be sure not to operate the vehicle for at least one hour after
installation in order to let the lock paint harden.
Be sure not to operate the vehicle at full torque for at least four
hours after installation in order to let the lock paint harden.
A K Play between differential gear and axle shaft spline area

in the rotating direction
B If the measured value is higher than the limit, replace the faulty parts.
A : Axle shaft
B : Play
15
01065
KM Backlash between differential gear and differential

pinion
17
15 06773
P Pinion assembly
[Removal]
20 Screw M121.25 mm bolts into two holes A provided for removing pinion
A assembly 20, then tighten bolts uniformly until the pinion assembly is
removed.
06756
27-37
21 [Inspection of starting torque after installation]
23 Apply load of approximately 39.2 kN {8.8 klbf, 4000 kgf} to companion
39.2 KN
{8.8 klbf, flange 3 or tighten lock nut 21 at specified torque.
4000 kgf}
Install spring balance B at 114 mm {4.49 in.} outer periphery point of
B bearing retainer 33.
33 If the measured value deviates from the specified value, adjust.
14335
NOTE
Be sure to secure companion flange 23 before measurement.
Be sure to remove oil seal 29 before measurement.
[Adjustment of starting torque]

If the measured value deviates from the specified value, replace collar 24
so that the tangential force conforms to the standard value.
Collar thicknesses :
15.600 to 16.200 mm {0.61 to 0.64 in.} (25 thicknesses available in
0.025 mm {0.00098 in.} increments)
[Adjustment when installing]

20
Carry out the following procedure so that C, D and E conform to the
standard dimension.
34 F Calculate shim thickness F according to the following formula based
E upon the machining error data stamped on pinion assembly 20 and
35 differential carrier 35.
C Formula for calculation:
D F = 0.5 {0.020}b+c+d
14316 c : Deviation from basic dimension C

d : Deviation from basic dimension D
e : Deviation from basic dimension E
Unit : mm {in.}
35 Location Standard How to calculate deviation
dimension
20 Shim thickness 0.5 {0.020}
C 203 The basic dimension, multiplied by 100,
{7.99} is stamped on the periphery of
differential carrier 35 flange
D 157 The basic dimension is stamped on the
* * {0.18} top of pinion assembly 20
E 46.5 Measure the deviation from E using a
02950 {1.8} dial gauge. However, if it is difficult to
measure the actual deviation, assume
a value from 0 to 0.2 {0 to 0.0079}
* : Stamped number position

NOTE
Thickness is stamped in millimeters.
Select shim 34 from shim thickness F.

Available thicknesses of shim 34 : 0.1 mm {0.0039 in.} and 0.2 mm
{0.0079 in.}
27-38
27
[Installation]
Apply lock paint to entire mounting surface G of pinion pilot bearing 26
of differential carrier 35.
26 CAUTION
Be sure to let the lock paint harden undisturbed for 30 minutes to
35 two hours after installation.
Be sure to wait at least three hours before running the vehicle,
and if possible wait 24 hours to let the lock paint harden.
G 06774
Assemble differential carrier 35 and pinion assembly 20 with their

alignment marks aligned.
0 35
34
P
20 02951
Removal of pinion assembly
B Using an appropriate cylinder A and press B, remove collar 24, lock ring
25, pinion pilot bearing 26, rear bearing inner race 27, and final drive
pinion 28 together.
24 27
28
26 A
UV
25
06759
25 Lock ring and pinion pilot bearing

[Removal]
A A : Gear puller (General tool)
26
06760
[Installation]
0 Press-fit pinion pilot bearing 26 in the direction as illustrated.
A : Lock ring
26
28
A A
28 06761
27-39
W Rear bearing inner race
[Removal]
0
28
27
02959
[Installation]
27
28
06762
Y Installation of oil seal
29
06763
0
Z Installation of front bearing inner race
30
06764
27-40
27
[ Front bearing outer race
[Removal]
Drive out front bearing outer race 31 evenly from three indented parts A
B in bearing retainer 33.
B : Pin-punch
33
A
31 06765
[Installation]
31
33
06766
\ Rear bearing outer race

[Removal]
Drive out rear bearing outer race 32 evenly from three indented parts A
in bearing retainer 33.
B
B : Pin-punch
33
32 A
06767
[Installation]
32
33
06768
27-41
Group 31
Wheel and Tire
Table of Contents
BACK
HOME
Pub No. TWSE9501-31

31
GROUP 31 WHEEL AND TIRE
SPECIFICATIONS .................................................................................. 2
WHEEL AND TIRE ................................................................................. 3
31-1
SPECIFICATIONS/TROUBLESHOOTING
SPECIFICATIONS

Tire size Application wheel
FE639 215/85R16(D) 450 {65, 4.50} 450 {65, 4.50} 166K-127-9
(GVWR : 11600 lb, 5260 kg) (wheel with 5 studs)
FE639 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50} 166K-127-9
(GVWR : 13500 lb, 6120 kg) (Wheel with 6 studs)
FE649 215/85R16(E) 550 {80, 5.50} 550 {80, 5.50} 166K-127-9
(GVWR : 14500 lb, 6580 kg) (wheel with 6 studs)
TROUBLESHOOTING
Symptoms Tire tread worn
Feather-edged wear from outside to inside

Feather-edged wear from inside to outside
Dished wear (one or more spots)
Pitted wear (dented) all around

Remarks
Both shoulders worn
Outside worn
Jagged wear
Center worn
Inside worn
Wavy wear
Possible causes
Overloading
Tire air pressure Insufficient
Excessive
Wheel alignment Toe-in Excessive
^ Gr 26 Insufficient
Camber Excessive
Insufficient
Toe-out excessive
Overall misalignment
Knuckle arm bent ^ Gr 26
Left and right tie rod lengths different ^ Gr 26
Wheel balance incorrect
Wheel bearing loose ^ Gr 26, 27
Ball joint loose ^ Gr 26
Tie rod end loose ^ Gr 37
Brake drum eccentric ^ Gr 35
Axle bent ^ Gr 26, 27
Sudden starting, sudden braking or sharp turn
Left and right front wheel turning radius incorrect ^ Gr 26
Road surface influence
31-2
WHEEL AND TIRE 31
Work for Removal and Installation of Wheel and Tire
2
1
1 2 3
14233
Work sequence
2 Jack up the front or rear axle using a garage jack placed under the center of the axle.
3 Support the frame on rigid racks.
WARNING
racks.
Work sequence after removal and installation

Follow the work sequence in reverse.
31-3
WHEEL AND TIRE
NOTE
Use right-hand threaded wheel nuts marked R for right side wheel and left-hand threaded wheel nuts marked
L for left side wheel.
< Single tire >
Removal sequence
6 2 1 Wheel nut
2 Tire assembly P31-5
5 Hub bolt
6 Hub
Cleaning before installation

5
1 P31-4
11387
< Double tire >

Removal sequence
6
1 Wheel nut (outer)
2 Tire assembly P31-5
3 Wheel nut (inner)
2 4 Tire assembly P31-5
5 Hub bolt
6 Hub
5
Cleaning before installation
1 P31-4
4 Installation sequence
14237

1, 3 Wheel nut 49049 {36036, 505}
Service procedure
D Cleaning before installation
6
G B To prevent wheel nuts 1 and 3 and hub bolt 5 from becoming loose
A
and to prevent mounting parts (tire assemblies 2 and 4 and hub 6)
F from being damaged, remove rust, dust, additional coatings of paint,
1 5 and foreign particles from the following areas:
2 C
D 6 A : Hub bolt thread area
G E
AB B : Wheel mounting surface of hub
C : Wheel alignment area of hub
C D : Disc wheel mating surface
1 3 F2 4 5 11388 E : Disc wheel nut mounting surface
F : Wheel nut thread area
G : Wheel nut spherical area
31-4
31
Tire Assembly
1 Tire
2 Disc wheel
Assembly sequence
verse.
11389

1 Horizontal deflection of tire (When assembled) 3.5 {0.14} or less
2 Disc wheel Flatness 0.4 {0.016} or less
(wheel with 5 studs) Horizontal 1.5 {0.059} or less
deflection
Vertical 1.5 {0.059} or less
deflection
Disc wheel Flatness 0.3 {0.012} or less
(wheel with 6 studs) Horizontal 1.5 {0.059} or less
deflection
Vertical 1.5 {0.059} or less
deflection
1
Service procedure
Deflection of tire
[Inspection]
If the measured value is higher than the limit, make corrections as
follows.
11390
31-5
WHEEL AND TIRE
[Correction]
A
Put chalk marks on tire 1, disc wheel 2, and hub bolt * (positions A as
illustrated).
Remove tire 1 from disc wheel 2.
2
*
11391
Measure deflection of disc wheel 2. If the most deflective position is

near the chalk mark, reinstall tire 1 rotating it half a turn from the chalk
mark and tighten nuts.
Remeasure deflection of tire 1.
If the measured value is still higher than the limit, replace tire 1 and
disc wheel 2 together as an assembly.
2
11392
Inspection of disc wheel
B (1) Flatness
A 2
Measure flatness at specified position B from the center of disc
wheel 2.
C Measure flatness at five equidistant points (wheel with 5 studs) or
six equidistant points (wheel with 6 studs) on the wheel.
D A : Dial gauge
B : 165 to 250 mm {6.50 to 9.84 in.}
05996 (wheel with 5 studs)
170 to 270 mm {6.69 to 10.6 in.}
(wheel with 6 studs)
C : Portable screw jacks (x 4)
D : Surface plate
Replace disc wheel 2 if the measured value is higher than the limit.
(2) Deflection
F
Replace disc wheel 2 if the measured value is higher than the limit.
10 mm
{0.39 in.} E E : Horizontal deflection measuring point
10 mm F : Vertical deflection measuring point
{0.39 in.}
2
05997
31-6
BACK HOME
Group 33 - Front
Suspension
Group 33 - Front
Suspension
1998 Minor Change <FG>
Group 33
Front Suspension
' 98 Minor Change

Table of Contents
BACK HOME

33
GROUP 33 FRONT SUSPENSION
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT

SUSPENSION .................................................................................. 33- 4
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY

< FE > .............................................................................................................. 33- 6
< FG > ............................................................................................................. 33- 8
LEAF SPRING ASSEMBLY

< FE > .............................................................................................................. 33- 12
< FG > ............................................................................................................. 33- 14
SHOCK ABSORBER
< FE > .............................................................................................................. 33- 16
< FG > ............................................................................................................. 33- 17
STABILIZER < FE > ........................................................................ 33- 18
33-1
1 Shock absorber
< FE >
1 2 Leaf spring assembly
3 Stabilizer < FE >
*b
*a : Front axle
*b : Frame
*a
3
27078
< FG >
*b
*a
27079
Leaf spring assembly 2, shock absorber 1, and stabilizer 3 < FE > are installed between frame *b and front axle *a to
support the vehicle body mass and absorb vibration and shock from the road surface to prevent them from being directly
transmitted to the vehicle body thereby protecting the crew, the vehicle body, and the cargo. In addition, irregular vibration
from the wheels is restrained, ensuring driving stability.
33-2
TROUBLESHOOTING 33
Symptoms
Impact transmitted from uneven road surface
Periodic jolts received from the road surface

Noise generated when vehicle is unloaded
Noise generated when vehicle is loaded

Excessive rolling while cruising
Remarks
Ride spongy
Possible causes
Leaf spring Cracked or damaged
Fractured
Spring hanger damaged
U-bolts loose
Spring bushing worn
Front axle bumper Damaged or broken
Front spring pad Damaged or broken

< FG >
Shock absorber Noticeable oil leaking or damping force decreased
Rubber bushing worn
Installation loose
Stabilizer < FE > Stabilizer deformed or bushing worn
Tire Tires worn unevenly
Tires and wheels unbalanced ^ Gr 31
Air pressure excessive
33-3
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT SUSPENSION
< FE > < FG >
6
6
4
< FG >
A
3 1
8 8
3 7
6
5
6
< FE > < FG >

27080
Removal sequence
5 Put alignment marks A on the front axle companion flange and the propeller shaft flange yoke, then remove the
nuts (on the joint between the front axle and the propeller shaft). < FG >
6 Remove the brake hose joint (on the frame).
7 Remove the clamp of the brake pad wear indicator harness and disconnect the connector on the frame side. < FE >
8 Remove the drag link. ^ Gr 37
WARNING
racks.
CAUTION
Be sure to protect the brake hose from dust by fitting plugs.
33-4
33
WARNING
CAUTION
Be sure that the brake hose is not twisted when you install it.

5 Nut (Front axle and properller shaft connecting) < FG > 59 to 74 {43 to 54, 6.0 to 7.5}
33-5
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FE >
Removal sequence
1 U-bolt nut
2 U-bolt
3 Front axle bumper
13 4 Nut
5 Spring pin
6 Rubber bushing
7 7 Nut
8 Shackle plate
10 9 Spring shackle
10 Rubber bushing
10
2 11 Leaf spring assembly P33-12
9
12 Front spring hanger
3 13 Front shackle hanger
12
*a : Stabilizer P33-18
4
*b : Front axle ^ Gr 26
NOTE
Do not remove front spring hanger 12 or
6 *b front shackle hanger 13 unless they are
faulty. ^ Gr 41
6
*a
27081

4 Nut (Spring pin mounting) 93 to 127 {69 to 94, 9.5 to 13.0}
7 Nut (Spring shackle mounting) 93 to 127 {69 to 94, 9.5 to 13.0}
33-6
33
5
Service procedure
Installation of spring pin
Install spring pin 5 to front spring hanger 12 with indent A of the spring
pin fitted to protrusion B of the front spring hanger.
B A
12
8
5 27082
Installation of shackle plate

8
Install shackle plate 8 with stamped mark facing the leaf spring.
G
06126
+, , Leaf spring assembly left/right height combinations

When replacing leaf spring assembly 11, select the members so that the
left and right height marks +, and are combined as shown
below.
Combination
Item
1 2 3 4 5
Right leaf spring assembly, assistant
+
drivers seat side
11 27083
Left leaf spring assembly, drivers seat side + +
CAUTION
Passengers side leaf spring assembly 11 differs from the driv-
ers side leaf spring assembly in camber (arch). Do not mix them
up when mounting, or this would cause vehicle tilt.
33-7
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY < FG >
15 Removal sequence
1 U-bolt nut
12 2 U-bolt
3 Front spring pad
*b 4 Nut
5 Spring pin
6 Rubber bushing
7 Nut
8 Shackle plate
9 Spring shackle
10 Rubber bushing
12 Nut
7 13 Front axle bumper
10
15 Front shackle hanger
2 10
9 *a : Front axle ^ Gr 26B
*b : Engine mounting support ^ Gr 41

4 NOTE
front shackle hanger 15 unless they are
*a
faulty. Gr 41
6
6
reverse.
1
27084

1 U-bolt nut (U-bolt mounting) 1067.8 {785.8, 10.80,8}
7 Nut (Spring shackle mounting) 93 to 127 {69 to 94, 9.5 to 13.0}
12 Nut (Front axle bumper mounting) 21 to 30 {15 to 22, 2.1 to 3.1}
33-8
33
3 3
Service procedure
Front spring pad
Mount front spring pad 3 with protrusion A facing the outside of the
vehicle.
A 06722
5 Installation of spring pin

B A
14
5
8
06982

8
G
06126

below.
Combination
Item
1 2 3 4 5
Right leaf spring assembly, assistant
+
drivers seat side
11 27085
Left leaf spring assembly, drivers seat side + +
CAUTION
up when mounting, or this world couse vehicle tilt.
33-9
13
I Front axle bumper
Mount front axle bumper 13 with arrow mark facing the outside of
the vehicle.

05839
33-10
33
MEMO
33-11
LEAF SPRING ASSEMBLY < FE >
1 Collar
2 Center nut
3 Caster shim
4 Rivet
5 Clip
6 6 Leaf spring
Assembly sequence
3 reverse.
1
27086

2 Center nut (Leaf spring mounting) 34 to 54 {25 to 40, 3.5 to 5.5}
2
Service procedure
Center nut
[Removal]
Put alignment marks A on the side of leaf springs 6.
6
27087
Compress leaf springs 6 using a press, lever up the bent parts of clips
5 using a cold chisel, then remove center nut 2.
2
5
6
27088
33-12
33
[Installation]
Align alignment marks A on the side of leaf springs 6, assemble the
2 component leaf springs, then tighten center nut 2 temporarily.
27089
Compress leaf springs 6 using a press, tighten center nut 2 at speci-

fied torque, then bend over clips 5.
2
6
5
4
27090
Rivet
[Removal]
Drill out staked end A of rivet 4 on a drill press, then remove clip 5.
A
4 05732
[Installation]
Using riveting machine B, mount inner clip 5 by staking rivet 4.
B
05733
33-13
LEAF SPRING ASSEMBLY < FG >
1 Collar
2 Center nut
3 Rivet
4 Clip
4 5 Rivet
7 6 Clip

7 Leaf spring
8
Assembly sequence
6
1 reverse.
27091

2
Service procedure
Center nut
[Removal]
7
27092
Compress leaf springs 7 using a press, lever up the bent parts of clip
4, 6 using a cold chisel, then remove center nut 2.
4, 6 2
7
27093
33-14
33
[Installation]
component leaf springs, then tighten center nut 2 temporarily.
2
7
27094

fied torque, then bend over clips 4, 6 using a hammer.
7
4, 6 2
35
27095
Rivet
[Removal]
Drill out staked ends A of rivets 3, 5 on a drill press, then remove clip 4
and inner clip 6.
4, 6
A
3, 5 05732
[Installation]
B Using riveting machine B, mount inner clip 6 and clip 4 by staking rivets
5, 3.
4, 6
5, 3
05733
33-15
SHOCK ABSORBER < FE >
Removal sequence
1
1 Lock nut
2
2 Upper side washer
3
3 Rubber bushing
4 Rubber bushing
5 Upper side washer
4 6 Nut
5 7 Eye washer
8 Washer
9 Rubber bushing
10 Shock absorber
8 9 05761

1 Lock nut (Shock absorber top mounting) 13 to 17 {9.4 to 12.3, 1.3 to 1.7}
10 6
Service procedure
Nut mounting
Tighten nut 6 so that the length of rubber bushing 9 for shock absorber
10 is as illustrated.
32 mm
F
9 {1.26 in.}
05763
Shock absorber mounting

4.5 to 5.0 mm
1
{0.18 to 0.20 in.} Tighten lock nut 1 so that the top of shock absorber 10 protrudes from
the lock nut by the amount as illustrated.
10
05762
33-16
SHOCK ABSORBER < FG > 33
Removal sequence
1 1 Lock nut
2 2 Upper side washer
3 3 Rubber bushing
4 Rubber bushing
4 5 Upper side washer
5 6 Nut
7 Rubber bushing
8 Shock absorber
7
6
05782

6 Nut (Shock absorber bottom eye mounting) 33 to 49 {25 to 36, 3.4 to 5.0}
4.0 to 4.5 mm
{0.16 to 0.18 in.}
1 8
Service procedure
Tighten lock nut 1 so that the top of shock absorber 8 protrudes from the
lock nut by the amount as illustrated.
8 05783
33-17
STABILIZER < FE >
Removal sequence
1 Lock nut
2 Upper side washer
1 *a 3 Rubber bushing
2 4 Centering washer
3 *b 5 Centering washer
6 Rubber bushing
4
7 Upper side washer
*c 8 Nut
*e
9 Stabilizer hanger
5 10 U-bolt nut
6 *d 11 Nut
7 12 Stabilizer upper bracket

11 13 Stabilizer lower bracket
14 Stabilizer bushing
15 Stabilizer rubber bushing
16 Stabilizer bar
14 *a : U-bolt
*b : Front axle bumper
16
*c : Leaf spring assembly
*d : Front axle ^ Gr 26
13 *e : Radiator support ^ Gr 14
8

10
08102

1 Lock nut (Stabilizer hanger top mounting) 13 to 17 {9.4 to 12.3, 1.3 to 1.7}
8 Nut (Stabilizer hanger bottom eye mounting) 70 to 95 {51 to 69, 7.0 to 9.5}
10 U-bolt nut 16215 {12011, 16.51.5}
11 Nut (Stabilizer upper bracket and lower bracket 35 to 55 {25 to 40, 3.5 to 5.5}
mounting)
33-18
33
5.0 to 5.5 mm
{0.20 to 0.22 in.}
1
9
Service procedure
Stabilizer hanger mounting
Mount stabilizer hanger 9 to radiator support *e perpendicularly.
Tighten lock nut 1 so that the top of stabilizer hanger 9 protrudes from
*e the lock nut by the amount as illustrated.
05911
6671 mm {26.30.039 in.}

H Stabilizer upper bracket mounting
Mount stabilizer upper brackets 12 with their end faces aligned with mark
16 A on stabilizer bar 16.
A
12
05583
33-19
Group 33
Front Suspension
Table of Contents
BACK
HOME
Pub No. TWSE9501-33

33
GROUP 33 FRONT SUSPENSION
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT

SUSPENSION ......................................................................................... 4
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY ....... 6
LEAF SPRING ASSEMBLY .................................................................... 8
SHOCK ABSORBER ............................................................................ 10
STABILIZER ......................................................................................... 12
33-1
1 Shock absorber
1 2 Leaf spring assembly
3 Stabilizer
*2
*1 : Front axle
*2 : Frame
*1
3
05760
Leaf spring assembly 2, shock absorber 1, and stabilizer 3 are installed between frame *2 and front axle *1 to support
the vehicle body mass and absorb vibration and shock from the road surface to prevent them from being directly
transmitted to the vehicle body thereby protecting the crew, the vehicle body, and the cargo. In addition, irregular vibration
from the wheels is restrained, ensuring driving stability.
33-2
TROUBLESHOOTING 33
Symptoms


Remarks
Ride spongy
Possible causes
Leaf spring Cracked or damaged
Fractured
Spring hanger damaged
U-bolts loose
Spring bushing worn
Front axle bumper Damaged or broken
Shock absorber Oil leaking noticeable or damping force decreased
Rubber bushing worn
Installation loose
Stabilizer Stabilizer deformed or bushing worn
Tire Tires worn unevenly
Tires and wheels unbalanced ^ Gr 31
33-3
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT SUSPENSION
3 1
7
6
5
14245
Removal sequence
6 Remove the clamp of the brake pad wear indicator harness and disconnect the connector on the frame side.
7 Remove the drag link. ^ Gr 37
WARNING
racks.
CAUTION
Be sure to protect the brake hose from dust by fitting blanking plugs.
33-4
33
WARNING
CAUTION
33-5
Removal sequence
1 U-bolt nut
2 U-bolt
3 Front axle bumper
4 Nut
13
5 Spring pin
6 Rubber bushing
7 7 Nut
8 Shackle plate
10 9 Spring shackle
10 Rubber bushing
10
9
3 13 Front shackle hanger
12
4 *1 : Stabilizer P33-12
*2 : Front axle ^ Gr 26
NOTE
*2 front shackle hanger 13 unless they are
6
faulty. ^ Gr 41
6
*1
11313

7 Nut (Spring shakle mounting) 93 to 127 {69 to 94, 9.5 to 13.0}
33-6
33
5
Service procedure
Installation of spring pin
B A
12
8
11314

8
G
06126
Leaf spring assembly left/right height combinations

+, ,
below.
Combination
Item
1 2 3 4 5
Right leaf spring assembly, passengers side +
11
05777 Left leaf spring assembly, drivers side + +
CAUTION
up when mounting, or this would cause vehicle tilt.
33-7
1 Collar
2 Center nut
3 Caster shim
4 Rivet
5 Clip
6 6 Leaf spring
Assembly sequence
3
verse.
1
05727

2
Service procedure
Center nut
[Removal]
6
05728
Compress leaf springs 6 using a press, lever up the bent parts of clips
5 using a cold chisel, then remove center nut 2.
2
5
6
05729
33-8
33
[Installation]
2 component leaf springs, then tighten center nut 2 temporarily.
05730

fied torque, then bend over clips 5.
2
6
5
4
05731
Rivet
[Removal]
Drill out caulked end A of rivet 4 on a drill press, then remove clip 5.
A
4 05732
[Installation]
Using riveting machine B, mount inner clip 5 by caulking rivet 4.
B
05733
33-9
SHOCK ABSORBER
Removal sequence
1
1 Lock nut
2
2 Upper side washer
3
3 Rubber bushing
4 Rubber bushing
5 Upper side washer
4 6 Nut
5 7 Eye washer
8 Washer
9 Rubber bushing
10 Shock absorber
8 9 05761

10 6
Service procedure
Nut mounting
Tighten nut 6 so that the length of rubber bushing 9 for shock absorber
10 is as illustrated.
32 mm
F
9 {1.26 in.}
05763

5.0 to 5.5 mm
1
{0.20 to 0.22 in.} Tighten lock nut 1 so that the top of shock absorber 10 protrudes from
the lock nut by the amount as illustrated.
10
05762
33-10
33
MEMO
33-11
STABILIZER
Removal sequence
1 Lock nut
2 Upper side washer
1 *1 3 Rubber bushing
2 4 Centering washer
3 *2 5 Centering washer
6 Rubber bushing
4
7 Upper side washer
*3 8 Nut
*5
9 Stabilizer hanger
5 10 U-bolt nut
6 *4 11 Nut
7 12 Stabilizer upper bracket

11 13 Stabilizer lower bracket
14 Stabilizer bushing
15 Stabilizer rubber bushing
16 Stabilizer bar
14 *1 : U-bolt
*2 : Front axle bumper
16
*3 : Leaf spring assembly
*4 : Front axle ^ Gr 26
13 *5 : Radiator support ^ Gr 14
8

10
08102

1 Lock nut (Stabilizer hanger top mounting) 13 to 17 {9.4 to 12.3, 1.3 to 1.7}
8 Nut (Stabilizer hanger bottom eye mounting) 70 to 95 {51 to 69, 7.0 to 9.5}
10 U-bolt nut 16215 {12011, 16.51.5}
11 Nut (Stabilizer upper bracket and lower bracket 35 to 55 {25 to 40, 3.5 to 5.5}
mounting)
33-12
33
5.0 to 5.5 mm
{0.20 to 0.22 in.}
1
9
Service procedure
Stabilizer hanger mounting
Mount stabilizer hanger 9 to radiator support *5 perpendicularly.
Tighten lock nut 1 so that the top of stabilizer hanger 9 protrudes from
*5 the lock nut by the amount as illustrated.
05911
6671 mm {26.30.039 in.}

H Stabilizer upper bracket mounting
Mount stabilizer upper brackets 12 with their end faces aligned with mark
A
12
05583
33-13
BACK HOME
Group 34 - Rear
Suspension
Group 34 - Rear
Suspension
Group 34
Rear Suspension
' 98 Minor Change

Table of Contents
BACK HOME

34
GROUP 34 REAR SUSPENSION
WORK BEFORE REMOVAL AND INSTALLATION

OF REAR SUSPENSION ................................................................ 34- 4

< FE > .............................................................................................................. 34- 6
< FG > ............................................................................................................. 34- 10
LEAF SPRING ASSEMBLY............................................................. 34- 14
SHOCK ABSORBER ....................................................................... 34- 17
STABILIZER < FE > ....................................................................... 34- 18
34-1
1 Leaf spring assembly
*a 2 Shock absorber
3 Stabilizer < FE >
2
*a : Frame
3 *b : Rear axle
*b
06786
Leaf spring assembly 1 and shock absorber 2 are installed between frame *a and rear axle *b to support the vehicle
body mass and absorb vibration and shock from the road surface to prevent them from being directly transmitted to the
vehicle body thereby protecting the crew, the vehicle body, and the cargo. In addition, irregular vibration from the wheels
is restrained, ensuring driving stability. Stabilizer 3 < FE > is installed to prevent sway.
34-2
TROUBLESHOOTING 34
Symptoms


Ride soft with gentle swaying
Remarks
Possible causes
Cracked or damaged
Damaged
Leaf spring Spring hanger broken
U-bolts loose
Spring bushing worn
Spring pins or shackle pins thrust play excessive
Shackle pins tightening torque excessive
Helper rubber or helper spring stopper damaged or broken
Noticeable oil leaking or damping force decreased
Shock absorber Rubber bushing worn
Bolt loose
Stabilizer < FE > Stabilizer deformed, bushing worn
Tires worn unevenly
Tire Tires and wheels unbalanced ^ Gr 31
34-3
WORK BEFORE REMOVAL AND INSTALLATION OF REAR SUSPENSION
1 4
3
< With load sensing valve >

7
5
14246
Removal sequence
3 Jack up the rear axle with a garage jack.
5 Put alignment marks A on the rear axle companion flange and the propeller shaft flange yoke, then remove the
nuts (on the joint between the rear axle and the propeller shaft).
< with disc brake >
8 Remove the nut (joint part of rear axle housing and the load sensing valve). < with load sensing valve >
WARNING
racks.
CAUTION
Be sure to protect the brake hose from dust by fitting plugs.
34-4
34
WARNING
You must bleed air from the brake system and install the load sensing valve (with load sensing valve) after
installing the brake hose, failure to do so would cause the brake to malfunction. ^ Gr 35
CAUTION

5 Nut (Rear axle and propeller shaft connecting) 98 to 120 {72 to 87, 10 to 12}
34-5
21 24
25
19
21
23 25
22
13
17
18

2 8
14 -
4 22
3
9
-
-5
1
06349
Removal sequence
1 U-bolt nut 10 Spring pin 19 Nut
2 U-bolt 11 Side washer 20 Helper rubber
3 Spring pad 12 Leaf spring assembly P34-14 21 Nut
4 Nut 13 Nut 22 Helper spring stopper
5 Grease nipple 14 Grease nipple 23 Rear spring hanger
6 Spring pin 15 Spring pin 24 Rear shackle hanger
7 Side washer 16 Side washer 25 Helper spring bracket
8 Nut 17 Bushing
9 Grease nipple 18 Spring shackle * : Rear axle ^ Gr 27
NOTE
Do not remove rear spring hanger 23, rear shackle hanger 24, or helper spring bracket 25 unless they are
faulty. ^ Gr 41
34-6
34
Standard value
6, 10, 12 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5 {0.020}
leaf spring assembly {[1.10] 0.0016 to 0.0055}
6, 23 Clearance between spring pin and rear [28] 0.02 to 0.08 1.0 {0.039}
spring hanger {[1.10] 0.00079 to 0.0031}
12, 18 Clearance between leaf spring assembly and 0.5 to 1.2 {0.020 to 0.047} 1.5 {0.059} Adjust side
spring shackle washer
12, 23 Clearance between leaf spring assembly and rear 0.5 to 1.2 {0.020 to 0.047} 1.5 {0.059} Adjust side
spring hanger washer
15, 17 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5 {0.020}
spring shackle {[1.10] 0.0016 to 0.0055}
18, 24 Clearance between spring shackle and rear 0.1 to 0.9 {0.0039 to 0.035} 1.0 {0.039} Adjust side
shackle hanger washer
10, 18 Clearance between spring pin and spring shackle [28] 0.02 to 0.08 1.0 {0.039}
{[1.10] 0.00079 to 0.0031}
15, 24 Clearance between spring pin and rear shackle [28] 0.02 to 0.08 1.0 {0.039}
hanger {[1.10] 0.00079 to 0.0031}

4 Nut (Spring pin mounting) 29.4 to 37.2 {22 to 27, 3.0 to 3.8}
19 Nut (Helper rubber mounting) 11.8 to 14.7 {8.7 to 11, 1.2 to 1.5}
21 Nut (Helper spring stopper mounting) 11.8 to 14.7 {8.7 to 11, 1.2 to 1.5}
- Lubricant
5, 9, 14 Supply via grease nipple Chassis grease [NLGI No.1 (Ca soap)] As required

6, 10, 15 Spring pin remover MB999112 Removal of spring pin
M221.5 06350
34-7
6FK
Service procedure
Remove spring pins 6, 10, 15 using 0 spring pin remover.
6, 10, 15
7GL
06351
23 Adjustment of side washer (for adjustment)

24
Using side washer 11, adjust the clearance between leaf spring as-
16
sembly 12 and spring shackle 18 to the standard value.
Using side washer 7, adjust the clearance between leaf spring assem-
bly 12 and rear spring hanger 23 to the standard value.
18 Using side washer 16, adjust the clearance between spring shackle
12
18 and rear shackle hanger 24 to the standard value.
7
Two different thicknesses are available for side washers 7, 11, 16
12 : 0.5 mm {0.020 in.} and 1.0 mm {0.039 in.}
H
11 06353

+, ,
below.
Combination
Item
1 2 3
Right leaf spring assembly, assistant drivers
+
12 seat side
06354
P
Left leaf spring assembly, drivers seat side +
Installation of helper rubber

Install helper rubber 20 with installation mark directed to the front of
20 the vehicle.
07600
34-8
34
MEMO
34-9
21 24
19 25
21
25
13
23
22
8 18
17
4 2
14 -
22
3
9-
5
-
1

08109
Removal sequence
1 U-bolt nut 10 Shackle pin 19 Nut
2 U-bolt 11 Side washer (for adjustment) 20 Helper rubber
7 Side washer (for adjustment) 16 Side washer (for adjustment) 25 Helper spring bracket
8 Nut 17 Bushing
NOTE
faulty. ^ Gr 41
34-10
34
Standard value
6, 12 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5
leaf spring assembly {[1.10] 0.0016 to 0.0055} {0.020}
6, 23 Clearance between spring pin and rear [28] 0.04 to 0.14 1.0
spring shackle {[1.10] 0.0016 to 0.0055} {0.039}
10, 12 Clearance between shackle pin and bushing of [28] 0.04 to 0.14 0.5
leaf spring assembly {[1.10] 0.0016 to 0.0055}} {0.020}
12, 18 Clearance between leaf spring assembly 0.1 to 0.7 1.0 Adjust side
and spring shackle {0.0039 to 0.028} {0.039} washer
12, 23 Clearance between leaf spring assembly 0.1 to 1.0 1.0 Adjust side
and rear spring hanger {0.0039 to 0.039} {0.039} washer
15, 17 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5
spring shackle {[1.10] 0.0016 to 0.0055} {0.020}
15, 24 Clearance between spring pin and rear shackle [28] 0.02 to 0.08 1.0
hanger {[1.10] 0.00079 to 0.0031} {0.039}
18, 24 Clearance between spring shackle and 0.1 to 0.7 1.0 Adjust side
rear shackle hanger {0.0039 to 0.028} {0.039} washer

- Lubricant

6, 15 Spring pin remover MB999112 Removal of spring pin
M221.5 06350
34-11
6FK
Service procedure
Removal of spring pin and shackle pin
Remove spring pins 6, 15 using 0 spring pin remover.
0 Knock shackle pin 10 out from the inside of the vehicle using a
hammer.
6, 15
15
7GL
10 06356
23 24 Adjustment of side washer (for adjustment)

16 Using side washer 11, adjust the clearance between leaf spring as-
12 7 18 and rear shackle hanger 24 to the standard value.
Two different thicknesses are available for side washers 7, 11, 16 :
12 0.5 mm {0.020 in.} and 1.0 mm {0.039 in.}
H
11 07589

When replacing leaf spring assembly 12, select the members so that left
and right height marks +, and are combined as shown below.
Combination
Item
1 2 3
Right leaf spring assembly, assistant drivers
+
seat side
P
12 06354 Left leaf spring assembly, drivers seat side +

Install helper rubber 20 with installation mark facing to the inside of
the vehicle.
20

27122
34-12
34
MEMO
34-13
1 Bushing
2 Bolt
7 3 Pipe
3
4 Center nut
8 5 Rivet
6 Clip
7 Helper spring
8 Spacer
6 2 9 Rivet
10 Clip
11 Main spring
3 11
2 verse.

06799

4 Center nut 69 to 93 {51 to 69, 7.0 to 9.5}

{1.18}
32.8
A : Bushing B {1.29}
1 installer A 25 MB999066
B : Bushing {0.98} A : MB999067 Removal and installation of bushing
installer B B : MB999068
A
28 {1.10}
25 {0.98}
06790
34-14
34
0
1
Service procedure
Removal and installation of bushing
0 : Bushing installer
11
7
06791
4 Center nut
[Removal]
Put alignment marks A on the sides of helper springs 7, spacer 8, and
main springs 11.
8
A
11 06792
Compress helper springs 7, spacer 8, and main springs 11, then

remove center nut 4.
7
8
11 06793
[Installation]
4 Align alignment marks A on the sides of helper springs 7, spacer 8,
7
and main springs 11, assemble the springs, then tighten center nut 4
temporarily.
8
A
11 06794

tighten center nut 4 at specified torque.
7
8
11
06793
34-15
OFF
ON
59
[Removal]
Rivet
Drill out staked ends A of rivets 5, 9 on a drill press, then remove clips 6,
10.
6, 10
A
5, 9 07605
[Installation]
B Using riveting machine B, mount clips 10, 6 by staking rivets 9, 5.
10, 6
9, 5
06796
34-16
SHOCK ABSORBER 34
Removal sequence
1 Nut
4 2 Washer
2 5
1 3 Washer
1 4 Rubber bushing
2 5 Shock absorber
4
3 3 Installation sequence
08168

34-17
STABILIZER < FE >
Removal sequence
4 1 Nut
2 Bolt
3 Stabilizer bracket
4 Stabilizer reinforcement
5 Bolt
6 Plate
1 2 7 Clamp
8 Bushing
3 9 Stabilizer hanger
6 10 Stabilizer bushing
2 11 Nut
12 Bushing
13 Stabilizer bar
14 U-bolt nut
8 15 Stabilizer bracket
*a 9
*a : U-bolt
*b : Spring pad
13 *c : Leaf spring assembly
*b
*c 12 Follow the removal sequence in reverse.
11 15 5

14
09790

1 Nut (Stabilizer bracket mounting) 33 to 49 {25 to 36, 3.4 to 5.0}
2 Bolt (Stabilizer reinforcement mounting) 38 to 59 {28 to 43, 3.9 to 6.0}
5 Bolt (Clamp and stabilizer hanger mounting) 12 to 15 {8.7 to 11, 1.2 to 1.5}
34-18
34
6851 mm {27.00.039 in.}

F
Service procedure
Stabilizer bushing
Mount stabilizer bushings 10 with their end surfaces aligned with marks
A
10 05597
34-19
Group 34
Rear Suspension
Table of Contents
BACK
HOME
Pub No. TWSE9501-34

34
GROUP 34 REAR SUSPENSION
WORK BEFORE REMOVAL AND INSTALLATION

OF REAR SUSPENSION ....................................................................... 4
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY ....... 6
LEAF SPRING ASSEMBLY.................................................................. 10
SHOCK ABSORBER ............................................................................ 13
STABILIZER ......................................................................................... 14
34-1
1 Leaf spring assembly
*1 2 Shock absorber
3 Stabilizer
2
*1 : Frame
3 *2 : Rear axle
*2
06786
Leaf spring assembly 1 and shock absorber 2 are installed between frame *1 and rear axle *2 to support the vehicle
body mass and absorb vibration and shock from the road surface to prevent them from being directly transmitted to the
vehicle body thereby protecting the crew, the vehicle body, and the cargo. In addition, irregular vibration from the wheels
is restrained, ensuring driving stability. Stabilizer 3 is installed to prevent rolling.
34-2
TROUBLESHOOTING 34
Symptoms


Ride soft with gentle swaying
Remarks
Possible causes
Cracked or damaged
Damaged
Leaf spring Spring hanger broken
U-bolts loose
Spring bushing worn
Shackle pins thrust play excessive
Helper rubber or helper stopper damaged or broken
Oil leaking noticeable or damping force decreased
Shock absorber Rubber bushing worn
Bolt loose
Stabilizer Stabilizer deformed, bushing worn
Tires worn unevenly
Tire Tires and wheels unbalanced ^ Gr 31
34-3
WORK BEFORE REMOVAL AND INSTALLATION OF REAR SUSPENSION
1 4
3
< With load sensing valve >

7
5
14246
Removal sequence
3 Jack up the rear axle with a garage jack.
5 Put alignment marks A on the rear axle companion flange and the propeller shaft flange yoke, then remove the
nuts (on the joint between the rear axle and the propeller shaft).
< with disc brake >
8 Remove the nut (joint part of rear axle housing and the load sensing valve). < with load sensing valve >
WARNING
racks.
CAUTION
Be sure to protect the brake hose from dust by fitting blanking plugs.
34-4
34
WARNING
You must bleed air from the brake system and install the load sensing valve (with load sensing valve) after
installing the brake hose, failure to do so would cause the brake to malfunction. ^ Gr 35
CAUTION

5 Nut (Rear axle and propeller shaft connecting) 98 to 120 {72 to 87, 10 to 12}
34-5
21 24
25
19
21
23 25
22
13
17
18

2 8
14 -
4 22
3
9
-
-5
1
06349
Removal sequence
1 U-bolt nut 10 Spring pin 19 Nut
2 U-bolt 11 Side washer 20 Helper rubber
7 Side washer 16 Side washer 25 Helper spring bracket
8 Nut 17 Bushing
NOTE
faulty. ^ Gr 41
34-6
34
Standard value
6, 10, 12 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5 {0.020}
leaf spring assembly {[1.10] 0.0016 to 0.0055}
6, 23 Clearance between spring pin and rear [28] 0.02 to 0.08 1.0 {0.039}
spring hanger {[1.10] 0.00079 to 0.0031}
12, 18 Clearance between leaf spring assembly and 0.5 to 1.2 {0.020 to 0.047} 1.5 {0.059} Adjust side
spring shackle washer
12, 23 Clearance between leaf spring assembly and rear 0.5 to 1.2 {0.020 to 0.047} 1.5 {0.059} Adjust side
spring hanger washer
15, 17 Clearance between spring pin and bushing of [28] 0.04 to 0.14 0.5 {0.020}
spring shackle {[1.10] 0.0016 to 0.0055}
18, 24 Clearance between spring shackle and rear 0.1 to 0.9 {0.0039 to 0.035} 1.0 {0.039} Adjust side
shackle hanger washer
10, 18 Clearance between spring pin and spring shackle [28] 0.02 to 0.08 1.0 {0.039}
{[1.10] 0.00079 to 0.0031}
15, 24 Clearance between spring pin and rear shackle [28] 0.02 to 0.08 1.0 {0.039}
hanger {[1.10] 0.00079 to 0.0031}

- Lubricant

6, 10, 15 Spring pin remover MB999112 Removal of spring pin
M221.5 06350
34-7
6FK
Service procedure
Remove spring pins 6, 10, 15 using 0 spring pin remover.
6, 10, 15
7GL
06351
23 Adjustment of side washer (for adjustment)

24
Using side washer 11, adjust the clearance between leaf spring as-
16
12
18 and rear shackle hanger 24 to the standard value.
7
Two different thicknesses are available for side washers 7, 11, 16
12 : 0.5 mm {0.020 in.} and 1.0 mm {0.039 in.}
H
11 06353

+, ,
below.
Combination
Item
1 2 3
Leaf spring assembly, left side +
12
P
06354 Leaf spring assembly, right side +

Install helper rubber 20 with installation mark directed to the front of
20 the vehicle.
07600
34-8
34
MEMO
34-9
1 Bushing
2 Bolt
7 3 Pipe
3
4 Center nut
8 5 Rivet
6 Clip
7 Helper spring
8 Spacer
6 2 9 Rivet
10 Clip
11 Main spring
3 11
2 verse.

