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Ezgo 1600xd Repair Manual

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1600xd

4x4

repair

manual

619728

ISSUED APRIL 2011

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Page 1 1600xd repair manual 619728 ISSUED APRIL 2011...
Page 3 PREFACE This manual is to provide servicing personnel with information on the general speci- ﬁ cations, service, operating principle, troubleshooting, exploded view including part name, removing and installing procedures for OFF - ROAD Utility Vehicle with high- end technology. All information in this manual is based on the latest product information available at the time of publication.
Page 5 TABLE OF CONTENTS CHAPTER 1 SAFETY FIRST CHAPTER 2 GENERAL CHAPTER 3 ENGINE CHAPTER 4 CHAPTER 5 TRANSMISSION CHAPTER 6 CHASSIS CHAPTER 7 REAR AXLE CHAPTER 8 BRAKE CHAPTER 9 FRONT AXLE CHAPTER 10 STEERING CHAPTER 11 HYDRAULIC SYSTEM CHAPTER 12 ELECTRIC SYSTEM CHAPTER 13 INDEX...
Page 7: Table Of Contents
SAFETY FIRST CHAPTER 1 TABLE OF CONTENTS 1. SAFETY DECALS ........1-2 3. SAFETY DECALS ........1-9 1.1 Alert symbols .......... 1-2 3.1 The location of safety decal ....1-9 2. SAFETY TIPS .......... 1-3 2.1 Safety gear ..........1-3 2.2 Workplace ..........
Page 8: Safety Decals
SAFETY FIRST - SAFETY DECALS 1. SAFETY DECALS • Most accidents can be avoided if basic safety in- structions and regulations are followed. Always fol- low the safety regulations and avoid any dangerous situation to prevent an accident. • You can be unexpectedly injured if inspecting or servicing the UTV without full knowledge of it.
Page 9: Safety Tips
SAFETY FIRST - SAFETY TIPS 2. SAFETY TIPS 2.1 SAFETY GEAR 2.2 WORKPLACE S76W007A 2.2.1 VENTILATING SYSTEM The service should be performed in a well-ventilated S76W006A area. If the engine should be started in an enclosed When operating on the vehicle, wear safety gloves, place, an exhaust gas vent pipe should be installed.
Page 10: Safety Instructions When Preparing Tractor
SAFETY FIRST - SAFETY TIPS 2.3 SAFETY INSTRUCTIONS WHEN 2.4 FIRE PREPARING TRACTOR S76W011A • Never smoke or allow ﬂ ames or sparks in your work S76W010A area when maintaining the fuel system. • Stop the engine and remove the key. •...
Page 11: Cautions When Handling The Battery
SAFETY FIRST - SAFETY TIPS 2.5 CAUTIONS WHEN HANDLING THE 2.6 CAUTIONS FOR HIGH PRESSURE HOSES BATTERY S76W015A S76W019A • Always disconnect the negative battery cable first • The hydraulic fluid leaks from high pressure and reconnect it last to avoid sparks from an acci- hoses or pipes can penetrate your skin.
Page 12: Use Of Appropriate Tools And Equipment
SAFETY FIRST - SAFETY TIPS 2.7 USE OF APPROPRIATE TOOLS AND 2.8 HANDLING OF HAZARDOUS MATERIALS EQUIPMENT • Use the standard tools in proper size. If an inap- • Do not blow out hazardous materials, such as clutch propriate tool is used, it can slip which can damage dust, with compressed air.
Page 13: Handling Of Rotating Shaft And Driving Belt
SAFETY FIRST - SAFETY TIPS 2.9 HANDLING OF ROTATING SHAFT AND 2.10 SCALD PREVENTION DRIVING BELT S76W024A • Do not set a hand or a foot into the vehicle’s rotat- ing shaft or belt. S76W027A • Be extra careful when you are in loose clothes. •...
Page 14: Disposal Of Environmental Waste
SAFETY FIRST - SAFETY TIPS 2.11 DISPOSAL OF ENVIRONMENTAL WASTE 2.12 CAUTIONS WHEN HANDLING TIRES S76W029A • Observe relevant environmental protection regula- • The tire rims can fall out of the tires. Therefore, stay tions when disposing used oil, transmission fluid, out of its way when checking or inﬂ...
Page 15 SAFETY FIRST - SAFETY DECALS 3. SAFETY DECALS • When replacing the existing part with a new one, attach the same safety decal to the new part. Otherwise, the customer's safety will be threatened. • If a decal is damaged or detached, attach the same decal to the part. •...
Page 16 SAFETY FIRST - SAFETY DECALS (1) Part No. : U3215-85011 (4) Part No. : T2615-54112 (5) Part No. : U3215-85101 (2) Part No. : U3215-85081 (6) Part No. : U3215-85071 (7) Part No. : T4625-52361 (3) Part No. : T4625-52351 SUUV-W00 Apr.
Page 17 SAFETY FIRST - SAFETY DECALS (8) Part No. : U3215-85091 (12) Part No. : U3215-85111 (13) Part No. : U3215-85051 (9) Part No. : U3215-85021 (10) Part No. : U3215-85031 (14) Part No. : U3215-85061 (11) Part No. : U3215-85041 (15) Part No.
