01ï1

INTRODUCTION ï HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

0108Rï05

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ”Diagnosis” (found in the ”Diagnostics” section), the 2nd pro-
cess of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting”, but
the 3rd process of ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book (4/4) to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed under the title where necessary.
(b) Nonïreusable parts, grease application area, precoated parts and tightening torque are specified in
the components drawing.
Example:

Filler Cap

Float Clevis Pin

z Gasket Clip
Reservoir Tank
Boot
z Grommet

Slotted Spring Pin 12 (120, 9)

Clevis
15 (155, 11)
Snap Ring
Washer Lock Nut
Push Rod
Piston

Cylinder

N·m (kgf·cm, ft·lbf) : Specified torque

z Nonïreusable part N17080
 03ï23
SERVICE SPECIFICATIONS ï FUEL
030YCï07

TORQUE SPECIFICATION
4B
Part tightened N·m kgf·cm ft·lbf
Fuel filter assembly x Body 8 83 3
Nozzle holder and nozzle set x Cylinder head 8 85 3
Nozzle leakage pipe assy x Nozzle holder and nozzle set 25 255 8
Injection pipe clamp x Injection pipe set 7.5 76 66 in.·lbf
Injection pump assy x Timing gear case sub assy 8.5 89 4
Pump stay x Injection pump assy 8.5 89 4
Pump stay x Cylinder block sub assy 37.5 382 28
Fuel filter to injection pump fuel pipe x Injection pump assy 26.55 260 9
Nozzle leakage pipe assy No. 2 x Injection pump assy 26.55 260 9
Injection pump assy x Timing gear case 8.5 89 4
Injection pump stay x Injection pump assy 8.5 89 4
Injection pump stay x Cylinder block 37.5 382 28
Injection pipe x Nozzle holder and nozzle set 25 255 8
Injection pipe x Injection pump assy 25 255 8
Fuel inlet hollow screw x Injection pump body 36.8 375 27
Regulator valve subïassy x Injection pump body 8.85 90 78 in.·lbf
Fuel feed pump cover x Injection pump body 2.95 30 26 in.·lbf
Timer cover x Injection pump body 8.35 85 74 in.·lbf
Timer adjusting screw x LH timer cover 4.2 45 0
Governor link x Injection pump body 3.75 40 0
Distributive head x Injection pump body .75 20 9
Delivery valve holder x Distributive head 58.85 600 43
Distributive head plug x Distributive head 88.3 900 65
Governor cover subïassy x Injection pump body 8.35 85 74 in.·lbf
Bolt for control lever support pin x Governor cover subïassy w/ HAC 6.35 70 6 in.·lbf
Bolt for lever connecting pin x Governor cover subïassy w/ HAC 2.75 25 9
Pneumatic bellows cover x Governor cover subïassy w/ HAC 7.35 75 65 in.·lbf
Adjusting lever x Governor cover subïassy 8.35 85 74 in.·lbf
Engine speed sensor x Injection pump body 22. 225 6
Fuel cut solenoid x Distributive head 20.6 20 5
Lead wire x Fuel cut solenoid .7 7.5 5 in.·lbf
Dash pot x Governor cover subïassy  5 8
Fuel pipe clamp x Injection pump body 2.55 220 6
Spline shaft x Injection pump drive shaft 84.3 860 62
Fuel sender gauge connector x Fuel tank subïassy .5 5 3 in.·lbf
5BïFTE
Part tightened N·m kgf·cm ft·lbf
Fuel filter assembly x Body 8 83 3
Nozzle holder and nozzle set x Cylinder head 2 20 5
Nozzle leakage pipe assy x Nozzle holder and nozzle set 2 25 9
Injection pipe clamp x Injection pipe set 7.5 76 66 in.·lbf
Injection pump assy x Timing gear case sub assy 8.5 89 4
05ï24
DIAGNOSTICS ï ECD SYSTEM (S05CïTB) 057FFï02

DTC 2 ENGINE SPEED SENSOR CIRCUIT

MALFUNCTION (TDC OR G CIRCUIT)

CIRCUIT DESCRIPTION
The composition of this sensor, mounted on the supply pump, is the same as that of the main engine revolu-
tion sensor, however, the coil volume is different. As the engine rotates, the protrusions and air gaps on the
center of the supply pump camshaft create magnetic field by the magnet in the sensor. Then, the magnetic
field generates alternative voltage in the coil.
The protrusions and air gaps exist for every 90 degrees of the camshaft (80 degrees of crankshaft angle),
and therefore 5 pulses are output for  revolution of the camshaft (2 revolutions of the engine).
And also, there is another protrusion and air gap to output a pulse. Based on this pulse, NE standard pulse
of the engine No.  cylinder can be recognized.
DTC No. DTC Detection Condition Trouble Area
S Open or short in crankshaft position sensor circuit
G signal has not been input when NE signal detects 3,600 S Camshaft position sensor
2
revolutions S Camshaft timing pulley
S ECM