06799

4 Center nut 69 to 93 {51 to 69, 7.0 to 9.5}

{1.18}
32.8
A : Bushing B {1.29}
1 installer A 25 MB999066
B : Bushing {0.98} A : MB999067 Removal and installation of bushing
installer B B : MB999068
A
28 {1.10}
25 {0.98}
06790
34-10
34
0
1
Service procedure
Removal and installation of bushing
11
7
06791
4 Center nut
[Removal]
Put alignment marks A on the sides of helper springs 7, spacer 8, and
main springs 11.
8
A
11 06792

remove center nut 4.
7
8
11 06793
[Installation]
4 Align alignment marks A on the sides of helper springs 7, spacer 8,
7
and main springs 11, assemble the springs, then tighten center nut 4
temporarily.
8
A
11 06794

tighten center nut 4 at specified torque.
7
8
11
06793
34-11
OFF
ON
59
[Removal]
Rivet
Drill out caulked ends A of rivets 5, 9 on a drill press, then remove clips 6,
10.
6, 10
A
5, 9 07605
[Installation]
B Using riveting machine B, mount clips 10, 6 by caulking rivets 9, 5.
10, 6
9, 5
06796
34-12
SHOCK ABSORBER 34
Removal sequence
1 Nut
4 2 Washer
2 5
1 3 Washer
1 4 Rubber bushing
2 5 Shock absorber
4
3 3 Installation sequence
08168

34-13
STABILIZER
Removal sequence
4 1 Nut
2 Bolt
3 Stabilizer bracket
4 Stabilizer reinforcement
5 Bolt
6 Plate
1 2 7 Clamp
8 Bushing
3 9 Stabilizer hanger
6 10 Stabilizer bushing
2 11 Nut
12 Bushing
13 Stabilizer bar
14 U-bolt nut
8 15 Stabilizer bracket
*1 9
*1 : U-bolt
*2 : Spring pad
13 *3 : Leaf spring assembly
*2
*3 12 Follow the removal sequence in reverse.
11 15 5

14
09790

2 Bolt (Stabilizer reinforcement mounting) 38 to 59 {28 to 43, 3.9 to 6.0}
5 Bolt (Clamp and stabilizer hanger mounting) 12 to 15 {8.7 to 11, 1.2 to 1.5}
34-14
34
6851 mm {27.00.039 in.}

F
Service procedure
Stabilizer bushing
Mount stabilizer bushings 10 with their end surfaces aligned with marks
A
10 05597
34-15
BACK HOME
Group 35 - Brake
Group 35 - Brake
1998 Minor Change <FE/FG>
Group 35A - Anti-Lock Brake

System (ABS)
/
Group 35A
Anti-Lock Brake System
(ABS)
' 00 Minor Change
Table of Contents
BACK HOME

35A
GROUP 35A ANTI-LOCK BRAKE SYSTEM (ABS)
SPECIFICATIONS ........................................................................ 35A- 2
STRUCTURE AND OPERATION ................................................. 35A- 2

Periodic Inspection Procedures ............................................................ 35A- 9
Inspection of Wheel Speed Sensor Signal Waveform
Using Oscilloscope ................................................................................. 35A-10
Hydraulic Unit Operation Check .............................................................. 35A-11
TROUBLESHOOTING
Troubleshooting Procedures .................................................................. 35A-13
Diagnosis Code Indication ...................................................................... 35A-14
Diagnosis Code Chart ............................................................................. 35A-17
Actuator Drive Chart ................................................................................ 35A-17
Service Data ............................................................................................. 35A-18
WHEEL SPEED SENSOR AND ROTOR

< FRONT AXLE : DISC BRAKE > ............................................................... 35A-20
< FRONT AXLE : DRUM BRAKE > ............................................................. 35A-24
< REAR AXLE : DISC BRAKE > ................................................................. 35A-30
< REAR AXLE : DRUM BRAKE > ............................................................... 35A-36
ELECTRIC CIRCUIT AND PART INSTALLATION

LOCATIONS .................................................................................. 35A-42
35A-1
SPECIFICATIONS
Item Specifications
Brake system Vacuum servo
Anti-lock brake system ABS (4S/4K)
(number of sensors/number of channels)
Manufacturer NIPPON ABS

Anti-lock Brake System (ABS)
The anti-lock brake system (ABS) prevents tire slippage due to wheel lockup caused by sudden braking and braking on
slippery road surfaces. The ABS provides a driver with vehicle controllability and directional stability in braking.
Wheel lockup
Rotating tires of a moving vehicle have a tendency to continue traveling in the direction of tire rotation. Because of this
characteristic, a driver can control the vehicles traveling direction by moving the front wheels to a desired direction
using the steering wheel.
In a vehicle not equipped with an anti-lock brake system, when a driver depresses the brake pedal with full force, the
wheels can lock up under certain conditions. Tires in a wheel lockup condition lose the tendency to maintain directional
characteristic, and the vehicle starts sliding in a direction of an externally applied force regardless of the tire direction. In
other words, when wheel lockup occurs, the vehicle loses its directional stability, disallowing the driver to control the
vehicles movement.
The following shows how a vehicle without ABS loses its directional stability when different tires lock up on slippery
road surfaces.
Front wheel lockup (both front tires)
Steering direction
Braking point
07729
The front tires lose directional stability, but the rear tires try to travel in the direction of rotation since they are not
locked up. Because of the front wheel lockup, a steering wheel operation does not change the vehicles moving
direction.
35A-2
35A
Rear wheel lockup (both rear tires)
Steering direction
Braking point
07730
When the steering wheel is operated with the rear wheels in a lockup condition, the front tires try to change the
vehicles traveling direction, but the rear tires slide sideways, causing the vehicle to spin. If wheel lockup occurs in a
vehicle traveling in a straight direction, the force of inertia continues to push the vehicle straight ahead from the back
of the vehicle due to the lack of stopping force in the rear tires, and the vehicle can spin.
All wheel lock up (front and rear tires)
Steering direction
Braking point
07731
When wheel lockup occurs in both front and rear tires, all four tires lose directional stability. Therefore, the vehicle
slips in the direction of inertia regardless of the steering direction.
Wheel lockup on surfaces with split factors (road surface with different friction coefficients for
right and left tires)
Non-slippery pavement
Slippery pavement
07732
The tires on a surface with a lower friction coefficient lock up first. The tires in a lockup condition start sliding, thus
failing to provide effective stopping force. Due to this imbalance in the stopping power between the right and left tires,
one side of the vehicle slows down while the other side continues traveling, thus resulting in the loss of directional
stability. When this happens during sudden braking, the vehicle spins.
35A-3
Structure of ABS
10 11 1 2 10
9 9
7
8
9
9
3 5 4
10 6 10
Brake fluid line

Electric line
P 35951
1 Brake booster (Mastervac) 7 Hydraulic unit

2 Brake master cylinder 8 Relay box
3 ABS warning lamp 9 Wheel speed sensor
4 Exhaust brake cut relay 10 Rotor
5 G sensor < FG > 11 Stop lamp switch
6 ECU
The ABS uses wheel speed sensors 9 and ECU 6 to monitor the rotating speed of each wheel. The FG models are also
equipped with G sensor 5 for the detection of the degree of vehicles forward and backward acceleration. When the wheel
speed exceeds the preset deceleration speed or slip rate during braking, the ECU detects it as a tendency leading to
wheel lockup, and sends control signals to hydraulic unit 7 and relay box 8. The signals activate the solenoid valves to
reduce the brake fluid pressure in the wheel brakes and ease the braking force to prevent wheel lockup. Then, when the
wheel speed increases, wheel speed sensors 9 send signals to the solenoid valves in hydraulic unit 7 by way of ECU 6 to
increase the brake fluid pressure in the wheel brakes to augment the braking force. This control cycle is repeated to
prevent wheel lockup on slippery pavements and ensure the vehicles directional stability during braking. The 4-sensor 4-
channel anti-lock brake system uses four wheel speed sensors 9, which are located at the front and rear wheels, to control
each of the four wheels.
35A-4
35A
ABS function
Input signals ECU Output signals

Hydraulic unit
Wheel speed sensor Solenoid valve (for front-axle left wheel)

Pressure holding valve
(for front-axle left wheel) Pressure reducing valve
Wheel speed sensor

Solenoid valve (for front-axle right wheel)
(for front-axle right wheel) Pressure holding valve
Pressure reducing valve
Wheel speed sensor Solenoid valve (for rear-axle left wheel)
(for rear-axle left wheel) Pressure holding valve
ABS control function (solenoid Pressure reducing valve
Wheel speed sensor valve regulating function)
(for rear-axle right wheel) Solenoid valve (for rear-axle right wheel)
Pressure holding valve
G sensor Pressure reducing valve
(acceleration detection)
< FG > Hydraulic
Motor
pump
Stop lamp switch
Motor power supply
Relay box
Motor relay
Hydraulic pump
Solenoid
power supply
Valve relay
Malfunction diagnosis function

[fail-safe, self-diagnosis, ABS warning lamp
MUT-II communication]
MUT-II
35A-5
ABS control function
To provide optimum stopping power, the ABS controls the
braking force based on the slip rate determined by the
relationship between the wheel speed and the vehicle
speed. When the brake is applied, the resulting force
slows down the wheel rotation, thus reducing the vehicle
speed. However, inertia acts on the vehicle and tries to
maintain the vehicles forward movement despite the stop-
ping force applied by the tires. When there is a difference
between the wheel speed and vehicle speed, slipping
occurs. The degree of slippage is expressed by a slip rate.
Vehicle speed Wheel speed

Slip rate (%) = 100
Vehicle speed
When the slip rate is 0%, there is no slippage between the

tires and pavement. The slip rate of 100% refers to a
wheel lockup condition.
Slip rate vs. friction coefficient curves The graph shows the time-based changes in the friction
1.0
coefficient of a rolling tire during the process of wheel
Dry asphalt lockup. When the brake is applied gradually while the tires
are rotating on pavement, the tires begin to slip while in
rotation.
Friction coefficient ()
Wet asphalt
When the brake is applied harder, the tires stop rotating
and start to slide on the pavement. This condition is called
wheel lockup.
The friction coefficient is highest when the slip rate is
0.5
within the shaded area on the graph.
Cornering force
In other words, tires provide maximum friction when the
braking force is appropriately controlled to maintain the
Snow-
covered road slip rate in the range indicated by the shaded area on the
Frozen road graph, rather than when the brake is applied at full force.
In a vehicle equipped with ABS, the ECU and hydraulic
0
0 50 100% unit adjust the braking force and maintain it within the
(Tire roll) (Wheel lockup) shaded area on the graph where the friction coefficient is
Slip rate (%) 03049 high, thus preventing tire slippage and ensuring braking
stability.
35A-6
35A
ABS Operation
ABS control characteristic curve
Actual vehicle speed
Vehicle speed
and wheel
speed Estimated vehicle speed
Slip rate setting Wheel

speed
+b
Wheel
acceleration/
deceleration
0
speed
b
Pressure
decrease
Pressure
Signal (from ECU) hold
Pressure
increase
Brake fluid
pressure
A B C D 07734
The above ABS control characteristic graph shows the time-based changes in vehicle speed, wheel acceleration/
deceleration speed and brake fluid pressure level during braking.
When the wheel deceleration speed exceeds the speed setting b at point A, the ECU sends a signal to maintain the
brake fluid pressure at the same level.
At the same time, the ECU estimates the vehicle speed according to a programmed calculation method.
When the vehicle speed decreases further and the slip rate exceeds the setting at point B, the ECU detects it as a
tendency leading to wheel lockup, and sends a signal to reduce the brake fluid pressure.
When the wheel speed increases because of the reduced brake fluid pressure and the wheel speed exceeds the
setting b at point C, the ECU sends a signal to maintain the brake fluid pressure at the same level.
When the wheel speed increases further and the wheel speed exceeds the setting + b at point D, the ECU determines
that there is no risk of wheel lockup and sends a signal to increase the brake fluid pressure.
By repeating the above control cycle, the ABS prevents wheel lockup and provides maximum friction between the tires
and pavement to ensure high stability during braking.
ABS and exhaust brake system
On slippery road surfaces, activation of the exhaust brake system can result in wheel lockup. If the exhaust brake
activates during an ABS braking operation, proper braking function cannot be provided by the ABS.
To prevent this, the exhaust brake system is deactivated during ABS operation even when the exhaust brake switch is turned ON.
When the ABS stops providing its function, the exhaust brake system becomes operable if the exhaust brake switch is ON.
35A-7
ECU
This component calculates the wheel speed
and estimates the vehicle speed based on sig-
nals sent from the wheel speed sensors. Based
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
on the calculation results, it determines the
degree of wheel lockup tendency, and sends
AK22A
brake fluid pressure control signals to the sole-
noid valves of the hydraulic unit to regulate
9 8 7 6 5 4 3 2 1 brake fluid pressure accordingly.
20 19 18 17 16 15 14 13 12 11 10 The ECU is equipped with a self-diagnosis
AK20A function. Should an abnormality occur, the
ECU turns on the warning lamp on the instru-
ment panel to indicate the system malfunction
and deactivates the ABS control to set the
brake system in normal condition (without anti-
P 36208
lock brake system control).
AK22A AK20A
Terminal Connection destination
No.
1 Ground G sensor (ground) < FG >
2 Ground G sensor (signal) < FG >
3
4 Hydraulic unit (motor drive) Meter cluster (ABS warning lamp)
Hydraulic unit (motor drive monitor) Starter switch terminal M
5 (ECU power supply)
Wheel speed sensor
6 (rear-axle right-wheel input)
Hydraulic unit (rear-axle right-wheel Wheel speed sensor
7 brake fluid pressure decrease) (rear-axle left-wheel input)
Hydraulic unit (rear-axle left-wheel Wheel speed sensor
8 brake fluid pressure decrease) (front-axle right-wheel input)
Hydraulic unit (front-axle right-wheel Wheel speed sensor
9 brake fluid pressure decrease) (front-axle left-wheel input) < FE >
Hydraulic unit (front-axle left-wheel G sensor (power supply) < FG >
10 brake fluid pressure decrease)
11 Ground
12 Ground MUT-II connector
13 MUT-II connector
14 Relay box (valve relay drive) Stop lamp switch
Relay box (valve relay and motor
15 relay power supply)
Exhaust brake cut relay Wheel speed sensor
16 (front-axle left-wheel input) < FG >
Exhaust brake cut relay Wheel speed sensor
17 (rear-axle right-wheel grounding)
Wheel speed sensor
18 (rear-axle left-wheel grounding)
Hydraulic unit (rear-axle right-wheel Wheel speed sensor
19 brake pressure hold) (front-axle right-wheel grounding)
Hydraulic unit (rear-axle left-wheel Wheel speed sensor
20 brake pressure hold) (front-axle left-wheel grounding)
Hydraulic unit (front-axle right-wheel
21 brake pressure hold)
Hydraulic unit (front-axle left-wheel
22 brake pressure hold)
35A-8
ON-VEHICLE INSPECTION AND ADJUSTMENT 35A
Periodic Inspection Procedures
(1) Periodic inspection of Anti-lock brake system
Inspect the vehicles Anti-lock brake system following the procedure
below.
If an abnormality is found in this inspection, further inspect the Anti-
lock brake system using 0 MUT-II (multi-use tester) by referring to
TROUBLESHOOTING section.
P35A-14
Inspection procedure
1 With the vehicle stationary, press the brake pedal and inspect
the hydraulic unit for fluid leaks.
If fluid leaks from the hydraulic unit, replace the unit. If fluid leaks
from the fluid pipe or connector, tighten the joint.
2 Inspection using brake tester
Check the braking force at each wheel with a brake tester by
following the inspection procedure for ordinary vehicles.
If an abnormality is found, inspect the wheel brake units, service
brake system and hydraulic unit.
3 Drive the vehicle and check the operation of the Anti-lock brake
system.
Conduct a test drive at an open area to ensure safety.
Conduct a test drive without cargo.
Attach white tape A on the sides of tires, so that it is easy to
observe the rotation of the front and rear wheels.
Turn the starter switch from the OFF position to the ON posi-
tion, and make sure that the warning lamp lights.
Then, check that the warning lamp turns off approxi-
A mately two seconds after the starter switch is turned on.
23971
Drive the vehicle at a speed of 20 to 30 km/h {12 to 19 mph},
and apply a sudden brake. Make sure that wheel lockup does
not occur in any of the tires.
35A-9
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope
Inspect the rotor for dents using an oscilloscope, since the tester cannot
be used for dent detection.
NOTE
Use an oscilloscope with a waveform recording function.
Lift the wheel to be tested off the ground, and disconnect the connec-
tor at the wheel speed sensor.
Connect the terminal of the oscilloscope to the terminal of the discon-
nected connector. Rotate the wheel at a constant speed. Check the
waveform shown on the oscilloscope to check for dents on the rotor.
Rotor dents are often made by the rotor press-fit on the hub end
Normal waveform (no dent on rotor) contacting the axle during installation of the hub and brake drum
assembly on the axle. When installing the hub & brake drum assem-
bly, pay close attention to prevent the rotor from contacting other
parts.
If the wave is noticeably narrower in width than other observed waves,
the rotor may be chipped. Visually inspect the rotor.
03122
35A-10
35A
Hydraulic Unit Operation Check
Operation check using MUT-II
Lift the vehicle using a jack and support it with rigid racks, or position
the tires on brake tester rollers.
WARNING
The brake tester rollers and tires must be dry during inspection.
To test the front brakes, apply the parking brake. To test the rear
brakes, place wheel chocks at the front tires to secure them in
position.
Disengage the parking brake, and feel the drag resistance of the
brake on each wheel.
When using a brake tester, record the indicated drag resistance of the
brake.
Set the starter switch to the OFF position, then connect the MUT-II.
Set the testing equipment and system on the MUT-II.
After making sure that the transmission is in the neutral position, start
the engine.
NOTE
When the engine is turned on, the ABS switches to the MUT-II
mode and the ABS warning lamp flashes.
When the ABS function is deactivated due to the ECUs fail-safe
function, the actuator test cannot be performed with the MUT-II.
35A-11

Press
Pedal
operation

Release MUT-II actuator test
(one of items Nos. 11 through 14)
Operation starting

Pressure
increase

Solenoid valve
position Pressure 3 sec
decrease

3 sec
Pressure hold

Lock

Braking force

check
Drag 6 sec
resistance
with no brake
applied 07755
If an abnormality is found during the inspection, take appropriate measures described in the following operating condition
evaluation chart.
Operating condition evaluation chart

Item MUT-II Judgment
Operation Cause Remedy
No. indication Normal Malfunction
Clogging in brake Inspect and clean

11 FR ABS MV ON (1) Depress the brake Wheel does not
pedal to lock wheels. line other than HU brake lines.
(2) On the MUT-II, select lock when brake
the wheel to be pedal is de-
Braking Clogging in hydraulic Replace HU
12 FL ABS MV ON tested and forcibly pressed.
force eases line inside HU assembly.
drive the actuator. for 6
(3) Rotate the selected seconds
13 RR ABS MV ON wheel using the from locked Erroneous HU brake Correct tube
tube connection connection.
brake tester or by condition. Braking force
hand, and check the does not ease.
change in braking Faulty HU solenoid Replace HU
14 RL ABS MV ON
power. valve assembly.
HU: Hydraulic unit After inspection, set the starter switch to OFF before disconnecting the MUT-II.
35A-12
TROUBLESHOOTING 35A
Troubleshooting Procedures
The MUT-II allows efficient inspection of the ABS.
The types of system inspections can be roughly divided according to the malfunction condition and diagnosis code, as
shown below.
Inspection based on individual malfunction diagnosis codes stored in the ECU
Inspection based on symptoms not indicated by diagnosis codes
Correcting non-recurring problems
Position vehicle for inspection.
Read diagnosis code.

Abnormal code output Normal code output
Normal code
output after Test-drive.
clearing ECU
memory
Normal Generation of malfunction
Locate and inspect cause of malfunc- Check for non-recurring Check cause of problem that does
tion indicated by diagnosis code. problems. ^ Gr 00 not generate diagnosis code.
Test-drive.
If a diagnosis code was generated during the test drive, locate and check the
cause of the diagnosis code generation.
If a diagnosis code stored in the ECU before the test drive did not generate,
conduct a non-recurring problem check in addition to the inspection based on the
diagnosis code.
Delete diagnosis code.
Cautions in malfunction diagnosis
The ABS uses electronic control to regulate the braking system. The following phenomena may occur during normal
ABS operation, but they do not denote a malfunction.
Phenomenon Description
When the engine starts, a slight clunking sound may be generated in the left side of the
System checking sound frame near the cargo bed. This sound is produced by the system conducting an operation
check, and does not denote a malfunction.
Motor noise from the hydraulic unit (humming sound)
Noise generated as the brake pedal feel changes (grinding sound)
ABS operating sound
Noise from the chassis produced by repeated ON and OFF operations of the ABS
(wheels: short squeak, suspension: slight thud)
ABS operation effect On snow-covered surfaces and gravel roads, a vehicle equipped with ABS may require a
(longer stopping longer distance to come to a complete stop. Therefore, when driving on such road surfaces,
distance) reduce the speed sufficiently and drive carefully to minimize the use of brakes.
35A-13
TROUBLESHOOTING
Inspection of ABS warning lamp
Check the ABS warning lamp to make sure that the following operation
turns on the lamp.
Set the starter switch to the ON position, and check that the ABS
warning lamp lights for about 1 second and turns off.
If the lamp does not light as described above, check diagnosis codes
stored in the ECU.
ABS
P 35952
ON
Starter
switch
OFF
Approx. 1 sec
ABS ON
warning
lamp OFF
07743
1 Diagnosis Code Indication

Without MUT-II
With the vehicle stationary, ground terminal No. 16 of MUT-II connec-
tor 1, then turn the starter switch to the ON position. The ABS warning
lamp will flash to indicate a diagnosis code.
The ABS warning lamp starts flashing 3.0 seconds after the starter
switch is turned ON. The flashing pattern of the warning lamp indi-
cates a diagnosis code.
35953
(Example) Indication of diagnosis A diagnosis code is indicated in the following manner.

code No. 12 To indicate the tens digit (left digit), the lamp remains ON for 1.5
1 2 seconds, then remains OFF for 0.5 seconds. To indicate the ones
digit (right digit), the lamp remains ON for 0.5 second, then remains
ON OFF for 0.5 second.
For multiple diagnosis codes, each code is indicated one time,
OFF insequence. When there is no other diagnosis code to indicate, the
2nd-time lamp repeats the diagnosis code indication from the beginning for 7
3.0s 1.5s 2.0s 0.5s 3.0s indication cycles.
0.5s 0.5s
07746 When there is no diagnosis code stored in the memory (normal
condition), the ABS warning lamp repeats On/Off in 0.25-second
intervals.
(Example) Indication of 12 and 13 When two or more diagnosis codes are stored in the ECU.
1st 1st 2nd 2nd 3rd 3rd
12 13 12 13 12 13
07747
35A-14
35A
Deletion of diagnosis codes
MUT-II Ground
connector With key off, connect terminal No. 16 of the MUT-II connector to the
terminal
No. 16 Open
chassis for grounding. Depress the brake pedal and turn on the starter
Starter ON switch and turn the stop lamp switch on and off ten times in intervals of 1
switch 3 sec 1 sec 1 sec Data
OFF
or less or less or less deletion second or less by depressing the brake pedal. Turn the key off.
disconnect the ground wire. This erases diagnosis codes from the
Stop ON memory.
lamp
switch OFF
1st 2nd 3rd 10th
time time time time
P 37199
Completion of diagnosis code check
The diagnosis code check completes when diagnosis codes are erased
from the ECU of terminal No. 16 of the MUT-II connector is discon-
nected.
NOTE
The diagnosis code check also ends when the vehicle moves
from a stationary condition during the diagnosis code check.
With MUT-II
0 Special tools
Inspection of Anti-lock brake system
MUT-II MB991496
19492
MUT-II harness
(for data communication) MK327601
19141
ROM pack
MK344606
(MRT-E6)
19493
35A-15
TROUBLESHOOTING

Inspection of Anti-lock brake system
MUT-II harness
MB991499
(for circuit tester)
20536
Memory card
MB991500
(for MUT-II)
20538

B Turn the starter switch to the LOCK position.
insert the 3 ROM Pack.
A
C NOTE
2 3 Instructions for operation of the MUT-II are given in the separate
1 MUT-II Reference Manual.
31469
Current diagnosis codes

Determine the fault location(s) in accordance with the MUT-II diagno-
sis code(s).

diagnosis code(s).
Diagnosis code erasure

Using the MUT-II, erase all diagnosis codes stored in the control unit.
35A-16
35A
Diagnosis codes can be read by using the MUT-II or ABS warning lamp.
Diagnosis Malfunction location

code MUT-II display Description of malfunction
11 FR-SNSR OPEN Broken wire to front-axle right-wheel speed sensor
Wheel speed
12 FL-SNSR OPEN Broken wire to front-axle left-wheel speed sensor
13 RR-SNSR OPEN Broken wire to rear-axle right-wheel speed sensor
sensor
14 RL-SNSR OPEN Broken wire to rear-axle left-wheel speed sensor
*15 ROTA OR SNSR Broken wire
16 ECU VOLTAGE Drop in power supply voltage
Wheel speed
21 FR-SNSR SHORT No broken wire to front-axle right-wheel speed sensor
22 FL-SNSR SHORT No broken wire to front-axle left-wheel speed sensor
23 RR-SNSR SHORT sensor No broken wire to rear-axle right-wheel speed sensor
24 RL-SNSR SHORT No broken wire to rear-axle left-wheel speed sensor
26 G SENSOR G sensor
35 EXB RLY Exhaust brake cut relay
38 STOP LAMP SW Stop lamp switch
41 FR-EV VALVE Front-axle right-wheel solenoid valve (pressure decrease)
42 FL-EV VALVE Front-axle left-wheel solenoid valve (pressure decrease)
Hydraulic unit
43 RR-EV VALVE Rear-axle right-wheel solenoid valve (pressure decrease)

44 RL-EV VALVE Rear-axle left-wheel solenoid valve (pressure decrease)
45 FR-AV VALVE Front-axle right-wheel solenoid valve (pressure hold)
46 FL-AV VALVE Front-axle left-wheel solenoid valve (pressure hold)
47 RR-AV VALVE Rear-axle right-wheel solenoid valve (pressure hold)
48 RL-AV VALVE Rear-axle left-wheel solenoid valve (pressure hold)
Relay box
51 VALVE RLY Valve relay

Motor relay or motor
53 MOTOR RLY
Motor monitor line
63 ECU ERR ABS ECU
Actuator Drive Chart
MUT-II display
Item No. Item name
11 FR ABS MV ON
12 FL ABS MV ON
13 RR ABS MV ON
14 RL ABS MV ON
35A-17
TROUBLESHOOTING
Service Data
MUT-II display Inspection condition Criterion

11 FR SPEED . MPH
12 FL SPEED . MPH
Constant-speed driving Same as speedometer indication
13 RR SPEED . MPH
14 RL SPEED . MPH
15 ECU VOLTAGE . V Starter switch ON Same as battery voltage
Brake pedal depressed ON
30 STOP LAMP SW ON/OFF
Brake pedal released OFF
35A-18
35A
MEMO
35A-19
WHEEL SPEED SENSOR AND ROTOR < FRONT AXLE : DISC BRAKE >
The following section describes the service procedures for the wheel speed sensors and rotor. For the service procedures
of related parts, refer to ^ Gr 26A. The illustration below shows the front-axle left wheel.
5 11
12
< FE639 >

6
14
1
14
10
9
< FE649 > 8
7
36109
Removal sequence
1 Bolt 8 Lock nut
2 Spacer 9 Lock washer
3 Wheel speed sensor 10 Outer bearing inner race
4 Clips 11 Oil seal
5 Dust cover < FE6394 > 12 Inner bearing inner race
6 Disc brake assembly 13 Rotor (ABS)
7 Hub cap 14 Wheel hub & rotor assembly
CAUTION
Before removing disc brake assembly 6, secure the disc brake assembly to the frame using wires, and do not
disconnect the brake hose. Never allow the weight of the disk brake caliper assembly to hang from the
hydraulic brake hose. Be sure to remove the harness clips to prevent damaging the pad wear indicator
harness during the removal process.
Follow the removal sequence in reverses.
WARNING
Do not allow oil or grease to adhere on the pad surface of disc brake assembly 6 or the rotor surface of wheel
hub & rotor assembly 14.
CAUTION
When installing wheel hub & rotor assembly 14, be careful not to damage rotor 13 or oil seal 11.
35A-20
35A
Service standards
Resistance between terminals 1600 10%
3 Wheel speed sensor
Insulation resistance 100 k minimum

1 Bolt (wheel speed sensor mounting) 9.8 to 14.8 {7.2 to 11, 1.0 to 1.5}
16 mm {0.63 in.}
2
Service procedure
Installation of spacer
Check the thickness of spacer 2 before installation.
CAUTION
Installation of spacer 2 with an improper thickness results in
inaccurate wheel speed detection, thus causing faulty ABS op-
eration.
3
06053
Wheel speed sensor

[Removal]
To prevent damaging pole piece A in wheel speed sensor 3, remove the
A wheel speed sensor before removing wheel hub & rotor assembly 14.
1
2 07677
[Installation]
The connector of wheel speed sensor 3 is color-coded. Install the wheel
speed sensors to the proper wheels according to the following table.
Installation location Connector color

Left wheel Gray
Right wheel Black
35A-21
WHEEL SPEED SENSOR AND ROTOR < FRONT AXLE : DISC BRAKE >
3 [Inspection]
Pole piece A in wheel speed sensor 3 is magnetized by a built-in magnet
and attracts metals. Do not allow metal particles to stick to the pole
piece.
A
07666
Measurement of resistance between terminals

Measure resistance between the terminals of wheel speed sensor 3.
3 If the measured value deviates from the standard value, replace the
wheel speed sensor.
07667
A Measurement of insulation resistance

Measure resistance between pole piece A, bracket B and each termi-
nal of wheel speed sensor 3.
B wheel speed sensor.
37124
Inspection of open circuit in harness

To check the harness for an open circuit, disconnect the harness
clamp from the vehicle side, then bend and pull harness at the clamp
to check if a momentary open circuit results. Also inspect the terminal
contact conditions in the connector.
If an abnormality is found, replace wheel speed sensor 3.
09939
35A-22
35A
4
4
A
*
34 Installation of wheel speed sensor harness and clips
Starting from the wheel brake side, secure the harness of wheel speed
sensor 3 in place at white tape sections A using clips 4, while making
4 sure that there is no interference, twisting or excessive sagging of the
A harness.
A
B : Shock absorber
* : Pad wear indicator harness
09938
3 B
4
A
4 A B A
4
A
I
09936
Rotor
[Inspection]
13
Check rotor 13 for chipped or crushed teeth (see section A in the
diagram).
If an abnormality is found, replace the rotor.
A
14
07679
[Removal]
C
B : Iron plate
B
C : Gear puller
13
14
09934
[Installation]
D Before installing rotor 13 to wheel hub & rotor assembly 14, heat the rotor
to approximately 150C {302F}. Using pipe D, install the rotor to the
13 wheel hub & rotor assembly by applying uniform pressure to prevent the
rotor from tilting.
14
09935
35A-23
WHEEL SPEED SENSOR AND ROTOR < FRONT AXLE : DRUM BRAKE > FG
of related parts, refer to ^ Gr 26B. The illustration below shows the front-axle left wheel.

13
19
*
10
12
18
17
6
9
8 1
7
5
3
2
36324
Removal sequence
1 Screw 8 Lock nut 15 Clips
2 Cover assembly 9 Outer bearing 16 Spring spacer
3 Snap ring 10 Bolt 17 Sensor holder
4 Bolt 11 Rotor (ABS) 18 Bolt
5 Housing assembly 12 Wheel hub & brake drum assembly 19 Sensor bracket
6 Bolt 13 Bolt
7 Lock washer 14 Wheel speed sensor * : Front brake assembly
*1918
1315
171614 987654321
121110
35A-24
35A
WARNING
Do not allow oil or grease to adhere on the lining surface of front brake assembly * or the inside surface of
wheel hub & brake drum assembly 12.
CAUTION
When installing wheel hub & brake drum assembly 12, be careful not to damage rotor 11, wheel speed sensor
14 or oil seal in the wheel hub.
Service standards

10 Bolt (rotor mounting) 8.8 to 13.8 {6.5 to 10, 0.9 to 1.4}
13 Bolt (sensor holder mounting) 8.8 to 13.8 {6.5 to 10, 0.9 to 1.4}
18 Bolt (sensor bracket mounting) 11.8 to 12.8 {8.7 to 9.4, 1.2 to 1.3}
G
Service procedure
Rotor
[Inspection]
11 A Check rotor 11 for chipped or crushed teeth (see section A in the
diagram).
12
16555
J Wheel speed sensor

[Inspection]
Pole piece A in wheel speed sensor 14 is magnetized by a built-in
magnet and attracts metals. Do not allow metal particles to stick to the
A pole piece.
14
36325
35A-25
14 Measure resistance between the terminals of wheel speed sensor 14.
wheel speed sensor.
36326
Measurement of insulation resistance

Measure resistance between body B and each terminal of wheel
B speed sensor 14.
If the measured value is lower than the standard value, replace the
wheel speed sensor.
14
36327

09939
JL Wheel speed sensor and spring spacer

The illustration shows the front-axle left wheel. The right wheel is sym-
metrical to the one shown in the diagram.
19 [Removal]
Remove wheel speed sensor 14 and sensor holder 17 as an assem-
bly.
14 17
16604
35A-26
35A
17 Using pliers, hold wheel speed sensor 14 at shaded section A in the
16 diagram, and remove it by turning it slightly.
14
CAUTION
Do not hold wheel speed sensor 14 with pliers at positions other
than shaded section A shown in the diagram.
Do not apply excessive force to remove wheel speed sensor 14,
A
such as by striking with a hammer, prying with a screwdriver,
and pulling the harness. Excessive force can break wires in the
36327 wheel speed sensor.
If only slight force is necessary to remove wheel speed sensor
14, replace spring spacer 16.
[Installation]
B B
17 14 Insert spring spacer 16 into sensor holder 17 until section B of the
spring spacer contacts the sensor holder.
17 Insert wheel speed sensor 14 until it contacts section B.
16
B 14
36328
Install wheel speed sensor 14 and sensor 17 as an assembly.
19
14 17
16604
Approx. 20 mm Carefully install wheel hub & brake drum assembly 12 to avoid dam-
* 12 aging oil seal C. Position the wheel hub & brake drum assembly at the
14 location where the distance indicated in the illustration is approxi-
11 mately 20 mm (to prevent wheel speed sensor 14 from contacting
rotor 11).
Slowly tighten lock nut 8 to the specified torque (primary tightening).
C Adjust and measure the starting torque of the wheel hub bearing.
8
^ Gr 26B
12
* 36329 CAUTION
Do not apply excessive force to install wheel speed sensor 14,
wheel speed sensor.
35A-27
JK Installation of wheel speed sensor harness and clips
sensor 14 in place at white tape sections A using clips 15, while making
sure that there is no interference, twisting or excessive sagging of the
harness.
15
B : Shock absorber
A
15
A B
15
14
16556
35A-28
35A
MEMO
35A-29
WHEEL SPEED SENSOR AND ROTOR < REAR AXLE : DISC BRAKE >
of related parts, refer to ^ Gr 27. The illustration below shows the rear-axle left wheel.

4
4 3
4 6
7
8
4
7 12
15 11
16 10
17
18
9
36120
Removal sequence
1 Wheel speed sensor 7 Disc brake assembly 13 Rotor (ABS)
2 Spring spacer 8 Rear axle shaft 14 Rotor flange
3 Nut 9 Outer oil seal 15 Inner oil seal
4 Bolt 10 Lock washer 16 Inner bearing
5 Clips 11 Lock nut 17 Rotor (brake)
6 Dust shield 12 Outer bearing 18 Rear wheel hub
CAUTION
Before removing disc brake assembly 7, secure the disc brake assembly to the frame using wires, and do not
disconnect the brake hose. Never allow the weight of the disk brake caliper assembly to hang from the
hydraulic brake hose. Be sure to remove the harness clips to prevent damaging the pad wear indicator
harness during the removal process.
Follow the removal sequence in reverses.
WARNING
Do not allow oil or grease to adhere on the pad surface of disc brake assembly 7 or the surface of rotor 17.
CAUTION
When installing rear wheel hub 18 to the rear axle, be careful not to damage rotor 13 or inner oil seal 15.
35A-30
35A

13 Rotor runout (ABS) 0.0039

3 Nut (clip mounting) 10 to 15 {72 to 108, 1.0 to 1.5}
4 Bolt (clip mounting) 12 to 15 {87 to 108, 1.2 to 1.5}
12
Service procedure
[Removal]
Wheel speed sensor and spacer
Using pliers, hold wheel speed sensor 1 at shaded section A in the

A
diagram, and remove it by turning it slightly.
2
CAUTION
Do not hold wheel speed sensor 1 with pliers at positions other
1
than shaded section A shown in the diagram.
5 Do not apply excessive force to remove wheel speed sensor 1,
36331
wheel speed sensor.
If only slight force is necessary to remove wheel speed sensor 1,
replace spring spacer 2.
B [Installation]
2 C
The connector of wheel speed sensor 1 is color-coded. Install the wheel
Right/left
Installation location Connector color Connector shape
identification tape
Left wheel Gray Female Yellow
Right wheel Black Male None
1 36192
Insert spring spacer 2 into holder section B of the backplate until
B C stopper section C contacts the holder section.
Insert wheel speed sensor 1 until it firmly contacts rotor 13.
Slowly rotate rear wheel hub 18 two or three turns (1 rotation per 2
seconds) to make sure it rotates smoothly.
CAUTION
Do not apply excessive force to install wheel speed sensor 1,
18 13 2 1 36330 wheel speed sensor.
35A-31
[Inspection]
Pole piece D in wheel speed sensor 1 is magnetized by a built-in magnet
piece.
1
36325

wheel speed sensor.
36326
Measurement of insulation resistance

Measure resistance between body E and each terminal of wheel
E speed sensor 1.
wheel speed sensor.
1
36327

09939
35A-32
35A
5
Starting from the wheel brake side, secure the harness of wheel
1 5 A 5 1 speed sensor 1 and the pad wear indicator harness in place at tape
sections A using clips 5, while making sure that there is no interfer-
A ence, twisting or excessive sagging of the harnesses.
A
A A A A
36332
D As shown in the diagram, position the harness of speed sensor 1 and

5 the pad wear indicator harness, starting from housing section B and
moving toward the frame, making sure that there is no twisting or
excessive sagging of the harnesses. Use clips 5 and cable ties C to
secure the harnesses in place, then connect connectors D.
B
C 07693
A
I Rotor
[Inspection]
13 Check rotor 13 for chipped or crushed teeth (see section A in the
diagram).
17
If the amount of runout of rotor 13 deviates from the standard value,
18 repeat the disassembly and reassembly procedures. If the amount of
runout still deviates from the standard value after the reassembly,
07697
replace faulty parts.
13 B : Platform
17
18
B 07698
35A-33
[Removal]
13
Install bolts (M6 1.0) in threaded holes B (holes for rotor removal) on
rotor 13, and tighten them evenly to remove the rotor.
B
06668
C [Installation]
Before installing rotor 13 to rotor flange 14, heat the rotor to approxi-
mately 150C {302F}. Using iron plate C, press-fit the rotor into the rotor
flange by applying uniform pressure, making sure that there is no gap
between the rotor and the rotor flange.
06669
35A-34
35A
MEMO
35A-35
WHEEL SPEED SENSOR AND ROTOR < REAR AXLE : DRUM BRAKE >
of related parts, refer to ^ Gr 27. The illustration below shows the rear-axle left wheel.
2 2
2
2
*
8
10 7
11 6
12
5
36119
Removal sequence
1 Wheel speed sensor 8 Outer bearing & race
2 Bolt 9 Rotor (ABS)
3 Clips 10 Inner oil seal
4 Rear axle shaft 11 Inner bearing & race
5 Outer oil seal 12 Wheel hub & drum assembly
6 Lock washer
7 Lock nut * : Rear brake assembly
WARNING
Do not allow oil or grease to adhere on the lining surface of rear brake assembly * or the lining surface of
wheel hub & drum assembly 12.
CAUTION
When installing wheel hub & drum assembly 12, be careful not to damage rotor 9 or inner oil seal 10.
35A-36
35A
Service standards

2 Bolt (clip mounting) 12 to 15 {87 to 108, 1.2 to 1.5}

[Removal]
1 To prevent damaging pole piece A of wheel speed sensor 1, remove the
wheel speed sensor before removing wheel hub & drum assembly 12.
[Installation]
A The connector of wheel speed sensor 1 is color-coded. Install the wheel
07687 Right/left
Installation location Connector color Connector shape
identification tape
Left wheel Gray Female Yellow
Right wheel Black Male None
[Inspection]
1
Pole piece A in wheel speed sensor 1 is magnetized by a built-in magnet
piece.
07666

wheel speed sensor.
07667
35A-37
WHEEL SPEED SENSOR AND ROTOR < REAR AXLE : DRUM BRAKE >
A Measurement of insulation resistance
Measure resistance between pole piece A, bracket B and each termi-
nal of wheel speed sensor 1.
B
wheel speed sensor.
37124

09939
3
1 3 3 A 3 3 1 sensor 1 in place at tape sections A using clips 3, while making sure that
A A there is no interference, twisting or excessive sagging of the harness.
A A
A
A A A A
3 3 3 3
06611
As shown in the diagram, position the harness of speed sensor 2,

C
starting from rear axle housing section A and moving toward the
4 frame, making sure that there is no twisting or unnecessary slack in
the harness. Use clips 4 and cable ties B to secure the harness in
place, then connect connectors C.
A B 07389
35A-38
35A
A
9 Rotor
[Inspection]
Check rotor 9 for chipped or crushed teeth (see section A in the dia-
9 gram).
12
07688
[Installation]
B
Before installing rotor 9 to wheel hub & drum assembly 12, heat the rotor
to approximately 150C {302F}. Using iron plate B, install the rotor to
9 the wheel hub & drum assembly by applying uniform pressure, making
sure that there is no gap between the rotor and the wheel hub & drum
assembly.
12
06619
35A-39
35A-40
35A
35A-41
ELECTRIC CIRCUIT AND PART INSTALLATION LOCATIONS
3
1
9 7
16
6
2
a 17
13 10 12 11
8 14
14
15 35924
35A-42
35A
k
2
3
9 a
6
8 7 4
b 10 11
15
13 17 16 c 14 12
35950
1 Starter switch 9 Meter cluster 13 Wheel speed sensor

2 Exhaust brake cut-off relay 10 Wheel speed sensor (front-axle left wheel)
3 Relay box (front-axle right wheel) 14 Hydraulic unit
4 Electric control unit 11 Wheel speed sensor 15 Relay box
5 Diode unit (rear-axle right wheel) 16 High-current fuse box
6 MUT-II connector 12 Wheel speed sensor 17 Battery
7 Fuse box (rear-axle left wheel) 18 G sensor <FG>
8 Stop lamp switch
35A-43
Group 35
Brake
' 98 Minor Change

Table of Contents
BACK HOME

35
GROUP 35 BRAKE
SPECIFICATIONS ........................................................................... 35- 2

Replacement of Brake Fluid ...................................................................... 35- 38
Air Bleeding of Brake System ................................................................... 35- 40
Inspection and Adjustment of Brake Pedal Free Play............................. 35- 42
Inspection and Adjustment of Clearance between
Brake Pedal and Floor Panel ..................................................................... 35- 42
Inspection and Replacement of Disc Brake Pad ..................................... 35- 43
Drum Brake Lining Thickness Inspection and Replacement ................. 35- 46
Inspection of Brake Shoe Clearance ........................................................ 35- 46
Inspection of Brake Booster (Master Vac) ............................................... 35- 47
Inspection of Bypass Valve ....................................................................... 35- 52
BRAKE MASTER CYLINDER ......................................................... 35- 54
BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC) ........... 35- 56
FRONT WHEEL BRAKE

< FE639 : DISC BRAKE > .............................................................................. 35- 58
< FE649 : DISC BRAKE > .............................................................................. 35- 62
< FG639 : DRUM BRAKE > ............................................................................ 35- 66
REAR WHEEL BRAKE

< FE639, FG639 : DRUM BRAKE > ............................................................... 35- 72
< FE649 : DISC BRAKE > .............................................................................. 35- 80
VACUUM PUMP .............................................................................. 35- 84
LOAD SENSING VALVE ................................................................. 35- 85
EXHAUST BRAKE SYSTEM .......................................................... 35- 86
35-1
SPECIFICATIONS
< Service Brake Equipment >
Vehicle model FE639, FG639 FE649
Item
Brake booster Type Tandem type
(Master vac) Diaphragm diameter in. 8+9 9+10
Manufacturer JIDOSHA KIKI
Brake master Inner diameter mm {in.} 30.16 {1.19} 31.75 {1.25}
cylinder Stroke Front mm {in.} 17.4 {0.69} 16.0 {0.63}
Rear mm {in.} 14.6 {0.57} 16.0 {0.63}
Vacuum pump Type Vane type
Delivery cm3 {cu. in.} 60 {3.66} 90 {5.49}
Manufacturer MITSUBISHI ELECTRIC
< Wheel Brake >

Vehicle model FE639
Item
Vehicle model FE649

Item
Vehicle model FG639

Item
Front Brake type Drum brake (2-leading type)
Brake lining width thickness mm {in.} 75 9.3 {2.95 0.37}
Brake lining width thickness mm {in.} 75 9.3 {2.95 0.37}
< Exhaust Brake System >

Item Specifications
Control system Combined electric and vacuum
Valve type Butterfly valve type
35-2
Brake System
2 4
1
3
5
8
9
A
B
C 10
11
12849
1 Brake booster (master vac) 9 Load sensing valve

2 Fluid tank 10 Rear wheel brake
3 Brake master cylinder 11 Front wheel brake
4 Vacuum tank
5 Vacuum switch A : Fluid line
6 Check valve B : Air line
7 Vacuum pump C : Hose
8 Bypass valve
The brake system is a vacuum servo all-wheel brake type, with brake booster (master vac) 1.
Load sensing valve 9 automatically changes the oil pressure of the rear wheel brakes according to the load changes,
preventing the rear wheels from locking too early.
Bypass valve 8 is fitted as a safety mechanism. It provides braking force if the front brake system is damaged and loses
hydraulic pressure. The bypass valve does this by making the hydraulic pressure of the rear brake system bypass load
sensing valve 9 and act directly on rear wheel brake 10.
35-3
Brake Booster (Master Vac) and Brake Master Cylinder
< Brake master cylinder > < Brake booster (master vac) >
1 2 3
15 5
6 7 8 9
21
20 22 19 18 17 16
10
11
14
13
12 05248
< Brake booster (master vac) > < Brake master cylinder >
1 Front diaphragm 16 Primary piston
2 Front diaphragm plate 17 Primary piston return spring
3 Rear diaphragm 18 Retainer
4 Rear diaphragm plate 19 Secondary piston
5 Rear shell 20 Secondary piston return spring
6 Valve plunger 21 Cylinder body
7 Poppet 22 Packing cup
8 Poppet spring
9 Valve return spring
10 Operating rod
11 Valve body
12 Center plate
13 Push rod
14 Front shell
15 Diaphragm plate spring
35-4
35
When depressing brake pedal
11 A 7
10
13 6 B
15
C D
12929
Action of brake booster (master vac)

When the brake pedal is released, chambers C and D are subjected to the vacuum created by the vacuum pump.
Depressing the brake pedal activates operating rod 10, placing poppet 7 in tight contact with the seat of valve body 11.
This action closes vacuum valve A, cutting off the vacuum to chamber D.
Depressing the brake pedal further separates valve plunger 6 from poppet 7, opening breather valve B permitting
atmospheric pressure to flow into chamber D, producing a pressure difference between chambers C and D.
This pressure difference between chambers C and D presses front diaphragm 1 and rear diaphragm 3, boosting the
depressing force.
This boosted pedal depression force overcomes the repercussive force of diaphragm plate spring 15, presses push rod
13, and actuates the brake master cylinder.
Action of brake master cylinder

Push rod 13 pushes in primary piston 16 and sec-
H ondary piston 19, and packing cup 22 passes return
H E E port E, generating hydraulic pressure in chamber H,
feeding the fluid to the respective brake systems.
K : To the front brake system

L : To the rear brake system
22 19 22 16 13
L K
12930
35-5
Fluid leakage in the front brake system
Depressing the brake pedal makes push rod 13
push in primary piston 16. However, if the brake fluid
in the front brake system leaks, hydraulic pressure is
18
not generated in the front brake system.
Depressing the brake pedal further makes primary
piston 16 compress primary piston return spring 17,
causing retainer 18 to push secondary piston 19,
thus generating hydraulic pressure only in the rear
brake system.
19 13 L : To the rear brake system

17 16
L
05243
Fluid leakage in the rear brake system

Depressing the brake pedal makes push rod 13
push in primary piston 16 and secondary piston 19.
However, if the brake fluid in the rear brake system
leaks, hydraulic pressure is not generated in the rear
brake system.
Depressing the brake pedal further makes the end of
secondary piston 19 contact cylinder body 21, push-
ing primary piston 16, thus generating hydraulic pres-
sure only in the front brake system.
21 K : To the front wheel brake system

19 16 13
K
05244
35-6
35
When releasing brake pedal
A 7
11
10
13 6 B
12
15
C D
12931
Action of brake booster (master vac)

When the brake pedal is depressed, atmospheric air flows into chamber D as chamber C is subjected to negative
pressure generated by the vacuum pump.
When the brake pedal is released, since the pressing force acting on the operating rod 10 also is released, valve
plunger 6 contacts poppet 7 tightly, closing breather valve B to cut off the flow of atmospheric air into chamber D. In
addition, valve plunger separates from valve body 11 to open vacuum valve A. Then, the negative pressure generated
by the vacuum pump creates a vacuum in chamber D, and the pressure difference between chambers C and D
diminishes.
This absence of a pressure difference between chambers C and D, allows rear diaphragm 3 to be pushed against the
rear shell 5 by the repercussive force of diaphragm plate return spring 15, and push rod 13 returns to its original
position.
F When push rod 13 returns to its original position, the
E
repercussive force of the secondary piston return
spring 20 immediately begins to return secondary
piston 19. However, the brake fluid delivered from
the brake master cylinder cannot return quickly due
to the absence of a pressure difference between
chambers H and G.
As secondary piston 19 begins to return, the pres-
sure in chamber H becomes lower than that in cham-
ber G, and this pressure difference deforms packing
cup 22 to open a small passage J. Then, the brake
H 20 22 J G 19 05246 fluid in chamber G is drawn into chamber H.
35-7
When secondary piston 19 returns to its original
position, the pressure difference between chambers
E G and H is diminished, and packing cup 22 closes
the small passage J. The hydraulic oil in the brake
pipe flows from chamber H to the fluid tank via
return port E.
The same operation takes place also on the primary
side.
H 22 J G 19
05247
35-8
35
Front Drum Brake Assembly
1 Back plate
1 2 2 Brake shoe assembly
3 Return spring
4 Wheel cylinder assembly
The front drum brake assembly has two-leading brakes

installed, and with single action wheel cylinder assembly 4,
the action coming from leading shoes when brake shoe
3 assembly 2 is forward provides increased braking force
through its independent double action.
4 27679
Wheel cylinder assembly

1 Spring and fitting
1 2 3 2 Pin
A
3 Lever
4 Piston assembly
5 Set spring
6 Adjuster assembly
7 Adjusting screw
A : Brake shoe assembly
The wheel cylinder assembly is equipped with an

auto adjusting mechanism to adjust the gap result-
ing from wear between the break lining and brake
4
drum, each time the brakes are applied.
5
6
7
05389
35-9
4 Automatic adjustment mechanism
Operation
B
When the brake pedal is pushed, hydraulic pressure
from the brake master cylinder enters chamber B,
driving out piston assembly 4 and pulling spring and
fitting 1. Lever 3 interlocks with spring and fitting 1,
rotating on pin 2.
C : Level travel
D : Protrusion of piston assembly
6
7
D
1 2 3 A
6
D 05401
When the clearance between the brake drum and