Page 18 (16) Part No. : U3215-85131 (17) Part No. : U3215-85161 SUUV-W00 Apr. 2011...
Page 19 GENERAL CHAPTER 2 TABLE OF CONTENTS 1. DESCRIPTION FOR SYMBOLS AND 8. TIRE MAINTENANCE ......2-13 ABBREVIATIONS ........2-2 8.1 Speciﬁ ed inﬂ ation pressure ....2-13 8.2 Tightening torque for wheel ....2-13 2. UTV APPEARANCE ........ 2-3 9. TIGHTENING TORQUES ...... 2-14 3.
Page 20: Description For Symbols And Abbreviations
GENERAL - DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS 1. DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS There are various symbols used in this manual. Their design and meanings are as follows: Symbols Abbreviations • 4WD ..Four Wheel Drive Headlamp - low Fuel-level beam •...
Page 21: Utv Appearance
GENERAL - UTV APPEARANCE / SERIAL NUMBER 2. UTV APPEARANCE UUVW101A 3. SERIAL NUMBER UTV serial number assignment standard 3.1 UTV SERIAL NUMBER LOCATION J Z9 1 00001 Production serial number Example) 0 0 0 0 1: The first chassis manu- factured in that year Tire Work Site Tire...
Page 22: Engine Serial Number Location
GENERAL - SERIAL NUMBER 3.2 ENGINE SERIAL NUMBER LOCATION 3.3 OTHERS LOCATION • Front axle case serial number UUVW102A UUVW2F5A The engine number(1) is stamped on the machined It is marked on the ﬂ at surface on the lower section of front surface below the fuel injection pump.
Page 23: Dimensions
GENERAL - DIMENSIONS 4. DIMENSIONS UUVW104B mm (inch) DESCRIPTION REMARKS A : Overall length 2,852 (112.3) B : Overall width 1,543 (60.7) C : Overall height 1,940 (76.4) D : Wheel base 1,940 (76.4) : Front 25 x 10 - 12 1,262 (49.7) E : Tread 25 x 11 - 12...
Page 24: Specifications
GENERAL - SPECIFICATIONS 5. SPECIFICATIONS DESCRIPTION Model 3C100LWU 4Cyl., In-line Vertical, Water-cooled, Type Indirect injection, diesel Max. power HP (Kw)/rpm 22 (16.2) / 2,800 Number of cylinders Bore x stroke mm (in.) 75 X 76 (2.95 X 2.99) Engine Displacement cc (cu in.) 1,007 (61.45) Rated revolution...
Page 25: Gear Arrangement And Driving Speed
GENERAL - GEAR ARRANGEMENT AND DRIVING SPEED GEAR ARRANGEMENT AND DRIVING SPEED 6.1 GEAR ARRANGEMENT OF TRANSMISSION UUVW105A SUUV-W00 Apr. 2011...
Page 26: Gear Arrangement Of Rear Axle
GENERAL - GEAR ARRANGEMENT AND DRIVING SPEED 6.2 GEAR ARRANGEMENT OF REAR AXLE T2185-43861 10 10 10 37 37 37 Diff. Lock OFF Diff. Lock ON 12 12 12 4T-32009X 20 20 20 37300-2817-2 UUVW106A 6.3 GEAR ARRANGEMENT OF FRONT AXLE LSD (Limit Slip Device) 12 12 12 14 14 14...
Page 27: Driving Speed
GENERAL - GEAR ARRANGEMENT AND DRIVING SPEED 6.4 DRIVING SPEED DESCRIPTION Rear tire size 25 x 11 - 12 Forward / Low 17 (10.6) Forward / High km/h (MPH) 40 (24.9) Reverse 25 (15.5) ● Calculation of driving speed Engine rpm CVT Pulley reduction ratio Rotating speed ratio Tire rolling circumference...
Page 28: Maintenance
GENERAL - MAINTENANCE 7. MAINTENANCE 7.1 MAINTENANCE SCHEDULE CHART Maintenance interval Run hour Run age Remarks Item 100 200 400 800 1000 year year ⊙ ○ Engine oil and ﬁ lter Replace ○ Fuel ﬁ lter Replace ⊙ ○ Fuel line and hose connection Check ○...
Page 29 GENERAL - MAINTENANCE IMPORTANT • must be performed only 1 time after the initial of operation. *1 The air cleaner should be cleaned more frequently in dusty conditions than in normal conditions. *2 Every year or every 5 times of cleaning, whichever comes ﬁ rst. *3 Replace only if necessary.
Page 30: Lubrication And Replenishment
GENERAL - MAINTENANCE 7.2 LUBRICATION AND REPLENISHMENT To prevent serious equipment damage, use only genuine DAEDONG oils or equivalents. Item Capacity Lubricants Fuel tank 28ℓ (7.39 U.S.gal.) Diesel fuel Radiator & 6.3ℓ (1.66 U.S.gal.) Fresh clean water with Ethylene glycol (50:50) water tank Engine oil: API Service Classiﬁ...