WIRING DIAGRAM

ECM
6 26
2 R R
C EA E4 G+
Camshaft
Position 3 25
Sensor
 G G
EA E4 Gï

9 23
2 B B
C3 EA2 E4 NE+
Crankshaft
Position 6 22
 W W
Sensor EA2 E4 NEï

A54230

INSPECTION PROCEDURE
HINT:
S Perform troubleshooting of DTC 2 first. If no trouble is found, troubleshoot the following mechanical
system.
S Read freeze frame data using the handïheld tester, as freeze frame data records the engine condi-
tions when a malfunction is detected. When troubleshooting, it is useful for determining whether the
vehicle was running or stopped, the engine was warmed up or not, the airïfuel ratio was lean or rich,
etc. at the time of the malfunction.
05ï22
DIAGNOSTICS ï ABS & BA SYSTEM 057EQï03

DTC C020/33 RIGHT REAR SPEED SENSOR CIRCUIT

DTC C025/34 LEFT REAR SPEED SENSOR CIRCUIT

CIRCUIT DESCRIPTION
Refer to DTC C0200/31, C0205/32 on page 05ï117.
DTC No. DTC Detection Condition Trouble Area
Detection of any of conditions 1. through 4:
1. Vehicle speed is 10km/h (6 mph) or more and open or
short circuit in the signal circuit of each vehicle speed
sensor has continued for 15 sec. or more
S Right rear and left rear speed sensors
C0210/33 2. Momentary interruption of each vehicle speed sensor
S Each speed sensor circuit
C0215/34 signal has occurred more than 7 times
S Speed sensor rotor
3. Vehicle speed is higher than 20 km/h (12 mph) and
S Sensor installation
noise on the abnormal wheel sensor signal continues for
5 sec. or more
4. Open circuit condition of the vehicle speed sensor signal
circuit has continued for more than 0.5 sec.

HINT:
DTC No. C0210/33 is for the right rear speed sensor.
DTC No. C0215/34 is for the left rear speed sensor.
WIRING DIAGRAM
*1: GVWR 5.5T
*2: Except GVWR 5.5T Skid Control ECU Assy
A16
ABS Speed Sensor (Shielded)
Rear RH W*2
3 (Shielded)
10 16
1*1 B*1 BB1 W*1 W
BA3 S11 RRï
2*2

4 9 17
2*1 W*1 B*1 B
BB1 BA3 S11 RR+
1*2

B*2 11 5
A15 GR GR GR
ABS Speed Sensor BA3 S11 RSS
Rear LH
1 R*2 8 18
1*1 B*1 BB1 R*1 R
BA3 S11 RLï
2*2

2 7 19
2*1 W*1 G*1 G
BB1 BA3 S11 RL+
1*2
G*2 (Shielded)
12
GR GR
BA3
(Shielded)
F45209
05ï234
DIAGNOSTICS ï SUPPLEMENTAL RESTRAINT SYSTEM 055OXï02

DTC B002/ SHORT IN D SQUIB CIRCUIT (TO GROUND)

CIRCUIT DESCRIPTION
The D squib circuit consists of the airbag ECU assy, spiral cable subïassy and horn button assy.
The SRS will deploy if the SRS deployment conditions are satisfied.
DTC B002/ is recorded when a ground short is detected in the D squib circuit.
DTC No. DTC Detection Condition Trouble Area
S Short circuit in D squib wire harness (to ground) S Horn button assy (D squib)
S D squib malfunction S Spiral cable subïassy
B002/
S Spiral cable subïassy malfunction S Airbag ECU assy
S Airbag ECU assy malfunction S Wire harness

WIRING DIAGRAM
See page 05ï226.
INSPECTION PROCEDURE
 CHECK D SQUIB CIRCUIT(AIRBAG ECU ASSYïHORN BUTTON ASSY)

(a) Disconnect the negative (ï) terminal cable from the bat-
D Squib
tery and wait at least for 90 seconds.
Spiral Airbag (b) Disconnect the connector between the airbag ECU assy
Cable ECU and the horn button assy.
Subïassy Assy (c) For the connector (on the spiral cable subïassy side) be-
tween the spiral cable subïassy and the horn button assy,
A9
measure the resistance between terminal D+ of the A9
connector and the body ground.
OK:
D+ Resistance:  M: or higher
NG Go to step 5