6 brake lining is correct, adjuster assembly 6 does not
C 3 rotate even when brakes are applied, as there is no
action from lever 3.
C : Lever travel
05391
35-10
35
When the clearance between the brake drum and
3 brake lining increases, movement of piston assem-
6 C 7 6 bly 4 and lever 3 increase.
C : Lever travel
E : portrusion of adjustor screw
The force of lever 3 increases the rotation of ad-

juster assembly 6 and the force of screw of adjuster
assembly ejects adjusting screw 7, and brake shoe
assembly A expands.
E
A
05390
< Before depressing
pedal >
6
C
3
< When depressing

pedal >
05402
By depressing break pedal adjuster assembly 6 keep

< When releasing pedal >
its rotated position while lever 3 goes back to the
position deviated one step, and adjust the gap be-
C
6 tween the brake drum and brake lining correctly.
C : Lever travel
3
05392
35-11
Front Disc Brake
1 Brake pad wear indicator
4 5 7 1
2 Disc rotor
3 Torque member
4 Outer pad
5 Inner pad
6 Caliper
7 Piston
Inner pad 5 is fitted with brake pad wear indicator 1 that

gives warning when it is time to replace outer pad 4 and the
inner pad.
6 3 2 05404
Rear Drum Brake Assembly

1 Backing plate
4 Return spring
The rear drum brake assembly is a dual 2-leading type

brake and is fitted with wheel cylinder assembly 3, the self-
servo action of which produces a great braking force by
4
using brake shoe assembly 2 as the leading shoe when the
vehicle is travelling forwards.
3
05476

1 2 3 A
2 Pin
3 Lever
4 Piston assembly
5 Set spring
6 Adjuster assembly
7 Adjusting screw
A: Brake shoe assembly
6 5
The wheel cylinder assembly has an automatic ad-
juster that corrects the increase in clearance that
occurs between the brake lining and the brake drum,
4 4 an increase caused by the wear of the brake lining.
This increase occurs whenever the brake pedal is
depressed.
7 6
05477
35-12
35
Automatic adjustment mechanism
4 B
4 Operation
When the brake pedal is pushed, hydraulic pressure from
the brake master cylinder enters chamber B, driving out
piston assembly 4 and pulling spring and fitting 1. Lever 3
interlocks with spring and fitting 1, rotating on pin 2.
C : Level travel
D : Protrusion of piston assembly
7 6
D
6 1 2 3 A
5
D
12836
When the clearance between the brake drum and brake

6 lining is correct, adjuster assembly 6 does not rotate even
C 3 when brakes are applied, as there is no action from lever 3.
C : Lever travel
05391
35-13
As the clearance between the brake drum and the brake
lining increases, the amount of protrusion of piston assem-
4 3
bly 4 also increases, as does the amount of travel of lever 3.
C
6 C : Lever travel
E : Protrusion of adjuster screw
The action of lever 3 increases the rotation of adjuster

assembly 6, the screw action pushes out adjuster screw 7,
expanding brake shoe assembly A.
A 7 6
E
12837
< Before depressing pedal >
6
C
3
< When depressing

pedal >
05402
When the brake pedal is released, since adjuster assembly

< When releasing pedal > 6 remains in its new position after turning, returned lever 3
enters the next position, moved by one notch. This assures
C
6 correct clearance between the brake drum and the brake
3 lining.
C : Lever travel
05392
35-14
35
Rear Disc Brake
6 2 Disc rotor
1 3 Torque member
4 Outer pad
5 Inner pad
6 Caliper
7 Piston
7 Inner pad 5 is fitted with brake pad wear indicator 1 that

5 inner pad.
2
3 4 05479
35-15
Vacuum Pump
1 Check valve assembly
A 2 Vane
1 3 Rotor
4 Housing
A : Inlet
B : Outlet
4
2
B 3 05224
The vacuum pump is installed on the timing gear case and is rotated by the injection pump gear or camshaft gear.
Check valve assembly 1 is fitted to prevent the atmospheric pressure and the lubricating oil from flowing in reverse from
the vacuum pump to the vacuum tank when the engine is stopped.
< Suction stroke > A Operation

Inside cylindrical housing 4, rotor 3 equipped with three vanes
4 (movable blades) 2 rotates, pressing the vanes against the inside
surface of the housing by centrifugal force.
Since rotor 3 is eccentric with respect to housing 4, as the rotor
2
rotates, the atmospheric pressure of the vacuum tank is drawn in
3 from inlet A and discharges from outlet B by the gradual compres-
sion of the air. This repetition of the suction, compression and
< Compression stroke > exhaust strokes generates a vacuum, realizing a near-vacuum in
the vacuum tank.
The engine oil that lubricates and cools the inside of housing 4 is
returned, along with air pressure, through outlet B to the oil pan.
< Exhaust stroke >
B 04213
35-16
35
Load Sensing Valve
A 1
2
3
4
7
5
6
12932 05589
1 Load sensing valve 6 Leaf spring

2 Packing cup 7 Valve body
3 Spring
4 Plunger A : Frame
5 Retainer B : Rear axle
The deflection of leaf spring 6, fixed on rear axle B, notifies load sensing valve 1 of any shifts in the load. This decreases
hydraulic pressure to the rear wheel brakes compared to the front wheel brakes. This maintains adequate braking
performance that corresponds to any shift in the load, preventing premature rear wheel lock.
35-17
Valve unit
Brake fluid is supplied from the brake master cylinder to
B the rear wheel brakes via chamber A, the clearance
2
4 between packing cup 2 and plunger 4, and chamber B.
05590
Hydraulic pressure A, supplied by the brake master cylin-

der, gradually increases on seal cross-section E of
plunger 4. This increase depresses spring 3 pushing the
plunger down onto packing cup 2 and cuts off the pas-
sage between chambers A and B. This is called the
B decompression point.
2 P35-19 (Performance characteristics chart)
Hydraulic pressure A at the brake master cylinder push-
4 3 ing plunger 4 up when the decompression point is
passed. On the other hand, hydraulic pressure B at the
rear wheel brakes works as a depressing force, so hy-
A draulic pressure A and B balance, cutting off the pas-
sage between chambers A and B.
At this time, hydraulic pressure at the brake master cylin-
der works at the donut-shaped cross-section (formed by
E the removal of cross-section D from cross-section C of
plunger 4). However, because hydraulic pressure B at
2 the rear wheels works on the whole cross-section E of
C the plunger seal, and the rear wheel brake side remains
at low hydraulic, balance is maintained.
Therefore, hydraulic pressure B at the rear wheel brakes
D
is lower than hydraulic pressure A at the brake master
cylinder.
4 The gradient of the performance characteristics of hy-
draulic pressure B is lower than that of hydraulic pres-
sure A.
P35-19 (Performance characteristics chart)
05591
35-18
35
Sensor unit
When the vehicle is loaded

When the vehicle is loaded, since the deflection of leaf
spring 6 is large and the amount of upward travel of
plunger 4 is also large, the amount of plunger downward
travel is small. Therefore, the decompression point rises
to supply higher brake pressure to the rear wheels, com-
pared to the unloaded state.
4
05593
When the vehicle is unloaded

When the vehicle is unloaded, since the deflection of leaf
spring 6 is small and the amount of upward travel of
plunger 4 is also small, the amount of plunger downward
travel is large. Therefore, the decompression point drops
to supply lower brake pressure to the rear wheels, com-
pared to the loaded state.
4
05595
Performance characteristics
The figure on the left shows the changes in braking per-
formance characteristics of the rear wheels. These changes
depend on the vehicle load and any shifts in the load
caused by sudden deceleration while cruising.
Hydraulic pressure at rear
Hydraulic pressure
characteristics
Decompression when loaded
point
wheel cylinder
Hydraulic pressure
characteristics
when unloaded
0
Hydraulic pressure at brake master cylinder
05594
35-19
Bypass Valve
1 Bleeder screw
1 2 Spring
3 Piston
4 Seal
2 3
If any failure occurred in the front brake system that de-
creased the hydraulic pressure, the decompression effect
of the load sensing valve would affect the hydraulic pres-
sure in the rear brake system. This would reduce the brak-
ing force of the rear brake system. The bypass valve is fitted
to prevent this from happening.
1 If the hydraulic pressure in the front brake system de-
creases, the hydraulic pressure in the rear brake system
4 12838 bypasses the load sensing valve and is fed directly to the
rear wheel brake.
When the hydraulic pressure in the front brake system

A C is normal
J
The hydraulic pressure flows through chamber G, pushes
E 3 piston 3, and cuts off bypass J with seal 4.
C : From front brake system
The hydraulic pressure in the rear brake system flows from
chamber E into chamber F.
A : From the rear brake system of the brake master cylin-
der
F B : To the load sensing valve
4 G
B 12839

A 1 decreases abnormally.
J The hydraulic pressure in chamber G decreases, reducing
C 2 the force pushing piston 3.
E 3 C : From the front brake system
The hydraulic pressure of the rear brake system pushes
seal 4, and overcomes the repercussive force of spring 2 to
push piston 3, opening bypass pass J.
The hydraulic pressure of the rear brake system flows from
chamber E into chamber H.
B 1 A : From the rear brake system of the brake master cylin-
G der
4 D : To the rear wheel brake
H
D 12840
35-20
35
MEMO
35-21
Exhaust Brake System
1 2 3 4
5
7 6
17
16
9 8
15
12
10 10
11
12841
2 3 4
5
1
7 6
17
9 8
15
A
13
10 10
14
12842
35-22
35
1 Fuse box 12 Clutch switch < Manual transmission >
2 Meter cluster 13 Inhibiter switch < Automatic transmission >
3 Exhaust brake indicator lamp 14 Automatic transmission electric control unit
4 Air cleaner < Automatic transmission >
5 Vacuum tank 15 Exhaust brake cut relay
6 Exhaust brake 3-way magnetic valve 16 Exhaust brake switch < Manual transmission >
7 Intake shutter 3-way magnetic valve 17 Accelerator switch
8 Exhaust brake unit 18 Clutch switch < Manual transmission >
9 Intake shutter
10 Butterfly valve A : From starter switch
11 Neutral switch < Manual transmission >
The exhaust brake uses pressure to push and return the piston in the exhaust stroke. This pressure is generated when
the exhaust pipe is shut and the pressure in the exhaust pipe increases.
A butterfly valve type exhaust brake unit 8 is fitted as an auxiliary brake to assist the foot brake. Intake shutter 9 is fitted
to reduce the suction noise generated when the exhaust brake is operated.
When the exhaust brake switch 16 is turned ON, excitation of the coil of exhaust brake 3-way magnetic valve 6 closes
the atmospheric valve and opens the vacuum valve. This makes the vacuum in the vacuum tank act on exhaust brake
unit 8 which closes butterfly valve 10, activating the exhaust brake.
35-23
Operation
Electrical System
2 3
1
7 6
17 A
16
15
12
11
12843
1 2 3
7 6
17
15
A
13
14
12844
When exhaust brake switch 16 is turned ON, exhaust brake indicator lamp 3 within meter cluster 2 lights up and the
exhaust brake 3-way magnetic valve 6 operates.
At this time, depressing the clutch pedal (clutch switch 12 OFF) or the accelerator pedal (accelerator switch 17 OFF)
temporarily releases the exhaust brake. When the transmission is in neutral (neutral switch 11 or inhibiter switch 13 ON)
because the vehicle is stopped or for some other reason, exhaust brake cut relay 15 operates, releasing the exhaust
brake after approximately 10 seconds.
If the accelerator pedal is depressed and released after the exhaust brake is released by the exhaust brake cut relay, the
exhaust brake operates again, and after approximately 10 seconds is released.
35-24
35
Exhaust Brake Unit
1 Spring
2 Diaphragm
3 Push rod
4 Butterfly valve
1
12835
Intake Silencer
1 Push rod
2 2 Actuator assembly
3 Butterfly valve
4 Intake pipe
4
13569
35-25
Brake Warning System
Vacuum system electric circuit, brake fluid level system electric circuit
1
6
5
3
12845
1 Fuse box 4 Brake warning lamp

2 Meter cluster 5 Brake fluid level switch
3 Vacuum warning lamp 6 Vacuum switch
The brake warning system consists of a vacuum system electric circuit which detects the drop in negative pressure inside
the vacuum tank, and a brake fluid level system electric circuit which detects the drop in the level of brake fluid inside the
fluid tank. In both cases a warning lamp lights up to give warning.
35-26
35
Vacuum system electric circuit
If the negative pressure in the vacuum tank drops

below the specified pressure, vacuum switch 6 turns
ON lighting vacuum warning lamp 3. The flow of cur-
1 rent at such time is as follows.
6
Fuse 1Vacuum warning lamp 3Vacuum switch

6Ground
12933
Brake fluid level system electric circuit
If the amount of brake fluid in the fluid tank drops below

the specified amount, brake fluid level switch 5 turns
ON lighting brake warning lamp 4. The flow of current
1
at such time is as follows.
Fuse 1Brake warning lamp 4Brake fluid level

switch 5Ground
5
4
2
13680
35-27
Brake fluid level switch
< FE639, FG639 > 1 Fluid tank

2 Float
3 Brake fluid level switch
1 *a : For brakes
*b : For clutch
2 Brake fluid level switch 3, installed on fluid tank 1, monitors

3 the brake fluid level in the fluid tank. If the brake fluid level
drops below the specified level, float 2 moves and lights up
the warning lamp within the meter cluster to alert the driver.
*a *b 27437
< FE649 >
2
3
*b *a
27484
A If the brake fluid level in fluid tank 1 drops and float 2 drops lower than
level L, magnetic force B that passes through the contact point
C (ferromagnetic body A), increases generating north and south poles
at the ends of the contact points. Therefore, the contact points pull
each other and overcome the repercussive force of the springs of the
contact points, forming an electric circuit.
C : Magnet
D : Glass
2
D 01668
35-28
35
Wear Indicator System Electric Circuit
3 2
4
5
*1 9
*2
*2
*2
*2
7 6
23301
1 Fuse box 8 Front brake pad wear indicator, LH

2 Meter cluster 9 Front brake pad wear indicator, RH
3 Disc brake warning lamp
4 Relay box *1 : < FE639 >
5 Lighting and alarm control unit *2 : < FE649 >
6 Rear brake pad wear indicator, LH < FE649 > : Warning signal
7 Rear brake pad wear indicator, RH < FE649 > : Wear indicator signal
The brake pad wear indicator system electrical circuit is provided for warning. When the brake pad is worn out, the disc
rotor disconnects wear indicators 6 to 9. Lighting and alarm control unit 5 detects this and gives a warning.
If one of pad wear indicators 6 to 9 is disconnected, lighting and alarm control unit 5 operates, lighting disc brake
warning lamp 3.
35-29
When normal operating
While lighting alarm control unit 5 is sending out wear

indicator signal , warning signal is not input.
Since warning signal is not being input, disc brake
warning lamp 3 will not light up.
The flow of current at such time is as follows.
Fuse 1Lighting alarm control unit 5Ground
Wear indicator signal Brake pad wear indica-

tor 6 to 9Ground
12847
When brake pad wear indicator cut off
When lighting alarm control unit 5 stops sending out

wear indicator signal , warning signal is input.
When warning signal is input, disc brake warning
lamp 3 lights up.
Lighting alarm control unit 5Ground

Fuse 1
Disc brake warning lamp 3
Warning signal
14763
35-30
35
MEMO
35-31
TROUBLESHOOTING
Wheel Brake
One-sided braking Noise and shock

Symptoms
when brakes are
applied
Noise generated when wheels are rotating, with

Braking force difference between left and right
Braking shoe return slow after releasing brake
Continuous noise generated while braking

Noise and shock when brakes are applied
Brake pedal stroke reduced
Braking force insufficient
Braking force unstable
Lock points difference

One-sided braking
vehicle jacked up
(at low speed)

pedal
Possible causes
Tires Air pressures uneven, etc. ^ Gr 31
Left and right tire sizes different ^ Gr 31
Axle Wheel hub bearing adjusted incorrectly

^ Gr 26, 26B, 27
Left and right wheelbase difference excessive

^ Gr 26, 26B, 27
Wheel alignment incorrect ^ Gr 26, 26B
Kingpin bushing worn ^ Gr 26, 26B
Trunnion bearings worn ^ Gr 26B
Wheel Backing plate ledge surface rough
brakes Backing plate ledge surface not smooth
Backing plate deformed, mounted incorrectly
Oil or water on brake lining or brake pad surfaces
Brake lining or brake pad changed in quality or wrong

material used
Brake lining or brake pad unevenly worn or surface

roughened
Brake lining or brake pad fading (surface change in

material)
Brake lining or brake pad worn out completely
Abrasive on brake lining or brake pad
Brake lining or brake pad worn
Brake lining or brake pad contact incorrect
Brake lining ground radius irregular
Wheel cylinder malfunctioning
Shoe return spring fatigued or broken
Brake drum or disc rotor worn unevenly
Brake drum or disc rotor warped
Brake drum or disc rotor worn
Brake drum or disc rotor surface roughened
Brake drum or disc rotor roughness excessive
35-32
35
Symptoms One-sided braking Noise and shock
when brakes are
applied


Noise and shock when brakes are applied

One-sided braking
vehicle jacked up
(at low speed)

pedal
Possible causes
Wheel Brake drum or disc rotor glazed
brakes Brake drum cracked
Brake drum clogged by foreign particles
Brake drum deformed or eccentric
Disc rotor thickness uneven
Brake shoe deformed or damaged
Brake shoe twisted or tilted
Shoe hold down cup broken
Moving parts greased insufficiently
Brake pedal Brake pedal stroke faulty (45 mm {1.77 in.} or more

at 490 N {110 lbf, 50 kgf} foot pressure)
Brake pedal adjusted incorrectly, looseness

excessive
Brake pedal return faulty
Brake pedal free play inadequate
Linkage rusted or deformed
Return spring fatigued or broken
Master vac operating rod pushing up
Brake fluid Brake fluid insufficient
system Brake fluid leaking
Air lock in system
Vapor lock
Brake fluid return insufficient because brake pipe
tightened excessively
Vacuum Degree of vacuum reduced

system
Master vac Master vac defective
Brake Piston cup faulty
master Return port clogged
cylinder
35-33
TROUBLESHOOTING
Symptoms Brake drums Brakes

overheating squeaking
Squeaking in new vehicle or after brake lining

Remarks
Brake pulsation/vibration

One wheel overheating
All wheels overheating
Brakes squeaking
Action too severe

replacement
Brake drags
Possible causes
Axle Wheel hub bearing adjusted incorrectly ^ Gr26,
26B, 27
Left and right wheelbase difference excessive ^ Gr26,
26B, 27
Wheel alignment incorrect ^ Gr26, 26B
Kingpin bushing worn ^ Gr26
Trunnion bearings worn ^ Gr26B
material used
roughened

material)
Brake drum or disk rotor worn unevenly
Brake drum or disk rotor warped
Brake drum or disk rotor worn
Brake drum or disk rotor surface roughened
Brake drum or disk rotor roughness excessive
Brake drum or disk rotor glazed
35-34
35

Remarks
Brake pulsation/vibration

Brakes squeaking
Action too severe

replacement
Brake drags
Possible causes
Wheel Brake drum cracked
brakes Brake drum clogged by foreign particle
Brake pedal adjusted, looseness excessive
Air lock in system
Vapor lock

system
cylinder
35-35
TROUBLESHOOTING
Exhaust Brake
Symptoms
Exhaust brake does not release

Exhaust brake does not work
Remarks
Possible causes
Vacuum Degree of vacuum insufficient
system Pipe crushed
3-way Does not work
magnetic ^ Gr 54
valve
Exhaust Valve assembly does not work
brake Valve assembly shaft stuck
unit
Vacuum chamber does not work
Electric Electric system faulty
^ Gr 54
system
35-36
35
MEMO
35-37
Replacement of Brake Fluid
Bypass valve 8.8 to 13.0 {6.5 to 9.4, 0.9 to 1.3}
- Fluid
WARNING
ging.
If you use a container for adding brake fluid, keep it solely for that
purpose.
CAUTION
paintwork.
NOTE
Supply and maintain the brake fluid level to the MAX level of
the fluid tank.
35-38
35
< FE : Front disc < FG : Front drum Start the engine and let it idle until you complete brake fluid replace-
brake > brake > ment.
Connect vinyl pipes A : one to the front disc brake < FE >, the front
drum brake < FG > one to the rear drum brake < FE639, FG639 > or
the rear disc brake < FE649 >, and two to the bypass valve.
Put the free ends of vinyl pipes A into containers B.
1
1 A
A
B B
12934 27427
< Rear drum brake >
< Rear disc brake >
A 1
B
B
06534
< Bypass valve >

1 A
1 B
12935
of the brake system is replaced with new fluid, and after you complete
the work, tighten each air bleeder 1 at specified torque.
12936
Bleed air from the brake system.
P35-40
07623
35-39
Air Bleeding of Brake System

Bypass valve 8.8 to 13.0 {6.5 to 9.4, 0.9 to 1.3}
- Fluid
WARNING
ging.
If you use a container for adding brake fluid, keep it solely for
that purpose.
CAUTION
paintwork.
NOTE
the fluid tank.
Make sure you maintain brake fluid at the MAX level of the fluid
tank since the brake fluid level drops during air bleeding.
35-40
35
< FE : Front disc < FG : Front drum Start the engine and let it idle until you complete air bleeding of the
brake > brake > brake system.
Connect vinyl pipes A : one to the front disc brake < FE >, the front
drum brake < FG >, one to the rear drum brake < FE639, FG639 > or
the rear disc brake < FE649 >, and two to the bypass valve.
Put the free ends of vinyl pipes A into containers B and bleed the
1 brake system as follows:
1 A
B B FG639 FE639, FE649
12937 27427
< Rear drum brake > Drum brake, RH Disc brake, RH
< Rear disc brake >

1 Drum brake, LH Disc brake, LH

A 1 FE639, FG639 FE649
A

B Drum brake, LH Disc brake, LH
B
08834
< Bypass valve > < Bypass valve system >

1 Bypass valve
A
1
B
12938
1 at specified torque.
12936 Make sure that the brake fluid level is at the MAX level of the fluid
tank, and depress the brake pedal several times to ensure that the
brake fluid does not leak from anywhere. Then, conduct a brake test.
35-41
Inspection and Adjustment of Brake Pedal Free Play

Free play of brake pedal 10 to 15 {0.39 to 0.59} Adjust
[Inspection]
Check if brake pedal free play A confirms to the standard valve with the
engine stopped. If the measured value deviates from the standard value,
adjust the position of the brake pedal.
[Adjustment]
P35-57
06539
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel

Clearance between brake pedal and floor panel 45 {1.77} or more Adjust
(with pedal depressed at 490 N {110 lbf, 50 kgf})
[Inspection]
Depress the brake pedal using 490 N {110 lbf, 50 kgf} when the engine is
idling to check if clearance A between the brake pedal and the floor
panel conforms to the standard value. If the measured value deviates
from the standard value, adjust the position of the brake pedal.
[Adjustment]
A P35-57
06540
35-42
35
Inspection and Replacement of Disc Brake Pad

5, 6 Thickness of FE639 Front disc brake 12 {0.47} 4 {0.16} Replace
outer and FE649 Front disc brake 14 {0.55} 4 {0.16} Replace
inner pads
Rear disc brake 14 {0.55} 4 {0.16} Replace

3 Slide pin bolt tightening 83.3 to 93.1 {61 to 69, 8.5 to 9.5} Wet
- Fluid
3 Thread area of slide pin bolt Brake fluid As required

Piston expander MB990520 Pushing back of piston when replacing

brake pad
5 {0.20}
50 {1.97}
06815
2 [Inspection]
B
1 When brake pad thickness A decreases to approximately 4 mm
{0.16 in.}, brake pad wear indicator 1 makes contact with disc rotor 2
and is disconnected. This lights up brake warning lamp B within the
meter cluster, indicating that the brake pad should be replaced.
A
14352
35-43
Remove lower slide pin bolt 3.
Turn caliper 4 upward and secure it using wire.
3 4
CAUTION
Make sure that you do not smear, or get dust on, the grease
applied to slide pin bolt 3.
Be careful when you secure caliper 4 that you do not use exces-
8 sive force on the brake hose or brake pad wear indicator 1.
7 Make sure that you secure caliper 4 securely.
5, 6
Check thickness A of outer pad 5 and inner pad 6 and if the thickness
is lower than the limit, replace the pads on the same axle as a unit.
A 12939 Check if any fluid is leaking from piston 7, and check if piston boot 8 is
damaged. If any fault is found, replace the faulty parts.
[Replacement]
Remove the following parts:
13 9 Outer shim
1 5 Outer pad
12
14 10 Inner shim A
11 Inner shim B
14 13 12 Clip
10 6 Inner pad
11
6 13 Pad liner A
5 9
16558 14 Pad liner B
Install brake pad wear indicator 1 on inner pad 6 in the pad kit using
clip 12.
12
6
1
16559
Clean torque member 15.

13 Install the kit parts onto torque member 15 in the following order:
15 Install pad liner A 13 and pad liner B 14 on torque member 15.
4 14 Install outer shim 9 on outer pad 5.
Install inner shims 10, 11 on inner pad 6.
Install outer pad 5 on torque member 15.
14 13
Install inner pad 6 on torque member 15.
10 Install inner pad 6 so that brake pad wear indicator 1 faces the
11 2
entrance side (when the vehicle is moving forwards) of disc rotor 2
6
5 9 12830 of caliper 4.
35-44
35
Push piston 7 until it makes contact with the bottom of caliper 4.
0 : Piston expander
4
06824
Slacken off caliper 4, taking care not to damage piston boot 8.

3 Bleed the bushing.
4 Apply rubber grease thinly to the outer periphery of slide pin 3. Apply
brake fluid thinly to the thread area of slide pin bolt.
Tighten slide pin bolt 3 at specified torque.
Wire up the harness of brake pad wear indicator 1. ^ Gr 26, 27
Inspect drag torque. P35-60, 64, 82
8 Depress the brake pedal several times.
Make sure that brake fluid is maintained at the MAX level of the fluid
12831 tank. If the level drops, add brake fluid. P35-38
35-45
Drum Brake Lining Thickness Inspection and Replacement

Thickness of brake lining 4 {0.16} Replace
(Side shoulder
means wear
limit)
[Inspection]
NOTE
A
2
Remove cover 1 from the backing plate.
Inspect through check hole A whether brake lining 2 is worn to the
2 point of side shoulder B of the brake lining (the limit).
1
B the same axle as a unit.
14361 After inspection, be sure to reinstall cover 1.
[Replacement]
P35-69, 75
Inspection of Brake Shoe Clearance
A Insert 0.2 mm {0.0079 in.} feeler gauge A into inspection hole B of the
backing plate, and make sure that you can move the gauge in and out
feeling some resistance. After this inspection, adjust the clearance if any
B
abnormality is found.
P35-67, 73
08177
35-46
35
Inspection of Brake Booster (Master Vac)
Service standards
Air tightness with no load (with vacuum meter at Vacuum drop after 15 seconds
67 kPa {19.7 in. Hg, 500 mmHg} and engine stopped) should be 3.3 kPa
{0.98 in. Hg, 25 mmHg} or less
Airtightness with load (with brake pedal slightly Replace
depressed, vacuum meter at 67 kPa {19.7 in. Hg,
500 mmHg} and engine stopped)
Boosting action (Fluid 8 in.+9 in. 4410 kPa {640 lbf/in2, 45 kgf/cm2} Replace
pressure with vacuum meter at (98 N {22 lbf, 10 kgf})
67 kPa {19.7 in. Hg, 8340 kPa {1210 lbf/in2, 85 kgf/cm2}
500 mmHg} and brake pedal (295 N {66 lbf, 30 kgf})
depressed at specified foot
9 in.+10 in. 3920 kPa {570 lbf/in2, 40 kgf/cm2}
pressure) (98 N {22 lbf, 10 kgf})
8830 kPa {1280 lbf/in2, 90 kgf/cm2}
(295 N {66 lbf, 30 kgf})
No boosting action (Fluid 8 in.+9 in. 295 kPa {43 lbf/in2, 3 kgf/cm2} Replace
pressure after vacuum meter (98 N {22 lbf, 10 kgf})
falls to 0 kPa {0 in. Hg, 1670 kPa {240 lbf/in2, 17 kgf/cm2}
depressed at specified foot 9 in.+10 in. 195 kPa {28 lbf/in2, 2 kgf/cm2}
1470 kPa {215 lbf/in2, 15 kgf/cm2}
(295 N {66 lbf, 30 kgf})
[Inspection]
Two types of inspection are used to inspect the brake booster (master
vac) operation, inspection without a tester and inspection with a simple
tester. Make sure that there is no fluid leak or damage at the joints of the
brake pipes and hoses before inspection.
(1) Inspection of check valve operation
Be sure to inspect the check valve both when opened and when
closed.
CAUTION
Make sure that your saliva does not enter the check valve
when blowing air through the vacuum hose as this would
cause the check valve to malfunction.
NOTE
06542
The check valve fitted to the vacuum hose cannot be removed.
Start the engine

Stop the engine

Immediately after the engine has stopped, remove the clamps on the vacuum
pipe and the vacuum hose, and hold the vacuum hose in your mouth

No passage of air by your blowing in There is passage of air only at the
(The valve is closed) moment you inhale and depress the
brake pedal (The valve is open)
YES YES NO

Good Faulty Good Faulty
35-47
(2) Inspection of brake booster (master vac) operation
NOTE
If the brake booster (master vac) is faulty, determine the qual-
ity of the brake booster (master vac) as an independent device
by means of a bench test specified by the makers service
station. This is because the above inspection of the brake
booster (master vac) operation is merely a simplified inspec-
tion. If any fault is found, hand the device over to the service
station without disassembling it, and replace the whole as-
sembly. P35-56
Inspection method without a tester
If the brake booster (master vac) is determined to be good by inspec-
tions 1 to 3 below, its operation is normal. If any fault is detected in any
of the three inspections, the following parts are likely to be faulty.
Check valve
Vacuum hose
Brake booster (master vac)
Vacuum pump
[Inspection 1]
After one to two minutes operation, stop the engine

Depress the brake pedal using normal foot pressure

The brake stroke is longest in the first brake application, but becomes
3 shorter gradually in the second and the third application
2
YES
NO
1 06543
Good Faulty
[Inspection 2]
Depress the brake pedal several times while the engine is stopped

With the brake pedal depressed, start the engine

The brake pedal goes down a little
YES NO

06544 Good Faulty
[Inspection 3]
With the brake pedal depressed while the engine is
running, stop the engine

The height of the brake pedal remains unchanged
for approximately 30 seconds
YES
NO
Good Faulty
06545
35-48
35
B Inspection with a simplified tester
Airtightness inspection
3
Before inspection, observe the operation of check valve 2 fitted to
vacuum hose 1. P35-47
Remove vacuum hose 1 from brake booster (master vac) 3, place
A the end without the white mark on the brake booster (master vac)
and connect it to vacuum meter A. Connect another vacuum hose
C
(without a built-in check valve) between the vacuum meter and the
brake booster (master vac).
Connect pressure gauges B and foot pressure meter C as illus-
21
06546 trated, and bleed the air from the pressure gauges.
If the results of the following two airtightness inspections are satis-
factory, the operation is normal. If any fault is found in any of the
two inspections, the following parts are likely to be faulty.
Vacuum hose
[No-load airtightness inspection]

Start the engine and stop it when the vacuum meter
indicates 67 kPa {19.7 in. Hg, 500 mmHg}

After the engine has stopped, the drop of the degree of vacuum for
approximately 15 seconds is standard value or less
YES NO

Good Faulty
[At load airtightness inspection]

Start the engine, and when the vacuum meter indicates 67 kPa
{19.7 in. Hg, 500 mmHg}

YES NO

Good Faulty
Be sure when you attach vacuum hose 1 to brake booster (master

vac) 3 after the inspection, that the end without the white mark
faces brake booster (master vac) 3.
35-49
Inspection of characteristics
Inspect characteristics after the airtightness inspection is finished.
If the results of the following two inspections are good, the opera-
tion is normal. If any fault is found in any of the two inspections, the
following parts are likely to be faulty.
Vacuum hose
[Boosting action inspection]

{19.7 in. Hg, 500 mmHg} and the brake pedal is depressed using
specified foot pressure, measure the fluid pressure

The measured value conforms to the standard value
YES NO

Good Faulty
[No boosting action inspection]

Stop the engine, and when vacuum meter indicates 0 kPa {0 in. Hg,
0 mmHg} and the brake pedal is depressed using specified foot
pressure, measure the fluid pressure

YES NO

Good Faulty
Be sure when you attach vacuum hose 1 to brake booster (master

vac) 3 after the inspection, that the end without the white mark
faces brake booster (master vac) 3.
35-50
35
< 8 inch+9 inch > Brake booster (master vac) performance diagram
93 {27.6, 700}
Vacuum pressure (kPa {in. Hg, mmHg})

7850 {1760, 800} 80 {23.6, 600}
Brake master cylinder force pushing
67 {19.7, 500}
5880 {1320, 600}

the push rod (N {lbf, kgf})
3920 {880, 400}
0 {0, 0}
1960 {440, 200}
0 {0, 0} 1960
980
{220, 100} {440, 200}
Force pushing the operating rod (N {lbf, kgf}) 06548
< 9 inch+10 inch >

93 {27.6, 700}
9810 {2200, 1000}

80 {23.6, 600}
67 {19.7, 500}
7850 {1760, 800}
5880 {1320, 600}
3920 {880, 400}
0 {0, 0}
1960 {440, 200}
0 {0, 0} 980 1960

{220, 100} {440, 200}
35-51
Inspection of Bypass Valve
Service standards
Fluid pressure (when master cylinder and bypass 3920 kPa Replace
outlet pressures balance) when the front brake {570 lbf/in2, 40 kgf/cm2} or less
system fails
- Fluid
WARNING
Before inspection do the following to prevent the vehicle from
moving accidently.
Carry out inspection on a level area.
Place chocks securely in place at the left and right front wheels.
Pull up the parking brake.
ging.
If you use a container for adding brake fluid, keep it solely for that
purpose.
CAUTION
paintwork.
NOTE
the fluid tank.
tank since the brake fluid level drops during inspection.
Make sure you maintain brake fluid at the MAX level of the fluid tank
since the brake fluid level drops during replacement.
35-52
35
Install oil pressure gauges C, D on inlet A of the master cylinder of the
D bypass valve, and outlet B of the bypass respectively.
C
1
12940
Bleed the brake system. P35-40
Connect vinyl pipes E to air bleeders 2 on the left and right front disc
brakes.
Put the free ends of vinyl pipes E into containers F.
Loosen air bleeder 2 by 90 to open the front brake system.
2
E
F 12934
Start the engine and let it idle.

D Depress the brake pedal gradually and read the gauges when the fluid
C
pressure from the brake master cylinder equals that from the bypass
outlet.
bypass valve 1.
< Fluid pressure at < Fluid pressure

bypass outlet > from brake
master cylinder >
12941
35-53
BRAKE MASTER CYLINDER
6
-
1
2 5
7 A
11381
1 Retaining ring 5 Clamp A : Master vac support
2 Primary piston assembly 6 Connector * : Brake pedal and brake
3 Set bolt 7 Cylinder body booster assembly P35-56
4 Secondary piston assembly
WARNING
Be sure not to damage the inner surface of cylinder body 7, since it will cause air to get mixed in or will result
in brake fluid leakage during the removal and installation of primary piston assembly 2 and secondary piston
assembly 4.
Assembly sequence

2 Primary piston FE639, FG639 99 to 120 N 93 N Replace
assembly (Installed length 37.7 {1.48}) {22 to 27 lbf, 10.1 to 12.3 kgf} {21 lbf, 9.5 kgf}
spring load FE649 (Installed length 36.3 {1.43}) 100 to 125 N 97 N Replace
{23 to 28 lbf, 10.5 to 12.7 kgf} {22 lbf, 9.9 kgf}
2, 4, 7 Clearance between primary and FE639 [30.16] 0.02 to 0.10 0.2 {0.0079} Replace
secondary piston assemblies and FG639 {[1.19] 0.00079 to 0.0039}
cylinder body FE649 [31.75] 0.02 to 0.10 0.2 {0.0079} Replace
{[1.25] 0.00079 to 0.0039}
4 Secondary FE639, FG639 76 to 92 N 72 N Replace
piston (Installed length 30.7 {1.21}) {17 to 21 lbf, 7.8 to 9.4 kgf} {16 lbf, 7.3 kgf}
assembly FE649 (Installed length 31.0 {1.22}) 76 to 92 N 72 N Replace
spring load {17 to 21 lbf, 7.8 to 9.4 kgf} {16 lbf, 7.3 kgf}
35-54
35
3 Set bolt 6.86 to 8.82 {5.1 to 6.5, 0.7 to 0.9}
- Lubricant
1 Periphery of retaining ring Rubber grease As required
4
Service procedure
Secondary piston assembly
[Removal]
A Using rod A, push in secondary piston assembly 4, then loosen set
bolt 3.
4
3 05325
B Put plugs D into brake fluid filling port B and discharge port C that
leads to the rear wheel brakes, then feed compressed air via dis-
charge port E to the front wheel brakes to extract the secondary piston
assembly.
C WARNING
You must apply compressed air gradually when you remove
D E secondary piston assembly 4. If you applied compressed air
strongly at one time, the secondary piston assembly would be
violently ejected.
05326
[Installation]
A Using rod A, push in secondary piston assembly 4, then tighten set bolt 3
4
3 05325
35-55
BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC)
4
1
12
-5
7 3
8
2
10
9 12942
1 Nut 6 Spring 10 Brake pedal
2 Clevis pin 7 Collar 11 Stop lamp switch
3 Brake booster (master vac) 8 Bushing ^ Gr 54
4 Nut 9 Pedal pad 12 Support assembly
5 Bolt
NOTE
Do not disassemble brake booster (master vac) 3 because it is a non-disassemble type.
Assembly sequence
Adjustment after assembly P35-57

{0.00079 to 0.010}
10 Brake pedal Height from pedal pad center to 264 {10.4} Adjust
instrument panel underside
Full stroke 170 {6.69} Adjust
10, 11 Clearance between brake pedal stopper and tip of 0 to 0.1 {0 to 0.0039} Adjust
stop lamp switch thread area
35-56
35
1 Nut (Brake booster mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4}
4 Nut (Brake pedal mounting) 34.3 to 53.9 {25 to 40, 3.5 to 5.5}
- Lubricant
5 Friction surface of bolt bushing Chassis grease [NLGI No.1 (Ca soap)] As required
Service procedure
1 Adjustment of brake pedal installation height

By turning operating rod C of brake booster (master vac) 1, adjust
height B from the center of pedal pad 9 to the underside of instrument
A C D panel A to the standard value, then secure in place using nut D.
WARNING
Make sure, when brake pedal 10 is depressed fully, that
operating rod C of brake booster (master vac) 1 functions as
the stopper and the pedal does not come to a stop by hitting
against the floor panel, since this will reduce brake effec-
B
tiveness.
9 10
Inspection of brake pedal full stroke
Make sure that full stroke E when brake pedal 10 is depressed fully
E If there is any fault, adjust the installation height of the brake pedal.
Inspection of play towards brake pedal Gr 35-42
G
05797
Adjustment of stop lamp switch

Turn stop lamp switch 11 to adjust clearance A between the top of the
thread area of the stop lamp switch and the stopper of brake pedal 10
to the standard value, and fasten with lock nut B.
10
WARNING
Make sure, when brake pedal 10 is released, that stop lamp
A
B switch 11 does not stop the pedal, since this will cause the
11 brake to drag.
05819
35-57
FRONT WHEEL BRAKE < FE639 : DISC BRAKE >
This illustration shows the left side wheel disc brake viewed from the left front.

12
-
11 -
19
14
-

15
6-
- 15
14

5

-

06971
1 Slide pin bolt 9 Inner shim A 16 Bushing
2 Piston boot 10 Inner shim B 17 Pin boot
3 Piston 11 Clip (Upper) 18 Cap
4 Piston seal 12 Brake pad wear indicator 19 Torque member
5 Air bleeder (Lower) (Upper)
6 Caliper 13 Inner pad * : Disc rotor ^ Gr 26
7 Outer shim 14 Pad liner A : Non-reusable parts
8 Outer pad 15 Pad liner B
WARNING
Make sure that oil or grease does not stick to the surface of outer pad 8, inner pad 13 or disc rotor * since this
will reduce brake effectiveness.
CAUTION
When assembling, use the grease contained in the seal kit.
Assembly sequence
1916171514
131211109
87
118
654
32
Repair kit : Pad kit
Seal kit
Pad wear indicator kit
35-58
35
8, 13 Thickness of outer and inner pads 12 {0.47} 4 {0.16} Replace
* Disc rotor Wobble (When installed on front axle) 0.07 {0.0028} or less 0.10 {0.0039} Replace
Thickness 20 {0.79} 18 {0.71} Replace
Drag torque Immediately after releasing brake 9.8 Nm {7.2 lbf.ft, 1.00 kgfm} Tangential
pedal (Approximately 5 seconds later) force at
hub bolt :
95 N {21 lbf,
9.7 kgf}
After rotating disc rotor 10 turns 6.9 Nm {5.1 lbf.ft, 0.70 kgfm} Tangential
force at
hub bolt :
67 N {15 lbf,
6.8 kgf}

1 Slide pin bolt 83.3 to 93.1 {61 to 69, 8.5 to 9.5} Wet
5 Air bleeder 6.9 to 8.8 {5.1 to 8.8, 0.7 to 0.9} Wet
- Lubricant and/or fluid

Location Points of application Specified lubricant and/or fluid Quantity
1 Slide pin bolt Periphery of slide *Rubber grease As required
Contact surfaces of bushing and pin boot Rubber grease As required
Thread area Brake fluid
(SAE J1703f or FMVSS No.116 DOT3) As required
3 Piston Brake fluid
6 Cylinder lip of caliper Rubber grease As required
16 Bushing Inner periphery Rubber grease As required
Contact surface with slide pin bolt Rubber grease As required
17 Contact surfaces of pin boot and slide pin bolt Rubber grease As required
19 Torque Groove of pin boot Rubber grease As required
member Guide hole of main side Rubber grease As required
Seat of cap Rubber grease As required
* : Rubber grease should be compatible with DOT3 brake fluid.
35-59
Service procedure
Measurement of dragging torque
Fasten spring balance A to hub bolt B and measure the tangential
force.
If the measured value is the specified value, the torque conforms to
the standard value.
If the measured value deviates from the specified value, inspect the
friction surface between piston seal 4 and piston 3.
B
A 06972
1 Installation of slide pin bolt

Apply brake fluid to thread area A lightly, and apply grease to slide
outer periphery B, bushing groove C or connecting surface D of pin
boot 17, then tighten slide pin bolt 1 at specified torque.
17 E D Bleed bushing 16 or pin boot 17.
B A 1
16 E C
Check that seal E of bushing 16 or pin boot 17 is installed in bushing
groove C of slide pin bolt 1 or connecting surface D of the pin boot.
06959
C
24 to Installation of piston boot, piston and piston seal
Apply brake fluid to the periphery of piston 3 to insert piston boot 2.
3 Spread the grease applied to piston seal 4 evenly and install it into the
seal groove of caliper 6.
2 Apply grease to cylinder lip area A of caliper 6 evenly.
B A Install the caliper side seal of piston boot 2 to the boot groove B of
4 caliper 6, then press in piston 3 slowly.
6 Make sure that the piston side seal of piston boot 2 is installed in the
boot groove C of piston 3.
06960
< Inner side > < Outer side >

8
7 FI to Installation of pad and shim
Make sure that you install the shims with pawls A facing the right way.
7
A
9 10
A A
A
A
A
A
13 06958
35-60
35
L Installation of bushing
A : Push bar approximately 8 mm {0.31 in.} long
19 After installation, apply grease to the whole inner periphery of bushing 16
and its contact surface with slide pin bolt 1.
A
16
06962
B 19 A 17
M Installation of pin boot
Apply grease to pin boot groove A of torque member 19, the whole
C surface of guide hole B, and contact surface C between slide pin bolt 1
and pin boot 17.
Install pin boot 17.
12943
19 1
N Installation of cap
Apply grease to cap seat surface A.
18
Install cap 18.
A
06964
E E
* Inspection of disc rotor
Inspect the friction surface E of disc rotor * visually.
A B If any cracks are found, correct or replace disc rotor *.
*
A : Net pattern cracks (Correct or replace)
B : Radial cracks that do not reach the outer periphery (Correct or
replace)
D
C : Radial cracks that have reached the outer periphery (Replace)
D C D : Through cracks (Replace)
12832
35-61
12
11 -
14
- -
18

15
15
-

14
6-
5
-
12648
3 Piston 11 Clip (Upper) 18 Torque member
4 Piston seal 12 Brake pad wear indicator
5 Air bleeder (Lower) (Upper) * : Disc rotor ^ Gr 26
6 Caliper 13 Inner pad : Non-reusable parts
7 Outer shim 14 Pad liner A
WARNING
CAUTION
Assembly sequence
1817161514
131211109
87
1
654
32
Seal kit
35-62
35
hub bolt :
95 N {21 lbf,
9.7 kgf}
force at
hub bolt :
67 N {15 lbf,
6.8 kgf}


35-63
Service procedure
force.
the standard value.
B
A 06972

B 17 E D 1 Bleed bushing 16 or pin boot 17.
16 E A
C
06970

C
Spread the grease applied to piston seal 4 evenly and install it into the
3
B Install the caliper side seal of piston boot 2 to the boot groove B of
A
06960
< Inner side >

9
< Outer side >
8
10 7
A
A
A
A
A
A 13 06975
35-64
35
A
16
06962
B 18 A 17
and pin boot 17.
12943
E E
*
replace)
D
12832
35-65
FRONT WHEEL BRAKE < FG639 : DRUM BRAKE >
Front Wheel Brake Assembly
9
13
11
10
12
9
17
14
4
16
15

6 2
3
- 2
05878
1 Return spring 12 Bolt
2 Shoe hold down cup 13 Connector
3 Shoe hold down spring 14 Bolt
4 Shoe hold down pin 15 Wheel cylinder assembly P35-71
5 Brake shoe assembly 16 Cover
6 Rivet 17 Cover
7 Brake lining 18 Backing plate
8 Brake shoe
9 Pipe assembly * : Brake drum ^ Gr 26B
10 Spacer : Non-reusable parts
11 Extension
WARNING
Make sure that oil or grease does not stick to the lining surface of brake shoe assembly 5 and the inner surface
of brake drum * since this will reduce brake effectiveness.
CAUTION
Be sure, when replacing brake shoe assembly 5, to wash and apply rubber grease to the adjuster and adjuster
screw of wheel cylinder assembly 15 since particles of brake lining 7 may have accumulated on these parts.
P35-71
Assembly sequence
Initial adjustment of brake shoe clearance after installation P35-67
35-66
35
1 Return spring load (Installed length 190 {7.48}) 195 to 235 N 175 N Replace
{44 to 53 lbf, 19.8 to 24.2 kgf} {40 lbf, 18 kgf}
5 Brake shoe assembly (Thickness of brake lining) 10.0 {0.39} 4.0 {0.16} Replace
(Side shoulder brake
means wear lining
limit)
* Brake drum Inner diameter 320 {12.60} *321 {12.64} 322 {12.68} Correct
or replace
Cylindrical accuracy 0.05 {0.0020} 0.2 {0.0079} Correct
or replace
*Refers to the correction limit.