Page 31: Tire Maintenance
GENERAL - TIRE MAINTENANCE 8. TIRE MAINTENANCE 8.1 SPECIFIED INFLATION PRESSURE Front Rear Tires Size Inﬂ ation pressure Size Inﬂ ation pressure 0.84 kg/cm² 1.27 kg/cm² Standard 25 x 10 - 12 6PR 82.7 Kpa 25 x 11 - 12 6PR 124 Kpa 12 psi 18 psi...
Page 32: Tightening Torques
GENERAL - TIGHTENING TORQUE 9. TIGHTENING TORQUES 9.1 GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not speciﬁ ed in this workshop manual should be tightened ac- cording to the table below. Mark on bolt No-grade or 4T head Material of...
Page 33: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
GENERAL - TIGHTENING TORQUE 9.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.5 Unit Diameter kgf-m lb-ft kgf-m lb-ft 5/16 23.1 ~ 27.8 2.35 ~ 2.84 17.0 ~ 20.5 32.5 ~ 39.3 3.31 ~ 4.01 24.0 ~ 29.0 47.5 ~ 57.0...
Page 34: Part Number Assignment Standard For Daedong Bolts And Nuts
GENERAL - PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS 10. PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS 10.1 BOLTS 0 1 1 3 3 - 5 1 0 5 5 Length: 55 mm In case the bolt length is over 100 mm, its length is identiﬁ ed by the last number. Bolt size: M10 Plating MFZn5-C (Electric zinc)
Page 35: Nuts
GENERAL - PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS 10.2 NUTS 0 2 1 1 4 - 5 0 0 8 0 Nut size: M8 Plating number MFzn5-C (Electric zinc plated) MFzn5-GR (Electric ﬂ at chrome plated) No plating Hardness, pitch, width Item Hardness...
Page 36: How To Install Spring Pin And Snap Ring
GENERAL - HOW TO INSTALL SPRING PIN AND SNAP RING 11. HOW TO INSTALL SPRING PIN AND SNAP RING 11.1 SPRING PIN INSTALLATION 11.2 SNAP RING ASSEMBLY In order to prevent displacement of a snap ring, as- Since a spring pin can be displaced depending on its semble its rounded area (R) against the opponent part direction that may cause shaking, it should be assem- as seen in the picture below.
Page 37: Unit Conversion Table
GENERAL - UNIT CONVERSION TABLE 12. UNIT CONVERSION TABLE Torque Pressure Weight x 0.738 lbf-ft kgf/cm² x 98 x 0.0353 lbf-ft x 1.356 x 0.0102 kgf/cm² x 28.350 kgf-m x 9.8 kgf/cm² x 14.22 x 2.2046 x 0.102 kgf-m x 0.0703 kgf/cm²...
Page 38 MEMO...
Page 39 ENGINE CHAPTER 3 TABLE OF CONTENTS 1. GENERAL INFORMATION ..... 3-3 3.1.11 MLS cylinder head gasket ..3-15 3.2 Lubrication system ....... 3-16 1.1 Engine views .......... 3-3 3.2.1 Engine oil ﬂ ow ......3-17 1.2 Engine identiﬁ cation ......3-3 3.2.2 Relief valve ........
Page 40 TABLE OF CONTENTS 5.4 Engine oil pressure ......3-36 6.2.1 Cylinder head ......3-58 5.5 Injection nozzle inspection ....3-37 6.2.2 Fuel injection pump ....3-60 5.6 Bubble test for radiator ......3-37 6.2.3 Speed control lever plate and governor spring ......3-61 5.7 Intake and exhaust valves ....
Page 41: General Information
ENGINE - GENERAL INFORMATION 1. GENERAL INFORMATION 1.1 ENGINE VIEWS ● ENGINE NUMBER The engine number is stamped on the cylinder block where the fuel injection pump is installed. IMPORTANT The engine number is necessary information that is requisite for the warranty registration form. This number should be on the form as well as the UTV number and the amount of runtime.
Page 42: Specifications
ENGINE - SPECIFICATIONS 2. SPECIFICATIONS 2.1 ENGINE DIMENSIONS mm (in.) 564 (22.2) UUVW204A SUUV-W00 Apr. 2011...
Page 43: General Speciﬁ Cations
ENGINE - SPECIFICATIONS 2.2 GENERAL SPECIFICATIONS DESCRIPTION Engine model 3C100LWU Bore I.D. × Stroke Ø 75×76 mm (Ø 2.953 x 2.992 in.) Honing Plateau honing Number of cylinders Ignition sequence 1 - 2 - 3 Displacement cc (cu) 1,007 ( 61.45) Max./Min.
Page 44: Service Speciﬁ Cations
ENGINE - SPECIFICATIONS 2.3 SERVICE SPECIFICATIONS 2.3.1 CYLINDER HEAD Item Reference Value Allowable Limit Distortion of cylinder head surface length. 0.05 mm (0.0020 in.) / 100 mm (4 in.) of cylinder head surface length. Thickness of gasket When tightened 1.15 ~ 1.25 mm (0.045 ~ 0.049 in.) Top clearance 0.7 ~ 0.9 mm (0.0275 ~ 0.0354 in.) Tightness of head bolts...