H01001
C81045 H4305

OK
 05ï299
DIAGNOSTICS ï AUDIO SYSTEM 05B7Jï0

CASSETTE TAPE CANNOT BE INSERTED OR PLAYED

WIRING DIAGRAM
4B, S05CïB, S05CïTA, W04DïJ
YïB
I6 R/B No.  Radio Receiver Assy
Ignition Switch
CIG 3
GR
  R ACC
9 AM ACC 4  2 J/C
 DOME A A A A 4
LïY LïY
A  J4 J23 J4 J23 R +B
G  2 *3 *4 *3 *4
WïL

2 IF 3 IF

G WïL
R/B No. 2 and J/B No. 2
2 2

2
MAIN
 
2
AM 2A
 W
2
2
ALT 7
 R GND

B
WïB* WïB*2
FL MAIN

A A
J3 J
J/C J/C
Battery
A

BïR WïB
*: LHD Regular Cab
*2: Except LHD Regular Cab
Battery *3: LHD Wide Cab
IF IE *4: Except LHD Wide Cab

I34790
11ï32
FUEL ï INJECTION PUMP ASSY (14B)

41. INSTALL FACE CAMPLATE SUBïASSY

Key Groove (a) Turn the drive shaft, and face the key groove upward.

A72761

(b) Install the coupling spring and camplate with the cam-
Pin
plate pin facing the governor cover side.
Pin Coupling
Spring

A72673

42. INSTALL GOVERNOR LINK

(a) Using SST, install the governor link with 2 new gaskets
and the 2 support bolts.
SST Torque: 13.75 N·m (140 kgf·cm, 10 ft·lbf)
SST 09260ï54012 (09269ï54040)
(b) Check that the governor link smoothly moves.

A72754

43. INSTALL PUMP PLUNGER

Shim (a) Place the selected new plunger adjusting shim on the
center of the camplate.
NOTICE:
Do not apply grease to the shim.

A58258

(b) Install the lower plunger plate (1), upper plunger plate (2),
Hole
lower spring seat (3) and spill ring (4) to the pump plunger.
(4) HINT:
The hole of the spill ring should face the lower spring seat.
(2)
(3)

(1)
A58259
11ï106
FUEL ï INJECTION PUMP ASSY (S05CïB)

Vernier Scale (d) Fill the pump camshaft chamshft chamber with engine oil.

Lock Screw

Main Scale

A720

6. ADJUST INJECTION TIMING

Blind Plug (a) Preparation of the preïstroke
Fuel Hose () Remove the screw plug from the preïstroke mea-
suring hole of the first cylinder.
(2) Remove the overflow valve, attach the inlet adaptor
and connect the fuel hose of the pump tester. Close
the fuel port of the injecion pump with a blind plug.
(3) Insall a preïstroke measuring instrument. Bring the
tappet of the first cylinder to its bottom dead center,
and set the pointer tip on the tappet.
Plunger
Spring (b) Measure the preïstroke (No.  plunger)
() Set the control rack at fullïload position.
(2) Loosen the overflow screw of each nozzle holder.
Pointer

Tappet

A7202

(3) Operate the highïpressure pump of the pump tes-

Overflow Pipe ter and let fuel run out of the overflow line.
High Pressure

A7203

Angle Dial (4) Move the angle dial to set the first cylinder of the
pump to bottom dead center and adjust the preï
stroke gauge to zero.
NOTICE:
Bottom dead center is the point at which the pointer of the
dial gauge does not move even when the angle dial is ro-
tated while fuel is flowing from the overflow line.

A7204
13ï18
INTAKE ï TURBOCHARGER SUBïASSY (S05CïTA, S05CïTB)
1306Aï01

ONïVEHICLE INSPECTION
1. INSPECT TURBOCHARGER EXTERIOR AND INSTALLATION
(a) Visually check for missing or loose nuts and bolts.
(b) Visually check for loose or damaged intake and exhaust pipes.
(c) Visually check for damaged oil supply and drain lines.
(d) Visually check for cracked or deteriorating turbocharger housings.
(e) Visually check for external oil or coolant leakage.
Correct all the problems about the installation. If the turbocharger parts are damaged, overhaul the unit after
the remaining procedures of this troubleshooting about the installation.
CAUTION:
Operation of the turbocharger without the intake pipe and air cleaner connected can result in person-
al injury and also damage to the equipment, such as foreign objects entering the turbocharger.