9 Pipe assembly 12.75 to 14.71 {9.4 to 11, 1.3 to 1.5}
11 Extension 12.75 to 14.71 {9.4 to 11, 1.3 to 1.5}
12 Bolt (Connector mounting) 7.85 to 11.77 {5.8 to 8.7, 0.8 to 1.2}
14 Bolt (Wheel cylinder assembly mounting) 37.27 to 49.03 {27 to 36, 3.8 to 5.0}
- Lubricant
5, 18 Contact surfaces between backing plate ledge and shoe rim, Brake grease As required
wheel cylinder assembly anchor area of shoe web,
and adjusting screw contact point
Service procedure
Initial adjustment of brake shoe clearance after installation
Turning the adjuster of wheel cylinder assembly 15 in arrow direction
expands brake shoe assembly 5, narrowing the clearance between
brake drum * and brake lining 7.
Jack up the vehicle to make sure that the wheel hub bearing has no
play. If there is any play, correct it. ^ Gr 26B
Remove covers 16 and 17.
35-67
Adjust the brake shoe clearance as follows, so that 0.3 mm {0.012 in.}
A
feeler gauge B can be inserted or extracted through check hole A,
* B between brake drum * and brake lining 7 with a little resistance.
5
00320
To increase brake shoe clearance

Insert a wire (approximately 2 mm {0.079 in.}) into the adjusting
E hole C and lift adjusting lever D of wheel cylinder assembly 15.
15 Turn adjuster E of wheel cylinder assembly 15, through adjusting
hole C, in the opposite direction to arrow F on backing plate 15.
C
F
27544
E To decrease brake shoe clearance

D Turn adjuster E in the arrow F direction marked on backing plate 18
through adjusting hole C.
F
18
14363
Extract the feeler gauge and depress the brake pedal two or three
times fully, then the specified value brake shoe clearance can be
obtained.
Insert a 0.2 mm {0.0079 in.} feeler gauge through check hole A and
make sure that it can be inserted or extracted with a little resistance. If
there is any fault, disassemble and inspect wheel cylinder assembly
15. P35-71
B
1 Return spring
[Removal]
A
To remove return spring 1, place screwdriver A into the hook of the
return spring, then pry and remove the return spring making use of wheel
cylinder assembly 15 adjusting screw B as a fulcrum.
15
1
05879
35-68
35
D [Installation]
5 Insert a small cross-point screwdriver C into the hook of return spring 1,
C
insert the tip of the screwdriver into return spring installation hole D of
brake shoe assembly 5 to pry on the return spring.
1
05880
7
5 Inspection of brake shoe assembly
If thickness A of brake lining 7 is lower than the limit, replace the brake
lining on the same axle as a unit.
12501
5 5N Installation of brake shoe assembly and backing plate

Apply grease to the points as illustrated, and install brake shoe assembly
5 and backing plate 18.
06215
18
06216
7 Brake lining
[Removal]
12806
35-69
[Installation]
Clean the mounting surfaces of brake lining 7 and brake shoe 8 with
8 cleaning fluid and dry them.
Insert rivets 6 from brake lining 7 side, and caulk the rivets at the
specified load so that there is no clearance between brake shoe 8 and
the brake lining.
7 Staking load for rivets : 211 kN {4630220 lbf, 2100100 kgf}
6
Make sure that you inspect contact with the inner surface of brake
00573 drum * after you replace brake linings 7. If contact is incorrect, correct
with the brake assembled.
WARNING
Do not leave lubricant on the surface of brake lining 7 because
this reduces braking performance.
CAUTION
Make sure that the type of brake linings 7 you fit are suitable for
the intended use of the vehicle. Make sure that you fit identical
size and color coated linings on the left and right sides of one
axle.
* Correction of brake drum

If the cylindrical accuracy of brake drum * is higher than the limit, or
there are grooves, correct by machining to the correction limit. Machining
of the brake drum should be done with the wheel hub attached as an
integral part.
35-70
35
Wheel Cylinder Assembly
2 3
1 Spring
3 Lever
4 Adjusting screw
5 Adjuster
6 Washer
7 7 Piston cup
8 Piston
9 Boot
10 Bleeder screw
11 10
9 11 Body

8- : Non-reusable parts
5-
Assembly sequence
4- 05376
11109
654321
87
Repair kit : Wheel cylinder kit

Standard value
8, 11 Clearance between piston and body [28.57 {1.12}] 0.02 to 0.08 0.2 {0.0079} Replace
{0.00079 to 0.0031} piston

10 Bleeder screw 6.9 to 8.8 {5.1 to 6.5, 0.7 to 0.9}
- Lubricant
4, 5, 8 Thread areas of adjusting screw and adjuster, friction area of *Rubber grease As required
piston, and friction area of adjuster
1
1
Service procedure
Installation of spring
Install the closed hook of spring 1 on body 11 side.
11
05377
35-71
REAR WHEEL BRAKE < FE639, FG639 : DRUM BRAKE >
Rear Wheel Brake Assembly
10
11
13
12
14
-
2
- 3
6 2
05972
1 Return spring 10 Spacer
2 Shoe hold down cup 11 Bolt
3 Shoe hold down spring 12 Wheel cylinder assembly P35-78
4 Shoe hold down pin 13 Cover
6 Rivet 15 Backing plate
7 Brake lining
8 Brake shoe * : Brake drum ^ Gr 27
9 Pipe assembly : Non-reusable parts
WARNING
CAUTION
screw of wheel cylinder assembly 12 since particles of brake lining 7 may have accumulated on these parts.
P35-78
Assembly sequence
35-72
35
means wear lining
limit)
or replace
or replace

- Lubricant
Service procedure
play. If there is any play, correct it. ^ Gr 27
35-73
A
5
00320

hole C and lift adjusting lever D of wheel cylinder assembly 12.
E
Turn adjuster E of wheel cylinder assembly 12, through adjusting
12
C
F
06385

F
15
14363
obtained.
12. P35-78
B
1 Return spring
[Removal]
A
12
1
05879
35-74
35
D [Installation]
C
1
05880
7
12501
5 5K Installation of brake shoe assembly and backing plate

06215
15
06216
7 Brake lining
[Removal]
12806
35-75
[Installation]
Insert rivets 6 from brake lining 7 side, and stake the rivets at the
the brake lining.
7 Staking load for rivets : 211 kN {4630220 lbf, 2100100 kgf}
6
WARNING
CAUTION
axle.

there are grooves, correct by machining to the correction limit. Machining
integral part.
35-76
35
MEMO
35-77
1 Spring
2 3 2 Spring and fitting

4 3 Lever
4 Piston cup
5 Piston
6 Boot
5 7 Adjusting screw
- 8 Adjuster
6
10 9 Washer
10 Piston cup
11 Piston
14 12 Boot
12 13
13 Bleeder screw

14 Body
11 -
8-
7-
Assembly sequence
05586
141312
9876
1110 321
54

Standard value
5, 11, 14 Clearance between piston and body [28.57 {1.12}] 0.02 to 0.08 0.2 {0.0079} Replace
{0.00079 to 0.0031} piston

- Lubricant
5, 7, Thread areas of adjusting screw and adjuster, friction area of *Rubber grease As required
8, 11 piston, and friction area of adjuster
35-78
35
1
1
Service procedure
14
05587
11 9 Installation of washer
Install the washer with its black side facing adjuster 8.
9
06149
35-79
REAR WHEEL BRAKE < FE649 : DISC BRAKE >
- 6-
15
- -
18 -

14 14
12 -
11
15
06979
1 Slide pin bolt 8 Outer pad 15 Pad liner B
2 Piston boot 9 Inner shim A 16 Bushing
3 Piston 10 Inner shim B 17 Pin boot
4 Piston seal 11 Clip 18 Torque member
5 Air bleeder 12 Brake pad wear indicator
WARNING
CAUTION
Assembly sequence
1817161514
131211109
87
1
654
32

Seal kit
35-80
35
* Disc rotor Wobble (When installed on rear axle) 0.07 {0.0028} or less 0.10 {0.0039} Replace
hub bolt :
88 N {20 lbf,
9 kgf}
force at
hub bolt :
62 N {14 lbf,
6.3 kgf}


Thread area Brake fluid As required
3 Piston Brake fluid As required
35-81
Service procedure
force.
the standard value.
B
A
06980

16 E A
C
06970

C
Spread the grease applied on piston seal 4 evenly to install it into the
3
A
06960
< Inner side >

9
< Outer side >
8
10 7
A
A
A
A
A
A 13 06981
35-82
35
18
After installation, apply grease to the whole inner periphery of bushing 16
A and its contact surface with slide pin bolt 1.
16
06962
B 18 A 17
and pin boot 17.
12943
E E
*
replace)
D
12832
35-83
VACUUM PUMP
7
-

8
3-
2
4
05412
1 Check valve assembly 5 Vane A : Positioning pin
2 Bolt 6 Rotor : Non-reusable parts
3 O-ring 7 O-ring
4 Cylinder 8 Flange
Assembly sequence
Service standards
3
Degree of vacuum 60 cm {3.66 cu. in.} : 93.3 kPa {27.6 in. Hg, 700 mmHg} Replace
of pump Engine speed 1500 rpm
90 cm3 {5.49 cu. in.} : 90.6 kPa {26.8 in. Hg, 680 mmHg} Replace
Engine speed 3000 rpm or more
- Lubricant
3, 7 Periphery of the O-ring Engine oil As required
35-84
LOAD SENSING VALVE 35

1 4 1 Bolt
2 Nut
11 3 Rod assembly
10 4 Nut
9 5 Nut
6 Bracket and bolt assembly
7 Nut
5
8 Plate
9 Leaf spring
8 10 Bracket
6
11 Load sensing valve
7
* : Rear axle bracket
3 NOTE
* Do not disassemble load sensing valve
2
11 because it is a non-disassemble type.
Assembly sequence
verse.

1 Bolt (Load sensing valve mounting) 16 to 25 {12 to 18, 1.68 to 2.52}
2 Nut (Rod assembly mounting) 5.9 to 7.9 {4.3 to 5.8, 0.6 to 0.8}
4, 5 Nut (Leaf spring adjusting) 11.8 to 17.6 {8.7 to 13, 1.2 to 1.8}
7 Nut (Leaf spring mounting) 5.9 to 7.9 {4.3 to 5.8, 0.6 to 0.8}
Service procedure
[Installation]
Install load sensing valve 11 on the vehicle when it is unloaded and
mount ball joint part A of rod assembly 3 to rear axle bracket *.
11 4 Loosen nut 4 and nut 5 and adjust as follows.
3
A
07401
[Adjustment]
9 Free leaf spring 9 to lift up the leaf spring and fit plunger B to roller C.
In this condition, position nut 5 17 mm {0.67 in.} below the tip of leaf
4
17 mm
spring 9, then tighten nut 4 at specified torque.
B C {0.67 in.}
5
07397
35-85
EXHAUST BRAKE SYSTEM
Exhaust Brake Unit
1 Bolt
2 Cover
3 Clevis pin
4 Nut
5 Clevis
6 Lock nut
6 7 Bearing
7
8 Vacuum chamber
9 Nut
10 Lever
3
11 Bolt
12 12 Nut
13 Adjusting bolt
14
14 Bracket
9 15 Valve assembly
13
4
2
11 1
12649

8 Airtightness in vacuum chamber 63 kPa {18.7 in. Hg, 475 mmHg} Replace
(Airtightness 15 seconds after applying negative or more
pressure 67 kPa {19.7 in. Hg, 500 mmHg})
14 Average value of upper and lower clearance 0.10 to 0.25 {0.0039 to 0.0098} Adjust
between butterfly valve and body, when butterfly
valve is totally closed (Degree of vacuum in vacuum
chamber 86.7 to 93.3 kPa {25.6 to 27.6 in. Hg,
650 to 700 mmHg})

1 Bolt (Cover mounting) 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7}
4 Nut (Vacuum chamber mounting) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
6 Lock nut (Clevis fixing) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
9 Nut (Lever mounting) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
11 Bolt (Bracket mounting) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
12 Nut (Adjusting bolt fixing) 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7}
35-86
35
5
8 5
Service procedure
Adjustment of clevis
Install vacuum chamber 8 on bracket 14, and adjust the position of clevis
5 so that the hole of the clevis is half the pitch of the hole of lever 10.
10
14
05257
B
8 Test of vacuum chamber airtightness
Arrange piping as illustrated, and apply vacuum of 67 kPa {19.7 in. Hg,
500 mmHg} or more to vacuum chamber 8, then stop vacuum pump A.
After 15 seconds, ensure that the value of vacuum gauge B is the
A standard value. If the measured value deviates from the standard value,
8 replace the vacuum chamber.
05268
K Adjustment of valve assembly

[Fully-opened adjustment]
A Adjust using adjusting bolt 13 so that butterfly valve A of valve assembly
15 is fully opened.
15
13
05269
[Fully-closed adjustment]
While applying vacuum 87 to 93 kPa {25.6 to 27.6 in. Hg, 650 to
700 mmHg} to vacuum chamber 8, adjust using adjusting bolt 13 so
that the average value of clearance C and D between butterfly valve A
D 8 and body B is within the standard value.
C
13
B A Clearance=(C+D)/2
05270
35-87
Intake Silencer
1 Bolt
2 Nut
3 Actuator
4 Spacer
5 Thrust plate
6 O-ring
7 Intake manifold
Assembly sequence
7
6- Adjustment after assembly P35-89

5
4
2
1
13255

3 Actuator (Push rod stroke when negative pressure 15 {0.59} or more Replace
of 40 kPa {11.8 in. Hg, 300 mmHg} applied)
Clearance between intake manifold and butterfly 3.6 to 4.0 {0.14 to 0.16} Adjust
valve when fully closed

2 Nut 8 {5.7, 0.8}
- Lubricant
6 O-ring Molybdenum disulfide grease As required
[NLGI No.2 Li soap]
35-88
35
Service procedure
Loosen bolts 1.
7
While applying negative pressure of 67 kPa {19.7 in. Hg, 500
7
mmHg} to actuator 3, adjust the position of the actuator so that
A clearance B between intake manifold 7 and butterfly valve A con-
Tighten bolts 1 and fix actuator 3.
B
3 1 13567
3 Inspection of actuator
Apply negative pressure of 40 kPa {11.8 in. Hg, 300 mmHg} to
3
actuator 3 and measure stroke A of the push rod.
40 kPa actuator 3.
{11.8 in. Hg,
300 mmHg}
A
13566
35-89
Exhaust Brake System Electric Equipment

8
6
12944
1 Accelerator switch ^ Gr 13, Gr 54

2 Clutch switch < Manual transmission > ^ Gr 21, Gr 54
3 Exhaust brake switch < Manual transmission > ^ Gr 37, Gr 54
4 Exhaust brake cut relay < Manual transmission > ^ Gr 54
5 Exhaust brake cut relay < Automatic transmission > ^ Gr 54
6 3-way magnetic valve (For exhaust brake) ^ Gr 54
7 3-way magnetic valve (For intake shutter) ^ Gr 54
8 Neutral switch < Manual transmission > ^ Gr 22, Gr 54
9 Inhibiter switch < Automatic transmission > ^ Gr 23, Gr 54
35-90
35
1
Service procedure
Adjustment of accelerator switch
Turn exhaust brake switch 3 ON, depress the accelerator pedal gradu-
ally, and make sure that when the engine revolution reaches 800 to
950 rpm, the exhaust brake operation indicator lamp within the meter
cluster goes OFF.
A If the indicator lamp goes OFF when the engine revolution is 800 rpm
or less, adjust accelerator switch 1 by screwing it in.
If the indicator lamp goes OFF when the engine revolution is 950 or
3
more, adjust accelerator switch 1 by unscrewing it.
12833
After adjustment, fix accelerator switch 1 using lock nut A.
35-91
Group 35
Brake
Table of Contents
BACK
HOME
Pub No. TWSE9501-35

35
GROUP 35 BRAKE
SPECIFICATIONS ................................................................................... 2

Replacement of Brake Fluid ............................................................................ 32
Air Bleeding of Brake System ......................................................................... 34
Inspection and Adjustment of Brake Pedal Free Play ................................... 36
Inspection and Adjustment of Clearance between
Brake Pedal and Floor Panel ........................................................................... 36
Inspection and Replacement of Disc Brake Pad ........................................... 37
Drum Brake Lining Thickness Inspection and Replacement ....................... 40
Inspection of Brake Shoe Clearance .............................................................. 40
Inspection of Brake Booster (Master Vac) ..................................................... 41
Inspection of Bypass Valve ............................................................................. 46
BRAKE MASTER CYLINDER .............................................................. 48
BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC) ................ 50
FRONT WHEEL BRAKE

< FE639 : DISC BRAKE > .................................................................................... 52
< FE649 : DISC BRAKE > .................................................................................... 56
REAR WHEEL BRAKE

< FE639 : DRUM BRAKE > .................................................................................. 60
< FE649 : DISC BRAKE > .................................................................................... 68
VACUUM PUMP ................................................................................... 72
LOAD SENSING VALVE ...................................................................... 74
EXHAUST BRAKE SYSTEM ............................................................... 76
35-1
SPECIFICATIONS
< Service Brake Equipment >
Vehicle model
FE639 FE649
Item
Brake booster Type Tandem type
(Master vac) Diaphragm diameter in. 8+9 9+10
Brake master Inner diameter mm {in.} 30.16 {1.19} 31.75 {1.25}
cylinder Stroke Front mm {in.} 17.4 {0.69} 16.0 {0.63}
Rear mm {in.} 14.6 {0.57} 16.0 {0.63}
Vacuum pump Type Vane type
Delivery cm3 {cu. in.} 60 {3.66} 90 {5.49}
< Wheel Brake >

Vehicle model
FE639
Item
Vehicle model
FE649
Item
< Exhaust Brake System >

Item Specifications
Control system Combined electric and vacuum
Valve type Butterfly valve type
35-2
Brake System
2 4
1
3
5
8
9
A
B
C 10
11
12849
1 Master vac 9 Load sensing valve

2 Fluid tank 10 Rear wheel brake
3 Brake master cylinder 11 Front wheel brake
4 Vacuum tank
5 Vacuum switch A : Fluid line
6 Check valve B : Air line
7 Vacuum pump C : Hose
8 Bypass valve
The brake system is a vacuum servo all-wheel brake type, with master vac 1.
Load sensing valve 9 automatically changes the oil pressure of the rear wheel brakes according to the load changes,
preventing the rear wheels from locking too early.
Bypass valve 8 is fitted as a safety mechanism. It provides braking force if the front brake system is damaged and loses
hydraulic pressure. The bypass valve does this by making the hydraulic pressure of the rear brake system bypass load
sensing valve 9 and act directly on rear wheel brake 10.
35-3
Brake Booster (Master Vac) and Brake Master Cylinder
1 2 3
15 5
6 7 8 9
21
20 22 19 18 17 16
10
11
14
13
12
05248
< Master vac > < Brake master cylinder >

1 Front diaphragm 16 Primary piston
2 Front diaphragm plate 17 Primary piston return spring
3 Rear diaphragm 18 Retainer
4 Rear diaphragm plate 19 Secondary piston
5 Rear shell 20 Secondary piston return spring
6 Valve plunger 21 Cylinder body
7 Poppet 22 Packing cup
8 Poppet spring
9 Valve return spring
10 Operating rod
11 Valve body
12 Center plate
13 Push rod
14 Front shell
15 Diaphragm plate spring
35-4
35
11 A 7
10
13 6 B
15
C D
12929
Action of master vac

When the brake pedal is released, chambers C and D are subjected to the vacuum created by the vacuum pump.
Depressing the brake pedal activates operating rod 10, placing poppet 7 in tight contact with the seat of valve body 11.
This action closes vacuum valve A, cutting off the vacuum to chamber D.
Depressing the brake pedal further separates valve plunger 6 from poppet 7, opening breather valve B permitting
atmospheric pressure to flow into chamber D, producing a pressure difference between chambers C and D.
This pressure difference between chambers C and D presses front diaphragm 1 and rear diaphragm 3, boosting the
depressing force.
This boosted pedal depression force overcomes the repercussive force of diaphragm plate spring 15, presses push rod
13, and actuates the brake master cylinder.

Push rod 13 pushes in primary piston 16 and sec-
H ondary piston 19, and packing cup 22 passes return
H E E port E, generating hydraulic pressure in chamber H,
feeding the oil to the respective brake systems.
K: To the front brake system

L: To the rear brake system
22 19 22 16 13
L K
12930
35-5
Oil leakage in the front brake system
Depressing the brake pedal makes push rod 13 push
in primary piston 16. However, if the brake fluid in
the front brake system leaks, hydraulic pressure is
18
not generated in the front brake system.
Depressing the brake pedal further makes primary
piston 16 compress primary piston return spring 17,
causing retainer 18 to push secondary piston 19,
thus generating hydraulic pressure only in the rear
brake system.
19 13 L : To the rear brake system

17 16
L
05243
Oil leakage in the rear brake system

Depressing the brake pedal makes push rod 13 push
in primary piston 16 and secondary piston 19. How-
ever, if the brake fluid in the rear brake system leaks,
hydraulic pressure is not generated in the rear brake
system.
Depressing the brake pedal further makes the end of
secondary piston 19 contact cylinder body 21, push-
ing primary piston 16, thus generating hydraulic pres-
sure only in the front brake system.
21 K : To the front wheel brake system

19 16 13
K
05244
35-6
35
When releasing brake pedal
A 7
11
10
13 6 B
12
15
C D
12931
Action of master vac

When the brake pedal is depressed, atmospheric air flows into chamber D as chamber C is subjected to negative
pressure generated by the vacuum pump.
When the brake pedal is released, since the pressing force acting on the operating rod 10 also is released, valve
plunger 6 contacts poppet 7 tightly, closing breather valve B to cut off the flow of atmospheric air into chamber D. In
addition, valve plunger separates from valve body 11 to open vacuum valve A. Then, the negative pressure generated
by the vacuum pump creates a vacuum in chamber D, and the pressure difference between chambers C and D
diminishes.
This absence of a pressure difference between chambers C and D, allows rear diaphragm 3 to be pushed against the
rear shell 5 by the repercussive force of diaphragm plate return spring 15, and push rod 13 returns to its original
position.
F When push rod 13 returns to its original position, the
E
repercussive force of the secondary piston return
spring 20 immediately begins to return secondary
piston 19. However, the brake fluid delivered from
the brake master cylinder cannot return quickly due
to the absence of a pressure difference between
chambers H and G.
As secondary piston 19 begins to return, the pres-
sure in chamber H becomes lower than that in cham-
ber G, and this pressure difference deforms packing
cup 22 to open a small passage J. Then, the brake
H 20 22 J G 19 05246 fluid in chamber G is drawn into chamber H.
35-7
When secondary piston 19 returns to its original
position, the pressure difference between chambers
E G and H is diminished, and packing cup 22 closes
the small passage J. The hydraulic oil in the brake
pipe flows from chamber H to the fluid tank via
return port E.
The same operation takes place also on the primary
side.
H 22 J G 19
05247
35-8
35
Front Disc Brake
4 5 7 1
2 Disc rotor
3 Torque member
4 Outer pad
5 Inner pad
6 Caliper
7 Piston
Inner pad 5 is fitted with brake pad wear indicator 1 that

inner pad.
6 3 2 05404
Rear Drum Brake Assembly

1 Backing plate
4 Return spring
The rear drum brake assembly is a dual 2-leading type

brake and is fitted with wheel cylinder assembly 3, the self-
servo action of which produces a great braking force by
4
using brake shoe assembly 2 as the leading shoe when the
vehicle is travelling forwards.
3
05476

1 2 3 A
2 Pin
3 Lever
4 Piston assembly
5 Set spring
6 Adjuster assembly
7 Adjusting screw
A: Brake shoe assembly
6 5
The wheel cylinder assembly has an automatic ad-
juster that corrects the increase in clearance that
occurs between the brake lining and the brake drum,
4 4 an increase caused by the wear of the brake lining.
This increase occurs whenever the brake pedal is
depressed.
7 6
05477
35-9
Automatic adjustment mechanism
4 B
4 Operation
When the brake pedal is depressed, the reduced pressure
from the brake master cylinder enters chamber B and
pushes out piston assembly 4, which in turn pulls spring and
fitting 1.
Therefore lever 3 turns around pin 2 that is linked to spring
and fitting 1.
7 6
C : Lever travel
D D : Protrusion of piston assembly
6 1 2 3 A
5
D
12836
When the clearance between the brake drum and the brake
6 lining is correct, depression of the brake pedal does not
C 3 affect lever 3, so adjuster assembly 6 does not turn.
C : Lever travel
05391
35-10
35
As the clearance between the brake drum and the brake
lining increases, the amount of protrusion of piston assem-
4 3
bly 4 also increases, as does the amount of travel of lever 3.
C
6 C : Lever travel
E : Protrusion of adjuster screw
The action of lever 3 increases the rotation of adjuster

assembly 6, the screw action pushes out adjuster screw 7,
expanding brake shoe assembly A.
A 7 6
E
12837
< Before depressing pedal >
6
C
3
< When depressing

pedal >
05402
When the brake pedal is released, since adjuster assembly

< When releasing pedal > 6 remains in its new position after turning, returned lever 3
enters the next position, moved by one notch. This assures
C
6 correct clearance between the brake drum and the brake
3 lining.
C : Lever travel
05392
35-11
Rear Disc Brake
6 2 Disc rotor
1 3 Torque member
4 Outer pad
5 Inner pad
6 Caliper
7 Piston
7 Inner pad 5 is fitted with brake pad wear indicator 1 that

5 inner pad.
2
3 4 05479
35-12
35
Vacuum Pump
1 Check valve assembly
A 2 Vane
1 3 Rotor
4 Housing
A : Inlet
B : Outlet
4
2
B 3 05224
The vacuum pump is installed on the timing gear case and is rotated by the injection pump gear or camshaft gear.
Check valve assembly 1 is fitted to prevent the atmospheric pressure and the lubricating oil from flowing in reverse from
the vacuum pump to the vacuum tank when the engine is stopped.
< Suction stroke > A Operation

Inside cylindrical housing 4, rotor 3 equipped with three vanes
4 (movable blades) 2 rotates, pressing the vanes against the inside
surface of the housing by centrifugal force.
Since rotor 3 is eccentric with respect to housing 4, as the rotor
2
rotates, the atmospheric pressure of the vacuum tank is drawn in
3 from inlet A and discharges from outlet B by the gradual compres-
sion of the air. This repetition of the suction, compression and
< Compression stroke > exhaust strokes generates a vacuum, realizing a near-vacuum in
the vacuum tank.
The engine oil that lubricates and cools the inside of housing 4 is
returned, along with air pressure, through outlet B to the oil pan.
< Exhaust stroke >
B 04213
35-13
Load Sensing Valve
A 1
2
3
4
7
5
6
12932 05589
1 Load sensing valve 6 Leaf spring

2 Packing cup 7 Valve body
3 Spring
4 Plunger A : Frame
5 Retainer B : Rear axle
The deflection of leaf spring 6, fixed on rear axle B, notifies load sensing valve 1 of any shifts in the load. This decreases
hydraulic pressure to the rear wheel brakes compared to the front wheel brakes. This maintains adequate braking
performance that corresponds to any shift in the load, preventing premature rear wheel lock.
35-14
35
Valve unit
Brake fluid is supplied from the brake master cylinder to
B the rear wheel brakes via chamber A, the clearance
2
4 between packing cup 2 and plunger 4, and chamber B.
05590
Hydraulic pressure A, supplied by the brake master cylin-

der, gradually increases on seal cross-section E of
plunger 4. This increase depresses spring 3 pushing the
plunger down onto packing cup 2 and cuts off the pas-
sage between chambers A and B. This is called the
B decompression point.
2 P35-16 (Performance characteristics chart)
Hydraulic pressure A at the brake master cylinder push-
4 3 ing plunger 4 up when the decompression point is
passed. On the other hand, hydraulic pressure B at the
rear wheel brakes works as a depressing force, so hy-
A draulic pressure A and B balance, cutting off the pas-
sage between chambers A and B.
At this time, hydraulic pressure at the brake master cylin-
der works at the donut-shaped cross-section (formed by
E the removal of cross-section D from cross-section C of
plunger 4). However, because hydraulic pressure B at
2 the rear wheels works on the whole cross-section E of
C the plunger seal, and the rear wheel brake side remains
at low hydraulic, balance is maintained.
Therefore, hydraulic pressure B at the rear wheel brakes
D
is lower than hydraulic pressure A at the brake master
cylinder.
4 The gradient of the performance characteristics of hy-
draulic pressure B is lower than that of hydraulic pres-
sure A.
P35-16 (Performance characteristics chart)
05591
35-15
Sensor unit
When the vehicle is loaded

When the vehicle is loaded, since the deflection of leaf
spring 6 is large and the amount of upward travel of
plunger 4 is also large, the amount of plunger downward
travel is small. Therefore, the decompression point rises
to supply higher brake pressure to the rear wheels, com-
pared to the unloaded state.
4
05593
When the vehicle is unloaded

When the vehicle is unloaded, since the deflection of leaf
spring 6 is small and the amount of upward travel of
plunger 4 is also small, the amount of plunger downward
travel is large. Therefore, the decompression point drops
to supply lower brake pressure to the rear wheels, com-
pared to the loaded state.
4
05595
Performance characteristics
The figure on the left shows the changes in braking per-
formance characteristics of the rear wheels. These changes
depend on the vehicle load and any shifts in the load caused
by sudden deceleration while cruising.
Hydraulic pressure at rear
Hydraulic pressure
characteristics
Decompression when loaded
point
wheel cylinder
Hydraulic pressure
characteristics
when unloaded
0
Hydraulic pressure at brake master cylinder
05594
35-16
35
Bypass Valve
1 Bleeder screw
1 2 Spring
3 Piston
4 Seal
2 3
If any failure occurred in the front brake system that de-
creased the hydraulic pressure, the decompression effect
of the load sensing valve would affect the hydraulic pres-
sure in the rear brake system. This would reduce the braking
force of the rear brake system. The bypass valve is fitted to
prevent this from happening.
1 If the hydraulic pressure in the front brake system de-
creases, the hydraulic pressure in the rear brake system
4 12838 bypasses the load sensing valve and is fed directly to the
rear wheel brake.

A C is normal
J
The hydraulic pressure flows through chamber G, pushes
E 3 piston 3, and cuts off bypass J with seal 4.
C : From front brake system
The hydraulic pressure in the rear brake system flows from
chamber E into chamber F.
A : From the rear brake system of the brake master cylin-
der
F B : To the load sensing valve
4 G
B 12839

A 1 decreases abnormally.
J The hydraulic pressure in chamber G decreases, reducing
C 2 the force pushing piston 3.
E 3 C : From the front brake system
The hydraulic pressure of the rear brake system pushes
seal 4, and overcomes the repercussive force of spring 2 to
push piston 3, opening bypass pass J.
The hydraulic pressure of the rear brake system flows from
chamber E into chamber H.
B 1 A : From the rear brake system of the brake master cylin-
G der
4 D : To the rear wheel brake
H
D 12840
35-17
Exhaust Brake System
1 2 3 4
5
7 6
17
16
9 8
15
12
10 10
11
12841
2 3 4
5
1
7 6
17
9 8
15
A
13
10 10
14
12842
35-18
35
1 Fuse box 12 Clutch switch < Manual transmission >
2 Meter cluster 13 Inhibiter switch < Automatic transmission >
3 Exhaust brake indicator lamp 14 Automatic transmission electric control unit
4 Air cleaner < Automatic transmission >
5 Vacuum tank 15 Exhaust brake cut relay
6 Exhaust brake 3-way magnetic valve 16 Exhaust brake switch < Manual transmission >
7 Intake shutter 3-way magnetic valve 17 Accelerator switch
8 Exhaust brake unit 18 Clutch switch < Manual transmission >
9 Intake shutter
10 Butterfly valve A : From starter switch
11 Neutral switch < Manual transmission >
The exhaust brake uses pressure to push and return the piston in the exhaust stroke. This pressure is generated when
the exhaust pipe is shut and the pressure in the exhaust pipe increases.
A butterfly valve type exhaust brake unit 8 is fitted as an auxiliary brake to assist the foot brake. Intake shutter 9 is fitted
to reduce the suction noise generated when the exhaust brake is operated.
When the exhaust brake switch 16 is turned ON, excitation of the coil of exhaust brake 3-way magnetic valve 6 closes
the atmospheric valve and opens the vacuum valve. This makes the vacuum in the vacuum tank act on exhaust brake
unit 8 which closes butterfly valve 10, activating the exhaust brake.
35-19
Operation
Electrical System
2 3
1
7 6
17 A
16
15
12
11
12843
1 2 3
7 6
17
15
A
13
14
12844
When exhaust brake switch 16 is turned ON, exhaust brake indicator lamp 3 within meter cluster 2 lights up and the
exhaust brake 3-way magnetic valve 6 operates.
At this time, depressing the clutch pedal (clutch switch 12 OFF) or the accelerator pedal (accelerator switch 17 OFF)
temporarily releases the exhaust brake. When the transmission is in neutral (neutral switch 11 or inhibiter switch 13 ON)
because the vehicle is stopped or for some other reason, exhaust brake cut relay 15 operates, releasing the exhaust
brake after approximately 10 seconds.
If the accelerator pedal is depressed and released after the exhaust brake is released by the exhaust brake cut relay, the
exhaust brake operates again, and after approximately 10 seconds is released.
35-20
35
Exhaust Brake Unit
1 Spring
2 Diaphragm
3 Push rod
4 Butterfly valve
1
12835
Intake Silencer
1 Push rod
2 2 Actuator assembly
3 Butterfly valve
4 Intake pipe
4
13569
35-21
Brake Warning System
Vacuum system electric circuit, brake fluid level system electric circuit
1
6
5
3
12845
1 Fuse box 4 Brake warning lamp

2 Meter cluster 5 Brake fluid level switch
3 Vacuum warning lamp 6 Vacuum switch
The brake warning system consists of a vacuum system electric circuit which detects the drop in negative pressure inside
the vacuum tank, and a brake fluid level system electric circuit which detects the drop in the level of brake fluid inside the
fluid tank. In both cases a warning lamp lights up to give warning.
35-22
35
Vacuum system electric circuit
If the negative pressure in the vacuum tank drops

below the specified pressure, vacuum switch 6 turns
ON lighting vacuum warning lamp 3. The flow of cur-
1 rent at such time is as follows.
6
Fuse 1Vacuum warning lamp 3Vacuum switch

6Ground
12933
Brake fluid level system electric circuit
If the amount of brake fluid in the fluid tank drops below

the specified amount, brake fluid level switch 5 turns
ON lighting brake warning lamp 4. The flow of current
1
at such time is as follows.
Fuse 1Brake warning lamp 4Brake fluid level

switch 5Ground
5
4
2
13680
35-23
Wear Indicator System Electric Circuit
3 2
4
5
*1 9
*2
*2
*2
*2
7 6
12846
1 Fuse box 8 Front brake pad wear indicator, LH

2 Meter cluster 9 Front brake pad wear indicator, RH
3 Disc brake warning lamp
4 Relay box *1 : < FE639 >
5 Lighting and alarm control unit *2 : < FE649 >
6 Rear brake pad wear indicator, LH < FE649 > : Warning signal
7 Rear brake pad wear indicator, RH < FE649 > : Wear indicator signal
The brake pad wear indicator system electrical circuit is provided for warning. When the brake pad is worn out, the disc
rotor disconnects wear indicators 6 to 9. Lighting and alarm control unit 5 detects this and gives a warning.
If one of pad wear indicators 6 to 9 is disconnected, lighting and alarm control unit 5 operates, lighting disc brake
warning lamp 3.
35-24
35
When normal operating
While lighting alarm control unit 5 is sending out

wear indicator signal , warning signal is not
input.
Since warning signal is not being input, disc brake
warning lamp 3 will not light up.
Fuse 1Lighting alarm control unit 5Ground
Wear indicator signal Brake pad wear indica-

tor 6 to 9Ground
12847
When brake pad wear indicator cut off
When lighting alarm control unit 5 stops sending out

wear indicator signal , warning signal is input.
When warning signal is input, disc brake warning
lamp 3 lights up.
Lighting alarm control unit 5Ground

Fuse 1
Disc brake warning lamp 3
Warning signal
14763
35-25
TROUBLESHOOTING
Wheel Brake
One-sided braking Noise and judder

Symptoms
when brakes are
applied

Noise and judder when brakes are applied


One-sided braking
vehicle jacked up
(at low speed)

pedal
Possible causes
Axle Wheel hub bearing adjusted incorrectly

^ Gr 26, 27
Left and right wheelbase difference excessive

^ Gr 26, 27
Wheel alignment incorrect ^ Gr 26
Kingpin bushing worn ^ Gr 26

material used

roughened

material)
Brake drum or disc rotor worn unevenly
Brake drum or disc rotor warped
Brake drum or disc rotor worn
Brake drum or disc rotor surface roughened
Brake drum or disc rotor roughness excessive
Brake drum or disc rotor glassy
35-26
35
Symptoms One-sided braking Noise and judder
when brakes are
applied

Noise and judder when brakes are applied


One-sided braking
vehicle jacked up
(at low speed)

pedal
Possible causes
brakes Brake drum clogged by foreign particles

Brake pedal adjusted incorrectly, looseness

excessive
Air lock in system
Vapor lock

system
cylinder
35-27
TROUBLESHOOTING


Remarks

Brakes squeaking
Action too severe
Brake juddering
replacement
Brake drags
Possible causes
Axle Wheel hub bearing adjusted incorrectly ^ Gr26, 27
Left and right wheelbase difference excessive ^ Gr26, 27
Wheel alignment incorrect ^ Gr26
Kingpin bushing worn ^ Gr26
material used
roughened

material)
Brake drum or disk rotor worn unevenly
Brake drum or disk rotor warped
Brake drum or disk rotor worn
Brake drum or disk rotor surface roughened
Brake drum or disk rotor roughness excessive
Brake drum or disk rotor glassy
35-28
35

Remarks

Brakes squeaking
Action too severe
Brake juddering
replacement
Brake drags
Possible causes
brakes Brake drum clogged by foreign particle
Brake pedal adjusted, looseness excessive
Air lock in system
Vapor lock

system
cylinder
35-29
TROUBLESHOOTING
Exhaust Brake
Symptoms
Exhaust brake does not release

Exhaust brake does not work
Remarks
Possible causes
Vacuum Degree of vacuum insufficient
system Pipe crushed
3-way Does not work
magnetic ^ Gr 54
valve
Exhaust Valve assembly does not work
brake Valve assembly shaft stuck
unit
Vacuum chamber does not work
Electric Electric system faulty
^ Gr 54
system
35-30
35
MEMO
35-31
Replacement of Brake Fluid
- Fluid
WARNING
ging.
purpose.
CAUTION
paintwork.
NOTE
the fluid tank.
35-32
35
Start the engine and let it idle until you complete brake fluid replace-
< Front disc brake >
ment.
Connect vinyl pipes A : one to the front disc brake, one to the rear
drum brake < FE639 > or the rear disc brake < FE649 >, and two to
the bypass valve.
Put the free ends of vinyl pipes A into containers B.
1
A
B 12934
< Rear drum brake >

< Rear disc brake >
A 1
B
B
06534
< Bypass valve >

1 A
1 B
12935
of the brake system is replaced with new fluid, and after you complete
the work, tighten each air bleeder 1 at specified torque.
12936
Bleed air from the brake system.
P35-34
07623
35-33
Air Bleeding of Brake System

- Fluid
WARNING
ging.
purpose.
CAUTION
paintwork.
NOTE
the fluid tank.
tank since the brake fluid level drops during air bleeding.
35-34
35
Start the engine and let it idle until you complete air bleeding of the
< Front disc brake >
brake system.
Connect vinyl pipes A : one to the front disc brake, one to the rear
drum brake < FE639 > or the rear disc brake < FE649 >, and two to
the bypass valve.
Put the free ends of vinyl pipes A into containers B and bleed the
brake system as follows:
1
12937 Disc brake, RH
B

< Rear drum brake >
< Rear disc brake >
Disc brake, LH
1
FE639 FE649
A 1
Rear drum brake, RH Disc brake, RH

A
Rear drum brake, LH Disc brake, LH
B
B
08834 < Bypass valve system >
< Bypass valve > Bypass valve
1
A
1
B
12938
1 at specified torque.
12936 Make sure that the brake fluid level is at the MAX level of the fluid
tank, and depress the brake pedal several times to ensure that the
brake fluid does not leak from anywhere. Then, conduct a brake test.
35-35
Inspection and Adjustment of Brake Pedal Free Play

Free play of brake pedal 10 to 15 {0.39 to 0.59} Adjust
[Inspection]
Check if brake pedal free play A confirms to the standard valve with the
engine stopped. If the measured value deviates from the standard value,
adjust the position of the brake pedal.
[Adjustment]
P35-51
06539
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel

Clearance between brake pedal and floor panel 45 {1.77} or more Adjust
(with pedal depressed at 490 N {110 lbf, 50 kgf})
[Inspection]
Depress the brake pedal using 490 N {110 lbf, 50 kgf} when the engine is
idling to check if clearance A between the brake pedal and the floor
panel conforms to the standard value. If the measured value deviates
from the standard value, adjust the position of the brake pedal.
[Adjustment]
A P35-51
06540
35-36
35
Inspection and Replacement of Disc Brake Pad

5, 6 Thickness of FE639 Front disc brake 12 {0.47} 4 {0.16} Replace
outer and FE649 Front disc brake 14 {0.55} 4 {0.16} Replace
inner pads
Rear disc brake 14 {0.55} 4 {0.16} Replace

3 Slide pin bolt tightening 83.3 to 93.1 {61 to 69, 8.5 to 9.5} Wet
- Fluid
3 Thread area of slide pin bolt Brake fluid

Piston expander MB990520 Pushing back of piston when replacing

brake pad
5 {0.20}
50 {1.97}
06815
2 [Inspection]
B
1 When brake pad thickness A decreases to approximately 4 mm
{0.16 in.}, brake pad wear indicator 1 makes contact with disc rotor 2
and is disconnected. This lights up brake warning lamp B within the
meter cluster, indicating that the brake pad should be replaced.
A
14352
35-37
Remove lower slide pin bolt 3.
Turn caliper 4 upward and secure it using wire.
3 4
CAUTION
Make sure that you do not smear, or get dust on, the grease
applied to slide pin bolt 3.
Be careful when you secure caliper 4 that you do not use exces-
8 sive force on the brake hose or brake pad wear indicator 1.
7 Make sure that you secure caliper 4 securely.
5, 6
Check thickness A of outer pad 5 and inner pad 6 and if the thickness
is lower than the limit, replace the pads on the same axle as a unit.
A 12650 Check if any fluid is leaking from piston 7, and check if piston boot 8 is
damaged. If any fault is found, replace the faulty parts.
[Replacement]
Remove the following parts:
13 9 Outer shim
1 5 Outer pad
12
14 10 Inner shim A
11 Inner shim B
14 13 12 Clip
10 6 Inner pad
11
6 13 Pad liner A
5 9
12651 14 Pad liner B
Install brake pad wear indicator 1 on inner pad 6 in the pad kit using
clip 12.
12
6
1
12652
Clean torque member 15.

13 Install the kit parts onto torque member 15 in the following order:
15 Install pad liner A 13 and pad liner B 14 on torque member 15.
4 14 Install outer shim 9 on outer pad 5.
Install inner shims 10, 11 on inner pad 6.
Install outer pad 5 on torque member 15.
14 13
Install inner pad 6 on torque member 15.
10 Install inner pad 6 so that brake pad wear indicator 1 faces the
11 2
entrance side (when the vehicle is moving forwards) of disc rotor 2
6
5 9 12830 of caliper 4.
35-38
35
Push piston 7 until it makes contact with the bottom of caliper 4.
06824
Slacken off caliper 4, taking care not to damage piston boot 8.