Page 45: Valve Rocker Arms
ENGINE - SPECIFICATIONS 2.3.4 VALVE ROCKER ARMS Reference Value Allowable Limit Item O.D. of rocker arm shafts 12.955 ~ 12.980 mm 0.5100 ~ 0.5110 in. I.D. of rocker arm bushings 13.000 ~ 13.025 mm 0.5118 ~ 0.5128 in. Clearance between rocker arm shafts and bush- 0.02 ~ 0.07 mm 0.12 mm ings...
Page 46: Pistons
ENGINE - SPECIFICATIONS 2.3.7 PISTONS Reference Value Allowable Limit Item 20.03 mm I.D. of piston bosses 20.000 ~ 20.013 mm 0.7885 in. 0.7874 ~ 0.7879 in. 20.002 ~ 20.011 mm O.D. of piston pin 0.7875 ~ 0.7878 in. I.D. of connecting rod small end bushings (ﬁ tted) 20.025 ~ 20.040 mm 0.7884 ~ 0.7890 in.
Page 47: Injection Pump
ENGINE - SPECIFICATIONS 2.3.10 INJECTION PUMP Item Reference Value Allowable Limit Tightness of plunger More than 60 seconds; initial pressure 30 seconds from 34.32 ~ 39.23 MPa 350 ~ 400 kgf/cm , 4,978 ~ 5,689 psi. More than 10 seconds; initial pressure Tightness of delivery valve 5 seconds from 20.59 ~ 21.57 MPa...
Page 48: Tightening Torque
ENGINE - SPECIFICATIONS 2.3.15 TIGHTENING TORQUE Indicate the bolts with ■ mark and manually tighten ﬁ rst. Item kgf-m lb-ft Head bolt Refer to "NOTE" below ■ Bearing case bolt 1 20.0 ~ 24.0 2.0 ~ 2.4 15.0 ~ 17.0 ■...
Page 49: Structure And Function
ENGINE - STRUCTURE AND FUNCTION 3. STRUCTURE AND FUNCTION 3.1 BODY AND POWER TRAIN 3.1.1 CYLINDER HEAD 3.1.2 CYLINDER BLOCK 196W208B 196W210B The engine features a high resilience tunnel-type cylinder block. Pressure-fitted cylinders allow effective cooling, less distortion, higher wear-resistance qualities and each cylinder having its own chamber helps to minimize noise.
Page 50: Crankshaft
ENGINE - STRUCTURE AND FUNCTION 3.1.3 CRANKSHAFT 3.1.4 PISTON AND PISTON RINGS 196W211C 196W212B (1) Crankshaft (5) Crankshaft bearing 2 (1) Rib (4) Hard chrome (2) Piston (6) Thrust bearing (2) Top ring (5) 2nd ring (3) Connecting rod (7) Counterweight (3) Surface (6) Coil expander ring (4) Crankshaft bearing 1...
Page 51: Camshaft And Fuel Camshaft
ENGINE - STRUCTURE AND FUNCTION 3.1.6 CAMSHAFT AND FUEL CAMSHAFT 3.1.7 ROCKER ARM ASSEMBLY 196W214B 196W216C (1) Rocker arm (4) Valve (2) Rocker arm shaft (5) Push rod (3) Rocker arm bracket The rocker arm assembly includes the rocker arms, arm brackets and arm shafts and converts the movement of the push rods to open/close of the inlet and exhaust valves.
Page 52: Timing Gears
ENGINE - STRUCTURE AND FUNCTION 3.1.9 TIMING GEARS 3.1.10 FLYWHEEL 196W218B 196W219C (1) Injection pump gear (5) Idle gear (1) Ring gear (3) Crankshaft (2) Fuel camshaft (6) Crankshaft gear (2) Flywheel (3) Camshaft gear (7) Crankshaft (4) Camshaft The crankshaft drives the oil pump and the idle gear en- The ﬂ...
Page 53: Mls Cylinder Head Gasket
ENGINE - STRUCTURE AND FUNCTION 3.1.11 MLS CYLINDER HEAD GASKET UUVW205A The MLS (Multi Layer Steel) cylinder head gasket has a triple-layered steel structure complemented with non- asbestos gasket features. The top clearance variation is minimized and the thermal load is reduced while increasing durability.
Page 54: Lubrication System
ENGINE - STRUCTURE AND FUNCTION 3.2 LUBRICATION SYSTEM 196W200C A. Oil sump screen C. Oil ﬁ lter cartridge and relief valve E. Rocker arm rocker arm shaft F. Piston B. Oil pump 3. To rocker arm shaft and cam- shaft 1.
Page 55: Engine Oil Fl Ow
ENGINE - STRUCTURE AND FUNCTION 3.2.1 ENGINE OIL FLOW Rocker arm shaft Rocker arm Rocker arm Rocker arm Engine oil pressure sensor Valve Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft shaft Valve cam shaft Valve cam shaft Valve cam shaft journal journal...
Page 56: Relief Valve
ENGINE - STRUCTURE AND FUNCTION 3.2.2 RELIEF VALVE 3.2.4 OIL PRESSURE SWITCH 196W222B 196W223C (1) Relief valve (4) From pump (1) Warning lamp (5) Contact (2) By-pass valve (5) To crankshaft (2) Battery (6) Oil passage (3) To rocker arm shaft and camshaft (3) Rubber gasket (7) Cylinder block (4) Contact rivet...