2. INSPECT TURBINE WHEEL AND HOUSING

(a) Remove the ducting from the turbine outlet. Using a
flashïlight, check the rub on the turbine wheel and hous-
ing, evidence of oil leakage or damage due to foreign ob-
jects. Damage to the turbine, due to foreign objects, is not
usually visible through the turbine outlet unless the dam-
age becomes severe.
(1) Check for rub on the wheel and housing.
A64390 If wheel rub is found when the housing is securely attached to
the hardware, then the turbocharger is way be damaged inter-
nally and must be overhauled.
(2) Check for oil leakage.
If oil deposits are found, determine whether the oil has come
from the engine exhaust or the turbocharger center housing.
If the oil has come from the engine, consult the chapter of EN-
GINE MECHANICAL and correct the problem. If oil deposits on
the wheel are heavy, the turbocharger should be disassembled,
cleaned, and overhauled, as necessary.
(3) Check for damage due to foreign objects.
If the turbine is obviously damaged due to foreign objects, the
turbocharger must be overhauled. Such damage destroys the
wheel’s balance and causes internal damage to the seal bores
and journal bearings. Be sure to find the source of the foreign
object. In many cases, the object has come from the engine,
and the engine may have damage, as well.
3. INSPECT COMPRESSOR WHEEL AND HOUSING
(a) Remove the ducting from the compressor inlet. Using a
flashïlight, check the rub on the compressor wheel and
housing, evidence of oil leakage and damage due to for-
eign objects.
(1) Check for rub on the wheel and housing.
If wheel rub is found when the housing is securely attached to
the hardware, then the turbocharger is way be damaged inter-
A64391 nally and must be overhauled.
14ï98
ENGINE MECHANICAL ï ENGINE COMPONENTS PARTS (S05CïB)

S If more than 20 minutes have passed since the seal pack-

ing is applied, do not assemble the parts. After removing
the seal packing completely, reapply it to assemble them.
S Do not start the engine for 2 hours after the installation.

17. INSTALL THERMOSTAT CASE

Example
(a) Make sure that the Oïring is attached to the upper flange
face of the water pump.
(b) Clean the cylinder head mounting surface of the thermo-
stat case.
(c) Apply seal packing to the thermostat case and install it
Seal Packing
onto the cylinder head within 20 minutes.
Seal packing: Part No. 08826ï00100 or equivalent
Coating width: 1.5 ï 2.5 mm (0.059 ï 0.098 in.)
HINT:
S If more than 20 minutes have passed since the seal pack-
ing is applied, do not assemble the parts. After removing
the seal packing completely, reapply it to assemble them.
S Do not start the engine for 2 hours after the installation.
(d) Tighten the 4 side ones of the thermostat case mounting
bolts.
Torque: 28.5 N·m (290 kgf·cm, 21 ft·lbf)
(e) Tighten the 2 upper ones of the water pump mounting
A71059 bolts.
Torque: 55 N·m (560 kgf·cm, 41 ft·lbf)
(f) Install the cooling line.

18. INSTALL FAN PULLEY

(a) Install the fan pulley and fan spacer.
Torque: 28.5 N·m (290 kgf·cm, 21 ft·lbf)
19. INSTALL FAN
Torque: 19 N·m (194 kgf·cm, 14 ft·lbf)

A78418
 16ï25
COOLING ï WATER PUMP ASSY (15BïFTE)

WATER PUMP ASSY (15BïFTE)

160K5ï01

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)
(See page 72ï2)
4. REMOVE PARKING BRAKE HOLE COVER (W/O TILT CAB CAB TYPE)
5. REMOVE PARKING BRAKE LEVER ASSY (W/O TILT CAB CAB TYPE) (See page 33ï11)
6. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUBïASSY (W/O TILT CAB CAB TYPE)
7. REMOVE SHIFTING HOLE COVER SUBïASSY AND SHIFT LEVER BOOT COVER (W/O TILT CAB
CAB TYPE) (See page 41ï19)
(a) Remove the 3 clips and shift lever boot cover.
8. REMOVE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (W/O TILT CAB CAB
TYPE)
9. REMOVE FLOOR SHIFT ASSY (W/O TILT CAB CAB TYPE)

10. REMOVE ENGINE SERVICE HOLE SUB COVER

SUBïASSY (W/O TILT CAB CAB TYPE)
(a) Remove the floor mat.
(b) Remove the 7 bolts and engine service hole sub cover.
HINT:
As shown in the illustration, slide and remove the engine ser-
vice hole sub cover, because there is a hook inside.