3 Bleed the bushing.
4 Apply brake fluid to the periphery of slide pin bolt 3 and its thread area.
Tighten slide pin bolt 3 at specified torque.
Wire up the harness of brake pad wear indicator 1. ^ Gr 26, 27
Inspect drag torque. P35-54, 58, 70
Depress the brake pedal several times.
8 Make sure that brake fluid is maintained at the MAX level of the fluid
tank. If the level drops, add brake fluid. P35-32
12831
35-39
Drum Brake Lining Thickness Inspection and Replacement

Thickness of brake lining 4 {0.16} Replace
(Side shoulder
means wear
limit)
[Inspection]
NOTE
A
2
Remove cover 1 from the backing plate.
Inspect through check hole A whether brake lining 2 is worn to the
2 point of side shoulder B of the brake lining (the limit).
1
B the same axle as a unit.
14361 After inspection, be sure to reinstall cover 1.
[Replacement]
P35-63
Inspection of Brake Shoe Clearance
A Insert 0.2 mm {0.0079 in.} feeler gauge A into inspection hole B of the
back plate, and make sure that you can move the gauge in and out
feeling some resistance. After this inspection, adjust the clearance if any
B
abnormality is found.
P35-61
08177
35-40
35
Inspection of Brake Booster (Master Vac)
Service standards
Air tightness with no load (with vacuum meter at Vacuum drop after 15 seconds
67 kPa {19.7 in. Hg, 500 mmHg} and engine stopped) should be 3.3 kPa
{0.98 in. Hg, 25 mmHg} or less
Airtightness with load (with brake pedal slightly Replace
depressed, vacuum meter at 67 kPa {19.7 in. Hg,
500 mmHg} and engine stopped)
Boosting action (Fluid 8 in.+9 in. 4410 kPa {640 lbf/in2, 45 kgf/cm2} Replace
pressure with vacuum meter at (98 N {22 lbf, 10 kgf})
67 kPa {19.7 in. Hg, 8340 kPa {1210 lbf/in2, 85 kgf/cm2}
depressed at specified foot
9 in.+10 in. 3920 kPa {570 lbf/in2, 40 kgf/cm2}
8830 kPa {1280 lbf/in2, 90 kgf/cm2}
(295 N {66 lbf, 30 kgf})
No boosting action (Fluid 8 in.+9 in. 295 kPa {43 lbf/in2, 3 kgf/cm2} Replace
pressure after vacuum meter (98 N {22 lbf, 10 kgf})
falls to 0 kPa {0 in. Hg, 1670 kPa {240 lbf/in2, 17 kgf/cm2}
depressed at specified foot 9 in.+10 in. 195 kP---a {28 lbf/in2, 2 kgf/cm2}
1470 kPa {215 lbf/in2, 15 kgf/cm2}
(295 N {66 lbf, 30 kgf})
[Inspection]
Two types of inspection are used to inspect the master vac operation,
inspection without a tester and inspection with a simple tester. Make
sure that there is no fluid leak or damage at the joints of the brake pipes
and hoses before inspection.
(1) Inspection of check valve operation
Be sure to inspect the check valve both when opened and when
closed.
CAUTION
Make sure that your saliva does not enter the check valve
when blowing air through the vacuum hose as this would
cause the check valve to malfunction.
NOTE
06542
The check valve fitted to the vacuum hose cannot be removed.
Start the engine

Stop the engine

Immediately after the engine has stopped, remove the clamps on the vacuum
pipe and the vacuum hose, and hold the vacuum hose in your mouth

No passage of air by your blowing in There is passage of air only at the

(The valve is closed) moment you inhale and depress the
brake pedal (The valve is open)

YES NO YES NO
Good Faulty Good Faulty

35-41
(2) Inspection of master vac operation
NOTE
If the master vac is faulty, determine the quality of the master
vac as an independent device by means of a bench test
specified by the makers service station. This is because the
above inspection of the master vac operation is merely a sim-
plified inspection. If any fault is found, hand the device over to
the service station without disassembling it, and replace the
whole assembly. P35-50
Inspection method without a tester
If the master vac is determined to be good by inspections 1 to 3 below,
its operation is normal. If any fault is detected in any of the three
inspections, the following parts are likely to be faulty.
Check valve
Vacuum hose
Master vac
Vacuum pump
[Inspection 1]
After one to two minutes operation, stop the engine

Depress the brake pedal using normal foot pressure

The brake stroke is longest in the first brake application, but becomes
3 shorter gradually in the second and the third application
2

1 06543 YES NO
Good Faulty
[Inspection 2]
Depress the brake pedal several times while the engine is stopped

With the brake pedal depressed, start the engine

The brake pedal goes down a little

YES NO
06544 Good Faulty
[Inspection 3]
With the brake pedal depressed while the engine is
running, stop the engine

The height of the brake pedal remains unchanged

for approximately 30 seconds

YES NO
Good Faulty
06545
35-42
35
B Inspection with a simplified tester
Airtightness inspection
3
Before inspection, observe the operation of check valve 2 fitted to
vacuum hose 1. P35-41
Remove vacuum hose 1 from master vac 3, place the end without
A the white mark on the master vac and connect it to vacuum
meter A. Connect another vacuum hose (without a built-in check
C
valve) between the vacuum meter and the master vac.
Connect pressure gauges B and foot pressure meter C as illus-
trated, and bleed the air from the pressure gauges.
21
06546 If the results of the following two airtightness inspections are satis-
factory, the operation is normal. If any fault is found in any of the
two inspections, the following parts are likely to be faulty.
Vacuum hose
Master vac
[No-load airtightness inspection]

Start the engine and stop it when the vacuum meter
indicates 67 kPa {19.7 in. Hg, 500 mmHg}

YES NO
Good Faulty
[At load airtightness inspection]

{19.7 in. Hg, 500 mmHg}


YES NO
Good Faulty
Be sure when you attach vacuum hose 1 to master vac 3 after the
inspection, that the end without the white mark faces the master
vac.
35-43
Inspection of characteristics
Inspect characteristics after the airtightness inspection is finished.
If the results of the following two inspections are good, the opera-
tion is normal. If any fault is found in any of the two inspections, the
following parts are likely to be faulty.
Vacuum hose
Master vac
[Boosting action inspection]

{19.7 in. Hg, 500 mmHg} and the brake pedal is depressed using
specified foot pressure, measure the fluid pressure


YES NO
Good Faulty
[No boosting action inspection]

Stop the engine, and when vacuum meter indicates 0 kPa {0 in. Hg,
0 mmHg} and the brake pedal is depressed using specified foot
pressure, measure the fluid pressure


YES NO
Good Faulty
Be sure when you attach vacuum hose 1 to master vac 3 after the
inspection, that the end without the white mark faces the master
vac.
35-44
35
< 8 inch+9 inch > Master vac performance diagram
93 {27.6, 700}

7850 {1760, 800} 80 {23.6, 600}
67 {19.7, 500}
5880 {1320, 600}

3920 {880, 400}
0 {0, 0}
1960 {440, 200}
0 {0, 0} 1960
980
{220, 100} {440, 200}
< 9 inch+10 inch >

93 {27.6, 700}
9810 {2200, 1000}

80 {23.6, 600}
67 {19.7, 500}
7850 {1760, 800}
5880 {1320, 600}
3920 {880, 400}
0 {0, 0}
1960 {440, 200}
0 {0, 0} 980 1960

{220, 100} {440, 200}
35-45
Inspection of Bypass Valve
Service standards
Fluid pressure (when master cylinder and bypass 3920 kPa Replace
outlet pressures balance) when the front brake {570 lbf/in2, 40 kgf/cm2} or less
system fails
- Fluid
WARNING
Before inspection do the following to prevent the vehicle from
moving accidently.
Carry out inspection on a level area.
Place chocks securely in place at the left and right front wheels.
Pull up the parking brake.
ging.
purpose.
CAUTION
paintwork.
NOTE
the fluid tank.
tank since the brake fluid level drops during inspection.
Make sure you maintain brake fluid at the MAX level of the fluid tank
since the brake fluid level drops during replacement.
35-46
35
Install oil pressure gauges C, D on inlet A of the master cylinder of the
D bypass valve, and outlet B of the bypass respectively.
C
1
12940
Bleed the brake system. P35-34
Connect vinyl pipes E to air bleeders 2 on the left and right front disc
brakes.
Put the free ends of vinyl pipes E into containers F.
Loosen air bleeder 2 by 90 to open the front brake system.
2
E
F 12934
Start the engine and let it idle.

D Depress the brake pedal gradually and read the gauges when the fluid
C
pressure from the brake master cylinder equals that from the bypass
outlet.
bypass valve 1.
< Fluid pressure at < Fluid pressure

bypass outlet > from brake
master cylinder >
12941
35-47
BRAKE MASTER CYLINDER
6
-
1
2 5
7 A
11381
1 Retaining ring 5 Clamp A : Master vac support
2 Primary piston assembly 6 Connector * : Master vac and brake pedal
3 Set bolt 7 Cylinder body assembly P35-50
4 Secondary piston assembly
WARNING
Be sure not to damage the inner surface of cylinder body 7, since it will cause air to get mixed in or will result
in brake fluid leakage during the removal and installation of primary piston assembly 2 and secondary piston
assembly 4.
Assembly sequence

2 Primary piston FE639 (Installed length 37.7 {1.48}) 99 to 120 N 93 N Replace
assembly {22 to 27 lbf, 10.1 to 12.3 kgf} {21 lbf, 9.5 kgf}
spring load FE649 (Installed length 36.3 {1.43}) 100 to 125 N 97 N Replace
{23 to 28 lbf, 10.5 to 12.7 kgf} {22 lbf, 9.9 kgf}
2, 4, 7 Clearance between primary and FE639 [30.16] 0.02 to 0.10 0.2 {0.0079} Replace
secondary piston assemblies and {[1.19] 0.00079 to 0.0039}
cylinder body FE649 [31.75] 0.02 to 0.10 0.2 {0.0079} Replace
{[1.25] 0.00079 to 0.0039}
4 Secondary FE639 (Installed length 30.7 {1.21}) 76 to 92 N 72 N Replace
piston {17 to 21 lbf, 7.8 to 9.4 kgf} {16 lbf, 7.3 kgf}
assembly FE649 (Installed length 31.0 {1.22}) 76 to 92 N 72 N Replace
spring load {17 to 21 lbf, 7.8 to 9.4 kgf} {16 lbf, 7.3 kgf}
35-48
35
3 Set bolt 6.86 to 8.82 {5.1 to 6.5, 0.7 to 0.9}
- Lubricant
1 Periphery of retaining ring Rubber grease As required
4
Service procedure
Secondary piston assembly
[Removal]
A Using rod A, push in secondary piston assembly 4, then loosen set
bolt 3.
4
3 05325
B Put plugs D into brake fluid filling port B and discharge port C that
leads to the rear wheel brakes, then feed compressed air via dis-
charge port E to the front wheel brakes to extract the secondary piston
assembly.
C WARNING
You must apply compressed air gradually when you remove
D E secondary piston assembly 4. If you applied compressed air
strongly at one time, the secondary piston assembly would be
violently ejected.
05326
[Installation]
A Using rod A, push in secondary piston assembly 4, then tighten set bolt 3
4
3 05325
35-49
BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC)
4
1
12
-5
7 3
8
2
10
9 12942
1 Nut 6 Spring 10 Brake pedal
2 Clevis pin 7 Collar 11 Stop lamp switch
3 Master vac 8 Bushing ^ Gr 54
4 Nut 9 Pedal pad 12 Support assembly
5 Bolt
NOTE
Do not disassemble master vac 3 because it is a non-disassemble type.
Assembly sequence
Adjustment after assembly P35-51

{0.00079 to 0.010}
10 Brake pedal Height from pedal pad center to 264 {10.4} Adjust
instrument panel underside
Full stroke 170 {6.69} Adjust
10, 11 Clearance between brake pedal stopper and tip of 0 to 0.1 {0 to 0.0039} Adjust
stop lamp switch thread area
35-50
35
1 Nut (Master vac mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4}
4 Nut (Brake pedal mounting) 34.3 to 53.9 {25 to 40, 3.5 to 5.5}
- Lubricant
5 Friction surface of bolt bushing Chassis grease [NLGI No.1 (Ca soap)] As required
Service procedure
1 Adjustment of brake pedal installation height

By turning operating rod C of master vac 1, adjust height B from the
center of pedal pad 9 to the underside of instrument panel A to the
A C D standard value, then secure in place using nut D.
WARNING
Make sure, when brake pedal 10 is depressed fully, that
operating rod C of master vac 1 functions as the stopper and
the pedal does not come to a stop by hitting against the floor
panel, since this will reduce brake effectiveness.
B
9 10 Inspection of brake pedal full stroke

Make sure that full stroke E when brake pedal 10 is depressed fully
If there is any fault, adjust the installation height of the brake pedal.
E
Inspection of play towards brake pedal Gr 35-36
G
05797
Adjustment of stop lamp switch

Turn stop lamp switch 11 to adjust clearance A between the top of the
thread area of the stop lamp switch and the stopper of brake pedal 10
to the standard value, and fasten with lock nut B.
10
WARNING
Make sure, when brake pedal 10 is released, that stop lamp
A
B switch 11 does not stop the pedal, since this will cause the
11 brake to drag.
05819
35-51

12
-
11 -
19
14
-

15
6-
- 15
14

5

-

06971
3 Piston 11 Clip (Upper) 18 Cap
4 Piston seal 12 Brake pad wear indicator 19 Torque member
5 Air bleeder (Lower) (Upper)
WARNING
CAUTION
Assembly sequence
1916171514
131211109
87
118
654
32
Seal kit
35-52
35
hub bolt :
95 N {21 lbf,
9.7 kgf}
force at
hub bolt :
67 N {15 lbf,
6.8 kgf}

- Lubricant and fluid

1 Slide pin bolt Periphery of slide Rubber grease As required
Seat of cap Rubber grease As required
35-53
Service procedure
force.
the standard value.
B
A 06972

17 E D Bleed bushing 16 or pin boot 17.
B A 1
16 E C
06959
C
3 Spread the grease applied to piston seal 4 evenly and install it into the
B A Install the caliper side seal of piston boot 2 to the boot groove B of
06960
< Inner side > < Outer side >

8
7
A
9 10
A A
A
A
A
A
13 06958
35-54
35
A
16
06962
B 19 A 17
and pin boot 17.
12943
19 1
N Installation of cap
Apply grease to cap seat surface A.
18
Install cap 18.
A
06964
E E
*
replace)
D
12832
35-55
12
11 -
14
- -
18

15
15
-

14
6-
5

-
12648
3 Piston 11 Clip (Upper) 18 Torque member
4 Piston seal 12 Brake pad wear indicator
5 Air bleeder (Lower) (Upper) * : Disc rotor ^ Gr 26
6 Caliper 13 Inner pad : Non-reusable parts
7 Outer shim 14 Pad liner A
WARNING
CAUTION
Assembly sequence
1817161514
131211109
87
1
654
32
Seal kit
35-56
35
hub bolt :
95 N {21 lbf,
9.7 kgf}
force at
hub bolt :
67 N {15 lbf,
6.8 kgf}


35-57
Service procedure
force.
the standard value.
B
A 06972

16 E A
C
06970

C
Spread the grease applied to piston seal 4 evenly and install it into the
3
A
06960
< Inner side >

9
< Outer side >
8
10 7
A
A
A
A
A
A 13 06975
35-58
35
A
16
06962
B 18 A 17
and pin boot 17.
12943
E E
*
replace)
D
12832
35-59
REAR WHEEL BRAKE < FE639 : DRUM BRAKE >
Rear Wheel Brake Assembly
10
11
13
12
14
-
2
- 3
6 2
05972
1 Return spring 10 Spacer
2 Shoe hold down cup 11 Bolt
3 Shoe hold down spring 12 Wheel cylinder assembly P35-65
4 Shoe hold down pin 13 Cover
6 Rivet 15 Backing plate
7 Brake lining
8 Brake shoe * : Brake drum ^ Gr 27
9 Pipe assembly
WARNING
CAUTION
screw of wheel cylinder assembly 12 since particles of brake lining 7 are clogged into them. P35-65
Assembly sequence
35-60
35
means wear lining
limit)
or replace
or replace

- Lubricant
Service procedure
play. If there is any play, correct it. ^ Gr 27
35-61
A
5
00320

hole C and lift adjusting lever D of wheel cylinder assembly 12.
E
Turn adjuster E of wheel cylinder assembly 12, through adjusting
12
C
F
06385

F
15
14363
obtained.
12. P35-65
B
1 Return spring
[Removal]
A
12
1
05879
35-62
35
D [Installation]
C
1
05880
7
12501
5 5K Installation of brake shoe assembly and backing plate

06215
15
06216
7 Brake lining
[Removal]
12806
35-63
[Installation]
Insert rivets 6 from brake lining 7 side, and caulk the rivets at the
the brake lining.
7 Caulking load for rivets : 211 kN {4630220 lbf, 2100100 kgf}
6
WARNING
CAUTION
shaft.

there are seams, correct by machining to the correction limit. Machining
integral part.
35-64
35
1 Spring
2 3 2 Spring and fitting
4 3 Lever
4 Piston cup
5 Piston
5 6 Boot
- 7 Adjusting screw
10 6
8 Adjuster
9 Washer
14 10 Piston cup
12 13
11 Piston

11 - 12 Boot
13 Bleeder screw
8- 14 Body
7-
Assembly sequence
141312
9876
1110 321
54

Standard value
5, 11, 14 Clearance between piston and body [28.57 {1.12}] 0.02 to 0.08 0.2 {0.0079} Replace
{0.00079 to 0.0031} piston

- Lubricant
5, 7, Thread areas of adjusting screw and adjuster, friction area of Rubber grease As required
8, 11 piston, and friction area of adjuster
35-65
1
1
Service procedure
14
05587
11 9 Installation of washer
Install the washer with its black side facing adjuster 8.
9
06149
35-66
35
MEMO
35-67
- 6-
15
- -
18 -

14 14
12 -
11
15
06979
1 Slide pin bolt 8 Outer pad 15 Pad liner B
2 Piston boot 9 Inner shim A 16 Bushing
3 Piston 10 Inner shim B 17 Pin boot
4 Piston seal 11 Clip 18 Torque member
5 Air bleeder 12 Brake pad wear indicator
WARNING
CAUTION
Assembly sequence
1817161514
131211109
87
1
654
32

Seal kit
35-68
35
* Disc rotor Wobble (When installed on rear axle) 0.07 {0.0028} or less 0.10 {0.0039} Replace
hub bolt :
88 N {20 lbf,
9 kgf}
force at
hub bolt :
62 N {14 lbf,
6.3 kgf}


Thread area Brake fluid As required
3 Piston Brake fluid As required
35-69
Service procedure
force.
the standard value.
B
A
06980

16 E A
C
06970

C
Spread the grease applied on piston seal 4 evenly to install it into the
3
A
06960
< Inner side >

9
< Outer side >
8
10 7
A
A
A
A
A
A 13 06981
35-70
35
L A:
Installation of bushing
Push bar approximately 8 mm {0.31 in.} long
18
After installation, apply grease to the whole inner periphery of bushing 16
A and its contact surface with slide pin bolt 1.
16
06962
B 18 A 17
and pin boot 17.
12943
E E
*
replace)
D
12832
35-71
VACUUM PUMP
6
1
A
7
-
8
3-
2
4
05412
1 Check valve assembly 5 Vane A : Positioning pin
2 Bolt 6 Rotor : Non-reusable parts
3 O-ring 7 O-ring
4 Cylinder 8 Flange
Assembly sequence
Service standards
Degree of vacuum 60 cm3 {3.66 cu. in.} : 93.3 kPa {27.6 in. Hg, 700 mmHg} Replace
of pump Engine speed 1500 rpm
90 cm3 {5.49 cu. in.} : 90.6 kPa {26.8 in. Hg, 680 mmHg} Replace
Engine speed 3000 rpm or more
- Lubricant
3, 7 Periphery of the O-ring Engine oil As required
35-72
35
MEMO
35-73
LOAD SENSING VALVE

1 4 1 Bolt
2 Nut
11 3 Rod assembly
10 4 Nut
9 5 Nut
6 Bracket and bolt assembly
7 Nut
5
8 Plate
9 Leaf spring
8 10 Bracket
6
11 Load sensing valve
7
* : Rear axle bracket
3 NOTE
* Do not disassemble load sensing valve
2
11 because it is a non-disassemble type.
Assembly sequence
verse.

1 Bolt (Load sensing valve mounting) 16 to 25 {12 to 18, 1.68 to 2.52}
2 Nut (Rod assembly mounting) 5.9 to 7.9 {4.3 to 5.8, 0.6 to 0.8}
4, 5 Nut (Leaf spring adjusting) 11.8 to 17.6 {8.7 to 13, 1.2 to 1.8}
7 Nut (Leaf spring mounting) 5.9 to 7.9 {4.3 to 5.8, 0.6 to 0.8}
Service procedure
[Installation]
Install load sensing valve 11 on the vehicle when it is unloaded and
mount ball joint part A of rod assembly 3 to rear axle bracket *.
Loosen nut 4 and nut 5 and adjust as follows.
11 4
3
A
07401
35-74
35
[Adjustment]
9 Free leaf spring 9 to lift up the leaf spring and fit plunger B to roller C.
In this condition, position nut 5 17 mm {0.67 in.} below the tip of leaf
4
17 mm
spring 9, then tighten nut 4 at specified torque.
B C {0.67 in.}
5
07397
35-75
Exhaust Brake Unit
1 Bolt
2 Cover
3 Clevis pin
4 Nut
5 Clevis
6 Lock nut
6 7 Bearing
7
8 Vacuum chamber
9 Nut
10 Lever
3
11 Bolt
12 12 Nut
13 Adjusting bolt
14
14 Bracket
9 15 Valve assembly
13
4
2
11 1
12649

8 Airtightness in vacuum chamber 63 kPa {18.7 in. Hg, 475 mmHg} Replace
(Airtightness 15 seconds after applying negative or more
pressure 67 kPa {19.7 in. Hg, 500 mmHg})
14 Average value of upper and lower clearance 0.10 to 0.25 {0.0039 to 0.0098} Adjust
between butterfly valve and body, when butterfly
valve is totally closed (Degree of vacuum in vacuum
chamber 86.7 to 93.3 kPa {25.6 to 27.6 in. Hg,
650 to 700 mmHg})

1 Bolt (Cover mounting) 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7}
4 Nut (Vacuum chamber mounting) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
6 Lock nut (Clevis fixing) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
9 Nut (Lever mounting) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
11 Bolt (Bracket mounting) 9.8 to 15.7 {7.2 to 12, 1.0 to 1.6}
12 Nut (Adjusting bolt fixing) 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7}
35-76
35
5
8 5
Service procedure
Adjustment of clevis
Install vacuum chamber 8 on bracket 14, and adjust the position of clevis
5 so that the hole of the clevis is half the pitch of the hole of lever 10.
10
14
05257
B
8 Test of vacuum chamber airtightness
Arrange piping as illustrated, and apply vacuum of 67 kPa {19.7 in. Hg,
500 mmHg} or more to vacuum chamber 8, then stop vacuum pump A.
After 15 seconds, ensure that the value of vacuum gauge B is the
A standard value. If the measured value deviates from the standard value,
8 replace the vacuum chamber.
05268
K Adjustment of valve assembly

[Fully-opened adjustment]
A Adjust using adjusting bolt 13 so that butterfly valve A of valve assembly
15 is fully opened.
15
13
05269
[Fully-closed adjustment]
While applying vacuum 87 to 93 kPa {25.6 to 27.6 in. Hg, 650 to
700 mmHg} to vacuum chamber 8, adjust using adjusting bolt 13 so
that the average value of clearance C and D between butterfly valve A
D 8 and body B is within the standard value.
C
13
B A Clearance=(C+D)/2
05270
35-77
Intake Silencer
1 Bolt
2 Nut
3 Actuator
4 Spacer
5 Thrust plate
6 O-ring
7 Intake manifold
Assembly sequence
7
6- Adjustment after assembly P 35-79

5
4
2
1
13255

3 Actuator (Push rod stroke when negative pressure 15 {0.59} or more Replace
of 40 kPa {11.8 in. Hg, 300 mmHg} applied)
Clearance between intake manifold and butterfly 3.6 to 4.0 {0.14 to 0.16} Adjust
valve when fully closed

2 Nut 8 {5.7, 0.8}
- Lubricant
6 O-ring Molybdenum disulfide grease As required
[NLGI No.2 Li soap]
35-78
35
Service procedure
Loosen bolts 1.
7
While applying negative pressure of 67 kPa {19.7 in. Hg, 500
7
mmHg} to actuator 3, adjust the position of the actuator so that
A clearance B between intake manifold 7 and butterfly valve A
Tighten bolts 1 and fix actuator 3.
B
3 1 13567
3 Inspection of actuator
Apply negative pressure of 40 kPa {11.8 in. Hg, 300 mmHg} to
3
actuator 3 and measure stroke A of the push rod.
40 kPa actuator 3.
{11.8 in. Hg,
300 mmHg}
A
13566
35-79
Exhaust Brake System Electric Equipment

8
6
12944
1 Accelerator switch ^ Gr 13, Gr 54

2 Clutch switch < Manual transmission > ^ Gr 21, Gr 54
3 Exhaust brake switch < Manual transmission > ^ Gr 37, Gr 54
4 Exhaust brake cut relay < Manual transmission > ^ Gr 54
5 Exhaust brake cut relay < Automatic transmission > ^ Gr 54
6 3-way magnetic valve (For exhaust brake) ^ Gr 54
7 3-way magnetic valve (For intake shutter) ^ Gr 54
8 Neutral switch < Manual transmission > ^ Gr 22, Gr 54
9 Inhibiter switch < Automatic transmission > ^ Gr 23, Gr 54
35-80
35
1
Service procedure
Adjustment of accelerator switch
Turn exhaust brake switch 3 ON, depress the accelerator pedal gradu-
ally, and make sure that when the engine revolution reaches 800 to
950 rpm, the exhaust brake operation indicator lamp within the meter
cluster goes OFF.
A If the indicator lamp goes OFF when the engine revolution is 800 rpm
or less, adjust accelerator switch 1 by screwing it in.
If the indicator lamp goes OFF when the engine revolution is 950 or
3
more, adjust accelerator switch 1 by unscrewing it.
12833
After adjustment, fix accelerator switch 1 using lock nut A.
35-81
Group 36
Parking Brake
Table of Contents
BACK
HOME
Pub No. TWSE9501-36

36
GROUP 36 PARKING BRAKE
SPECIFICATIONS .................................................................................. 2

Adjustment of Parking Brake Shoe Clearance
and Ratchet Bar Pulling Stroke ......................................................................... 5
PARKING BRAKE CONTROL ............................................................... 6
PARKING BRAKE ASSEMBLY .............................................................. 8
BACKING PLATE AND SHOE ASSEMBLY ......................................... 10
36-1
SPECIFICATIONS
Item Specifications
Brake Type Propeller shaft internal expanding type brake
Operation type Mechanical cable type
Parking brake Type Dual-servo type
assembly Inner diameter of drum mm {in.} 190 {7.48}
Lining width Thickness mm {in.} 454.0 {1.770.16}

Parking Brake Control
1 Parking brake ratchet bar
2 Parking brake cable
3 3 Parking brake assembly
14106
Parking Brake Assembly < Dual-servo Type >
3 1 Parking lever
2 Strut
4 3 Shoe return spring
2 4 Backing plate
5 Shoe and lining assembly
Pulling the parking brake ratchet bar pulls the parking brake cable,
which in turn pulls parking brake lever 1 installed in the parking brake
1 body, operating shoe and lining assembly 5.
5
03569 Activation of parking lever 1 expands one shoe and lining assembly 5
via strut 2, the parking lever itself expands the other shoe and lining
assembly. Therefore, both shoe and lining assemblies function as
leading shoes.
When the ratchet bar (parking lever) is returned, the repercussive
force of shoe return spring 3 releases the brake.
36-2
36
Parking Brake Electrical System
1 Fuse box
1 2 2 Meter cluster
3 3 Brake indicator lamp
A 4 Diode unit
5 Parking brake switch
A : To the brake fluid level switch

4
The parking brake electrical system is provided for
indicating, its detecting and indicating function is
5 activated by pulling the parking brake ratchet bar.
When the parking brake ratchet bar is pulled, the
contact point of parking brake switch 5 closes (ON),
and brake indicator lamp 3 is lit, indicating that the
14530
parking brake is operating.
The current flows as below:

Fuse 1 Brake indicator lamp 3 Diode unit 4
Parking brake switch 5 Ground
36-3
TROUBLESHOOTING
Symptoms
Parking brake does not release smoothly (dragging)

Parking brake does not work
Remarks
Possible causes
Inner cable stretched or damaged
Parking brake cable Inner cable rusted
Inner spring of cable deteriorated, fractured
Ratchet bar and ratchet pawl engaging incorrectly
Parking brake
ratchet bar Pulling stroke insufficient
Pulling stroke excessive
Shoe clearance insufficient
Shoe clearance excessive
Parking brake drum inner surface deformed or distorted
Parking brake Parking brake drum inner surface greasy or oily
assembly Linings worn unevenly
Lining surface greasy or oily
Shoe return spring deteriorated, fractured
36-4
Adjustment of Parking Brake Shoe Clearance and Ratchet Bar Pulling Stroke

Brake shoe clearance 0.2 to 0.25 {0.0079 to 0.0098} Adjust
4 Ratchet bar pulling stroke 80 to 120 {3.15 to 4.72} Adjust
(Operating force : 295 N {66 lbf, 30 kgf})

6 Lock nut 19 to 27 {14 to 20, 1.9 to 2.8}
(1) Shoe clearance

1 2 When parking lever 1 is released, turn adjuster 2 in the expansion
A direction, using a screwdriver inserted through the shoe adjusting hole
of the parking brake drum, and return 8 to 10 notches from the position
where shoe 3 is in close contact with the drum. Then, the shoe
B
clearance will be the standard value.
3 A : Contraction
B : Expansion
03599
(2) Ratchet bar pulling stroke

Adjust the adjusting nut of the parking brake cable so that the ratchet
bar pulling stroke is the standard value when parking brake ratchet bar
4 is pulled from the released position by an operating force of 295 N
80 to 120 mm
{3.15 to 4.72 in.} {66 lbf, 30 kgf}.
4 Operate ratchet bar two or three times after adjusting to verify the
pulling stroke, to make sure that the parking brake is operating prop-
erly and that the parking brake drum does not drag when the parking
brake is released.
03600
[Adjustment]
7 Tighten adjusting nut 5 until mark C can be seen.
C Tighten lock nut 6 to the position of adjusting nut 5.
Tighten lock nut 6 at specified torque.
Check clearance when the outer cable of parking brake cable 7 is
5 6 pulled by an operating force of 59 to 98 N {13 to 22 lbf.ft, 6 to 10
kgfm}.
3 to 7 mm {0.12 to 0.28 in.} 03602
36-5
PARKING BRAKE CONTROL
14107
Removal sequence
1 Parking brake ratchet bar assembly P36-7
2 Parking brake cable
* : Parking brake assembly P36-8
WARNING
You must place wheel chocks securely in place to prevent the vehicle from moving.
36-6
36
Parking Brake Ratchet Bar Assembly
2 Disassembly sequence
1 Push nut
- 2 Pin
6 3 Ratchet pawl
1
4 Ratchet spring
5 Push nut
6 Pin
11 3 7 Return spring
8 Ratchet bar
10 5 9 Parking brake switch ^ Gr 54
4 10 Grommet
11 Clip
9 12 Support
12 7
Assembly sequence
8 verse.
14108
- Lubricant
6 Sliding area between pin and ratchet bar Wheel bearing grease [NLGI No.2 (Li soap)] As required
36-7
PARKING BRAKE ASSEMBLY
1 Nut
2 Lock nut
3 O-ring
8 4 Dust plug
*2
5 Parking brake drum
6 Companion flange
5 7 Bolt
8 Backing plate and shoe assembly
P36-10
3 *1 : Propeller shaft ^ Gr 25
*2 : Parking brake cable P36-6
*1
4 2 WARNING
You must place wheel chocks securely
in place to prevent the vehicle from mov-
1 ing.
Do not remove the chocks until the en-
tire operation is completed.
03607
Assembly sequence

5 Parking brake drum Inner 190 +0.2
0 191 Replace
diameter

+0.0079
{7.52}
7.48
0
Squareness 0.05 {0.0020} or less
Concentricity 0.1 {0.0039} or less
Cylindrical 0.05 {0.0020} or less
accuracy
Static rotation 0.49 Ncm
imbalance {0.0036 lbf.ft, 50 gfcm} or less

1 Nut (Propeller shaft mounting) 98 to 120 {72 to 87, 10 to 12}
2 Lock nut (Companion Manual transmission 245 to 345 {180 to 255, 25 to 35}
flange mounting) Automatic transmission 195 to 450 {145 to 330, 20 to 46}
7 Bolt (Backing plate and shoe assembly mounting) 52 to 67 {38 to 49, 5.3 to 6.8}
36-8
36
90 {3.54}
100 {3.94}
6 Flange puller MH061848 Removal of companion flange
95 {3.74}
03618
6
6
Service procedure
Removal of companion flange
0
03609
36-9
BACKING PLATE AND SHOE ASSEMBLY
1 Shoe return spring
*2 2 Washer
3 Strut spring
4 Shoe hold down cup
5 Shoe hold down spring
1 6 Shoe hold down pin
2
7 Adjuster
8 Adjuster spring
3
6 9 Strut
10 Retainer
*1 9 11 Parking lever
12 Shoe and lining assembly
- 13 Backing plate
10 *1 : Retainer
8 *2 : Parking brake cable P36-6
11
4 -
5 Assembly sequence
4
verse.
03405
WARNING
Do not leave grease or oil on the surface of shoe and lining assembly 12 because this reduces braking
performance.
NOTE
If shoe and lining assembly 12 has been replaced with a new part, check correctness of contact with the
parking brake drum.

1 Installed load of shoe return spring 595.9 N {131.3 lbf.ft, 60.6 kgf} 49 N Replace
(Installed length : 67.1 {2.64}) {11 lbf, 5 kgf}
3 Installed load of strut spring 292.9 N {6.60.7 lbf.ft, 30.3 kgf} 26 N Replace
(Installed length : 49 {1.93}) {6 lbf, 2.7 kgf}
5 Installed load of shoe hold down spring 787.8 N {181.8 lbf.ft, 80.8 kgf} 71 N Replace
(Installed length : 15.5 {0.61}) {16 lbf, 7.2 kgf}
8 Installed load of adjuster spring 595.9 N {131.3 lbf.ft, 60.6 kgf} 49 N Replace
(Installed length : 78.2 {3.08}) {11 lbf, 5 kgf}
12 Thickness of lining 4 {0.16} 1.4 {0.055} Replace
- Lubricant
7 Contact surfaces of both ends of adjuster with shoe Brake grease As required
and lining assembly
13 Anchor pin area and sliding face (6 points) of backing plate Brake grease As required
36-10
36
D 7
7I
Service procedure
Applying grease to adjuster and backing plate
Apply grease to contact surface C between both ends of adjuster 7
13 and shoe and lining assembly 12.
Apply grease to area D of the anchor pin and sliding face E (6 points)
of backing plate 13.
12
12 12
AA E
BB
A
12 A
12
13
C B C
H
03567
Inspection of shoe and lining assembly

Measure thickness A of the lining. If the measured value is lower the
12
limit, replace shoe and lining assembly 12.
14921
36-11
Group 37 - Steering
Group 37 - Steering
BACK HOME
Group 37
Steering
' 98 Minor Change

Table of Contents
BACK HOME

37
GROUP 37 STEERING
SPECIFICATIONS ........................................................................... 37- 2

Change of Power Steering Fluid ............................................................... 37- 11
Bleeding of Power Steering System ......................................................... 37- 12
Steering Wheel Play ................................................................................... 37- 12
Performance Verification Test of Power Steering System ..................... 37- 13
STEERING SYSTEM ....................................................................... 37- 14
STEERING COLUMN SUBASSEMBLY .......................................... 37- 20
POWER STEERING BOOSTER

< FE > .............................................................................................................. 37- 24
< FG > ............................................................................................................. 37- 30
POWER STEERING OIL PUMP ...................................................... 37- 36
POWER STEERING OIL TANK....................................................... 37- 40
POWER STEERING FLUID LINE ................................................... 37- 41
DRAG LINK ..................................................................................... 37- 42
TIE ROD ASSEMBLY ...................................................................... 37- 44
37-1
SPECIFICATIONS
Model FE FG
Item
Steering wheel Type 2-spoke type
Outer diameter mm {in.} 400 {15.7}
Steering shaft Type Universal joint type (High tilt and telescopic type)
Power steering Manufacturer KOYO SEIKO
booster Type Ball nut type
Form Integral type
Gear ratio 22.6
Cylinder diameter mm {in.} 78 {3.07}
Mass (without pitman arm and fluid) 18.2 {40} 16.7 {37}
kg {lb}
Power steering Manufacturer NIPPON POWER STEERING
oil pump Type Vane type
Discharge amount 9.6 {0.59}
cm3 {cu.in.}/rev
Regulated flow amount 7 {7.4}
L {qts}/min
Regulated pressure
(relief valve) 9.3 {1350, 95} 10.3 {1490, 105}
MPa {lbf/in2., kgf/cm2}
Permissible revolutions rpm 600 to 6500
Mass (without drive gear and fluid) 1.64 {3.6}
kg {lb}
37-2
Steering System
1 Steering wheel
2 Steering column subassembly
3 Power steering booster
1
4 Pitman arm
2 5 Drag link
6 Knuckle arm
7 Tie rod
8 Tie rod arm
5 8
4
6
08220
Shifting lock lever A from lock position B to release

H position C produces high tilt D, and turning telescopic
lever E (counterclockwise) from lock position F to re-
D
lease position G allows telescopic movement H. In this
way, the structure of steering column subassembly 2
2 can be adjusted for optimum driving position.
F G
E
C
B
07017
37-3
Power Steering System
1 Power steering oil tank
1 2 Power steering oil pump
: Fluid flow
2
08371
Power Steering Booster
13
12
14
4 11
15
5 16
3
10
1 2
17
6 9
7 18
8
19
20
21
29 28 27 26 25 24 23 22
27494
37-4
37
1 Lock nut 11 Valve housing 21 Backup ring
2 Sector shaft 12 Dust cover 22 U-packing
3 Gear box 13 Input shaft 23 Needle bearing
4 Steel ball 14 Oil seal 24 Needle bearing
5 Circulator 15 Bearing 25 U-packing
6 Adjusting plate 16 Rotary valve 26 Backup ring
7 Side cover 17 Lock screw 27 Oil seal
8 Nut 18 Main shaft 28 Dust cover
9 Torsion bar 19 Rack piston 29 Pitman arm
10 Bearing 20 Adjusting bolt
Rotary valve 16 is the central part of the power steering booster. Torsion bar 9 allows the steering reaction force and
valve return to operate lightly and smoothly at low speed, and ensures stable steering feel even at high speed.
Straight-ahead drive operation

A
13 When steering torque is not applied by the steering wheel, input shaft
A 16 13 is not activated and remains in neutral. At this time, pressurized
D fluid from the oil pump flows through the input shaft and the hole of
rotary valve 16, and returns to the oil tank without flowing into cylinder
A
chambers B, C.
A A : From the oil pump
C B D : To the oil tank
06590
Steering operation
A
13 Turning the steering wheel rotates input shaft 13, causing rotary valve
A 16 to close the fluid feed passage to cylinder chamber C. This pro-
D 16 duces a pressure difference between cylinder chambers B, C, which
A causes rack piston 19 to move, and facilitates rotation of main shaft
18.
A The illustration shows right-turn steering, and should be reversed for
19
C B left-turn steering.
06591
Operation when hydraulic circuit is faulty

E
18 The safety structure means that when the fluid circuit is faulty, the
stopper of input shaft 13 directly contacts the groove at the large end
of main shaft 18 to transmit steering force, enabling manual operation.
13
06592
37-5
Power Steering Oil Pump
1 2 3 6 7
4 8 9 10 11
15
14
20 19
12
13
18 17 16
06801
1 Cam ring 9 Oil seal 17 Relief valve assembly

2 Vane 10 Side plate 18 Flow control spring
3 Rotor 11 Bolt 19 Bolt
4 Pin 12 Cover 20 Body
5 Lock nut 13 Suction connector
6 Gear 14 Shaft A : Direction of rotation
7 Snap ring 15 Key
8 Bearing 16 Connector
37-6
37
Relief Valve Assembly
Operation of flow control valve
C (1) When not operating (Oil pump rotating at low speed)

A
18 Since pressure generated from pressure chamber A is low when the
D oil pump is rotating at low speed, fluid pressure in chamber B is also
low. Therefore, relief valve assembly 17, which is pressed by the
repercussive force of flow control spring 18 is not activated.
C : Direction of rotation
D : To the power steering booster
17 B 06802
(2) When operating (Oil pump rotating at middle or high speed)

Since pressure generated from pressure chamber A is high when the
C oil pump is rotating at middle or high speed, fluid pressure in chamber
A
18 B is also high. This will activate relief valve assembly 17, overcoming
D the repercussive force of flow control spring 18, and open port E,
making excess fluid return to the inlet port to adequately regulate the
flow of fluid to power steering booster D.
17 E B 06803
Operation of relief valve

When the steering is lock-to-lock, pressure in chambers B and F
H
C increases and overcomes the repercussive force of relief spring G
A
J opening relief valve J, which was closed by steel ball H, causing the
18 D fluid to be returned to the inlet port through port E. Thus, if pressure in
F chamber F decreases, the relief valve closes again.
17 G E B 06804
37-7
TROUBLESHOOTING
Symptoms
Steering angle insufficient or difference between right and left

Steering wheel play excessive and unstable
Oil pump fluid pressure abnormal

Steering wheel pulls to one side
Steering wheel operation heavy
Steering wheel self-return bad

Remarks
Steering wheel does not turn

Steering wheel vibration
Oil pump squeaks

Oil pump gurgles
Oil pump growls

Fluid leaking
Possible causes
Bearing damaged or worn
Ball or groove of ball screw set shaft worn
Air bled insufficiently
Fluid viscosity unsuitable
Power steering booster system faulty
Flow control valve malfunctioning
Power steering mechanism faulty
Rack or ball screw set shaft gear worn

Sector shaft bearing worn
Power steering booster mounting bolt loose
Ball screw set shaft and sector shaft play incorrect
Edge of valve control damaged or control seal
ring broken
Power steering system fluid unsuitable

Rack engagement starting torque adjusted

incorrectly
Fluid circuit clogged
Sector shaft gear worn
Torsion shaft serration damaged or worn
Power steering booster body faulty
O-ring or oil seal faulty
Sealant applied incorrectly
Universal joint worn abnormally, damaged,
Steering column and

link mechanism faulty
lubricated incorrectly
Link deformed
Drag link ball stud excessive play
Tie rod end ball stud excessive play
Tie rod bent
Pitman arm mounting position incorrect
Steering wheel center offset
37-8
37
Symptoms


Remarks

Oil pump squeaks

Oil pump gurgles
Oil pump growls

Fluid leaking
Possible causes
Kingpin lubricated incorrectly
Front wheel alignment (toe-in, camber,

caster) incorrect
Thrust bearing damaged
Wheel hub bearing worn or damaged ^ Gr 26
Front axle faulty
Kingpin or bushing worn or damaged ^ Gr 26B

Front axle deformed
Knuckle arm, tie rod arm, knuckle, etc.
tightened incorrectly
U-bolt of front spring, nut loose ^ Gr 33

Front axle parts overtightened
Turning angle adjusted incorrectly
^ Gr 26
Mounting parts, connection point loose ^ Gr 26B
Knuckle stopper bolt adjusted incorrectly
Oil pump body faulty
O-ring, oil seal faulty
Bolt tightened incorrectly
Maximum generated fluid pressure
Oil pump faulty
insufficient
Fluid line crushed or clogged

Air lock in oil pump
Oil pump interior seized
Mounting bolt or nut loose
Pump body faulty
Valve malfunctioning
37-9
TROUBLESHOOTING
Symptoms

Remarks


Oil pump squeaks

Oil pump gurgles
Oil pump growls

Fluid leaking
Possible causes

Oil tank
Oil tank leaking due to overflowing

faulty
Oil tank leaking due to air lock

Fluid level insufficient
Load too far forward of load-carrying platform
Load too far rearward of load-carrying platform
Load too far to one side of load-carrying platform
Wheelbase gap between left and right excessive
Propeller shaft run out excessive ^ Gr 25
Front axle bent < FE > ^ Gr 26
Other malfunctions
Front axle housing bent < FG > ^ Gr 26B

Rear axle housing bent
Final drive gear and final drive pinion damaged ^ Gr 27

or engaged incorrectly ^ Gr 26B
Tire pressure insufficient
Tire pressure excessive
Tire wear difference between left and right

excessive ^ Gr 31
Tire outer diameter difference between left

and right
Front tire radial and lateral runout, static

balance or dynamic balance faulty
One-sided braking ^ Gr 35
37-10
ON-VEHICLE INSPECTION AND ADJUSTMENT 37
Change of Power Steering Fluid

[Draining]
steering booster.
specified torque.
[Filling]
P37-12
08583
37-11
Bleeding of Power Steering System
- Fluid
1 Power steering oil tank Automatic transmission fluid (DEXRON Filler cap
or DEXRON II type) dipstick
between
MIN and
MAX
CAUTION
3 Do not keep the steering wheel turned fully to the left or right for
1 more than fifteen seconds when the engine is running, as this
2
can cause the power steering oil pump to seize up.
A 2.
07236 dropped, add fluid to maintain the fluid level within range A.
NOTE
right repeatedly. When the fluid level has dropped, add the fluid to
maintain the fluid level within range A. Repeat these steps until the
fluid level does not drop.
wheel several times to raise fluid temperature to approximately 60 to
80C {140 to 176F}, then stop the engine and wait for approximately
five minutes.
1, and pipe and hose connections for fluid leaks.
Steering Wheel Play
Steering wheel play (Measure at the outer 0 to 50 {0 to 1.97} Adjust
circumference of steering wheel)
Point the wheels directly forward, start the engine and gently turn the
steering wheel left and right to measure play at the outer circumference.
If the play deviates from the standard value, adjust tightening points and
power steering booster backlash. P37-26, 33
08372
37-12
37
Performance Verification Test of Power Steering System
Service standards
2 2
Steering system fluid pressure (With hands off 490 kPa {71 lbf/in , 5 kgf/cm } Repair
steering wheel)
Relief set pressure (Measure with engine FE 9.3 MPa {1350 lbf/in2, 95 kgf/cm2} Maximum Replace
speed at 1000 to 1500 rpm and +195 kPa
stop valve closed) {28 lbf/in2,
2 kgf/cm2}
Minimum
295 kPa
{43 lbf/in2,
3 kgf/cm2}
FG 10.3 MPa {1490 lbf/in2, 105 kgf/cm2} Maximum Replace
0 kPa
{0 lbf/in2,
0 kgf/cm2}
Minimum
490 kPa
{71 lbf/in2,
5 kgf/cm2}
Verify that the power steering booster and the power steering oil pump
are operating properly by testing the following items.
CAUTION
Do not keep the steering wheel turned fully to the left or right for
A more than fifteen seconds when the engine is running, as this
B
can cause the power steering oil pump to seize up.
1 NOTE
If the fluid pressure is higher than 490 kPa {71 lbf/in2, 5 kgf/cm2}
08373 with engine idling and the steering wheel free, inspect power
steering booster 1 and fluid circuit for clogging.
Test item Test procedure Assembly standards
Verification of Jack up the front wheels and turn steering wheel fully left Smooth operation through-
smooth operation and right out test
Install oil pressure gauge A capable of measuring above
10.8 MPa {1560 lbf/in2, 110 kgf/cm2} and stop valve B, then
Measurement
bleed air
conditions
With engine idling, turn steering wheel left and right several
times to raise fluid temperature to 50 to 60C {122 to 140F}
With the engine idling, open stop valve B
Measurement of fluid Measure fluid pressure with hands off steering wheel 490 kPa {71 lbf/in2, 5 kgf/cm2}
pressure
Measurement of Gradually increase engine speed and maintain it at 1000 Relief set pressure 9.3 MPa
relief pressure to 1500 rpm, and close stop valve B to measure maximum {1350 lbf/in2, 95 kgf/cm2} < FE >,
fluid pressure 10.3 MPa {1490 lbf/in2, 105 kgf/
cm2} < FG >
37-13
STEERING SYSTEM
5

6
8
2
9
4
10
14
12
13 18
- 11
3
< FE > 1

29
15

32
19
*
23
32
33 * 22
21
20
28
< FG >
27
29

32
30
33
32
27001
37-14
37
Removal sequence
1 Column cover outer lower 15 Bracket 28 Return tube P37-41
2 Column cover outer upper 16 Head cutting bolt 29 Drag link P37-42
3 Column cover inner lower 17 Starter switch ^ Gr 54 30 Nut
4 Column cover inner upper 18 Spring 31 Power steering booster
5 Horn pad 19 Band P37-24, 30
6 Nut 20 Nut 32 Nut
7 Telescopic lever 21 Dust cover 33 Tie rod assembly
8 Nut 22 Dust cover P37-44
10 Horn spring 24 Bolt * : Front axle assembly
11 Cover assembly 25 Bolt < FE > ^ Gr 26
12 Steering wheel 26 Steering column subassembly < FG > ^ Gr26B
13 Screw P37-20
14 Combination switch ^ Gr 54 27 Pressure tube P37-41 : Non-reusable parts
CAUTION
When disconnecting pressure tube 27 and return tube 28, clean the ports to keep them free from dust and

6 Nut (Telescopic lever mounting) 8.8 to 9.8 {6.5 to 7.2, 0.9 to 1.0}
30 Nut (Power steering booster mounting) 83.5 to 108 {61 to 80, 8.5 to 11.0}
- Lubricant
37-15
STEERING SYSTEM
B
A
7
Service procedure
Telescopic lever
[Removal]
18mm
Secure screw A (M50.8 mm) in tapped hole in telescopic lever 7 and
{0.71 in.} remove telescopic lever from telescopic shaft B.
or more
M50.8 mm
7
24477
[Installation]
D
Locate telescopic lever 7 at the specified position (locked), and adjust
until the specified torque is applied to telescopic shaft B.
Free
CAUTION
Do not crush the screw tip of telescopic shaft B.
Locked 9 B 6
7
8 C 06995
37-16
37
>
<
Rotate telescopic shaft B counterclockwise with your fingers and check
for looseness
<
<
Using a flat-blade screwdriver turn telescopic shaft B > Set telescopic lever 7 to specified lock po-
sition D, marked
clockwise and drive it in until it hits lightly with a
clunk, but do not turn it any further
>
<
CAUTION
Be careful not to tighten too forcibly or you will
crush the end of the telescopic shaft, requiring
replacement of telescopic shaft assembly C
<
<

will not slip
Lock
<
position 30
Tighten telescopic shaft B at operating torque 6.9 to
06709
8 kgf} 100 mm {3.94 in.}from the center of steering When telescopic lever 7 is released, and tel-
wheel assembly 9 escopic shaft B is retightened at operating
<

tion 30
<
range range
NOTE
Remove telescopic lever 7 following the descrip-
<
tion under [Removal], taking care not to loosen Joggle steering wheel assembly 9 up and
telescopic shaft B. down and check for looseness

<
<
Procedure is
completed
CAUTION
Be sure not to operate telescopic shaft B while steering wheel assembly 9 is removed.
NOTE
Be sure to assemble telescopic lever 7 only after steering wheel assembly 9 has been installed.
37-17
STEERING SYSTEM
16
LM
[Removal]
cutting bolt 16.
15
17
B 07241
[Installation]
16 16
15
24
07242
25 TU Installation of bolt
Thread area A of bolt 24 is elliptical to facilitate grounding of the horn
circuit.
26 A
07243
V[ Removal and installation of steering column

31
08374
V Steering column subassembly

A
26
A
07254
37-18
37
MEMO
37-19
STEERING COLUMN SUBASSEMBLY

4 2
1
2
5
23 -
24
- 23
3
25
11 6 14
- 20
16

20
19
21

26 -
8 15
18 -
9
-
07019
37-20
37
1 Return spring 11 Nut 21 Lever support
2 Nut 12 Lock lever 22 Clevis pin
3 Support bracket 13 Split pin 23 Bolt
4 Spring seat 14 Return spring 24 Column support upper
5 Steering column assembly 15 Return spring 25 Telescopic shaft assembly
6 Nut 16 Snap ring 26 Column support lower
7 Stopper 17 Cam
8 Bearing spacer 18 Lock plate : Non-reusable parts
9 Grease nipple 19 Wave washer
10 Steering shaft assembly 20 Bolt
Assembly sequence
54321
25 24
5: 23 22 21 20 19 18 17 16 15 14 13 12 11
6
26 10 9 8 7

2 Nut (Support bracket mounting) 17 to 26 {12 to 19, 1.7 to 2.6}
6 Nut (Steering shaft assembly and telescopic 53 to 65 {39 to 48, 5.4 to 6.6}
shaft assembly mounting)
11 Nut (Lock lever mounting) 4 to 6 {2.9 to 4.3, 0.4 to 0.6}
20 Bolt (Lever support mounting) 7 to 10 {5.1 to 7.2, 0.7 to 1.0}
23 Bolt (Column support upper and column support 15 to 20 {11 to 14, 1.5 to 2.0}
lower mounting)

9 Supply via grease nipple Wheel bearing grease [NLGI No.2 (Li soap)] As required
15 Friction surface of return spring and washer Wheel bearing grease [NLGI No.2 (Li soap)] As required
16 Friction surfaces of lever support and snap ring Wheel bearing grease [NLGI No.2 (Li soap)] As required
18 Friction surfaces of cam and lock plate return spring clevis pin Wheel bearing grease [NLGI No.2 (Li soap)] As required
23 Thread area of bolt THREEBOND thread lock super 103Q As required
or LOCTITE 271
Friction surface of column support upper and bolt Wheel bearing grease [NLGI No.2 (Li soap)] As required
37-21
8 7
Service procedure
Installation of stopper
Install stoppers 7 on steering shaft assembly 10 in the direction as
illustrated so that they straddle bearing spacer 8.
F
10 7 11310
Steering shaft assembly

Before removing steering shaft assembly 10, be sure to make align-
ment mark A.
25 Install the steering shaft with direction B of the telescopic shaft assem-
B B
bly 25 yoke and steering shaft assembly 10 yoke aligned or at phase
angle of 90.
H
10
A 07255
Installation of lock lever

Install lock lever 12 so it is within the working angle when locked.
After installing lock lever 12, make sure that the lever operates
17 mm smoothly (operating force less than 49 N {11 lbf, 5 kgf}). With the lever
{0.67 in.} free, make sure that high tilt operates smoothly.
Locked
Free
I
12
06998
Installation of split pin

Bend split pin 13 to face outwards as illustrated.
13
B=
4.5 mm
{0.18 in.} 18 21
07246
M Installation of cam
Adjust lever support 21 so that the top surface A of cam 17 is within
2.5 mm
{0.098 in.} 17 dimension B of lock plate 18 to install the cam.
A
18
17
06999
37-22
37
R Installation of clevis pin
Drive clevis pin 22 into column support upper 24 so that the drive
dimension is obtained.
13 mm {0.51 in.} 24
22 07000
37-23
POWER STEERING BOOSTER < FE >
- 14
15
20

1

17
-
- 3
19

9 18
- 10
11 16
12
5
25
4 24

- 22 -

6
7 -
27495

P37-26
1 Lock nut 11 U-packing 21 Oil seal
2 Pitman arm 12 Backup ring 22 Needle bearing
3 Dust cover 13 Side cover 23 U-packing
4 Nut 14 Dust cover 24 Backup ring
5 Bolt 15 Bolt 25 Gear box
6 Adjusting bolt 16 O-ring
7 Adjusting plate 17 O-ring : Non-reusable parts
8 Sector shaft 18 Seal ring
9 O-ring 19 O-ring
10 Needle bearing 20 Ball screw set shaft
NOTE
Do not disassemble needle bearing 10, 22 and ball screw set shaft 20 unless they are faulty.
Replace U-packings 11, 23 together with backup rings 12 and 24.