Page 57: Oil Pump
ENGINE - STRUCTURE AND FUNCTION 3.3 COOLING SYSTEM 3.2.5 OIL PUMP 196W224B (1) Inlet (3) Inner rotor (2) Outlet (4) Out rotor The oil pump is a gear pump, whose rotors have trochoid lobes. The inner rotor (3) has 4 lobes and the outer rotor (4) 196W225C has 5 lobes, and they are eccentrically engaged with each other.
Page 58: Water Pump
ENGINE - STRUCTURE AND FUNCTION 3.3.2 THERMOSTAT 3.3.1 WATER PUMP 196W227B 196W226B (1) Seat (6) Wax (Solid) (1) Water pump impeller (3) Water pump body (2) Mechanical seal (4) Bearing unit (2) Valve (7) Spring (3) Pellet (8) Leak hole (4) Spindle (9) Wax (Liquid) (5) Synthetic rubber...
Page 59: Radiator
ENGINE - STRUCTURE AND FUNCTION 3.3.3 RADIATOR 3.3.4 RADIATOR CAP 196W228A 196W229A (1) Cooling air (3) Fin (1) Pressure valve (2) Vacuum valve (2) Tube The radiator core consists of water carrying tubes (2) with The pressure type cap is installed on the radiator, which ﬁ...
Page 60: Fuel System
ENGINE - STRUCTURE AND FUNCTION 3.4 FUEL SYSTEM 3.4.1 FLOW OF FUEL 3.4.3 BLEEDING THE FUEL SYSTEM Make sure that the amount of fuel in the fuel tank is sufﬁ cient. If there is air in the fuel ﬁ lter, turn the ﬁ lter petcock (1), shown in the ﬁ...
Page 61: Fuel Feed Pump
ENGINE - STRUCTURE AND FUNCTION 3.4.4 FUEL FEED PUMP 3.4.5 FUEL INJECTION PUMP From fuel ﬁ lter To injection pump S76W234A (1) Suction valve (5) Chamber (2) Push rod (6) Diaphragm S76W234A (3) Tappet (7) Fuel camshaft (a) To injection nozzle (b) From fuel feed pump (4) Discharge valve (1) Delivery valve holder...
Page 62 ENGINE - STRUCTURE AND FUNCTION B. OPERATION OF PUMP ELEMENT A. PUMP ELEMENT T46W237A T46W238A (1) Pump element (5) Control sleeve (1) Delivery chamber (4) Feed hole (2) Plunger (5) Fuel chamber (2) Cylinder (6) Control groove (3) Plunger (7) Sliding surface (3) Delivery valve (6) Control groove (4) Feed hole...
Page 63 ENGINE - STRUCTURE AND FUNCTION C. AMOUNT OF FUEL DELIVERY D. DELIVERY VALVE T46W241A T46W239A (1) Valve spring (4) Fuel chamber (1) Slot (4) Delivery chamber (2) Delivery valve (5) Valve face (2) Plunger (5) Feed hole (3) Valve seal (6) Relief plunger (3) Control rack (6) Control groove...
Page 64 ENGINE - STRUCTURE AND FUNCTION E. INJECTION NOZZLE Supplied fuel Excessive fuel T46W242A (1) Nozzle holder assembly (4) Push rod (7) Needle valve (2) Adjusting washer (5) Lock nut (8) Heat seal (3) Nozzle spring (6) Nozzle body (9) Packing This injection nozzle is throttle type nozzle.
Page 65: Governor System
ENGINE - STRUCTURE AND FUNCTION 3.5 GOVERNOR SYSTEM 3.5.1 DISASSEMBLED VIEW 196W239B (1) Pin (6) Fork lever shaft (11) Steel ball (2) Governor spring 1 (7) Fork lever holder (12) Governor sleeve (3) Governor spring 2 (8) Governor lever (13) Steel ball (4) Fork lever 1 (9) Fuel injection camshaft (14) Fork lever pin...
Page 66: Basic Principle Of Governor System
ENGINE - STRUCTURE AND FUNCTION 3.5.2 BASIC PRINCIPLE OF GOVERNOR SYSTEM FRONT OF ENGINE 15 14 Torque spring screw Torque control T46W246D (1) Governor spring 1, 2 (6) Steel ball (11) Governor sleeve (2) Solenoid guide (7) Governor lever (12) Fork lever 2 (3) Stop solenoid (8) Idle spring (13) Fork lever 1...
Page 67: Operation Of Governor
ENGINE - STRUCTURE AND FUNCTION 3.5.3 OPERATION OF GOVERNOR E. LOAD INCREASE AT HIGH SPEED A. WHEN STOPPED The fuel is blocked since the solenoid (3) pushes the speed control rack (4) to the left. B. WHEN TURNING THE KEY SWITCH ON When the electromagnet in the stop solenoid operates and the pin is retracted, the speed rack (4) of the fuel injection pump is pushed to the right by the start spring...