A68331

11. DISCONNECT RADIATOR HOSE INLET

12. DISCONNECT RADIATOR HOSE OUTLET
13. REMOVE FAN SHROUD
14. REMOVE WATER PUMP ASSY
(a) Remove the 2 bolts.
(b) Disconnect the radiator hose from the water pump, and remove the radiator pipe.

(c) Remove the 5 bolts.

(d) (d) Disconnect the water bypass hose to the water pump,
and remove the water pump and gasket.

A69527
 17ï41
LUBRICATION ï OIL W/BRACKET COOLER ASSY (S05CïTA)

OIL W/BRACKET COOLER ASSY (S05CïTA)

17078ï02

COMPONENTS

24.5 (250, 18)

Pipe

z Gasket

z OïRing

24.5 (250, 18)

Oil w/bracket Cooler Assy

Ventilation
Pipe 24.5 (250, 18)

N˜m (kgf˜cm, ft˜lbf) : Specified torque

z Nonïresuable part A54217
29ï42
DIFFERENTIAL ï DIFFERENTIAL CARRIER ASSY REAR (SH3)

6. REMOVE DRIVE PINION SUBïASSY

(a) Remove the 6 bolts.
(b) Remove the drive pinion assy, shims and Oïring from the
differential carrier.
HINT:
For easy removal, Remove the outer races, using a brass bar
and hammer.

D30840

7. REMOVE PILOT BEARING OUTER RACE

(a) Remove the bolt, nut and 2 bearing retainers.
(b) Remove the pilot bearing outer race from the differential
carrier.

C60242

8. REMOVE SIDE BEARING INNER RACE

(a) Using SST, remove the 2 side bearing inner races from
the differential case.
SST 09950ï60020, (0995ï00680), 09950ï400,
(09957ï0400), 09950ï00020, 09950ï00030.
If reusing the bearings, arrange them so that right bearing and
left bearings can be distinguished.

C60243

9. REMOVE RING GEAR

(a) Place matchmarks on the ring gear and differential case.
(b) Using a press, fix the differential carrier.
(c) Remove the 2 bolts and 2 nuts.
(d) Using a plastic hammer, remove the ring gear to separate
it from the differential case.
Matchmarks NOTICE:
Be careful not to drop the ring gear.
C60244

0. REMOVE DIFFERENTIAL CASE

(a) Place matchmarks on the LH and RH cases.
(b) Remove the 8 bolts.
(c) Using a plastic hammer, separate the LH and RH cases.

Matchmarks

C60245
 32ï35
BRAKE ï VACUUM PUMP ASSY (S05CïB, S05CïTA, S05CïTB)

4. INSTALL END COVER

(a) Place the vacuum pump on a vise.
(b) Install a new Oïring.
(c) Install the end cover in place, and temporarily install the
3 bolts.
(d) Using a pin punch and hammer, tap in the 2 straight pins.
(e) Tighten the 3 bolts.
Torque: 7.8 N˜m (80 kgf˜cm, 69 in.˜lbf)
C94070 NOTICE:
Do not tighten the vise.

5. INSTALL VACUUM PUMP GEAR

(a) Temporarily install the key, gear and lock nut to the pump.
Soft Jaws (b) Using soft jaws on a vise, clamp the gear in the vise.
(c) Tighten the gear lock nut.
Torque: 0 N˜m (,25 kgf˜cm, 8 ft˜lbf)

C94062

6. INSTALL VACUUM PUMP ASSY

(a) Install a new Oïring to the pump.
(b) Install the pump to the engine with the 2 bolts.
Torque: 55 N˜m (560 kgf˜cm, 4 ft˜lbf)

C93808

(c) Install the union bolt and a new gasket, and then connect
the union tube.
Torque: 3.7 N˜m (40 kgf˜cm, 0 ft˜lbf)
(d) Install the bolt and clip to the tube.
(e) Install the clip and connect the vacuum hose.

C93807
 87ï5
POWER TAKEïOFF ï POWER TAKEïOFF ASSY

H351

Manual Transmission

39 (398, 29) Connector

39 (398, 29)

39 (398, 29)
EïRing

z Gasket

Spacer

z Gasket
39 (398, 29)

39 (398, 29)

Power Takeïoff Assy

39 (398, 29)
N·m (kgf·cm, ft·lbf) : Specified torque
z Nonïreusable part B6836