P37-26
37-24
37
Assembly sequence
25 24 23 22 21 16
15 14 5 4 3 2 1

20 19 18 17

13 12 11 10 9

678
Repair kit : Seal kit

Standard value
6, 8 Axial play of center shaft and adjusting bolt 0.1 {0.0039} or less 0.1 {0.0039} Replace
Sector shaft
assy
8 Axis diameter of sector shaft (at gear box) [42] 0.008 to +0.005 0.003 Gap between
{[1.65] 0.00031 to +0.00020} {0.00012} worn area
and unworn
area
20 Rotating torque of ball screw set shaft 15 to 69 Ncm
{0.11 to 0.51 lbf.ft, 1.5 to 7.0 kgfcm}
20, 25 Clearance between ball screw set shaft and gear box 0.022 to 0.069 {0.00087 to 0.0027} Replace
25 Inner diameter of gear box [78] 0.012 to 0.034 0.05 Gap between
{[3.1] 0.00047 to 0.0013} {0.0020} worn area
and unworn
area
Total starting torque with power steering booster 98 Ncm {0.72 lbf.ft, 10 kgfcm} Adjust
or less
Engagement torque 20 to 49 Ncm Adjust
{0.14 to 0.36 lbf.ft, 2 to 5 kgfcm}

1 Lock nut (Pitman arm mounting) 245 to 294 {180 to 215, 25 to 30}
4 Nut tightening 29 to 39 {22 to 29, 3 to 4}
5, 15 Bolt (Side cover and valve housing mounting) 98 to 115 {72 to 87, 10 to 12}

3, 14 Pack interior of dust cover Wheel bearing grease [NLGI No.2 (Li soap)] As required
4 Nut fixing point THREEBOND 1104 As required
6 Head of the adjusting bolt Wheel bearing grease [NLGI No.2 (Li soap)] As required
11, 23 Inside periphery of U-packing Wheel bearing grease [NLGI No.2 (Li soap)] As required
37-25
49 {1.93}
76 {2.99}
2 Pitman arm puller MH062472 Removal of pitman arm
01355
Service procedure
[Measurement of total starting torque]
Before disassembly, measure the total starting torque for a reference
during assembly.
27496

While turning ball screw set shaft 20, one quarter of a turn left and
right from the neutral position using a torque meter, drive adjusting
bolt 6 in, then adjust so that the total starting torque or the engage-
20 ment torque is within the standard value.
2
27497
Pitman arm
0
[Removal]
0 : Pitman arm puller
2
27498
37-26
37
[Installation]
2 Align slit B of the V-groove of sector shaft 8 on the same line as slit A of
the V-groove of pitman arm 2 when installing it.
8
A
8I
06691
20 Sector shaft and side cover

[Removal]
Turn ball screw set shaft 20 counterclockwise to the lock position, then
turn it clockwise approximately 2.6 turns, so that slit A of the V-groove
8 at the end of sector shaft 8 is in the neutral position as illustrated.
NOTE
At this time, make sure that slit A of the V-groove at the end of
sector shaft 8 is at right angles to the axial line of ball screw set
A
27499 shaft 20.
8 Loosen nut 4 and remove bolt 5. After making sure that sector shaft 8
is in the neutral position, tap the end of the sector shaft, and pull out
B
side cover 13 together with the sector shaft.
13
B : Plastic-headed mallet
4
5
27500
[Installation]
A 8 With ball screw set shaft 20 in the neutral position, insert sector shaft 8
and side cover 13.
13 CAUTION
Insert sector shaft 8 with the thread area of the shaft end and
serration area protected by cover A to prevent damage to the oil
seal.
20
27501 NOTE
Turn ball screw set shaft 20, and make sure that the shaft rotates
approximately five turns lock-to-lock.
If the number of turns is less, inspect engagement of ball screw
set shaft 20 and sector shaft 8.
37-27
11, 23 A 12, 24
GS Installation of U-packing
Apply grease to lip area A of U-packing 11, 23 and install into gear box
25 as illustrated.
25
Q
27502
A Apply grease to lip area A of oil seal 21 and install into gear box 25 as
21
illustrated.
25
27503
37-28
37
MEMO
37-29
POWER STEERING BOOSTER < FG >
- 17
18 25
24
- 19
22
21 28

1
-
20 27 - 3
9 26
10
11
32
5 14
31
- 30 15
7
6
08221

P37-32
1 Lock nut 13 Special nut 25 Seal ring
2 Pitman arm 14 O-ring 26 Seal ring
3 Dust cover 15 Bearing 27 O-ring
4 Bolt 16 End cover 28 Ball screw set shaft
5 Nut 17 Dust cover 29 Oil seal
6 Adjusting plate 18 Bolt 30 Needle bearing
7 Adjusting bolt 19 O-ring 31 U-packing
8 Sector shaft 20 O-ring 32 Gear box
9 O-ring 21 Bearing
10 Needle bearing 22 Bearing : Non-reusable parts
11 U-packing 23 Oil seal
12 Side cover 24 Valve housing
37-30
37
NOTE

P37-33
Assembly sequence
16 15 14

32 31 30 29

18 17 13 4 3 2 1

28 27 26 25
24 23 22 21 20 19
12 11 10 9
5
768

adjusting
plate
{[1.57] 0.00031 to +0.00020} {0.00012} worn area
and unworn
area
28 Main shaft outer diameter of ball screw set shaft [22.5] 0.05 to 0 {[0.89] 0.0020 to 0} Replace
Rotating torque of ball screw set shaft 29 to 69 Ncm Adjust
{[3.1] 0.00047 to 0.0013} {0.0020} worn area
and unworn
area
or less

4 Bolt (Side cover mounting) 74 to 98 {54 to 72, 7.5 to 10}
13 Special nut mounting 177 to 226 {130 to 165, 18 to 23}
18 Bolt (Valve housing mounting) 44 to 54 {33 to 40, 4.5 to 5.5}
37-31
23, 29 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required

49 {1.93}
76 {2.99}
01355
19 {0.75}
8 {0.31}
13 Special nut wrench MH061594 Removal and installation of special nut

70 {2.76}
100 {3.94} 06600
4.8 47.5
{0.19} {1.87}
16 End cover wrench MH061593 Removal and installation of end cover

400 {15.7}
60 {2.36}
06687
Service procedure
during assembly.
06688
37-32
37
2
08222
Pitman arm
0
[Removal]
0 : Pitman arm puller
06704
[Installation]
8
A
8H
06691

[Removal]
NOTE
A
08223 shaft 28.
37-33
B is in the neutral position, tap the end of the sector shaft, and pull out
12
5
4
06693
[Installation]
and side cover 12.
12 CAUTION
seal.
28
06694 NOTE
I
Removal and installation of special nut

13 0 : Special nut wrench
L
06568
End cover
16
[Removal]
0 : End cover wrench
06569
37-34
37
[Installation]
32
Install inner race of bearing 15 onto the end of ball screw set shaft 28,
then install the outer race of the bearing onto end cover 16 and screw
15
into gear box 32.
28
16 08224
Making sure that the rotation torque of ball screw set shaft 28 is not
28 uneven, drive in end cover 16, using 0 end cover wrench, until the
16 rotation torque is within the standard value.
06695
At the point where the rotation torque is fixed, tighten special nut 13 at
0 specified torque, using 0 special nut wrench.
13
23 A
08225

Apply grease to lip area A of oil seal 23 and install into valve housing 24
as illustrated.
Y
24 06699

29 A
Apply grease to lip area A of oil seal 29 and install into gear box 32 as
illustrated.
32 06698
37-35
POWER STEERING OIL PUMP
16 14
11
18
6
8
7
20
10
2 21
22
5
1
3
06805
1 Lock nut 10 Flow control spring 19 Side plate
2 Gear 11 Bolt 20 O-ring
3 Bolt 12 Pin 21 O-ring
4 Suction connector 13 Cover 22 Body and shaft assembly
5 O-ring 14 Cartridge assembly
6 O-ring 15 Vane : Non-reusable parts
7 O-ring 16 Rotor
8 Connector 17 Cam ring
9 Relief valve assembly 18 O-ring
Assembly sequence
1918 1312 876

222120141110 954321
14 : 151617
Repair kit : Seal kit, Cartridge assembly kit

37-36
37
Standard value
9, 22 Clearance between relief valve assembly and body [14] 0.01 to 0.02 0.03 {0.0012}
and shaft assembly {[0.55] 0.00039 to 0.00079}
10 Flow control spring free length 36.5 {1.44} 33.5 {1.32}
13 Wear of cover 0.05 {0.0020}
15, 16 Clearance between vane and rotor 0.01 {0.00039} 0.06 {0.0024}
19 Wear of side plate 0.05 {0.0020}

1 Lock nut (Gear mounting) 34 to 45 {25 to 33, 3.5 to 4.6} Wet
3 Bolt (Suction connector mounting) 6 to 10 {4.3 to 7.2, 0.6 to 1.0}
8 Connector 49 to 69 {36 to 51, 5 to 7}
11 Bolt (Cover mounting) 18 to 22 {13 to 16, 1.8 to 2.2}

13 Bushing of cover Automatic transmission fluid (DEXRON As required
or DEXRON II type)
A
9
Service procedure
Inspection of relief valve assembly
Block one side of the hole of relief valve assembly 9, with your finger C,
9 then when air pressure A of 390 to 490 kPa {57 to 71 lbf/in2, 4 to 5 kgf/
cm2} is applied from the other side, check whether air is released from
small hole B at the rear. If air is not released, it is normal.
B C
06807
13
HI Installation of pin and cover
Press-fit pin 12 into cover 13, to the press-fitting height.
Apply hydraulic oil to bushing area A of the cover.
A
12
14.5 mm {0.57 in.}
06808
37-37
15
K Installation of vane
With R point of vane 15 facing outside A, install it on rotor 16 and make
sure that the vane moves smoothly. If it is faulty, replace cartridge 14.
A
16
R point
MO
06809
Installation of cam ring and side plate

17
Since the mounting direction of side plate 19 is determined, mount the
side plate, so that relief valve side A is aligned with round hole B
(standard pin side) and slotted hole C is located on a diagonal.
19 17
A
22 22
B
19 C 06811
Align cam ring 17 with pin 12 of cover 13, then install the cam ring.
13
12
17
07426
37-38
37
MEMO
37-39
POWER STEERING OIL TANK
3
1 Filler cap
2 Strainer
3 Screw
1 4 Filter
4 5 Packing
6 Tank
2
5 Assembly sequence
verse.
6
27004

3 Screw (Filter mounting) 1.270.29 {0.940.22, 0.130.03}
37-40
POWER STEERING FLUID LINE 37
Removal sequence
*a 1 Nut
6 2 Pressure hose
3 5 5 3 Clamp
4 *b 4 Rubber hose
1
5 Clamp
3
6 Rubber hose
7 Pressure tube
8
8 Return tube
*a : Power steering oil tank

*b : Power steering oil pump
*c : Power steering booster
7
*c
CAUTION
Be sure to bleed air if the fluid line was removed,
failure to do so would cause the power steering
to malfunction. P37-12
07256

1 Nut (Pressure hose mounting) 29 to 39 {22 to 29, 3 to 4}
7 Pressure tube (Pressure hose and power steering 29 to 39 {22 to 29, 3 to 4}
booster connection)
8 Return tube (Power steering booster connection) 39 to 49 {29 to 36, 4 to 5}
2
Service procedure
Installation of pressure hose
Install pressure hose 2 so indent A of pressure hose 2 contacts the
2
A suction connector of power steering oil pump *b.
*b
07250
37-41
DRAG LINK
-

13
-
10
- 11 *a
- 12
14
-
6
7
*b *b - -
5
- 4
< FG > < FE > 3
-
08376
1 Split pin 9 End plug *a : Pitman arm
2 End plug 10 Ball stud seat P37-24, 30
3 Spring 11 Ball stud seat *b : Knuckle arm
4 Ball stud seat 12 Spring < FE > ^ Gr 26
5 Ball stud seat 13 Grease nipple < FG > ^ Gr 26B
6 Grease nipple 14 Dust cover : Non-reusable parts
7 Dust cover 15 Drag link
8 Split pin
Assembly sequence
- Lubricant
4, 5, Whole area of ball stud seat Chassis grease [NLGI No.1 (Ca soap)] As required
10, 11
6, 13 Supply via grease nipple Chassis grease [NLGI No.1 (Ca soap)] As required
7, 14 Arm mounting port of dust cover Chassis grease [NLGI No.1 (Ca soap)] As required
15 Pack interior of drag link Chassis grease [NLGI No.1 (Ca soap)] As required
37-42
37
Approximately 4 mm {0.16 in.} 1289

Service procedure
Installation of split pin and end plug
Tighten end plug 2, 9 fully, then slacken it off by one half of a turn.
Place split pins 1, 8 so that the heads face the outside of the vehicle.
Stake the heads of split pins 1, 8 until they are approximately 4 mm
{0.16 in.} thick.
1, 8
2, 9 07258
K Installation of drag link

Install drag link 15 with front mark FL facing the front of the vehicle.
FL
15
08377
37-43
TIE ROD ASSEMBLY
1 Clip
2 Dust cover
3 Clamp bolt
4 Tie rod end
-2
5 Tie rod
NOTE
Do not remove clip 1 or dust cover 2 unless they
3 are faulty.
-
Assembly sequence

5 Bend of tie rod 1 {0.039} or less 1 {0.039} Replace

3 Clamp bolt (Tie rod end clamp tightening) 255 {183.6, 2.50.5}
- Lubricant
2 Lip area of dust cover Wheel bearing grease [NLGI No.2 Li soap] As required
4 Pack interior of dust cover of tie rod end Wheel bearing grease [NLGI No.2 Li soap] As required
1
Service procedure
Installation of clip
Install clip 1 with alignment port A in the direction as illustrated.
A
1
07261
37-44
37
4 Tie rod end
[Inspection]
Move ball stud area A vertically and horizontally to inspect for looseness.
Ensure that ball B rotates evenly.
A
07262
D : 74 mm {2.91 in.} < FE > [Installation]

68 mm {2.68 in.} < FG > Screw in tie rod end 4 so that dimension D of the tie rod end and clamp
E C differs by 1.5 mm {0.059 in.} or less between left and right.
Secure axis E E so that it is parallel both left and right.
C NOTE
Deviation of the left and right screw-in amount of tie rod end 4
should be within one turn.
4
E 07263
Approximately Approximately
5 Bending of tie rod
Measure the bend of tie rod 5 at the center point. If the measured value
40 mm {1.57 in.} 5 40 mm {1.57 in.} exceeds the limit, correct or replace the tie rod.
NOTE
To measure the deflection of tie rod 5, turn it one full rotation and
read the dial gauge indicator. The deflection is one half of the
A
indicated value.
B
07264
A : V-block
B : Surface plate
37-45
Group 37
Steering
Table of Contents
BACK
HOME
Pub No. TWSE9501-37

37
GROUP 37 STEERING
SPECIFICATIONS .................................................................................. 2

Change of Power Steering Fluid ..................................................................... 11
Bleeding of Power Steering System ............................................................... 12
Steering Wheel Play ......................................................................................... 12
Performance Verification Test of Power Steering System ........................... 13
STEERING SYSTEM ............................................................................ 14
STEERING COLUMN SUBASSEMBLY ............................................... 18
POWER STEERING BOOSTER .......................................................... 22
POWER STEERING OIL PUMP ........................................................... 28
POWER STEERING OIL TANK............................................................ 32
POWER STEERING FLUID LINE ........................................................ 33
DRAG LINK .......................................................................................... 34
TIE ROD ASSEMBLY ........................................................................... 36
37-1
SPECIFICATIONS
Item Specifacations
Steering wheel Type 2-spoke type
Outer diameter mm {in.} 400 {15.7}
Steering shaft Type Universal joint type (High tilt and telescopic type)
Power steering Manufacturer KOYO SEIKO
booster Type Ball nut type
Form Integral type
Model No. 2710-5WLO
Gear ratio 22.6
Cylinder diameter mm {in.} 78 {3.07}
Mass (without pitman 16.7 {37}
arm and fluid) kg {lb}
Power steering Manufacturer NIPPON POWER STEERING
oil pump Type Vane type
Model No. 20210-70924
Discharge amount 9.6 {0.59}
cm3 {cu.in.}/rev
Regulated flow amount 7 {7.4}
L {qts}/min
Regulated pressure
(relief valve) 10.3 {1490, 105}
MPa {lbf/in2., kgf/cm2}
Permissible revolutions rpm 600 to 6500
Mass (without drive gear and fluid) 1.64 {3.6}
kg {lb}
37-2
Steering System
1 Steering wheel
2 Steering column subassembly
1
4 Pitman arm
2 5 Drag link
6 Knuckle arm
7 Tie rod
8 Tie rod arm
5 8
4
6
08220
Shifting lock lever A from lock position B to release

H position C produces high tilt D, and turning telescopic
lever E (counterclockwise) from lock position F to re-
D
lease position G allows telescopic movement H. In this
way, the structure of steering column subassembly 2
2 can be adjusted for optimum driving position.
F G
E
C
B
07017
37-3
Power Steering System
1 Power steering oil tank
1 2 Power steering oil pump
: Fluid flow
2
08371
Power Steering Booster
13
12 14
11
15
4
16
5 10
3
1 2 6
7 9
17
8
18
22
29
28
27 26
25 23
24
19
20
21
08204
37-4
37
1 Lock nut 11 Valve housing 21 Special nut
2 Sector shaft 12 Dust cover 22 Adjusting bolt
3 Gear box 13 Input shaft 23 U-packing
4 Steel ball 14 Oil seal 24 Needle bearing
5 Circulator 15 Bearing 25 Needle bearing
6 Adjusting plate 16 Rotary valve 26 U-packing
7 Side cover 17 Rack piston 27 Oil seal
8 Nut 18 Main shaft 28 Dust cover
9 Torsion bar 19 Bearing 29 Pitman arm
10 Bearing 20 End cover
Rotary valve 16 is the central part of the power steering booster. Torsion bar 9 allows the steering reaction force and
valve return to operate lightly and smoothly at low speed, and ensures stable steering feel even at high speed.
Straight-ahead drive operation

A
13 When steering torque is not applied by the steering wheel, input shaft
A 16 13 is not activated and remains in neutral. At this time, pressurized
D fluid from the oil pump flows through the input shaft and the hole of
rotary valve 16, and returns to the oil tank without flowing into cylinder
A
chambers B, C.
A A : From the oil pump
C B D : To the oil tank
06590
Steering operation
A
13 Turning the steering wheel rotates input shaft 13, causing rotary valve
A 16 to close the fluid feed passage to cylinder chamber C. This pro-
D 16 duces a pressure difference between cylinder chambers B, C, which
A causes rack piston 17 to move, and facilitates rotation of main shaft
18.
A The illustration shows right-turn steering, and should be reversed for
17
C B left-turn steering.
06591
Operation when hydraulic circuit is faulty

E
18 The safety structure means that when the fluid circuit is faulty, the
stopper of input shaft 13 directly contacts the groove at the large end
of main shaft 18 to transmit steering force, enabling manual operation.
13
06592
37-5
Power Steering Oil Pump
1 2 3 6 7
4 8 9 10 11
15
14
20 19
12
13
18 17 16
06801
1 Cam ring 9 Oil seal 17 Relief valve assembly

2 Vane 10 Side plate 18 Flow control spring
3 Rotor 11 Bolt 19 Bolt
4 Pin 12 Cover 20 Body
5 Lock nut 13 Suction connector
6 Gear 14 Shaft A : Direction of rotation
7 Snap ring 15 Key
8 Bearing 16 Connector
37-6
37
Relief Valve Assembly
Operation of flow control valve
C (1) When not operating (Oil pump rotating at low speed)

A
18 Since pressure generated from pressure chamber A is low when the
D oil pump is rotating at low speed, fluid pressure in chamber B is also
low. Therefore, relief valve assembly 17, which is pressed by the
repercussive force of flow control spring 18 is not activated.
C : Direction of rotation
D : To the power steering booster
17 B 06802
(2) When operating (Oil pump rotating at middle or high speed)

Since pressure generated from pressure chamber A is high when the
C oil pump is rotating at middle or high speed, fluid pressure in chamber
A
18 B is also high. This will activate relief valve assembly 17, overcoming
D the repercussive force of flow control spring 18, and open port E,
making excess fluid return to the inlet port to adequately regulate the
flow of fluid to power steering booster D.
17 E B 06803
Operation of relief valve

When the steering is lock-to-lock, pressure in chambers B and F
H
C increases and overcomes the repercussive force of relief spring G
A
J opening relief valve J, which was closed by steel ball H, causing the
18 D fluid to be returned to the inlet port through port E. Thus, if pressure in
F chamber F decreases, the relief valve closes again.
17 G E B 06804
37-7
TROUBLESHOOTING
Symptoms



Remarks

Oil pump squeaks

Oil pump gurgles
Oil pump growls

Fluid leaking
Possible causes
Bearing damaged or worn
Ball or groove of ball screw set shaft worn
Air bled insufficiently
Fluid viscosity unsuitable
Power steering booster system faulty
Flow control valve malfunctioning
Power steering mechanism faulty
Rack or ball screw set shaft gear worn

Sector shaft bearing worn
Power steering booster mounting bolt loose
Ball screw set shaft and sector shaft play incorrect
Edge of valve control damaged or control seal
ring broken
Power steering system fluid unsuitable

Rack engagement starting torque adjusted

incorrectly
Fluid circuit clogged
Sector shaft gear worn
Torsion shaft serration damaged or worn
Power steering booster body faulty
O-ring or oil seal faulty
Sealant applied incorrectly
Universal joint worn abnormally, damaged,
Steering column and

link mechanism faulty
lubricated incorrectly
Link deformed
Drag link ball stud excessive play
Tie rod end ball stud excessive play
Tie rod bent
Pitman arm mounting position incorrect
Steering wheel center offset
37-8
37
Symptoms


Remarks

Oil pump squeaks

Oil pump gurgles
Oil pump growls

Fluid leaking
Possible causes
Kingpin lubricated incorrectly
Front wheel alignment (toe-in, camber,

caster) incorrect
Thrust bearing damaged
Wheel hub bearing worn or damaged ^ Gr 26
Front axle faulty
Kingpin or bushing worn or damaged

Front axle deformed
Knuckle arm, tie rod arm, knuckle, etc.
tightened incorrectly
U-bolt of front spring, nut loose ^ Gr 33

Front axle parts overtightened
Turning angle adjusted incorrectly
^Gr 26
Mounting parts, connection point loose
Knuckle stopper bolt adjusted incorrectly
Oil pump body faulty
O-ring, oil seal faulty
Bolt tightened incorrectly
Maximum generated fluid pressure
Oil pump faulty
insufficient
Fluid line crushed or clogged

Air lock in oil pump
Oil pump interior seized
Mounting bolt or nut loose
Pump body faulty
Valve malfunctioning
37-9
TROUBLESHOOTING
Symptoms

Remarks


Oil pump squeaks

Oil pump gurgles
Oil pump growls

Fluid leaking
Possible causes

Oil tank
Oil tank leaking due to overflowing

faulty
Oil tank leaking due to air lock

Fluid level insufficient
Load too far forward of load-carrying platform
Load too far rearward of load-carrying platform
Load too far to one side of load-carrying platform
Wheelbase gap between left and right excessive
Propeller shaft run out excessive ^ Gr 25
Front axle bent ^ Gr 26
Other malfunctions
Rear axle housing bent

Final drive gear and final drive pinion damaged ^ Gr 27

or engaged incorrectly
Tire pressure insufficient
Tire pressure excessive
Tire wear difference between left and right

excessive ^ Gr 31
Tire outer diameter difference between left

and right
Front tire radial and lateral runout, static

balance or dynamic balance faulty
One-sided braking ^ Gr 35
37-10
Change of Power Steering Fluid

[Draining]
steering booster.
specified torque.
[Filling]
P37-12
08583
37-11
Bleeding of Power Steering System
- Fluid
1 Power steering oil tank Automatic transmission fluid (DEXRON Filler cap
or DEXRON II type) dipstick
between
MIN and
MAX
3 2.
1
2 With the engine stopped, jack up the front wheels and turn the steer-
NOTE
A Check the fluid level without screwing on filler cap 3.
07236 right repeatedly. When the fluid level has dropped, add the fluid to
maintain the fluid level within range A. Repeat these steps until the
fluid level does not drop.
wheel several times to raise fluid temperature to approximately 60 to
80C {140 to 176F}, then stop the engine and wait for approximately
five minutes.
1, and pipe and hose connections for fluid leaks.
Steering Wheel Play

Steering wheel play (Measure at the outer 0 to 50 {0 to 1.97} Adjust
circumference of steering wheel)
Point the wheels directly forward, start the engine and gently turn the
steering wheel left and right to measure play at the outer circumference.
If the play deviates from the standard value, adjust tightening points and
power steering booster backlash. P37-25
08372
37-12
37
Performance Verification Test of Power Steering System
Service standards
2 2
Steering system fluid pressure (With hands off 490 kPa {71 lbf/in , 5 kgf/cm } Repair
steering wheel)
Relief set pressure (Measure with engine speed at 10.3 MPa {1490 lbf/in2, 105 kgf/cm2} Maximum Replace
1000 to 1500 rpm and stop valve closed) +490 kPa
{71 lbf/in2,
5 kgf/cm2}
Minimum
195 kPa
{28 lbf/in2,
2 kgf/cm2}
Verify that the power steering booster and the power steering oil pump
are operating properly by testing the following items.
NOTE
If the fluid pressure is higher than 490 kPa {71 lbf/in2, 5 kgf/cm2}
A with engine idling and the steering wheel free, inspect power
B
steering booster 1 and fluid circuit for clogging.
08373
Test item Test procedure Assembly standards
Verification of Jack up the front wheels and turn steering wheel fully left Smooth operation through-
smooth operation and right out test
Install oil pressure gauge A capable of measuring above
10.8 MPa {1560 lbf/in2, 110 kgf/cm2} and stop valve B, then
Measurement
bleed air
conditions
With engine idling, turn steering wheel left and right several
times to raise fluid temperature to 50 to 60C {122 to 140F}
With the engine idling, open stop valve B
Measurement of fluid Measure fluid pressure with hands off steering wheel 490 kPa {71 lbf/in2, 5 kgf/cm2}
pressure
Measurement of Gradually increase engine speed and maintain it at 1000 Relief set pressure 10.3 MPa
relief pressure to 1500 rpm, and close stop valve B to measure maximum {1490 lbf/in2, 105 kgf/cm2}
fluid pressure
Do not keep stop valve B closed for more than fifteen
seconds
37-13
STEERING SYSTEM
5
6
8
2
9 4
10
14
12
13 18
- 11 3
1
15
19

23
29
22
21
20
32 * 28
27
32
33 30
12129
Removal sequence
1 Column cover outer lower 15 Bracket 28 Return tube P37-33
2 Column cover outer upper 16 Head cutting bolt 29 Drag link P37-34
3 Column cover inner lower 17 Starter switch ^ Gr 54 30 Nut
4 Column cover inner upper 18 Spring 31 Power steering booster
5 Horn pad 19 Band P37-22
6 Nut 20 Nut 32 Nut
7 Telescopic lever 21 Dust cover 33 Tie rod assembly
8 Nut 22 Dust cover P37-36
10 Horn spring 24 Bolt * : Front axle assembly ^ Gr 26
11 Cover assembly 25 Bolt
12 Steering wheel 26 Steering column subassembly : Non-reusable parts
13 Screw P37-18
14 Combination switch ^ Gr 54 27 Pressure tube P37-33
CAUTION
When disconnecting pressure tube 27 and return tube 28, clean the ports to keep them free from dust and
37-14
37

6 Nut (Telescopic lever mounting) 8.8 to 9.8 {6.5 to 7.2, 0.9 to 1}
30 Nut (Power steering booster mounting) 83.5 to 108 {61 to 80, 8.5 to 11}
- Lubricant
C 7
Service procedure
Installation of telescopic lever
Locate telescopic lever 7 at the specified position, and adjust until the
specified torque is applied to telescopic shaft A.
Free
A
CAUTION
Locked 9 6 Do not crush the screw tip of telescopic shaft A.
8 B 7
06995
37-15
STEERING SYSTEM
>
<
Rotate telescopic shaft A counterclockwise with your fingers and check
for looseness
<
<
Using a flat-blade screwdriver turn telescopic shaft A > Set telescopic lever 7 to specified lock po-
sition C, marked
clockwise and drive it in until it hits lightly with a
clunk, but do not turn it any further
>
<
CAUTION
Be careful not to tighten too forcibly or you will
crush the end of the telescopic shaft, requiring
replacement of telescopic shaft assembly B
<
<

will not slip
Lock
<
position 30
Tighten telescopic shaft A at operating torque 6.9 to
06709
8 kgf} 100 mm {3.94 in.}from the center of steering When telescopic lever 7 is released, and tel-
wheel assembly 9 escopic shaft A is retightened at operating
<

tion 30
<
range range
NOTE
Remove telescopic lever 7 by prying it out verti-
<
cally, taking care not to loosen telescopic shaft

Joggle steering wheel assembly 9 up and
A. Prying the lever horizontally can loosen the
down and check for looseness
telescopic shaft

<
<
Procedure is
completed
37-16
37
16
LM
[Removal]
cutting bolt 16.
15
17
B 07241
[Installation]
16 16
15
24 25
07242
TU Installation of bolt
Thread area A of bolt 24 is elliptical to facilitate grounding of the horn
circuit.
26 A
07243
V[ Removal and installation of steering column

31
08374
V Steering column subassembly

A
26
A
07254
37-17

4 2
1
2
5
23 -
24
- 23
3
25
11 6 14
- 20
16

20
19
21

26 -
8 15
18 -
9
-
07019
37-18
37
1 Return spring 11 Nut 21 Lever support
2 Nut 12 Lock lever 22 Clevis pin
3 Support bracket 13 Split pin 23 Bolt
4 Spring seat 14 Return spring 24 Column support upper
5 Steering column assembly 15 Return spring 25 Telescopic shaft assembly
6 Nut 16 Snap ring 26 Column support lower
7 Stopper 17 Cam
8 Bearing spacer 18 Lock plate : Non-reusable parts
9 Grease nipple 19 Wave washer
10 Steering shaft assembly 20 Bolt
Assembly sequence
54321
25 24
5: 23 22 21 20 19 18 17 16 15 14 13 12 11
6
26 10 9 8 7

2 Nut (Support bracket mounting) 17 to 26 {12 to 19, 1.7 to 2.6}
6 Nut (Steering shaft assembly and telescopic 53 to 65 {39 to 48, 5.4 to 6.6}
shaft assembly mounting)
11 Nut (Lock lever mounting) 4 to 6 {2.9 to 4.3, 0.4 to 0.6}
20 Bolt (Lever support mounting) 7 to 10 {5.1 to 7.2, 0.7 to 1.0}
23 Bolt (Column support upper and column support 15 to 20 {11 to 14, 1.5 to 2.0}
lower mounting)

9 Supply via grease nipple Wheel bearing grease [NLGI No.2 (Li soap)] As
required
15 Friction surface of return spring and washer Wheel bearing grease [NLGI No.2 (Li soap)] As
required
16 Friction surfaces of lever support and snap ring Wheel bearing grease [NLGI No.2 (Li soap)] As
required
18 Friction surfaces of cam and lock plate return spring clevis pin Wheel bearing grease [NLGI No.2 (Li soap)] As
required
23 Thread area of bolt THREEBOND thread lock super 103Q As required
or LOCTITE 271
Friction surface of column support upper and bolt Wheel bearing grease [NLGI No.2 (Li soap)] As
required
37-19
8 7
Service procedure
Installation of stopper
Install stoppers 7 on steering shaft assembly 10 in the direction as
illustrated so that they straddle bearing spacer 8.
F
10 7 11310
Steering shaft assembly

Before removing steering shaft assembly 10, be sure to make align-
ment mark A.
25 Install the steering shaft with direction B of the telescopic shaft assem-
B B
bly 25 yoke and steering shaft assembly 10 yoke aligned or at phase
angle of 90.
H
10
A 07255
Installation of lock lever

Install lock lever 12 so it is within the working angle when locked.
After installing lock lever 12, make sure that the lever operates
17 mm smoothly (operating force less than 49 N {11 lbf, 5 kgf}). With the lever
{0.67 in.} free, make sure that high tilt operates smoothly.
Locked
Free
I
12
06998
Installation of split pin

Bend split pin 13 to face outwards as illustrated.
13
B=
4.5 mm
{0.18 in.} 18 21
07246
M Installation of cam
Adjust lever support 21 so that the top surface A of cam 17 is within
2.5 mm
{0.098 in.} 17 dimension B of lock plate 18 to install the cam.
A
18
17
06999
37-20
37
R Installation of clevis pin
Drive clevis pin 22 into column support upper 24 so that the drive
dimension is obtained.
13 mm {0.51 in.} 24
22 07000
37-21
- 17
18 25
24
- 19
22
21 28

1
-
20 27 - 3
9 26
10
11
32
5 14
31
- 30 15
7
6
08221

P37-24
1 Lock nut 13 Special nut 25 Seal ring
2 Pitman arm 14 O-ring 26 Seal ring
3 Dust cover 15 Bearing 27 O-ring
4 Bolt 16 End cover 28 Ball screw set shaft
5 Nut 17 Dust cover 29 Oil seal
6 Adjusting plate 18 Bolt 30 Needle bearing
7 Adjusting bolt 19 O-ring 31 U-packing
8 Sector shaft 20 O-ring 32 Gear box
9 O-ring 21 Bearing
10 Needle bearing 22 Bearing : Non-reusable parts
11 U-packing 23 Oil seal
12 Side cover 24 Valve housing
37-22
37
NOTE

P37-25
Assembly sequence
16 15 14

32 31 30 29

18 17 13 4 3 2 1

28 27 26 25
24 23 22 21 20 19
12 11 10 9
5
768

adjusting
plate
{[1.57] 0.00031 to +0.00020} {0.00012} worn area
and unworn
area
28 Main shaft outer diameter of ball screw set shaft [22.5] 0.05 to 0 {[0.89] 0.0020 to 0} Replace
Rotating torque of ball screw set shaft 29 to 69 Ncm Adjust
{[3.1] 0.00047 to 0.0013} {0.0020} worn area
and unworn
area
or less

4 Bolt (Side cover mounting) 74 to 98 {54 to 72, 7.5 to 10}
13 Special nut mounting 177 to 226 {130 to 165, 18 to 23}
18 Bolt (Valve housing mounting) 44 to 54 {33 to 40, 4.5 to 5.5}
37-23
23, 29 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required

49 {1.93}
76 {2.99}
01355
19 {0.75}
8 {0.31}
13 Special nut wrench MH061594 Removal and installation of special nut

70 {2.76}
100 {3.94} 06600
4.8 47.5
{0.19} {1.87}
16 End cover wrench MH061593 Removal and installation of end cover

400 {15.7}
60 {2.36}
06687
Service procedure
during assembly.
06688
37-24
37
2
08222
Pitman arm
0
[Removal]
06704
[Installation]
8
A
8H
06691

[Removal]
NOTE
A
08223 shaft 28.
37-25
B is in the neutral position, tap the end of the sector shaft, and pull out
12
5
4
06693
[Installation]
and side cover 12.
12 CAUTION
seal.
28
06694 NOTE
I
Removal and installation of special nut

13
L
06568
End cover
16
[Removal]
06569
37-26
37
[Installation]
32
Install inner race of bearing 15 onto the end of ball screw set shaft 28,
then install the outer race of the bearing onto end cover 16 and screw
15
into gear box 32.
28
16 08224
Making sure that the rotation torque of ball screw set shaft 28 is not
28 uneven, drive in end cover 16, using 0 end cover wrench, until the
16 rotation torque is within the standard value.
06695
At the point where the rotation torque is fixed, tighten special nut 13 at
0 specified torque, using 0 special nut wrench.
13
23 A
08225

Apply grease to lip area A of oil seal 23 and install into valve housing 24
as illustrated.
Y
24 06699

29 A
Apply grease to lip area A of oil seal 29 and install into gear box 32 as
illustrated.
32 06698
37-27
17
15
12
19
7
9
8
21
11
22
27
3 -
2
1 6
23
5
06805
1 Lock nut 11 Flow control spring 21 O-ring
2 Gear 12 Bolt 22 O-ring
3 Key 13 Pin 23 Snap ring
4 Bolt 14 Cover 24 Bearing
5 Suction connector 15 Cartridge assembly 25 Shaft
6 O-ring 16 Vane 26 Oil seal
7 O-ring 17 Rotor 27 Body
8 O-ring 18 Cam ring
9 Connector 19 O-ring : Non-reusable parts
10 Relief valve assembly 20 Side plate
Assembly sequence
2019 1413 987

2726

23222115121110654321
2524
15 : 161718
Repair kit : Seal kit, Cartridge assembly kit
37-28
37
Standard value
10, 27 Clearance between relief valve assembly and body [14] 0.01 to 0.02 0.03 {0.0012}
{[0.55] 0.00039 to 0.00079}
11 Flow control spring free length 36.5 {1.44} 33.5 {1.32}
14 Wear of cover 0.05 {0.0020}
16, 17 Clearance between vane and rotor 0.01 {0.00039} 0.06 {0.0024}
20 Wear of side plate 0.05 {0.0020}
25 Wear of shaft oil seal lip area 0.05 {0.0020}

1 Lock nut (Gear mounting) 34 to 45 {25 to 33, 3.5 to 4.6} Wet
4 Bolt (Suction connector mounting) 6 to 10 {4.3 to 7.2, 0.6 to 1}
9 Connector 49 to 69 {36 to 51, 5 to 7}
12 Bolt (Cover mounting) 18 to 22 {13 to 16, 1.8 to 2.2}

14 Bushing of cover Automatic transmission fluid (DEXRON As required
or DEXRON II type)
26 Periphery of lip area of oil seal Wheel bearing grease [NLGI No. 2 (Li Soap)] As required
A
F
Service procedure
Inspection of relief valve assembly
Block one side of the hole of relief valve assembly 10, with your finger C,
10 then when air pressure A of 390 to 490 kPa {57 to 71 lbf/in2, 4 to 5 kgf/
cm2} is applied from the other side, check whether air is released from
small hole B at the rear. If air is not released, it is normal.
B C
06807
14
IJ Installation of pin and cover
Press-fit pin 13 into cover 14, to the press-fitting height.
Apply hydraulic oil to bushing area A of the cover.
A
13
14.5 mm {0.57 in.}
06808
37-29
16
L Installation of vane
With R point of vane 16 facing outside A, install it on rotor 17 and make
sure that the vane moves smoothly. If it is faulty, replace cartridge 15.
A
17
R point
NP
06809
Installation of cam ring and side plate

18
Since the mounting direction of side plate 20 is determined, mount the
side plate, so that relief valve side A is aligned with round hole B
(standard pin side) and slotted hole C is located on a diagonal.
20 18
A
27 27
B
20 C 06811
Align cam ring 18 with pin 13 of cover 14, then install the cam ring.
14
13
18
T
07426
Press-fitting of bearing
A
With a suitable pipe A on the inner race of bearing 24, press-fit onto the
stepped part of the shaft 25.
24
25
U
06812
A Installation of shaft
24 With bearing 24 installed on shaft 25, press-fit the shaft into body 27
using a suitable pipe A on the outer race of the bearing.
27
25
06813
37-30
37
V Press-fitting of oil seal
Apply grease to periphery A of oil seal 26 and lip B, then press-fit the
C
oil seal into body 27, using jig C (ring-type plate).
Press-fit oil seal 26 so that the press-fitting amount from seat surface
D is as illustrated.
26
27
CAUTION
To prevent damage to the lapped surface of body 27 protect it
E with a soft cloth E.
D
2.50.1 mm
{0.0980.0039
in.}
27
A
26
B
06814
37-31
POWER STEERING OIL TANK
4 1 Packing
2 Filler cap
3 Strainer
2
4 Screw
5 Filter
5 6 Packing
7 Tank
1 3
6
Assembly sequence
verse.
7
06827

4 Screw (Filter mounting) 1.270.29 {0.940.22, 0.130.03}
37-32
POWER STEERING FLUID LINE 37
Removal sequence
1 Nut
*1 2 Pressure hose
6 3 Clamp
3 5
5 4 Rubber hose
4 *2
1 5 Clamp
3 6 Rubber hose
8 7 Pressure tube
8 Return tube
*1 : Power steering oil tank

*2 : Power steering oil pump
7 *3 : Power steering booster
*3
CAUTION
07256 Be sure to bleed air if the fluid line was removed,
failure to do so would cause the power steering
to malfunction. P37-12

1 Nut (Pressure hose mounting) 29 to 39 {22 to 2.9, 3 to 4}
7 Pressure tube (Pressure hose and power steering 29 to 39 {22 to 29, 3 to 4}
booster connection)
8 Return tube (Power steering booster connection) 39 to 49 {29 to 36, 4 to 5}
2
Service procedure
Installation of pressure hose
Install pressure hose 2 so indent A of pressure hose 2 contacts the
2 suction connector of power steering oil pump *2.
A
*2
07250
37-33
DRAG LINK
-
13

-
10
- 11 *1
- 12
14
-
*2 6
- 7
- 5
- 4
- 3
12130
1 Split pin 9 End plug *1 : Pitman arm
2 End plug 10 Ball stud seat P37-22
3 Spring 11 Ball stud seat *2 : Knuckle arm
4 Ball stud seat 12 Spring ^ Gr 26
5 Ball stud seat 13 Grease nipple : Non-reusable parts
6 Grease nipple 14 Dust cover
7 Dust cover 15 Drag link
8 Split pin
Assembly sequence
- Lubricant
4, 5, Whole area of ball stud seat Chassis grease [NLGI No.1 (Ca soap)] As required
10, 11
6, 13 Supply via grease nipple Chassis grease [NLGI No.1 (Ca soap)] As required
7, 14 Arm mounting port of dust cover Chassis grease [NLGI No.1 (Ca soap)] As required
15 Pack interior of drag link Chassis grease [NLGI No.1 (Ca soap)] As required
37-34
37
Approximately 4 mm {0.16 in.} 1289

Service procedure
Installation of split pin and end plug
Tighten end plug 2, 9 fully, then slacken it off by one half of a turn.
Place split pins 1, 8 so that the heads face the outside of the vehicle.
Caulk the heads of split pins 1, 8 until they are approximately 4 mm
{0.16 in.} thick.
1, 8
2, 9 07258
K Installation of drag link

Install drag link 15 with front mark FL facing the front of the vehicle.
FL
15
08377
37-35
TIE ROD ASSEMBLY
1 Clip
2 Dust cover
3 Clamp bolt
4 Tie rod end
-2
5 Tie rod
NOTE
Do not remove clip 1 or dust cover 2 unless they
3 are faulty.
-
Assembly sequence

5 Bend of tie rod 1 {0.039} or less 1 {0.039} Replace

3 Clamp bolt (Tie rod end clamp tightening) 255 {183.6, 2.50.5}
- Lubricant
2 Lip area of dust cover Wheel bearing grease [NLGI No.2 Li soap] As required
4 Pack interior of dust cover of tie rod end Wheel bearing grease [NLGI No.2 Li soap] As required
1
Service procedure
Installation of clip
Install clip 1 with alignment port A in the direction as illustrated.
A
1
07261
37-36
37
4 Tie rod end
[Inspection]
Move ball stud area A vertically and horizontally to inspect for looseness.
Ensure that ball B rotates evenly.
A
07262
D : 74 mm {2.91 in.} [Installation]

E Screw in tie rod end 4 so that dimension D of the tie rod end and clamp
C differs by 1.5 mm {0.059 in.} or less between left and right.
C Secure axis E E so that it is parallel both left and right.
NOTE
Deviation of the left and right screw-in amount of tie rod end 4
4
should be within one turn.
E 07263
5 Bending of tie rod
Measure the bend of tie rod 5 at the center point. If the measured value
40 mm {1.57 in.} 5 40 mm {1.57 in.} exceeds the limit, correct or replace the tie rod.
NOTE
To measure the deflection of tie rod 5, turn it one full rotation and
read the dial gauge indicator. The deflection is one half of the
A
indicated value.
B
07264
A : V-block
B : Surface plate
37-37
Group 41
Frame
Table of Contents
BACK
HOME
Pub No. TWSE9501-41

41
GROUP 41 FRAME
SPECIFICATIONS .................................................................................. 2
INSPECTION AND REPAIR OF FRAMES ............................................. 2
41-1
SPECIFICATIONS/STRUCTURE AND OPERATION/INSPECTION AND REPAIR OF FRAMES
SPECIFICATIONS
Item Specifications
Frame type Ladder type
Cross section configuration of side rail shape channel section

1 Side rail
2 Transmission mounting cross member
3 Cross member
3
4 Front engine mounting support
2 5 Front engine mounting support
bracket
6 Shock absorber bracket
1
5
4
11223
INSPECTION AND REPAIR OF FRAMES

: Bolt (M101.25)
: Bolt (M121.25)

11224
41-2
41
Tightening torque Unit : Nm {lbf.ft, kgm}
Bolt ( area bolt : M101.25) 60 to 80 {43 to 58, 6 to 8}
Bolt ( area bolt : M121.25) 98 to 120 {72 to 87, 10 to 12}
Service procedure
Cleaning of frame
Carefully remove mud, grease, rust, etc. that is stuck to the outer and
inner surfaces of the frame.
Inspection for frame deformation

If any fault such as deformation is found, repair the frame.
Inspection for cracks in frame

Remove paint from any areas that are seemingly faulty and carefully
inspect.
If visual inspection is difficult, inspect using color contrast penetrant
examination or other methods.
If a crack is found, repair as follows.
Repair of crack in frame

With the vehicle unloaded, level the frame.
Drill a hole, about twice the thickness of the frame, 10 mm {0.39 in.}
from the end of the crack.
NOTE
If a crack is found inside the frame, drill holes at both ends of the
crack.
00238
If the edges of the crack are not flush, make them flush with each
other.
00240
41-3
Using a grinder, etc., grind a 90 V-section channel, two-thirds of the
frame thickness, then weld.
WARNING
You must cover any inflammable materials, such as pipelines,
wiring harnesses, rubber parts, and the fuel tank, that are near
the welding site.
CAUTION
00241 Do not use gas welding because the high temperature produced
alters the material properties and weakens the welded area. Be
sure, therefore, to use electric welding.
Be sure to remove the negative terminal of the battery, then
Approximately 2/3 of
frame thickness ground the welder near the area to be welded to prevent reversed
flow of current from the welder which might burn out electrical
Approxi-
components.
mately Be sure to protect mountings such as main sills that can be
90
damaged by heat, by using heat insulators, etc.
NOTE
00242
Use low-hydrogen type coated CO2 and arc welding electrodes
for welding to prevent harmful defects such as undercutting,
blow holes, etc.
Preheat the area to be welded to approximately 50 to 350C {122
to 662F} before welding when the workshop temperature is
below 0C {32F}.
Next, grind a V-section channel, as described above, on the opposite

side of the weld and weld. At the same time, fill the holes at both ends
of the crack by welding.
NOTE
In cold districts, heat the welded area to approximately 200C
{392F} after welding.
41-4
41
B After welding, grind bead A at right angles B to remove shaded area
C as illustrated and grind the area flat.
A Finish the surface so that the frame thickness is identical to the
original thickness.
A C
B
00243
[Repairing cracks caused by rivets or bolt holes]

To make the edges of the holes flush at the cracked area, temporarily
D
tighten bolt D in the hole.
E Weld cracked point E at least 20 mm {0.79 in.} from the center of the
bolt.
F For welding method refer to the above-mentioned procedures for
repairing cracks. P41-3.
After removing the bolt and making the edges flush, weld remaining
area F and fill the hole.
00244 After drilling a hole in the filled area, install a rivet or bolt.
[Repairing using reinforcement plate]

G To prevent concentrated stress being produced at ends G of the
G reinforcement plate, weld the plate with angle H at both ends opened
30 or less.
Do not weld area J.
H
The reinforcement plate must have enough strength for the cracked
area.
NOTE
J : 20 mm {0.79 in.} J : 20 mm {0.79 in.} Thickness of reinforcement plate : same as frame thickness
00245 Reinforcement plate material : SAPH440 (hot-rolled sheet steel
for automobiles), SS400 (sheet steel for general construction), or
equivalent strength.
After welding, heat the shaded area to 600 to 700C {1112 to 1292F}.
50 mm CAUTION
{1.97 in.}
Be sure to protect mountings such as main sills that can be
damaged by heat, by using heat insulators, etc.
00246
41-5
Inspection for loose rivets
Gently tap the rivet head using an inspection hammer and judge the
condition by checking the vibration using the tip of your finger, or by
listening to the sound.
Rust between rivet and frame indicates that the rivet is loose.
CAUTION
Be sure to replace loose rivets because they can break or cause
cracking of the frame in the area around the rivet hole, causing
accidents.
00247
Repair of rivet
When removing rivets, use a center punch to make an indent in the
center of the rivet head; then, drill out using drill A or grind.
B : Incorrect
A C : Correct
CAUTION
Make sure that you do not damage the rivet hole.
B C
00248
When rivetting, first clamp both plates tightly near the rivet hole using
a clamp to eliminate gaps between plates.
Using a rivetting machine, insert the rivet (cold rivet).