Page 68: Intake And Exhaust System
ENGINE - STRUCTURE AND FUNCTION 3.6 INTAKE AND EXHAUST SYSTEM 3.6.1 FLOW OF INTAKE AIR AND EXHAUST GAS UUVW2F6A (A) Inlet air (1) Inlet manifold (3) Mufﬂ er (B) Exhaust gas (2) Air cleaner (4) Exhaust manifold 3.6.2 AIR CLEANER 3.6.3 MUFFLER The exhaust noises are absorbed and dumped, while the gas pass through a series of holes on the inner tube and...
Page 69: Pcv Valve
ENGINE - STRUCTURE AND FUNCTION 3.6.4 PCV VALVE A. PCV (POSITIVE CRANKCASES VENTILATION) T46W248A T46W249A (1) Head cover bolt (7) Bleeding pipe (2) Oil ﬁ ller ﬂ ange (8) Intake valve (3) Oil bafﬂ e plate (9) Cylinder head (4) Head cover gasket (10) Cylinder head cover (5) Cylinder head cover (11) Oil bafﬂ...
Page 70: Troubleshooting
ENGINE - TROUBLESHOOTING 4. TROUBLESHOOTING Symptom Cause Solution Engine does not • No fuel • Add fuel start • Air in fuel system • Bleed air • Water in fuel system • Change fuel and repair or ﬂ ush fuel system •...
Page 71 ENGINE - TROUBLESHOOTING Symptom Cause Solution Either black or • Overheat or overload • Reduce load dark gray exhaust • Low grade fuel used • Use the speciﬁ ed fuel smoke is produced • Clogged fuel ﬁ lter • Clean or replace •...
Page 72: Inspection And Adjustment
ENGINE - INSPECTION AND ADJUSTMENT 5. INSPECTION AND ADJUSTMENT 5.1 FAN BELT TENSION ADJUSTMENT 5.2 MEASURING THE PISTON COMPRESSION PRESSURE UUVW206A UUVW207A 1. Measure the deflection, depressing the belt halfway 1. Run the engine until warm. between the fan drive pulley and the alternator pulley 2.
Page 73: Checking And Adjusting The Injection Timing
ENGINE - INSPECTION AND ADJUSTMENT 5.3 CHECKING AND ADJUSTING THE INJECTION TIMING Park the vehicle on ﬁ rm and level ground. FUEL Then, engage the parking brake and stop the en- gine. Remove the CVT cover. S76W253A Remove the fuel in the nozzle holder with cloth and leave only small amount of fuel.
Page 74: Engine Oil Pressure
ENGINE - INSPECTION AND ADJUSTMENT 5.4 ENGINE OIL PRESSURE UUVW209A UUVW211A When the injection timing is measured, stop the 1. Remove the oil pressure switch and install adaptors and pressure tester. ﬂ ywheel and mark the position (B) for the injection 2.
Page 75: Injection Nozzle Inspection
ENGINE - INSPECTION AND ADJUSTMENT 5.5 INJECTION NOZZLE INSPECTION 5.6 BUBBLE TEST FOR RADIATOR CAUTION REMARK • Never come in contact with spraying diesel fuel Check if water is leaked through crack on the under pressure, which can have sufﬁ cient force cylinder wall.
Page 76: Intake And Exhaust Valves
ENGINE - INSPECTION AND ADJUSTMENT 5.7 INTAKE AND EXHAUST VALVES 5.7.1 CLEARANCE ADJUSTMENT 5. Turn the flywheel just one turn to position the 1st cylinder piston at top dead center. (At this time, two valves are in their over lap position without any gab between rocker arms and valves.) ●...
Page 77: Valve Spring Inspection
ENGINE - INSPECTION AND ADJUSTMENT 5.7.2 VALVE SPRING INSPECTION 5.7.3 VALVE SPRING SQUARENESS (TILT) (LENGTH, TENSION AND SQUARENESS) S76W263A S76W265A Measure the free length of the spring with vernier Place the spring on a flat plate and then put a calipers.
Page 78: Rocker Arm Assembly Check
ENGINE - INSPECTION AND ADJUSTMENT 5.8 ROCKER ARM ASSEMBLY CHECK 5.9 CYLINDER HEAD CHECK 5.9.1 CYLINDER HEAD SURFACE FLATNESS S76W267A S76W269A Thoroughly clean the cylinder head surface. Place a straight edge on the cylinder head and measure the clearance with a feeler gage as shown in the ﬁ...
Page 79: Cylinder Head Valve Recess
ENGINE - INSPECTION AND ADJUSTMENT 5.9.2 CYLINDER HEAD VALVE RECESS 5.9.3 CYLINDER BORE CHECK Check the worn condition of the honing groove on the bore. Check the bore for scufﬁ ng or scoring. S76W270A Clean the cylinder head, the valve face and the valve seat.
Page 80: Piston Check
ENGINE - INSPECTION AND ADJUSTMENT 5.10 PISTON CHECK 5.10.1 PISTON PIN BORE 5.10.2 CLEARANCE BETWEEN PISTON PIN AND BUSHING S76W274A S76W273A Measure the I.D. of the piston pin bore (lengthwise and widthwise of the piston) with a cylinder gauge. If the measured value exceeds the allowable limit, replace the piston.