If rivetting is impossible, ream the rivet hole, drive in a reamer bolt,
fully tightening the nut, then weld it in place.
A flange bolt and flange nut should be used for the reamer bolt and
nut.
00249
Inspection for loose bolts and nuts

Inspect the mounting bolts in all areas for looseness. Loosened bolts
should be tightened at specified torque. P41-2
41-6
Group 42
Cab
Table of Contents
BACK
HOME
Pub No. TWSE9501-42

42
GROUP 42 CAB
SPECIFICATIONS .................................................................................. 2

Adjustment of Cab Tilt ..................................................................................... 17
Adjustment of Door Fitting .............................................................................. 18
REMOVAL AND INSTALLATION OF CAB .......................................... 20
FRONT CAB MOUNTING .................................................................... 28
REAR CAB MOUNTING ....................................................................... 30
CAB TILT LINK ..................................................................................... 32
DOOR ................................................................................................... 35
CAB EXTERIOR FITTING .................................................................... 40
MIRROR ................................................................................................ 44
WIPER AND WASHER ......................................................................... 46
CAB INTERIOR FITTING ..................................................................... 49
INSTRUMENT PANEL .......................................................................... 51
WINDOW GLASS ................................................................................. 54
42-1
SPECIFICATIONS
Item Specifications
Cab assembly Type Cab over type (Forward control type)
Cab tilt Type Torsion bar type
Tilt angle 45
Cab mounting Type Fixed type
Windshield Laminated glass
Glass other than windshield Tempered glass
Door glass opening and closing mechanism Manual control type (Cable driven)
42-2
Front Cab Mounting
1 2 3 4
6 5
8 08036
1 Anchor lever 6 Front rubber assembly

2 Bushing 7 Front cab mounting bracket, RH
3 Torsion bar 8 Adjusting bolt
4 Front floor cross member assembly
5 Front cab mounting bracket, LH
Since torsion bar 3 has torsional direction, it is marked R on its right end to indicate the torsional direction, preventing
mistaken installation.
Rear Cab Mounting

1 Side rubber
4
2 Anchor hook
3 Spacer
2 L R 4 Rear mounting post
1 3 5 Metal fixture
6 Lower rubber
7 Upper rubber
8 5
8 Cab hold bracket
7
10777
Anchor hooks 2 are marked L and R to identify left and right.

Between anchor hook 2 and cab hold bracket 8 is spacer 3. By increasing or decreasing the number of spacers, the
cab tilt operating force can be adjusted.
42-3
Cab Tilt Link
1 2 3 A 4
6 5
05794
1 Lock handle rod 5 L-lever 9 Cab tilt lock switch

2 Link assembly, LH 6 L-lever rod
3 Center rod 7 Lock handle A : Center rod adjusting point
4 Link assembly, RH 8 Lock latch
The length of center rod 3 can be adjusted at mounting part A (center rod adjusting point) of link assembly RH 4.
Cab tilt lock switch 9, mounted on lock latch 8, detects whether lock handle 7 is locked securely.
Cab Tilt Warning Electric Circuit
2 1 Fuse box
1 3
2 Cab tilt warning lamp
3 Cab tilt lock switch
06008
Door Locking System

1 Door lock knob
1 2 Door lock rod
3
4 Inside handle
5 Door lock cylinder
4
6 Door lock cylinder rod
7 Outside handle
9 Door lock latch
6 5
08021
42-4
42
Door Glass Opening System
1 Door glass
2 Carrier plate
5 3 Glass holder
4 Cable
5 Run channel
6 Lower sash
7 Rail
8 Regulator
3 9 Regulator handle
1 2
A : Carrier plate moving range
4
Both ends of cable 4 are secured to car-

rier plate 2, and regulator 8 is installed in
6 the middle of the cable.
9 Regulator 8 winds cable 4, and moves
A
carrier plate 2 vertically to open and close
8 door glass 1.
Carrier plate 2 and door glass 1 are se-
cured by glass holder 3.
Regulator handle 9 turns regulator 8.
To allow removal and installation of door
7 glass 1, lower sash 6 is removable.
05834
42-5
Wiper and Washer
F 2
3
F A
B
7
C
5 9 8 6
D
5 4
FF
H
H
10
G
D C B 12
11
E
14 13
HH
11295
1 Wiper arm and blade assembly 12 Washer hose

2 Nut 13 Hose joint
3 Pivot cap 14 Nut
4 Nut
5 Wiper link assembly A: Weatherstrip ends
6 Packing washer B: Front garnish
7 Nut C: Front panel
8 Wiper motor D: Front rail
9 Wiper motor bracket E: Cab harness
10 Washer tank
11 Washer motor
The viewpoint of this illustration is from inside the cab.
42-6
42
Wiper and Washer Electric Circuit
1 Fuse box
2 Relay box
3 Wiper relay (HIGH)
4 Wiper relay (LOW)
5 Multipurpose timing control unit
6 Wiper motor
7 Washer motor
8 Combination switch
9 Wiper and washer switch
Wiper motor 6 section

A : Cam
B : Plate
C : Contact point
D : Circuit breaker
: Wiper motor driving signal

(when wiper operating intermittently)
: Intermittent switch signal
(when wiper operating intermittently)
G : Cam signal (when wiper stops)
H : Washer switch signal
08433
When wiper operating at LOW speed
Position of wiper and washer switch 9 : LO

1 (F21) 4 (coil) 9 (LO) Ground
1 (F21) 4 (contact point) 3 (contact point)
6 (LO) 6 (D) Ground
Wiper motor 6 rotates at low speed.
08434
42-7
When wiper operating at HIGH speed
Position of wiper and washer switch 9 : HI

1 (F21) 3 (coil) 9 (HI) Ground

4 (coil)
6 (HI) 6 (D) Ground
Wiper motor 6 rotates at high speed.
08435
When wiper stops
Position of wiper and washer switch 9 : OFF

1 (F21) 6 (B) 6 (A) 4 (contact point)
3 (contact point) 6 (LO) 6 (D) Ground
Wiper motor 6 continues to rotate at low speed.
09928
When cam A is separated from plate B by rotation of

wiper motor 6, the current to the motor is cut off.
Wiper motor 6 continues to rotate due to the inertia
force of the motor and the wiper link.
When cam A of wiper motor 6 makes contact with
contact point C, the following ungrounded circuit is
formed.
6 (LO) 6 (D) 6 (C)
3 (contact point) 4 (contact point) 6 (A)
Wiper motor 6 stops by dynamic (electric) braking
because of this circuit.
09929
42-8
42
When wiper operating intermittently
Wiper and washer ON
switch 9 (INT) OFF
ON
Operation mode with multipurpose timing control unit 5
Wiper motor 6
OFF
ON
Cam signal G
OFF
Wiper relay ON
LOW 4 OFF 1 second 1 second
Approximately 4 seconds
08654
Position of wiper and washer switch 9 : INT

1 (F20) 5 (B) Ground
5 (INT) 9 (INT) Ground
Multipurpose timing control unit 5 sends wiper motor
driving signal when it receives intermittent switch
signal .
1 (F21) 4 (coil) 5 (RLY)
6 (LO) 6 (D) Ground
Multipurpose timing control unit 5 sends wiper motor
driving signal , then sends cam signal G .
1 (F21) 6 (B) 6 (A) G 5 (MTR)
When cam A of wiper motor 6 is separated from

09931 plate B, cam signal G turns OFF.
When cam signal G is turned OFF, multipurpose
timing control unit 5 turns wiper motor driving signal
OFF for specified time.
The illustrated part of the circuit turns OFF.
Wiper motor 6 stops. Gr 42-8
After specified time has passed, multipurpose timing
control unit 5 sends wiper motor driving signal
again.
09932
42-9
When washer operating
Wiper and ON
washer switch 9 OFF
(WASH) Approximately Approximately Operation mode with multipurpose timing control unit 5
0.8 seconds 2.5 seconds
Wiper relay ON
LOW 4 OFF
11125
Position of wiper and washer switch 9 : WASH
1 (F20) 5 (B) Ground

1 (F21) 7 9 Ground

5 (WASH) H
When washer motor 7 operates to spray washer fluid,

multipurpose timing control unit 5 transmits washer
switch signal H .
1 (F21) 4 (coil) 5 (RLY)
Washer switch signal H makes multipurpose timing
control unit 5 input wiper motor drive signal .
6 (LO) 6 (D) Ground
Wiper motor 6 operates at LOW speed.
When wiper and washer switch 9 is turned to OFF,
washer motor 7 stops.
Then, washer switch signal H is turned off and mul-
tipurpose timing control unit 5 turns off wiper motor
drive signal after specified time.
Wiper motor 6 automatically stops.
P42-8
11126
42-10
42
Emergency Locking Retractor (ELR) Type Seat Belt
1 2
4
5
7
8
16
15 9
14 10
11
13
12
14187
1 Sash guide 7 Emergency locking retractor 12 Pawl

2 Cover assembly 13 Ratchet gear
3 Webbing 8 Spindle 14 Sensor spring
4 Buckle assembly 9 Locking gear 15 Lock arm
5 Tongue plate 10 Mechanism lever 16 Clutch
6 Tongue stopper 11 Mechanism weight
CAUTION
Do not disassemble emergency locking retractor assembly 7, or malfunctions might occur.
42-11
Webbing detecting lock
3
When the vehicle is subjected to a sudden impact, such as
a crash, webbing 3 retracts according to the movement of
15 passengers, and spindle 8 rotates.
As the rotation of spindle 8 is higher than the specified
8 value, the repercussive force of sensor spring 14 can no
longer retain lock arm 15. Then, the arm is pulled out from
the specified position and is locked by clutch 16.
9 If spindle 8 further rotates, clutch 16 lifts pawl 12 to lock with
ratchet gear 13, making spindle rotation impossible.
10 Body detecting lock
16 When the body is tilted excessively, mechanism weight 11
11
14 is tilted, engaging mechanism lever 10 with locking gear 9,
13 locking it.
If spindle 8 further rotates, clutch 16 operates as described
above, and the spindle cannot rotate.
12
07371
42-12
TROUBLESHOOTING 42
Cab as a Whole
Symptoms
Cab or steering wheel high-frequency vibration (above 20 Hz)
Cab cannot be locked to rear mounting post

Cab shimmy (pitching and rolling vibration)
Cab tilt warning lamp does not go out

Cab tilt warning lamp does not light
Remarks
Cab cannot be tilted up

or noise
Possible causes
Cab mounting loose or play
Front rubber, rear rubber deteriorated
Cab mounted incorrectly
Link assembly from anchor hook does not release
L-lever release faulty
Torsion bar damaged or fatigued
Cab-related Torsion bar arm installation position incorrect
Link assembly not hooked to anchor hook
Link assembly contact with side cushion incorrect
Cab tilt lock switch adjusted incorrectly
Cab tilt lock switch faulty
Cab tilt warning lamp bulb burnt-out
Fuse, high-current fuse blown
Crossed axes angle of propeller shaft excessive due to

increased tilt caused by deteriorated engine mounting
Engine-related Engine installation faulty ^ Gr 10
Intake and exhaust system installation faulty
Transmission-related Transmission installation faulty ^ Gr 22, 23
Propeller shaft run-out excessive
Universal joint worn excessively
Propeller Slip yoke joint spline play

shaft-related Center bearing play excessive ^ Gr 25
Crossed axes angle of mounting dimension excessive due to

deteriorated center bearing cushion rubber, etc.
Crossed axes angle of propeller shaft excessive due to

increased tilt of drive axis caused by overloading
42-13
TROUBLESHOOTING
Symptoms
Cab or steering wheel high-frequency vibration (above 20 Hz)
Cab cannot be locked to rear mounting post

Cab shimmy (pitching and rolling vibration)
Cab tilt warning lamp does not go out

Cab tilt warning lamp does not light
Remarks
Cab cannot be tilted up

or noise
Possible causes
Front axle-related Axle seat resonance ^ Gr 26
Reduction gear engaged incorrectly
Rear axle-related ^ Gr 27
Differential gear engaged incorrectly
Wheel and tire run-out excessive
Wheel and Wheel and tire unbalanced
^ Gr 31
tire-related Size and kinds of tire unequal
Wheel mounting surface warped
Front Leaf spring friction between leaves excessive
^ Gr 33
suspension-related
Brake drum unbalanced
Brake-related Brake drum eccentric ^ Gr 35
Rotor of disc brake eccentric
42-14
42
Door Lock
Symptoms
Door does not lock when door look knob is pressed
Door does not open using outside door handle

Door does not open using inside door handle
Door does not lock when key is turned
Inside door handle self-return poor

Door does not shut completely
Door and cab interference

Remarks
Possible causes
Door installation faulty
Striker installation faulty
Door latch lock faulty
Door latch rod deformed
Door latch rod removed
Door latch rod obstructed
Door lock cylinder deformed
Left side outside door handle faulty
Inside door handle installation faulty
Inside door handle spring fatigued
42-15
TROUBLESHOOTING
Wiper and Washer
Symptoms
Wiper intermittent operation does not work

Wiper blade stop position incorrect
Washer fluid jetting insufficient

Washer motor does not work
Noise during wiper operation
Wiper operation inadequate
Washer fluid does not jet

Remarks
Wiper does not stop

Wiper doe not work
Possible causes
Wiper motor faulty
Washer motor faulty
Wiper and washer switch faulty
^ Gr 54
Multipurpose timing control unit faulty
Wiper relay faulty
Fuse, high-current fuse blown
Wiper motor crank arm set position faulty
Wiper link and wiper arm connection faulty
Wiper blade faulty
Wiper arm faulty
Washer hose twisted
Washer hose connected incorrectly
Washer nozzle clogged
Washer fluid insufficient
42-16
Adjustment of Cab Tilt

1 Lock nut (Anchor hook mounting) 83 to 98 {61 to 72, 8.5 to 10.0}
4 Bolt (Lock handle mounting) 29 to 39 {22 to 29, 3.0 to 4.0}
(1) Adjustment of lock handle operating force

2 Adjust the lock handle operating force by increasing or decreasing
3 the number of spacers 3 as follows:
1 : Lock nut
2 : Anchor hook
Number of spacers
Heavy operating force Increased
1 Light operating force Decreased
08023
(2) Adjustment for unsmooth latch

If latch operation is not smooth, loosen bolt 4, and adjust installation
of lock handle 5.
5
05862
42-17
Adjustment of Door Fitting

2 Bolt (Upper and lower hinge mounting) 17 to 25 {12 to 19, 1.7 to 2.6}
7 Screw (Striker mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4}
Adjust door fitting at hinge and striker.

(For door fitting dimensions: P42-19.)
(1) Adjustment of hinge
For adjustment, use front-side bolt 2 of lower hinge 1 as the refer-
ence point.
3 : Upper hinge
05875
(2) Adjustment of striker
4 Engagement condition between door lock latch 4 and striker 5

should be adjusted with shim 6 within illustrated range A.
7 : Screw
5
A : 13.3 mm
7 {0.52 in.}
6
05876
42-18
42
Door Fitting Dimensions
6.91.0 mm 12.42.0 mm
{0.270.039 in.} {0.490.079 in.}
6.41.0 mm
{0.250.039 in.} 11.91.0 mm 6.21.0 mm
12.42.0 mm
{0.470.039 in.} {0.490.079 in.} {0.240.039 in.}
CC
AA BB
12.32.5 mm
{0.480.098 in.}
A C C
B
102.0 mm
A {0.390.079 in.}
D D
J 6.21.0 mm
J
F E {0.240.039 in.}
H H
DD
G F E
112.0 mm
G {0.430.079 in.}
92.0 mm
{0.350.079 in.}
7.11.0 mm
{0.280.039 in.}
EE
6.461.0 mm
{0.250.039 in.} 112.0 mm
JJ 102.0 mm {0.430.079 in.}
{0.390.079 in.}
112.0 mm
{0.430.079 in.}
6.51.0 mm
6.451.0 mm {0.260.039 in.}
{0.250.039 in.}
HH GG FF
05877
42-19
REMOVAL AND INSTALLATION OF CAB
Preliminary Work
7
5
A
1
4
11375
1 Battery (negative terminal) ^ Gr 54 Work items
2 Front grille P42-40 Draining, filling, and air bleeding of clutch fluid and
3 Pressure cap ^ Gr 14 brake fluid ^ Gr 21, Gr 35A
4 Radiator drain plug ^ Gr 14 Draining, filling, and air bleeding of coolant
5 Crankcase drain plug ^ Gr 14 ^ Gr14
6 Clutch fluid pipe
< Manual transmission > ^ Gr 21
7 Brake fluid pipe ^ Gr 35
A : Wheel chock
WARNING
Put chocks A securely in place because the vehicle cannot be maintained at a standstill just by using the
parking brake during removal and installation of the cab.
Do not remove chocks A until the entire operation is completed.
Assembly sequence
42-20
42
Work Inside Cab
Assembly sequence
1
11380
Work from Front of Cab

1 Speedometer cable
2 Connection between cab
harness and chassis
harness
3 Horn harness
1
Assembly sequence
Follow the disassembly se-
quence in reverse.
11376
42-21
Work with Cab Tilted Up
7
6
11377
1 Vacuum hose 5 Range selector cable < Automatic transmission >
2 Heater hose (Engine in) ^ Gr 55B ^ Gr 23
3 Heater hose (Engine out) ^ Gr 55B 6 No.2 shift rod < Manual transmission > ^ Gr 22
4 Accelerator control cable ^ Gr 13 7 No.2 selector rod < Manual transmission > ^ Gr 22
Assembly sequence
42-22
42
MEMO
42-23
Removal and Installation of Tilt Cab Body
1 Nut
2 Bolt
3 Bolt
4 Anchor lever
5 Bolt
6 Bolt
7 Bolt
8 Bolt
9 Cab assembly
*1 : Cab stay
*3 *2 : Front floor cross member
7 *3 : Steering yoke
*4 : Steering shaft
*5 : Front cab mounting bracket
*4
*1
Assembly sequence
reverse.
8 *2

3 4 6 *5 5 1 2
11378

1 Nut (Anchor lever adjusting bolt locking) 59 to 83 {43 to 60, 6 to 8.5}
3 Bolt (Anchor lever mounting) 34 to 54 {25 to 40, 3.5 to 5.5}
5, 6, 8 Bolt (Front floor cross member mounting) 70 to 95 {51 to 70, 7.1 to 9.7}
7 Bolt (Cab stay mounting) 19 to 27 {14 to 21, 1.9 to 2.8}
42-24
42
9
Service procedure
Cab assembly
[Removal]
Tilt cab assembly 9 and lock cab stay *1 securely.
Remove bolt 3, and remove anchor lever 4.
Of the three bolts that retain front floor cross member *2, remove
9 bolts 5, 6 at rear side, leaving bolt 8 at front side.
6
*2
5
8
3 4
08045
To separate cab stay *1 from cab assembly 9, support the cab

A 9 securely using crane A that is capable of lifting the cab.
B : Use a wood block for protecting the rear of the cab
B Using crane A, lower cab assembly 9 until cab stay *1 can be
removed, then remove it.
*1
08046
Fully lower cab assembly 9 to remove remaining bolt 8 that retains

front floor cross member *2.
9
8
*2
08047
42-25
Set up hoist attachment C for the cab as illustrated.
C
CAUTION
E
D Make sure when you set up hoist attachment C that it is capable
of lifting cab assembly 9 which weighs approximately 390 kg
{860 lb}.
Make sure you install rubber E on hoist attachment C to prevent
cab roof D being deformed when the cab is lifted.
02266
Mount hoist attachment C at center-of-gravity point F of cab assembly

9 9. Verify the position at which the cab can be lifted horizontally when
C
*3 the cab is lifted slightly.
G Slowly lift cab assembly 9 straight up, and finish lifting when steering
F yoke *3 is pulled out from steering shaft *4. Make alignment mark G
*4 before the steering yoke is pulled out from the steering shaft.
WARNING
Never get under cab assembly 9 when it is being lifted.
15154
CAUTION
Make sure, when lifting cab assembly 9, that the wiring harness,
cable, hoses, etc. are completely disconnected when the cab is
lifted slightly.
[Installation]
C Mount hoist attachment C at center-of-gravity point F of cab assembly
9
9.
08049
Slowly lower cab assembly 9 horizontally to insert steering yoke *3

9 into steering shaft *4, aligning alignment mark G.
*3
G
*4
15155
42-26
42
Slowly lower cab assembly 9 further, and remove hoist attachment C
*2 after it comes down fully.
9
Tighten front bolt 8, one of the three bolts used for installing front floor
cross member *2.
08055
Securely support cab on crane A to tilt cab assembly 9.

A 9 B : Use a wood block for protecting the rear of the cab
Using crane A tilt cab assembly 9, and install cab stay *1.
B WARNING
You must pay close attention to the tilt angle when tilting cab
assembly 9 using crane A. It is very dangerous to tilt the cab
excessively because it will topple over.
*1
08056 After installing cab stay *1, tilt cab assembly 9 slowly until it is
completely tilted, securely lock cab stay, then detach the cab from
crane A.
Tilt cab assembly 9, and securely lock cab stay *1.

Tighten bolts 5, 6 to install front floor cross member *2.
Position and install pointer J of front cab mounting bracket *5 in
4 convex area H of anchor lever 4 and fix it with bolt 3.
Position bolt 2 on anchor lever 4 and lock it with nut 1.
*5 After mounting cab assembly 9, check and adjust the operating force
9 J
H required for the lock handle. P42-17
6
*2
5
3 4
2
1
08057
42-27
FRONT CAB MOUNTING
-
1 Bolt
12 14
2 Bolt
3 Nut
4 Bolt
5 Anchor lever
6 Bolt
7 Front cab mounting bracket, RH
8 Front rubber assembly, RH
9 Bushing, RH
10 Torsion bar
11 Front floor cross member assembly
12 Bushing, LH
1 13 Front rubber assembly, LH
14 Front cab mounting bracket, LH
* : Frame
5 9
4 Assembly sequence
- Follow the disassembly sequence in re-
verse.
6 * 3 2

10785
NOTE
Since the following parts are assembled at the time the cab is mounted, see removal and installation of cab
( P42-24) for assembly procedure.
1 : Bolt (Connection of front floor cross member assembly and cab assembly)
2 : Bolt (Adjustment of anchor lever)
3 : Nut
4 : Bolt (Installation of anchor lever)
5 : Anchor lever

1 Bolt (Front floor cross member assembly 70 to 95 {51 to 70, 7.1 to 9.7}
and cab assembly mounting)
3 Nut (Lock of anchor lever adjustment bolt) 59 to 83 {43 to 61, 6 to 8.5}
4 Bolt (Anchor lever mounting) 34 to 54 {25 to 40, 3.5 to 5.5}
6 Bolt (Front cab mounting bracket mounting) 70 to 85 {51 to 63, 7.1 to 8.7}
42-28
42
- Lubricant
8, 13 Contact area between front rubber assemblies and front floor Rubber grease As required
cross member assembly
8 A B
8I
Service procedure
Installation of front rubber assembly
Install front rubber assembly RH 8 and LH 13 fitting protrusions A to
B A the indents B of mounting bracket RH 7 and LH 14 respectively.
13 14
7
F
08031
Installation of torsion bar

Install torsion bar 10 to front floor cross member assembly 11 in the
11
R CAUTION
Be sure not to mistake the left side for the right side, when
installing torsion bar 10, because the torsion bar will be damaged
if its torsion direction is reversed.
10
G
08032
11 Installation of front floor cross member assembly

A A
Install front floor cross member assembly 11, adjusting front cab mount-
ing bracket LH 14 so there is no gap between the front floor cross
member assembly and front rubber assembly RH 8 and LH 13 at points
A.
8 13
14
08033
42-29
REAR CAB MOUNTING
12
1 Bolt
2 Nut
3 Lower rubber
8 4 Metal fixture
5 Anchor hook
6 6 Spacer
9 7 Nut
8 Side rubber
7 9 Cab hold bracket
10 Upper rubber
10 11 Metal fixture
12 Rear mounting post
11
* : Frame
1
3 Assembly sequence
*
10786 verse.

1 Bolt (Rear mounting post mounting) 78 to 105 {58 to 80, 8 to 11}
2 Nut (Anchor hook mounting) 83 to 98 {61 to 72, 8.5 to 10.0}
7 Nut (Side rubber mounting) 16 to 20 {12 to 14, 1.6 to 2.0}
< LH >
L
< RH >
R
5
Service procedure
L:
Installation of anchor hook
Left identification mark
R: Right identification mark
10780
42-30
42
MEMO
42-31
CAB TILT LINK
10 9
7
6 5
-
8 2
1
3
11293
1 Bolt 7 Bolt
2 Cab tilt lock switch ^ Gr 54 8 L-lever assembly
3 Lock handle assembly 9 Bolt
4 Center rod 10 Link assembly, RH
5 Bolt
6 Link assembly, LH * : Rear mounting post
Assembly sequence
42-32
42
1 Bolt (Lock handle assembly mounting) 29 to 39 {22 to 29, 3 to 4}
5 Bolt (Link assembly, LH mounting) 29 to 39 {22 to 29, 3 to 4}
7 Bolt (L-lever assembly mounting) 29 to 39 {22 to 29, 3 to 4}
9 Bolt (Link assembly, RH mounting) 29 to 39 {22 to 29, 3 to 4}
- Lubricant
4 Connecting area between center rod link assembly, LH and Wheel bearing grease [NLGI No2 (Li soap)] As required
lock handle assembly
Service procedure
Make sure that operating force for lock handle assembly 3 is correct. If it
4
is too heavy or too light, adjust. P42-17
Installation of center rod

C Adjust the length of center rod 4 using lock nut C to optimize locking and
6 4 unlocking of rear cab mounting.
Raise lock handle assembly 3 all the way, unlocking it.
Turn and adjust lock nut C so that shafts A of link assembly LH 6 and
RH 10 contact brackets B.
3 10
B A
11294
42-33
CAB TILT LINK
Cab Stay
Removal sequence
1 Bolt
2 Cab stay assembly
3 Bolt
WARNING
You must use a hoist to support the cab when
you remove the cab stay assembly.
1 2
12405

1 Bolt (Cab stay mounting) 19 to 27 {14 to 20, 1.9 to 2.8}
3 Bolt (Cab stay mounting) 59 to 78 {43 to 65, 6 to 8}
42-34
DOOR 42
Door Hinge and Striker
1 Door harness
2 Bolt
3 Bolt
4 Door assembly P42-36
4 5 Bolt
6 Upper hinge
7 Bolt
5
8 Lower hinge
-6 9 Screw
10 Striker
2 9 10 11 11 Shim

12 Grommet
1 13 Door switch ^ Gr 54
7 Assembly sequence
12 13 Follow the disassembly sequence in re-
-8 verse.
3 Inspection and adjustment after
08026 assembly
P42-18
NOTE
For adjustment of door fitting: P42-
18.

2, 3 Bolt (Door assembly mounting) 17 to 25 {12 to 19, 1.7 to 2.6}
5 Bolt (Upper hinge mounting) 17 to 25 {12 to 19, 1.7 to 2.6}
7 Bolt (Lower hinge mounting) 17 to 25 {12 to 19, 1.7 to 2.6}
9 Screw (Striker mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4}
- Lubricant
6 Upper hinge checker pin roller Chassis grease [NLGI No.1 (Ca soap)] As required
8 Lower hinge checker pin roller Chassis grease [NLGI No.1 (Ca soap)] As required
42-35
DOOR
Door Assembly
16 17 13 3
13
1
35 14 5
15 39
29 28
6
27 -
33 8
23
31
- 24
4
7
37
- 26 25 9
- 40
38 19 30 36 32
- 21 20
- - -
08027
1 Cover 15 Side combination lamp ^ Gr 54 29 Lower sash
2 Door lock knob 16 Outer weatherstrip 30 Nut
3 Bushing 17 Inner weatherstrip 31 Glass holder
4 Cover 18 Waterproof cover 32 Bolt
5 Guard bar 19 Speaker 33 Glass holder
6 Pull handle cover 20 Inside handle 34 Door glass
7 Ashtray 21 Clip 35 Run channel
8 Inside handle cover 22 Door lock cylinder 36 Bolt
9 Regulator handle 23 Door lock rod 37 Regulator and rail assembly
10 Door trim 24 Door opening rod 38 Door panel
11 Front garnish 25 Screw 39 Weatherstrip
12 Rear garnish 26 Door lock assembly 40 Weatherstrip
13 Clip 27 Outside handle
14 Outer garnish 28 Bolt
Assembly sequence
NOTE
Service procedure describes details for right side door, the left side door has the same structure.
42-36
42
25 Screw (Door lock assembly mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6}
30 Nut (Door glass mounting) 6.9 to 11 {5.1 to 8, 0.7 to 1.1}
32 Bolt (Door glass mounting) 6.9 to 11 {5.1 to 8, 0.7 to 1.1}
36 Bolt (Regulator and rail assembly mounting) 6.9 to 11 {5.1 to 8, 0.7 to 1.1}

20 Turning part of inside handle Wheel bearing grease [NLGI No.2 (Li soap)] As required
26 Friction part of door lock assembly Wheel bearing grease [NLGI No.2 (Li soap)] As required
27 Friction part of outside handle Wheel bearing grease [NLGI No.2 (Li soap)] As required
30 Thread area of nut LOCTITE DRYLOCK No.203 As required
31, 32 Thread area of bolt LOCTITE DRYLOCK No.203 As required
37 Friction part of regulator and rail assembly DYNAMIC GB As required
38 Door panel waterproof cover mounting surface BUTYL TAPE As required
1
2
Service procedure
Installation of door lock knob
Screw door lock knob 2 onto door lock rod 23 and turn to the right fully.
Slacken off door lock knob 2 to the left by one or two turns.
Install cover 1 to prevent door lock knob 2 from turning excessively.
2
23
F
05701
Installation of door trim

At front pillar, tap door trim 10 against lip area A of run channel 35 .
35 In belt line, insert door trim 10 into lip area B of inner weatherstrip 17
10 A and install.
10 B
05702
42-37
DOOR
11 13
GH Installation of front garnish and rear garnish
Install clips 13 on door panel 38.
Install front garnish 11 and rear garnish 12 on clips 13.
38
13 12
38
N
05703
Installation of waterproof cover

Apply butyl tape A to door panel 38 as illustrated.
A
Stick waterproof cover 18 over butyl tape A.
18
R
38 05704
Installation of door lock cylinder

A 21 : Clip
A: Front of the vehicle
21
22
^
05705
Removal and installation of door glass

Remove all parts supporting door glass 34 and remove the door glass
from the door opening.
Raise door glass 34 to the upper limit.
34 Remove bolt 28 through hole A of door panel 38 to remove lower sash
29 which is inserted into upper sash B.
B
A 29
29
28
38
10442
42-38
42
Lower door glass 34 to the level where nut 30 and bolt 32 can be seen
through holes C and D of door panel 38 respectively.
Hold door glass 34 with your hands and remove glass holders 31, 33.
Remove door glass 34 via the door opening.
34 For installation, follow the removal sequence in reverse.
C D
31
38 34
30
32 33
10443
42-39
CAB EXTERIOR FITTING
Front Panel
13
14
11 A
12 6
10
9
B 8
7
15
* 5
1
11362
1 Screw 8 Wiper arm and blade assembly 14 Nut
2 Front grille P42-46 15 Hose joint
3 Front side panel, RH 9 Pivot cap 16 Front garnish
4 Front side panel, LH 10 Nut
5 Side garnish, RH 11 Packing washer P42-46 * : Cab assembly
6 Side garnish, LH 12 Instrument panel P42-53 A : Pawl (Front side panel)
7 Nut 13 Washer hose B : Magic tape
Assembly sequence

7 Nut (Wiper arm and blade assembly mounting) 9.8 to 15 {7.2 to 11, 1.0 to 1.5}
10 Nut (Packing washer mounting) 14 to 20 {10 to 14, 1.4 to 2.0}
14 Nut (Hose joint connecting) 0.59 to 0.88 {0.43 to 0.65, 0.06 to 0.09}
42-40
42
2
Service procedure
Removal and installation of front grille
Remove screws 1 (two points) from front grilles 2.
200 mm D
{7.87 in.} F Lift up the ends of clips C (two points), located in the center of front
grilles 2, using a screwdriver, and unlock them from the clips.
30 mm
Pull out front grilles 2 horizontally, in the vehicle forward running
{1.18 in.} direction, to remove them.
10 mm {0.39 in.}
CAUTION
E Be careful not to apply too much force to front grilles 2, because
2 this would damage them. Be especially careful to avoid applying
force to clips D at both sides, support the clips using your hands.
If it is hard to remove the front grilles, remove them using nylon
1 jig E as illustrated.
Be careful not to use force when you pull out clips F (five points)
C from the tops of front grilles 2, because this would damage them.
For installation, follow the removal sequence in reverse.
34
14132
Installation and removal of front side panels RH, LH

Move front side panels RH 3, LH 4 to the outside of the vehicle to
A remove them from the cab assembly *.
FF A : Pawl
*
(The illustration shows front side panel LH 4.)
4 For installation, follow the removal sequence in reverse.
4
A
F E F *
E EE
D
L
10695
Installation of front garnish

G
NOTE
B 16 When installing front garnish 16, be careful not to catch weather-
16
strip G of the windshield.
B
B: Magic tape (3 points)
460 mm 460 mm
{18.1 in.} {18.1 in.}
11384
42-41
CAB EXTERIOR FITTING
Step and Fender
11240
Removal sequence
1 Step
2 Step garnish
3 Fender garnish
4 Set bolt
* : Cab assembly
NOTE
This illustration only shows the step and fender for the left side; the same service procedure described above
is used for the right side.
42-42
42
MEMO
42-43
MIRROR
Removal sequence
1 Outside mirror stay assembly, LH

2 2 Nut
5
3 Washer (Stainless)
3 4 Washer
7
9 5 Sub mirror stay
4
6 Sub mirror stay
6 7 Mirror holder B
8 Mirror holder
10 9 Packing
10 Outside mirror
11 Lower bracket
12 Main mirror stay
11 13 Outside mirror stay assembly, RH
13
11367
NOTE
For outside mirror stay assembly RH 13, follow the same service procedure as for outside mirror stay
assembly LH 1.

2 Nut (Sub mirror stay and main mirror stay mounting) 24.5 to 29.4 {18 to 22, 2.5 to 3.0}
42-44
42
A 12 8
8
Service procedure
Installation of mirror holder
Install mirror holder 8 onto main mirror stay 12 in the direction as
illustrated.
A : Indent of main mirror stay 12.
11368
H Installation of main mirror stay

Install main mirror stay 12 and lower bracket 11 so that alignment marks
are aligned.
12
11

11369
42-45
WIPER AND WASHER

24
10
9
25 1
27 20
19
12

28
18 26 15
11
16 14
23 13

*2 7
*1
17
5
4 3
08001
1 Nut 17 Washer tank
2 Wiper arm and blade assembly 18 Washer motor ^ Gr 54
3 Wiper blade 19 Nut
4 Blade rubber 20 Wiper link assembly
5 Screw 21 Packing washer
6 Washer nozzle assembly 22 Packing washer
7 Hose 23 Nut
8 Wiper arm 24 Bolt (L : 16 mm {0.63 in.})
9 Pivot cap 25 Bolt (L : 12 mm {0.47 in.})
10 Nut 26 Wiper motor bracket
11 Washer hose 27 Bolt
12 Nut 28 Wiper motor ^ Gr 54
13 Hose joint
14 Washer hose *1 : Front garnish P42-40
15 Joint *2 : Assistant drivers side lower panel P42-51
16 Screw
NOTE
Before disassembling parts 11 to 28, remove the instrument panel to allow access to them. P42-49
Assembly sequence
Service standards
2 Wiping force of wiper arm 5.70.49 N {1.280.11 lbf, 0.580.05 kgf} Replace
42-46
42
1 Nut (Wiper arm and blade assembly mounting) 9.8 to 15 {7.2 to 11, 1 to 1.5}
10 Nut (Packing washer mounting) 14 to 20 {10 to 14, 1.4 to 2}
12 Nut (Hose joint mounting) 0.6 to 0.9 {0.4 to 0.7, 0.06 to 0.09}
19 Nut (Wiper link mounting) 9.8 to 15 {7.2 to 11, 1 to 1.5}
23 Nut (Wiper motor and wiper link mounting) 1.7 to 2.4 {1.2 to 1.7, 0.17 to 0.24}
24, 25 Bolt (Wiper motor bracket mounting) 9.8 to 15 {7.2 to 11, 1 to 1.5}
27 Bolt (Wiper motor mounting) 5.4 {4, 0.55}
25 to 50 mm {0.98 to 1.97 in.} 2

Service procedure
Installation of wiper arm and blade assembly
Install wiper arm and blade assembly 2 so that dimensions from the
edges of the weatherstrip are as illustrated.
{2.170.20 in.} {2.170.20 in.}
6
555 mm 555 mm 08002
Inspection of washer nozzle assembly

D G F E D C B A
Make sure that washer fluid spreading target positions H are within
dimensions A to G. (Illustration shows the view from inside cab.)
Unit : mm {in.}
H H
H
< Drivers side > < Passengers

A 110 {4.33}
side >
Passengers side B 90 {3.54}
08003
C 170 {6.69}
D 15 {0.59}
E 90 {3.54}
Drivers side F 90 {3.54}
J
G 160 {6.30}
If washer fluid spreading target positions H deviate from these dimen-

sions, adjust the jet hole angle of washer nozzle assembly 6 using wire J.
6 CAUTION
00540
Be careful not to damage the jet hole of washer nozzle assembly
6 with wire J when adjusting the angle.
42-47
WIPER AND WASHER
8 Inspection of wiper arm
If the measured value deviates from the standard value, replace wiper
arm 8.
06156
21 QR Packing washer
Because the shape of packing washer 21 for the passengers side and
packing washer 22 for the drivers side are different, be careful not to mix
them up during assembly.
22
11385
42-48
CAB INTERIOR FITTING 42
Trim
14 16
12 15
6
5
13
4
1 17
3
11
9
10
12242
Removal sequence
1 Front pillar grip, LH 7 Scuff plate, LH 13 Lower rear pillar trim, RH
2 Front pillar trim, LH 8 Scuff plate, RH 14 Upper rear pillar trim, RH
3 Roof side trim, LH 9 Seat belt assembly, LH 15 Rear trim clip
4 Front pillar grip, RH 10 Lower rear pillar trim, LH 16 Upper rear trim
5 Front pillar trim, RH 11 Upper rear pillar trim, LH 17 Lower rear trim
6 Roof side trim, RH 12 Seat belt assembly, RH
CAUTION
Do not disassemble seat belt assemblies 9, 12 because this might cause malfunction of the emergency locking
retractor.
42-49
CAB INTERIOR FITTING
Headlining
4
7
3 8
6
2
12373
Removal sequence
1 Grip 6 Sun visor, LH
2 Lens 7 Hook
3 Cab lamp assembly ^ Gr 54 8 Headlining clip
4 Sun visor, RH 9 Headlining
5 Hook
42-50
INSTRUMENT PANEL 42
Lower Panel
7 8
*2
B
6
4
A
*3
9 10 5
*1
1 3
2
*4
*5
11296
1 Bolt 8 Side panel bracket *3 : Water hose
2 Bolt 9 Fuse box lid *4 : Cooling unit
3 Passengers side lower panel 10 Center lower panel *5 : Blower unit
4 Window washer tank
5 Center lower panel *1 : Front floor A : Fixed on heater unit
6 Drivers side lower panel *2 : Instrument panel B : Fixed on joint duct
7 Side panel P42-53
Assembly sequence
42-51
INSTRUMENT PANEL
Meter Bezel
8 9
7
*
6
3
10
16
5 13
12 11 15
4 14
17
1 2
11297
1 Ashtray 10 Bracket, LH
2 Cup holder 11 Bracket, RH
3 Meter bezel 12 Radio < Option >
4 Cigarette lighter ^ Gr 54 13 Box
5 Protector 14 Bracket, LH
6 Meter cluster ^ Gr 54 15 Bracket, RH
7 Card holder 16 Glove compartment
8 Heater control assembly ^ Gr 55B 17 Cup holder base
9 Cool air bypass control assembly
^ Gr 55B * : Instrument panel P42-53
Assembly sequence
42-52
42
Instrument Panel
4 9
*2
5 2
8
3
*3
12
*1
10
15
*1
11
13 14 11298
1 Fluid tank lid 8 Side demister grille 15 Instrument panel bracket
2 Glove compartment 9 Air outlet grille
3 Glove compartment lid 10 Instrument panel frame *1 : Front inner pillar
4 Glove compartment 11 Relay bracket *2 : Fluid tank ^ Gr 35
5 Glove compartment lid 12 Instrument panel support *3 : Front window rail
6 Instrument panel 13 Instrument panel bracket
7 Side demister grille 14 Instrument panel bracket
Assembly sequence
42-53
WINDOW GLASS
1 Weatherstrip
2 Windshield
3 Weatherstrip
- 4 Rear window glass
Assembly sequence
- verse.