Page 81: Piston Ring End Gap
ENGINE - INSPECTION AND ADJUSTMENT 5.10.3 PISTON RING END GAP 5.10.4 PISTON RING CLEARANCE S76W276A S76W277A Place the piston ring to be measured on the top face Clean the piston ring and piston ring grooves, and of the piston in the cylinder block and slightly push in install each ring in its groove.
Page 82: Crankshaft Check
ENGINE - INSPECTION AND ADJUSTMENT 5.11 CRANKSHAFT CHECK 5.11.1 CRANKSHAFT DEFLECTION 5.11.2 OIL CLEARANCE BETWEEN CRANKSHAFT JOURNAL AND BEARING 1 UUVW212A S76W279A Place the crankshaft on V blocks with its journals supported and set a dial indicator with its tip on the intermediate journal.
Page 83: Oil Clearance Between Crankshaft
ENGINE - INSPECTION AND ADJUSTMENT 5.11.3 OIL CLEARANCE BETWEEN 5.11.4 OIL CLEARANCE BETWEEN CRANK PIN AND CRANKSHAFT JOURNAL AND BEARING 2 CONNECTING ROD BIG END BEARING S76W281A S76W282A Place a plastigauge in lengthwise on the center of Place a plastic gauge in lengthwise on the center of the journal.
Page 84: Timing Gear
ENGINE - INSPECTION AND ADJUSTMENT 5.12 TIMING GEAR 5.12.1 TIMING GEAR SETTING 5.12.2 TIMING GEAR BACKLASH UUVW214A UUVW215A • The crankshaft gear drives the valve camshaft gear and fuel camshaft gear by driving idle gear. The tim- ings for opening and closing the valves is very im- portant to achieve the effective air intake and gas exhaust.
Page 85: Idle Gear Side Clearance
ENGINE - INSPECTION AND ADJUSTMENT 5.12.3 IDLE GEAR SIDE CLEARANCE 5.12.4 VALVE CAMSHAFT GEAR SIDE CLEARANCE UUVW218A 6501 UUVW217A T46W2B1B T46W2B2A (1) Camshaft (3) Camshaft stopper (2) Camshaft gear Pull the idle gear collar 2 (1) and push the idle gear Pull the cam gear (2) forward.
Page 86: Idle Gear Oil Clearance Measurement
ENGINE - INSPECTION AND ADJUSTMENT 5.12.5 IDLE GEAR OIL CLEARANCE 5.12.6 VALVE CAMSHAFT OIL CLEARANCE MEASUREMENT MEASUREMENT S76W290A S76W292A S76W291A UUVW219A Measure the idle gear shaft O.D. with an outside Measure the O.D. of the camshaft journal with an micrometer. outside micrometer.
Page 87: Valve Camshaft Deﬂ Ection Check
ENGINE - INSPECTION AND ADJUSTMENT 5.12.7 VALVE CAMSHAFT DEFLECTION CHECK 5.12.8 VALVE CAM HEIGHT MEASUREMENT UUVW220A UUVW221A Place the camshaft on V blocks with its journals Measure the height of the camshaft lobe at largest supported and set a dial indicator with its tip on the O.D.
Page 88: Flywheel Deﬂ Ection And Crankshaft End Play Check
ENGINE - INSPECTION AND ADJUSTMENT 5.13 FLYWHEEL DEFLECTION AND 5.14 OIL PUMP CHECK CRANKSHAFT END PLAY CHECK ▶ CLEARANCE BETWEEN ROTOR AND LOBE OF OIL PUMP UUVW222A S76W297A Set a dial indicator with its tip on the rear friction face of the ﬂ ywheel near the edge. Turn the ﬂ...
Page 89 ENGINE - INSPECTION AND ADJUSTMENT 0.11 ~ 0.15 mm Speciﬁ ed Clearance value (0.0043 ~ 0.0059 in.) between outer rotor and 0.20 mm Allowable inner rotor limit (0.0079 in.) 0.07 ~ 0.15 mm Speciﬁ ed Clearance value (0.0028 ~ 0.0059 in.) between outer rotor Allowable...
Page 90: Disassembly, Service And Assembly
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6. DISASSEMBLY, SERVICE AND ASSEMBLY 6.1 ENGINE REMOVAL Park the vehicle on level ground, stop the engine, and then apply the parking brake. UUVW225A UUVW223A UUVW226A Unscrew the four lower screen mounting screws (M5, 1) and remove the lower screen. Then, place UUVW224A a container under the rear of the radiator and un- screw the drain cock (2) of the radiator to drain the...
Page 91 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW231A UUVW228A Unscrew the 16 mounting screws (M6, 1) for the fender middle covers (LH, RH) to remove the covers. UUVW232A Unscrew the six seat frame assembly mounting bolts (M10, 1), two air cleaner mounting nuts (M8, 2), UUVW229A two air cleaner mounting bolts (M8, 3), air cleaner Unscrew the two parking brake cover mounting...
Page 92 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW2G3A UUVW2G4A 10. Unscrew the four heat shield mounting bolts (M6, 1) 12. Undo the clamps for the CVT intake hose (1) and to remove the heat shield. Then, unscrew the four disconnect the intake hose. muffler pipe mounting bolts (M8) and two muffler pipe mounting nuts (M10, 2) and disconnect the spring to remove the mufﬂ...