10440
- Lubricant
1, 3 Lip area of weatherstrip Soapy water As required
1
B
12
Service procedure
[Removal]
Weatherstrip and windshield
2
From the inside of the cab, separate lip A of weatherstrip 1 from flange
lip B of the cab.
C : Screwdriver
A C Push windshield 2 outward to remove it from the cab.
05828
[Installation]
1 When installing the windshield, pull cord H attached to weatherstrip 1
and turn over lip A, following the procedure below:
F
Position drain hole D and joint part E of weatherstrip 1 as illustrated
E 2 and install them on windshield 2.
F : Outside
G : Inside
G
D 05829
2 Lay cord H in the cab mounting groove of weatherstrip 1 as illustrated,

H and overlap the cord at the lower side of the glass by the specified
1
length, see J.
2 Apply soapy water K to weatherstrip 1.
Align windshield 2 with the cab.
J
1
H
K 05830
42-54
42
Push windshield 2 inward from the outside of the cab firmly.
Inside the cab, pull one end of cord H to install lip A of weatherstrip 1
into flange lip B of the cab.
2
1
A
B H
00032
H Pull cord H in the numbered order as illustrated and at the same time
have someone push windshield 2 into weatherstrip 1, tapping the
windshield with a rubber-headed mallet.
L K : approximately 100 mm {3.94 in.} from the starting point of
the straight section
L : up to the end of the straight section
K
CAUTION
Make sure that windshield 2 is installed correctly into the cab
00033 before hitting the windshield with the rubber-headed mallet,
otherwise the windshield might be broken.
Provide an overlapped margin N on weatherstrip 1 and side garnish M

to prevent water flowing backwards from the water drain hole.
43 mm
{0.160.12 in.} 1
N 11386
34 Weatherstrip, rear window glass

Install so that joint A of weatherstrip 3 is at the bottom center of rear
window 4.
4 A 3 B : Water drain hole
Except for the point mentioned above, follow the same service proce-
dure as for installation of the windshield. P42-54
B
05841
42-55
Group 54 - Electrical
Group 54 - Electrical
BACK HOME
Group 54
Electrical
' 98 Minor Change

Table of Contents
BACK HOME

54
GROUP 54 ELECTRICAL
SPECIFICATIONS < ALTERNATOR > ........................................... 54 -2
STRUCTURE AND OPERATION < ALTERNATOR > .................... 54- 3
10 0 ON-VEHICLE INSPECTION AND ADJUSTMENT ............... 54- 6
10 6 ALTERNATOR ...................................................................... 54- 8
401 METER CLUSTER ............................................................... 54- 16
8 1 0 FOUR-WHEEL DRIVE CIRCUIT .......................................... 54- 18
This group covers FG only. Please refer to FE for an explanation on parts and items not described here.
54-1
SPECIFICATIONS < ALTERNATOR >
Item Specifications
Type Alternator with built-in regulator (with brush and built-in fan)
Model A3TN1988
Output V-A 12100
54-2
STRUCTURE AND OPERATION < ALTERNATOR > 54
L
B
R
E
1 2 3
12
A
11
4
10 9 5
8 6
7 26979
1 Rectifier 7 Fan A: Neutral diode

2 Stator assembly 8 Rear bracket B: Terminal B
3 Rotor assembly 9 Brush spring E: Terminal E
4 Pulley 10 Regulator and brush holder L: Terminal L
5 Front bearing 11 Brush R: Terminal R
6 Front bracket 12 Rear bearing
A() Features
B
In addition to the present alternator, this alternator has a
neutral diode A ( diode, diode).
N With this neutral diode A, direct output during high speed
C L rotation has increased in contrast to alternators without a
neutral diode.
B : Alternator terminal B
R C : Starter coil
D : IC regulator
A() E : Alternator terminal E
E L : Alternator terminal L
N : Neutral
D R : Alternator terminal R
07033
54-3
STRUCTURE AND OPERATION < ALTERNATOR >
J Neutral electrical fluctuation and neutral diode operation
(V)
K Electrical potential of the neutral point N fluctuate vertically
F around the neutral point of direct current voltage (1/2 G of
the output voltage) as1234567
shown.
1234567
The area (shown as 1234567
1234567) indicates where neutral N volt-
G age taken out of neutral diode A, rises to exceed12345678 output

12345678
voltage F (14V), and the area (shown as 12345678 12345678) shows
where it falls below ground electric potential H (0 V), when
the alternator is rotating at high speed. Previous direct
Voltage H
current output has been exceeded.
Radian 07400
F : Output voltage
G : Average neutral voltage (1/2 of output voltage)
H : Ground electric potential
J : {Neutral voltage} waves at times of high speed revolu-
tion
K : {Neutral voltage} waves at times of low speed revolution
All voltage and electrical potential conditions for neutral
diode A are as follows:
When {neutral points voltage} exceeds 0 V, and is less than
14 V:
The existing diodes (six units) operate.
When {neutral voltage} exceeds 14 V:

A() Neutral diode A ( side) conducts, adding to the existing
B direct current output and supply all mechanisms.
07034
When {neutral voltage} is below 0 V

B Neutral diode A ( side) conducts, passing via the existing
diodes (three units) and supply neutral output.
A()
07035
54-4
TROUBLESHOOTING 54
Symptoms
Charge warning lamp does not light when

turning starter switch ON, with engine stopped
Alternator is normal but battery discharged
Battery is normal but discharged
Remarks
Possible causes
Connector connection faulty, harness broken, grounding faulty
Fuse blown
V-belts loose ^ Gr 14
V-belts damaged ^ Gr 14
Battery faulty
Stator coil broken
Stator coil short-circuited with core
Field coil broken
Alternator Rectifier faulty
Regulator faulty
Brushes worn
Brush spring fatigued
Wiring faulty
Meter cluster faulty
BBaa
tttetery
ry ov
ele erhe
ctr ating
oly
te
de
cre
ase
st
oo
ea
rly
54-5
10 0 ON-VEHICLE INSPECTION AND ADJUSTMENT
Inspection of Alternator
A V Performance test
Connect the meters to the alternator as illustrated.
B A : Ammeter (150 amperes class)
C C : Switch
D : Terminal
V : Voltmeter
WARNING
D
Terminal D is always loaded with voltage from the battery.
16115
You must handle terminal D carefully, it will short-circuit if it
touches any part other than terminal B on the alternator.
CAUTION
The wire connected to switch C should be thicker than the chas-
sis side harness connected to terminal B.
Turn switch C on, and check that battery voltage is displayed on the
voltmeter.
Start the engine.
Turn the switches ON of all the lamps on the vehicle immediately.
Increase engine revolution immediately, and measure current flow at
about 2600 rpm.
The alternator is assumed to be normal if the measured value is
higher than 70% of the specified output.
Specified output of alternator

Voltage Output
12 V 100 A
NOTE
Since the above inspection is only a simplified check, it is neces-
sary to conduct a stringent test bench for an official check.
P54-10
54-6
54
Inspection of Regulator
Service standards
Adjustment voltage of regulator 14.70.3 V Replace

A : Ammeter (150 amperes class)
A V B : Terminal B on alternator
C : Switch

B D : Terminal

C V : Voltmeter
WARNING
D
16117
CAUTION
The wire connected to switch C should be thicker than the chas-
sis side harness connected to B terminal.
To ensure the current consumer is not activated during the inspection,

the lamp and heater switches etc., should be turned off.
Turn switch C on and start the engine.
Measure voltage at B terminal, when output current is less than 5A
with engines revolution at about 2600 rpm.
NOTE
When output current is between 5A - 10A, values measured
(adjustment voltage) may be slightly low.
14V- 0.2-0.3V
When output voltage exceeds 5A, do either of the following.

Turn the engine on and charge the battery.
Replace the battery with a fully charged one.
Where the measured value deviates the limits, reconfirm with the test
bench.
54-7
10 6 ALTERNATOR
Removal sequence
1 1 Chassis harness
2 Adjusting bolt
3 V-belts
A 4 Alternator P54-10
5 Adjusting plate
*a : Timing gear case ^ Gr 11

B
5 *b : Power steering oil pump ^ Gr 37
B : To terminal B
WARNING
Terminal B is always loaded with voltage
from the battery, supplied via chassis
*b
3 the harness from terminal B, make sure
*a 2 that tools do not touch any adjacent parts
28107
Service standards
4 Output current (* When alternator is At 1500 rpm 41 A or more Inspect
hot and 13.5 V is loaded ) At 2500 rpm 73 A or more
Adjustment voltage of regulator (When alternator 14.70.3 V Replace
rotates at 5000 rpm and load is 5 A or less)
* : The value is measured after running the alternator at 5000 rpm (at ambient temperature) with maximum output for 30
minutes.
54-8
54
A V
12 volts
DC
4
Service procedure
Inspection of alternator

C : Switch
C D : Switch
F : Load resistance (variable resistance)
D
4
B L : Terminal L on alternator
V : Voltmeter
G F Set load resistance to MAX (almost no load current flows).
Turn switches C and D ON.
E
Run the alternator at 5000 rpm for 30 minutes to warm it.
Adjust load resistance F until nominal current is achieved.
Alternator nominal current: 12V-100A
Measure current of alternator 4 at each specified rpm.

If the measured value deviates from the standard
R value, disassemble and inspect alternator 4.
16132 P54-10

V 12 volts
A DC Connect each unit to the alternators as illustrated.
A : Ammeter
C : Switch
C
V : Voltmeter
B 4 Turn switch C ON.
Operate alternator 4 at low speed.
Measure the voltage (adjustment voltage) while increas-
G ing revolution rate of alternator 4 up to 5000 rpm. At the
E same time check that current remains at under 5A.
Where the measured values are outside the limits do the
L following:
Measured values exceed the limits:
Replace the regulator
Measured values are below the limits:
Check all parts of the alter-
nator before replacing the
R regulator.
16133
54-9
10 6 ALTERNATOR
Alternator
6
7
9
8
3
2
16
14
11
16197
1 Rotor and front bracket assembly 10 Stator assembly
2 Nut 11 Cover
3 Pulley 12 Brush
4 Rear bearing 13 Regulator and brush holder
5 Rotor assembly 14 Slinger
6 Cover 15 Rectifier
7 Front bearing 16 Rear bracket
8 Front bracket
9 Stator and rear bracket assembly
NOTE
Do not remove parts 4, 7, 10, 12 unless they are faulty.
Assembly sequence
14 13 12 11 876
91 9: 16 10 1: 32
15 54
54-10
54
5 Rotor assembly Field coil resistance (At 20C) 2.1 to 2.5 Replace
Slip ring outer diameter 33 {1.30} 32.4 {1.28}
12 Length of brush 23 {0.91} 8 {0.31} Replace

2 Nut (pulley mounting) 132 to 162 {98 to 120, 13.5 to 16.5}
10
8
1
Service procedure
[Removal]

CAUTION
B A
9 1
16198
[Installation]
16 C
When brush 12 is protruding out of regulator and brush holder 13, rotor
assembly 5 cannot be installed on rear bracket 16, so perform the
following.
Insert brush 12 into regulator and brush holder 13.
Insert pin C from the rear end of rear bracket 16, attach the pin against
pin hole D and secure the brush 12.
If the pin hole D is gone due to worn brush 12, secure front end of the
D 12 13 16199 brush with pin.
After installation, remove pin C carefully.
54-11
10 6 ALTERNATOR
[Disassembly]
F CAUTION
E of the core claws. Gripping claws F can damage them.
E E
4
5 16223
Removal of rear bearing

A
CAUTION
Do not damage slip ring A when mounting the bearing puller.
If the slip ring is damaged, brushes will not fit properly.
5
16224
Inspection of rotor assembly

A
(1) Field coil resistance
Measure resistance between gaps of slip ring A.
If the measured value deviates from the limits, replace rotor assembly
5.
04757
(2) Continuity between slip ring and core

B A Check there is no continuity between slip ring A and core B.
If continuity is found, replace rotor assembly 5 as there is a short
circuit.
04758
(3) Outer diameter of slip ring

If outside diameter of slip ring A is less than the limit, replace rotor
14 assembly 5.
If the outer peripheral diameter of slip ring A is rough or worn on one
side, polish it smooth with sandpaper or a lathe.
CAUTION
Do not polish slip ring until its outer diameter deviates from the
specified limits.
04759
54-12
54
15
F Stator assembly
[Removal and installation]
Disconnect lead A of stator assembly 10 from rectifier 15. The lead is
B soldered to diode B of rectifier 16 at four points.
10 CAUTION
diode is heat sensitive.
A
26980
[Inspection]
Make sure that each lead wire has continuity.
If there is no continuity, the lead wire is broken. Replace stator
assembly 10.
02336

Make sure that there is no continuity between lead wires and the
core.
If there is continuity, replace stator assembly 10, since it might be
short-circuited.
H
02337
Brushes
[Removal]
13 A Remove cover A, separate the soldered connection on the lead wire to
brush 12 and remove brush from regulator and brush holder 13.
12
16225
[Installation]
Install brush 12 in regulator and brush holder 13 facing the direction
13 indicated.
After installation solder the lead wire to brush 12 onto regulator and
brush holder 13.
Replace cover A to its original position.
12 16231
54-13
10 6 ALTERNATOR
[Inspection]
If the length of brush B is approaching permissible wear line B, it must be
replaced.
I
04786
Removal of regulator and brush holder

13 Disconnect regulator and brush holder 13 from the 2 soldered joints
A on rectifier 15, as illustrated.
CAUTION
When the soldered joints are removed, the operation must be
A A performed quickly, (within 5 seconds.)
The diode may be damaged if heat is applied for long period.
15 16232
K
For installation, follow the removal sequence in reverse.
Inspection of rectifier
E
any fault is found, replace the rectifier.
A
B Resistance is infinite at both ends ............ open
C F Resistance is near 0 at both ends ......... short-circuited
D A, B, C, D : Lead connecting area of stator coil
E, G : Heat sink area
F : Regulator connecting area
G
15270 Inspect the rectifier twice, before and after the side and side of
A B G C D the tester have been changed over.
CAUTION
When inspecting using a tester, the current becomes weaker
smaller. Therefore, use as large a range as possible.
E 16201
54-14
54
MEMO
54-15
401 METER CLUSTER
Meter Cluster Internal Circuit
This diagram only illustrates the internal circuits of FG meter cluster. Service information is same as for FE.
FUEL GAUGE
WATER
TEMPERATURE
SENSOR
ILLUMINATION
LAMP
TACHOMETER
LOW
VACUUM
BRAKE
27005
54-16
54

B
AU16A
A
07417
Terminal Terminal Terminal

AU10A AU13A AU16A
No. No. No.
1 Turn, LH 11 Fuel gauge 24 Tachograph < optional >
2 Beam 12 25 Illumination
3 Beam 13 Tachometer 26
4 Exhaust brake 14 Charge 27 Illumination
5 Turn, RH 15 28 Ground
6 Glow 16 Engine oil 29 Water temperature gauge
7 Glow 17 Engine oil 30 Cab tilt
8 Vacuum 18 Engine oil level 31
9 19 32 (Power take-off)
10 Brake 20 Pre-stroke control 33 (Power take-off)
21 Tachometer 34
22 35 Transfer low switch
23 36 Starter switch terminal M
37
Not used 38
Terminal 39 Transfer four-wheel drive switch
AU10A
No.
40
41
42
43
44
45
46
47
48
49
Terminal AL2A
No.
A Buzzer
B Buzzer
54-17
810 FOUR-WHEEL DRIVE CIRCUIT
2 1
Fuse box Meter cluster
Cab Meter
Cab
Cab ground
c
Chassis To backup
lamp switch
Chassis ground
Transfer four-wheel drive switch Transfer low switch

3 4
26467
54-18
54
1 Meter cluster 401
2 Fuse box 104
3 Transfer low switch
4 Transfer four-wheel drive
1 a 2 switch
26468
3
Service procedure
Inspection of transfer low switch
Conduct the continuity test as following.
1 2
ON OFF
OFF
0
ON
18 1.3 mm
If any fault is found, replace transfer low switch 3. ^ Gr 24
4
07204
Inspection of transfer four-wheel drive switch

Conduct the continuity test as following.
1 2
ON OFF
OFF
0
ON
18 1.3 mm
If any fault is found, replace transfer four-wheel drive switch 4.
07204
^ Gr 24
54-19
Group 54
Electrical
Table of Contents
BACK
HOME
Pub No. TWSE9501-54

CONNECTOR CONFIGURATION CHART 54
Model
of pins)
AA AA 1 A
AA 2 A
AA 2 B
AA 3 A
AA 3 B
AA 4 A
AA 4 B
AA 6 A
TB 54-0-3
Model
of pins)
AA AA 6 B
AA 8 A
AA10A
AA12A
AB AB 2 A
AB 3 A
AB 4 A
AB 6 A
AC AC 1 A
54-0-4 TB
54
Model
of pins)
AC AC 2 A
AC 3 A
AC 4 A
AD AD 1 A
AD 2 A
AE AE 2 A
AE 3 A
AE 5 A
AE 7 A
TB 54-0-5
Model
of pins)
AE AE 9 A
AE11A
AE13A
AE15A
AE16A
(White, Gray,
Black)
AE16B
(Green)
AE16C
(Blue)
AE17A
AG AG16A
54-0-6 TB
54
Model
of pins)
AG AG20A
AH AH10A
AH12A
AH18A
AH18B
TB 54-0-7
Model
of pins)
AH AH24A
AJ AJ 2 A
AJ 4 A
AJ 8 A
AJ10A
AJ12A
54-0-8 TB
54
Model
of pins)
AJ AJ16A
TB 54-0-9
Model
of pins)
AJ AJ20A
AK AK 2 A
AK 3 A
AK 4 A
AK 6 A
54-0-10 TB
54
Model
of pins)
AK AK 8 A
AK10A
AK14A
AK18A
AK20A
TB 54-0-11
Model
of pins)
AK AK20B
AK22A
AK22B
AL AL 1 A
or
or
AL 2 A
or
or
54-0-12 TB
54
Model
of pins)
AL AL 2 B
AL 3 A
or
or
AL 3 B
AL 3 C
AL 3 D
or
AL 3 E
or
TB 54-0-13
Model
of pins)
AL AL 4 A
or or
AL 4 B
AL 6 A
or or
AL 6 B
AL 8 A
or or
AL 8 B
54-0-14 TB
54
Model
of pins)
AM AM 2 A
AM 2 B
AM 2 C
AM 4 A
AM 4 B
AM 6 A
AM 6 B
AM 8 A
AM 8 B
TB 54-0-15
Model
of pins)
AM AM10A
AN AN 1 A
AN 2 A
AN 3 A
AN 4 A
AN 4 B
AN 6 A
AN 6 B
AN 8 A
54-0-16 TB
54
Model
of pins)
AN AN 8 B
AP AP 1 A
AP 1 B
AP 2 A
AP 2 B
AP 2 C
AQ AQ 3 A
AQ 3 B
AQ13A
TB 54-0-17
Model
of pins)
AQ AQ15A
AQ20A
AR AR 2 A
AR 2 B
AR 2 C
AR 2 D
AR 2 E
AR 2 F
54-0-18 TB
54
Model
of pins)
AR AR 3 A
AS AS 1 A
AS 2 A
AS 2 B
AT AT 4 A
AU AU 6 A
AU 8 A
AU10A
TB 54-0-19
Model
of pins)
AU AU12A
AU13A
AU16A
AV AV 1 A
AV 2 A
AW AW 1 A
AW 1 B
AW 2 A
AX AX 4 A
54-0-20 TB
54
Model
of pins)
AY AY 2 A
AZ AZ 2 A
BA BA 3 A
BB BB 2 A
BB 3 A
BC BC 3 A
BD BD 8 A
BE BE 6 A
BF BF12A
TB 54-0-21
Model
of pins)
BG BG16A
BH BH 4 A
BJ BJ 9 A
BL BL 2 A
BM BM 2 A
BM 2 B
BM 2 C
54-0-22 TB
54
1 POWER, CHARGING AND GROUND
SPECIFICATIONS .......................................................................... 54-1-2
STRUCTURE AND OPERATION ................................................... 54-1-3
TROUBLESHOOTING .................................................................... 54-1-6
10 0 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

Inspection of Alternator ................................................................ 54-1-8
Inspection of Regulator ................................................................ 54-1-9
101 BATTERY ........................................................................... 54-1-10
10 4 FUSE ................................................................................. 54-1-14
10 6 ALTERNATOR ................................................................... 54-1-16
110 POWER CIRCUIT .............................................................. 54-1-22
115 RESERVE POWER CIRCUIT ............................................ 54-1-32
125 BATTERY CHARGING CIRCUIT ....................................... 54-1-34
130 GROUND ........................................................................... 54-1-36
54-1-1
SPECIFICATIONS
Battery
Item Specifications
Model 95D31R
VoltageNo. V 122 (Parallel connection)
Capacity (5-hour rating) Ah 70
Alternator
Item Specifications
Type Alternator with built-in regulator (without brush, external fan)
Model A4TU0088
Output V-A 1280
54-1-2
Alternator
B
R
2 3 4
1
11
6
9
10
8 7
10214
1 Rectifier 7 Front bracket B: Terminal B

2 Stator assembly 8 Field coil E: Terminal E
3 Rotor assembly 9 Rear bracket L: Terminal L
4 Fan 10 Regulator R: Terminal R
5 Pulley 11 Rear bearing
6 Front bearing
54-1-3
Battery Charging Circuit
08541
1 Battery A : To each unit

2 High-current fuse box B : Terminal B
3 Alternator L : Terminal L
4 Meter cluster R : Terminal R
5 Charge warning lamp
6 Fuse box
7 Starter switch
At engine standstill (before starting)

Position of starter switch 7 : ON
12 (FH5)76 (F19)
6 (F20)
3 (RBody ground)
53 (LBody ground)
Charge warning lamp 5 lights up.

To improve the low-speed power generation
build-up performance of alternator 3, current
is fed to terminal R immediately after the
engine is started.
08542
54-1-4
54
After engine start-up
Alternator 3 starts to generate power.
The voltage at terminal B of alternator 3
rises higher than the voltage of battery 1.
As alternator 3 starts to charge battery 1,
units A are supplied with power.
3(B)2(FH7)1Ground
(FH5)76(F19)A
Since there is no electric potential difference
between the output voltage of terminal L of
alternator 3 and the voltage of battery 1,
charge warning lamp 5 goes off.
08543
54-1-5
TROUBLESHOOTING
Symptoms
Charge warning lamp does not light when

turning starter switch ON, with engine stopped
Alternator is normal but battery discharged
Battery electrolyte decreases too early
Battery is normal but discharged

Remarks
Battery overheating
Possible causes
Connector connection faulty, harness broken, grounding faulty
Fuse blown
V-belts loose ^ Gr 14
V-belts damaged ^ Gr 14
Battery faulty
Stator coil broken
Stator coil short-circuited with core
Field coil broken
Alternator Rectifier faulty
Regulator faulty
Wiring faulty
Meter cluster faulty
54-1-6
54
MEMO
54-1-7
10 0 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Inspection of Alternator
Performance test
V Connect the meters to the alternator as illustrated.
A
C : Switch
D : Terminal
D V : Voltmeter
C WARNING
B
10349
Turn switch C ON to supply battery voltage to terminal B on the

alternator.
Start the engine.
Turn the switches ON of all the lamps on the vehicle immediately.
Measure the current when the engine speed reaches approximately
2260 rpm.
The alternator is assumed to be normal if the measured value is
higher than 70% of the specified output.
Specified output of alternator
Alternator model Voltage Output
A4TU0088 12 V 80 A
NOTE
Since the above inspection is only a simplified check, it is neces-
sary to conduct a stringent test bench for an official check.
P54-1-17
54-1-8
54
Inspection of Regulator
Service standards
Adjustment voltage of regulator 14.70.3 V Replace

V B : Terminal B on alternator
L
C : Switch
B D : Terminal
D V : Voltmeter
A
WARNING
C
10350
Turn switch C ON and make sure that voltmeter V indicates 0 volt.
If the needle of voltmeter V oscillates, something is wrong with the
alternator or the wiring.
Turn switch C OFF and start the engine.
CAUTION
Do not start the engine with switch C turned ON because the
starter current will flow into ammeter A and damage it.
If the charge current is five amperes or less and the engine speed is
approximately 2260 rpm, measure the adjustment voltage.
If the charge voltage is five amperes or more, do one of the following :
Run the engine for a while to charge the battery.
Replace the old battery with a fully-charged one.
Connect a 1/4 (25 W) resistor in series with the battery to limit the
charge current.
If the measured value deviates from the standard value, change the
regulators.
54-1-9
101 BATTERY
1 Removal sequence
1 Battery cover
2 Ground cable
3 Battery cable
4 Starter cable
5 Chassis harness
6 Battery cable
6 7 Battery side cover
4 8 Battery
9 Battery box
5
3
7
10908
DANGER
Since flammable hydrogen gas is generated by battery 8, be sure to obey the following warnings :
Do not wear metal objects on your arms and lean over battery 8.
Because the battery electrolyte is diluted sulfuric acid and is corrosive, when handling battery 8 wear safety
glasses and rubber gloves to protect the eyes and hands.
WARNING
To prevent a short-circuit be sure that disconnected battery cables 3 and 6 do not accidentally touch the
battery terminals.
CAUTION
Make sure that you disconnect battery cable 3 first when you disconnect battery cables 3 and 6.
Make sure that all electrical switches of the vehicle are OFF before connecting battery cables 3 and 6.
Make sure that you connect battery cable 6 before you connect battery cable 3.
54-1-10
54
8
Service procedure
Inspection of battery
(1) Visual inspection

A brush.
If cracks or defects are found on battery 8, replace it since the
CAUTION
A
corroded.
13973
C If bleed hole C of vent plug B is clogged, clean the hole.

C
13974
(2) Inspection of fluid level

LOWER.
13975
(3) Measurement of specific gravity

D
Blue : Good
13976
54-1-11
101 BATTERY
(4) Charging
Although, as a rule, charging of battery 8 should be done
you stop the engine and disconnect battery cable 3.
Upper limit
of fluid
(C {F})

Normal
1.240 charge 1.2(to 1.5) 45
1.220 10 Charge
{113} current (A)
1.200
Charge
1.120 charge 0.5 55
1.5
1.080 {131}
Amount of
0 10 20 30 40 50 60 70 80 90 100 discharge (%)
100
07789
discharge (%).
Use diluted sulfuric acid, made up of sulfuric acid and
refined or distilled water, as the battery electrolyte.
DANGER
Keep naked lights away from the battery while charging
it or it might explode.
the surface.
9 Inspection of battery box

If battery box 9 is corroded, scrub off the corrosion from it using a wire
brush and apply acid resistant coating.
If battery box 9 is corroded excessively or if it is broken or cracked,
replace it.
54-1-12
54
MEMO
54-1-13
10 4 FUSE
Installation Position
F18 to 34
F1 to 17
FH7
FH6
FH5
FH4
FH3
FH2
FH1
2
07998
1 Fuse box
CAUTION
Make sure that you remove the terminal of the battery cable before removing high-current fuses FH1 to
7. 101
54-1-14
54

No.
FH3
FH4
Fuse box
Fuse Main load Capacity Fuse Main load Capacity
No. No.
F2 Headlamp, RH 15 A < Manual transmission >
Inhibitor switch
F3 Stop lamp, horn 15 A
F4 Turn signal lamp, pre-stroke control unit 15 A
F19 Backup lamp 10 A
F20 Meter cluster 10 A
F5 Fuel-cut motor 10 A
F21 Wiper 10 A
F6 Cab lamp 10 A
F22 Reserve power (MAIN) 10 A
F7 Reserve power (BATT) 10 A
F8
F9
F25 Pre-stroke cut relay 15 A
(Memory clear switch) F26
F11 F27 Exhaust brake 10 A
F12 F28
F13 Cigarette lighter 15 A F29
F14 Radio 10 A F30
F15 Reserve power (ACC) 10 A F31
F16 F32 * Condenser fan 15 A
F17 Fuel-cut relay 10 A F33 Blower fan 25 A
F34 Tail lamp 15 A
are installed.
NOTE
malfunctions.
54-1-15
10 6 ALTERNATOR
Removal sequence
1 Chassis harness
2 Adjusting bolt
1
3 V-belts
B 4 Alternator P54-1-18
5 Adjusting plate
3
A * : Timing gear case and front plate
5 ^ Gr 11
B : To terminal B
WARNING
Terminal B is always loaded with voltage
from the battery, supplied via chassis
the harness from terminal B, make sure
2
that tools do not touch any adjacent parts
*
10293
Service standards
4 Output current (* When alternator is At 1500 rpm 38 A or more Inspect
hot and 13.5 V is loaded ) At 2500 rpm 65 A or more
Adjustment voltage of regulator (When alternator 14.70.3 V Replace
rotates at 5000 rpm and load is 5 A or less)
* : The value is measured after running the alternator at 5000 rpm (at ambient temperature) with maximum output for 30
minutes.
54-1-16
54
A V 12 volts
DC
4 Inspection of alternator

A : Ammeter
C : Switch
C D : Switch
D F : Load resistance (variable resistance)
4
E L : Terminal L on alternator
V : Voltmeter
F
G Turn switches C, D OFF.
Run alternator 4 at 5000 rpm.
B
Adjust load resistance F to maintain the specified cur-
rent.
L
Specified output of the alternator : 12 V-80 A
After adjustment, run alternator 4 for 30 minutes.

R Maximize load resistance F (current hardly flows).
09502 Turn switches C, D ON.
Increase the rotation of alternator 4 gradually and meas-
ure current at specified rpm.
If the measured value deviates from the standard value,
disassemble and inspect alternator 4. P54-1-18

V 12 volts
A DC Connect each unit to the alternators as illustrated.
A : Ammeter
C : Switch
C G : Alternator drive motor
V : Voltmeter
E 4 Turn switch C ON.
Run alternator 4.
Make sure that the value of the current at 5000 rpm is five
G amperes or less.
Measure voltage (adjustment voltage).
B If the measured value deviates from the standard value,
L replace the regulator (in alternator 4).
R
09503
54-1-17
10 6 ALTERNATOR
Alternator
- -
7 6
- 8
9
10
11
5
3 4
2
12
17
15
07043
1 Rotor and front bracket assembly 11 Front bracket
2 Nut 12 Stator and rear bracket assembly
3 Pulley 13 Stator assembly
4 Fan 14 Field coil
5 Spacer 15 Regulator
6 Rear bearing 16 Rectifier
7 Rotor assembly 17 Rear bracket
8 Cover
9 Front bearing : Non-reusable parts
10 Oil seal
NOTE
Do not remove parts 6, 9, 13 unless they are faulty.
Assembly sequence
17 16 11 10 9 8
12 1 12 : 14 13 1: 5432
15 76
54-1-18
54
Service standards
14 Field coil resistance (20C {68F}) 2.6 to 3.4 Replace

2 Nut (pulley mounting) 132 to 162 {98 to 120, 13.5 to 16.5}
- Lubricant
6 Rear bearing inner periphery Engine oil As required
7 Front bearing installation part of rotor assembly Engine oil As required
9 Front bearing outer periphery Engine oil As required
13
A
11
1
Service procedure
[Removal]
CAUTION
12 1
07044
54-1-19
10 6 ALTERNATOR
[Disassembly]
D
CAUTION
C of the core claws. Gripping claws D can damage them.
7
I
C 02319
Stator assembly
[Removal and installation]
Disconnect lead A of stator assembly 13 from rectifier 16. The lead is
soldered to diode B of rectifier 16 at three points.
A CAUTION
B diode is heat sensitive.
16
13 02335
[Inspection]
Make sure that each lead wire has continuity.
If there is no continuity, the lead wire is broken. Replace stator
assembly 13.
02336

Make sure that there is no continuity between lead wires and the
core.
If there is continuity, replace stator assembly 13, since it might be
short-circuited.
J
02337
Inspection of field coil

14
Measure the resistance between the terminals of field coil 14.
If the measured value deviates from the standard value, replace field
coil 14.
02325
54-1-20
54
D
L Inspection of rectifier
any fault is found, replace the rectifier.
A
A, B, C : Lead connecting area of stator coil
B E D, E : Heat sink area
C F : Regulator connecting area
Inspect the rectifier twice, before and after the side and side of
the tester have been changed over.
F
13084 CAUTION
D When inspecting using a tester, the current becomes weaker
E
smaller. Therefore, use as big a range as possible.
A B F C
13083
54-1-21
110 POWER CIRCUIT
Power Supply (Battery to High-current Fuse Box and Fuse Box)
Battery
To starter
To alternator
Chassis
Cab
To each unit
Fuse box Starter switch
10528
54-1-22
54
Fuses F1 to F4
To high-current fuse box

(FH1)
Fuse box
To flasher unit
To pre-stroke
Gr 13 control unit
To van body dome light

relay
To meter cluster
(Power for tachography)
To stop lamp switch
To horn
To headlamp, RH
(HIGH/LOW)
To headlamp relay
(HIGH)
To meter cluster
(HIGH beam)
To headlamp, LH
(HIGH/LOW)
To headlamp relay
(LOW)
10529
54-1-23
110 POWER CIRCUIT
Fuses F5 to F7

(FH2)
Fuse box
To optional connector
To lighting and alarm

control unit
To cab lamp
To radio connector
To engine oil level

check switch
To fuel-cut motor
10530
54-1-24
54
Fuse F10

(FH2)
Fuse box

Gr 23 To automatic transmission fluid
cooler fan relay
Gr 23 To automatic transmission
electric control unit

Gr 23
To shift lock actuator
: Automatic transmission
10531
54-1-25
110 POWER CIRCUIT
Fuses F13 to F18
To starter switch (Terminal A)
To starter switch (Terminal F)
To starter switch (Terminal S)
Fuse box
Gr 13 To pre-stroke control unit
To multipurpose timing
control unit
To sub-starter relay

To inhibitor switch

To transmission neutral relay
To fuel-cut relay
To radio connector
To cigarette lighter
Gr 23 To key interlock control unit
1 : Manual transmission
2 : Automatic transmission
10532
54-1-26
54
Fuses F19 to F22
To starter switch (Terminal M)
Fuse box
To washer motor
To wiper motor
To wiper relay (HIGH)
To wiper relay (LOW)
Diode
To engine oil level relay
To multipurpose timing
control unit
To lighting and alarm
control unit
To meter cluster
Gr 23 < Automatic transmission >

To power mode switch
To van body dome light switch

Cab Meter
To overheating relay
To sub-starter relay
To alternator

Cab Chassis
To blower fan relay
To turn signal lamp relay
1 : Manual transmission
2 : Automatic transmission
10533
54-1-27
110 POWER CIRCUIT
Fuses F23 and F24
Fuse box
Gr 13 To pre-stroke cut relay
Gr 13 To pre-stroke control unit

Gr 23 To meter cluster
(Overdrive OFF indicator)

fluid cooler fan relay

To inhibitor switch

Diagnosis switch

Gr 23 To key interlock control unit

To shift lock actuator
: Automatic transmission
10534
54-1-28
54
Fuses F27 to F30
Fuse box
To accelerator switch
To exhaust brake cut relay
10535
54-1-29
110 POWER CIRCUIT
Fuses F31 to F34
To high-current fuse
(FH6)
Relay box
Tail lamp relay
Fuse box
To clearance To identification lamp

and
marker lamp
Roof
Cab
To lighting switch
To blower fan relay
To air-conditioner relay connector
To condenser fan relay connector
To meter cluster (Illumination)
To rheostat switch
Cab Meter
To clearance lamp To heater control assembly
To radio connector
Cab Center panel
Chassis
To front clearance lamp
To front identification lamp
Rear chassis
To rear clearance lamp
To rear identification lamp
To license lamp
To rear side marker lamp

To rear combination lamp
10536
54-1-30
54
MEMO
54-1-31
115 RESERVE POWER CIRCUIT
To flasher unit
3
2
Optional
Fuse box connector
ACC
BATT
MAIN
IL
GROUND
Relay box
To chassis
Tail lamp relay ground
Cab ground
b
To lighting switch
To meter cluster
(Power for tachography)
Cab Meter a
To rear combination
lamp, LH
10328
54-1-32
54
a
1
b
3 2 10877
1 Relay box 604

2 Fuse box 104
3 Optional connector
54-1-33
6
4
Battery
Alternator

5

Chassis
d
Cab Starter switch
To pre-stroke
control unit
1
Gr 13
To diode
3
Fuse box
To diode
To multipurpose
timing control unit
Cab
c
Meter
a b
: Manual transmission
Meter cluster
2
10357
54-1-34
54
2 a b
5
6
10882
1 Starter switch 210

2 Meter cluster 401
3 Fuse box 104
4 Alternator 106
5 High-current fuse box 104
6 Battery 101
54-1-35
130 GROUND
Ground Point
4
5
10849
* : Wiper motor
54-1-36
54
Location Name Circuit No. Wire diameter-wire color Remarks
1 Cab ground 1 EA01 3-B
2 Battery ground 60-BY
3 Engine ground 40-BY Manual transmission
60-BY Automatic transmission
4 Chassis ground EA01 3-B
EA02 3-B
FEE1 B
5 Cab ground 2 EA02 3-B
54-1-37
130 GROUND
Entire Ground
This diagram indicates grounding points.
See the following pages for branching of grounding (wiring for ). (in circuit No. order)

Cab ground 1 Cab ground 2
Cab
Chassis
Battery

To fuel gauge unit
Chassis ground Tightened together

Chassis ground
10538
54-1-38
54
Circuit No.EA01
Automatic transmission Cab To clearance and

< Automatic transmission > identification lamp, RH
To P range switch Gr 23
To clearance and
< Automatic transmission > identification lamp, LH
To overdrive OFF switch Gr 23
To identification
lamp, RH
To vehicle speed sensor Gr 23 To identification
(Cab side) lamp, LH
To automatic transmission Gr 23 To identification lamp
control unit (Center)
To cab tilt lock switch
To cab lamp
To side turn signal
lamp, LH Cab Roof
To front turn signal
lamp, LH To fuel-cut relay
To clearance
lamp, LH To multipurpose
timing control unit
To van body
dome light relay Rear chassis
To headlamp relay (LOW) To rear van body

dome light
To wiper motor
To license plate
lamp
To headlamp relay (HIGH) Cab To disc pad
sensor
Chassis
To condenser fan To license plate
motor connector lamp
To idle-up 3-way To rear combination
magnetic valve lamp, RH
To front van To back buzzer

body dome light
To engine oil To rear combination
level sensor lamp, LH
To sub-starter switch
To exhaust brake 3-
way magnetic valve
To intake shutter
3-way magnetic valve To fuel-cut motor
To disc pad sensor To automatic
Gr 23 transmission fluid
cooler fan
To automatic
Gr 23 transmission fluid
thermostat switch
Gr 23 To automatic
transmission fluid
1 : Automatic transmission temperature switch
2 : FE639
3 : FE649
10539
54-1-39
130 GROUND
Circuit No.EA02
To pre-stroke
control unit
Gr 13
Diagnosis switch
(Pre-stroke)
To lighting and
To lighting switch alarm control unit
To wiper and
washer switch
To hazard switch
To blower fan relay
To clearance
lamp, RH
To front turn
signal lamp, RH
To radio connector
To side turn Center panel

signal lamp, RH Cab
Heater
Door, RH
Cab
Meter To blower motor
To meter cluster To air-conditioner

relay connector
To van body To side condenser
dome light switch fan relay connector
To rheostat switch
To turn signal lamp
relay
To power mode switch Gr 23
To optional
Brake fluid connector
level switch
< Automatic
To meter cluster Gr 23 transmission >
To key interlock
(Automatic transmission control unit
shift indicator) Gr 23
< Automatic
< Automatic transmission > Gr 23 transmission >
To automatic
transmission electric
Cab control unit
Chassis
To boost air < Manual
temperature Gr 13 transmission >
sensor To transmission
neutral switch
*1 : Manual transmission
*2 : Automatic transmission
10540
54-1-40
54
2 STARTING, PREHEATING AND

STOPPING ENGINE
SPECIFICATIONS .......................................................................... 54-2-2
STRUCTURE AND OPERATION ................................................... 54-2-3
TROUBLESHOOTING .................................................................. 54-2-10
200 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

Inspection of Engine Preheating System ....................................... 54-2-12
201 STARTER .......................................................................... 54-2-13
210 ENGINE STARTING CIRCUIT

< Manual Transmission > ................................................................. 54-2-26
< Automatic Transmission > ............................................................ 54-2-30
212 SUB-STARTER CIRCUIT

< Manual Transmission > ................................................................. 54-2-34
< Automatic Transmission > ............................................................ 54-2-36
215 ENGINE STOPPING CIRCUIT........................................... 54-2-38
220 ENGINE PREHEATING CIRCUIT ..................................... 54-2-42
225 ENGINE WARMING UP CIRCUIT ..................................... 54-2-46
54-2-1
SPECIFICATIONS
Item Specifications
Starter Manufacturer MITSUBISHI ELECTRIC
Reduction gear system Planetary gear
Model M8T55071
Power VkW 123.0
Magnetic switch operating 8 or less
voltage V
Starter relay Model U1X15072
Voltage rating VA 12-4
Magnet closing voltage V 8 or less
Magnet opening voltage V 3.5 or less
Glow plug Model Sheathed type
Voltageamperage VA 115.5
Glow relay Model U1T06296
Voltageamperage VA 12127
Magnet closing voltage V 8 or less
Magnet opening voltage V 3.5 or less
Fuel-cut motor Minimum operating 10 or less
voltage V
Operating amperage A 10 or less
54-2-2
Starter
View A
SW
S
6 5 4 3
B
23 M 87
9
A 10 2
1
22
11 21
12 13 14 15 16 17 18 19 20
10297
1 Pinion stopper 11 Rear bearing 21 Front bearing

2 Spring 12 Rubber packing 22 Pinion
3 Front bracket 13 Armature 23 Starter relay
4 Lever 14 Yoke assembly
5 Ball 15 Rubber packing B: Terminal B
6 Magnetic switch 16 Planetary gear M: Terminal M
7 Brush holder 17 Internal gear S: Terminal S
8 Brush spring 18 Gear shaft SW : Terminal SW
9 Brush 19 Washer
10 Rear bracket 20 Overrunning clutch
This starter uses planetary gear 16 for the reduction gear system.
16
13388
54-2-3
Engine Starting Circuit
1 Battery
2 Starter relay
3 Starter
5 Diode
6 Transmission neutral relay
7 Fuse box
8 Starter switch
13148

1 Battery
2 Starter relay
3 Starter
4 Inhibitor switch
5 Fuse box
6 Starter switch
10911
54-2-4
54
Sub-starter Circuit
1 Battery
3 Fuse box
4 Sub-starter switch
5 Relay box
6 Sub-starter relay
7 Transmission neutral relay
8 Diode
10 Starter
11 Starter relay
12 Starter switch

Position of sub-starter switch 4 : ON
12123 (F19)6 (coil)49Ground
12123 (F19)6 (contact point)7 (coil)
89Ground
12123 (F19)6 (contact point)7
13405 (contact point)11 (coil)Ground
Starter relay 11 operates to turn starter 10.

1 Battery
3 Fuse box
4 Sub-starter switch
5 Relay box
6 Sub-starter relay
7 Inhibitor switch
8 Starter
9 Starter relay
10 Starter switch

Position of sub-starter switch 4 : ON
12103 (F19) 6 (coil)4Ground
12103 (F19) 6 (contact point)7
9 (coil)Ground
Starter relay 9 operates to turn starter 6.
13406
Engine Stopping Circuit

^ Gr 13
54-2-5
Engine Preheating Circuit
1 Starter switch
2 Fuse box
3 Alternator
4 Relay box
5 Multipurpose timing control unit
P54-9-2
6 Meter cluster
7 Engine preheating indicator lamp
8 Battery
9 Glow relay
10 Glow plug
Engine start signal

Alternator charge signal
Glow relay activation signal
_ lighting-up signal
Engine coolant temperature signal
13103
54-2-6
54
Engine Preheating Circuit
This circuit improves the engine starting performance
when the engine coolant temperature is low. The
preheating system is controlled by multipurpose timing
control unit 5. P54-9-2
Basic preheating operation

Operation mode P54-2-8
When engine coolant temperature is low
(Approximately 60C {140F} or less)
12 (F20)5Ground
11Ground
Multipurpose timing control unit 5 detects the engine

coolant temperature.
When the engine coolant temperature is low, multi-
purpose timing control unit 5 outputs glow relay acti-
vation signal .
5 9Ground
13434 Glow relay 9 operates to feed power to glow plug 10

and lights up engine preheating indicator lamp
_ 7.
89 (contact point)10Ground
75Ground
When engine coolant temperature is high
(Approximately 60C {140F} or more)
12 (F20)5Ground
11Ground
Multipurpose timing control unit 5 detects the engine

coolant temperature.
When the engine coolant temperature is high, multi-
purpose timing control unit 5 does not output glow

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HOME

1996 Group 00 - General

For U.S.A. Pub. No. TWSE9501-5

This Service Manual contains maintenance and repair meth-

Location Parts to be tightened Tightening torque Remarks

Gr 11A ENGINE <4M50T2> B Gr 11A ENGINE <4M50T2>

Newly introduced flywheel PTO-

A Adjust the threaded section A of the engine

160 161 162

Gr 13A FUEL & ENGINE CONTROL B Gr 13A FUEL&ENGINE CONTROL <4M50T2>

Torque Type 3-element, 1-stage, 2-phase (with lock-up clutch)

Automatic 2nd 1.548

FG639 automatic transmission assembly Automatic Transmission Assembly

STRUCTURE AND OPERATION

As a troubleshooting procedure for

Stall speed standard values for FE640 Stall speed

As standard values for road tests of <FE640>

P Lock-up vehicle speeds Unit: km/h {mph}

Throttle opening Shifting Power mode

The above standard values are based on the following conditions.

Throttle opening Shifting Power mode

P Lock-up vehicle speeds Unit: km/h {mph}

Throttle opening Shifting Power mode

The above standard values are based on the following conditions.

REPLACEMENT OF AUTOMATIC Automatic Installation of oil seal

Gr. 24 Transfer <FG>

Transfer for automatic transmission newly

Gr. 27 Rear axle Vehicle model

For 4M5 For 4D3

110 POWER CIRCUIT P54-8

125 BATTERY CHARGING CIRCUIT P54-10

130 GROUND P54-12

2. STARTING, PREHEATING AND

210 ENGINE STARTING CIRCUIT <4M5 Automatic Transmission> P54-28

6. CAB SIDE ELECTRICAL

8. ENGINE AND TRANSMISSION

Inspection of speed sensor

Standard Low puls 0.5V or less

802 additionally provided with some

POWER TRAIN TABLE ......................................................................... 00-2

VEHICLE IDENTIFICATION NUMBER ................................................ 00-3

ENGINE NUMBER ................................................................................ 00-3

PRECAUTIONS FOR MAINTENANCE OPERATION .......................... 00-4

FE639C, E, 4D34T3 C4W30 M035S5 P3 R033T D033H

FE639C, E, C4W30 M035S5

FG639C,E 4D34T3 C4W30 M035S5+TF3 P2 D1H modi-

FE649C, E, 4D34T3 C4W30 M035S5 P3 D033H

FE649C, E, Torque M035A4

FE640C, E, 4M50T2 D033H

*a: Torque cut when 1st/reverse is selected

HOW TO READ THE MAINTENANCE SCHEDULE TABLES .............. 01-2

MAINTENANCE SCHEDULE TABLES ................................................ 01-3

LUBRICATION ...................................................................................... 01-13

New vehicle at 4000 km/

Every 250000 km/

Every 10000 km/

Every 20000 km/

Every 30000 km/

Every 40000 km/