Page 93 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY REMARK • REMOVAL TOOL FOR CVT DRIVE PULLEY Part number : UCVT-P10 UUVW238A UUVW241A 9 /16 -18 UUVW307A UUVW239A 14. Unscrew the CVT drive pulley mounting bolt (1) and CVT driven pulley mounting bolt (2) and ﬁ t the remov- al tool into the CVT drive pulley bolt hole.
Page 94 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY CAUTION UUVW248A UUVW245A • When installing the internal CVT cover, remove 17. Remove the engine by hooking a hoist to the hook any Three Bond residual from the mating surface on the cylinder head. of the flywheel’s engine installation plate and apply a sufﬁ...
Page 95 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY CAUTION REMARK • Make sure that the coolant is not hot before opening the radiator ﬁ ller cap. IMPORTANT • The coolant mixture ratio of water to anti-freeze should be 50:50. When adding the coolant, pour it slowly.
Page 96: Engine Component Disassembly And Assembly
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.2 ENGINE COMPONENT DISASSEMBLY AND ASSEMBLY 6.2.1 CYLINDER HEAD Set the engine on level surface and unscrew the drain plug under the oil pan to drain the engine oil. Remove the alternator or other components if nec- essary.
Page 97 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW261A UUVW262A Unscrew the 14 cylinder head bolts (M10) in order Remove and replace the cylinder head gasket (1). using the 13 mm socket wrench and remove the If necessary, remove the injection nozzle holder as- cylinder head.
Page 98: Fuel Injection Pump
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.2.2 FUEL INJECTION PUMP ● DISASSEMBLY UUVW263A UUVW264A Unscrew and pull out the idle adjusting screw shaft (1). UUVW265A Unscrew the two injection pump mounting bolts (M8, UUVW266A 1) and two nuts (M8, 2) to remove the injection pump assembly.
Page 99: Speed Control Lever Plate And Governor Spring
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.2.3 SPEED CONTROL LEVER PLATE AND GOVERNOR SPRING ● ● ASSEMBLY DISASSEMBLY 1. Apply the liquid gasket (Three bond 1215, 1104 or equivalent) on the pump installation surface of the cylinder block. 2. Install the shims same as the previous state. UUVW267A UUVW299A When installing the fuel injection pump, the pump...
Page 100: Fuel Camshaft (Gear Case)
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY ● ASSEMBLY 6.2.4 FUEL CAMSHAFT (GEAR CASE) UUVW2A2A UUVW270A Be careful not to drop the engine stop solenoid guide (1) when installing the stop solenoid. UUVW271A Unscrew the crankshaft mounting nut (1), and re- move the fan drive pulley (2) using a puller.(29mm) UUVW2A3A Mounting nut...
Page 101 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW272A UUVW274A UUVW273A UUVW275A Unscrew the 14 gear case mounting bolts (M6, 1) Unscrew the two fuel supply pump mounting nuts and remove the gear case using the 10 mm socket (M6, 1) to remove the fuel supply pump. Then, pull wrench and T type socket wrench.
Page 102: Valve Camshaft
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.2.5 VALVE CAMSHAFT Pull out the tappets for each cylinder in order. UUVW276A Unscrew the two governor fork lever mounting bolts UUVW279A (M6, 1) to remove the fork lever (2). Then, unscrew the two stopper mounting bolts (M6, 3) to remove the stopper (4).
Page 103: Idle Gear Shaft, Oil Pump And Oil Pan
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.2.6 IDLE GEAR SHAFT, OIL PUMP AND OIL PAN UUVW281A UUVW283A Unscrew the three idle gear shaft mounting bolts Unscrew the one engine oil filter 1 mounting bolt (M6, 1), one oil pump gear mounting nut (M10, 2) (M8, 1) to remove the engine oil ﬁ...
Page 104: Piston, Fl Ywheel And Crankshaft
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.2.7 PISTON, FLYWHEEL AND CRANKSHAFT ● DISASSEMBLY UUVW284A UUVW287A Unscrew the 17 main bearing case cover mounting bolts (M8, 1) and remove the main bearing case cover, oil seal, bearing case gasket and bearing case cover gasket in order.
Page 105 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW289A UUVW290A Tap the crankshaft from its gear side with a rubber hammer to push out the crankshaft assembly to the ﬂ ywheel side. UUVW291A Unscrew the main bearing case bolts 1 (1), and remove the bearing case (2), crankshaft bearing (3) and side bearing (4) in order.
Page 106 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY ● ASSEMBLY Install in the reverse order of removal. UUVW293A UUVW292A When installing the main bearing case cover, make sure that the mark “UP” on it faces the upper side. Also, tighten its outer bolts ﬁ rst and then its inner bolts.
Page 107 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW295A UUVW297A Apply oil onto the connecting rod cover bolts, and tighten them to the speciﬁ ed torque using a torque wrench. Connecting rod bolt Speciﬁ ed torque .....26.0 ~ 30.0 Nm 2.7 ~ 3.1 kgf-m 20.0 ~ 22.0 lb-ft IMPORTANT •...
Page 108: Engine Component Disassembly And Assembly
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3 ENGINE COMPONENT DISASSEMBLY AND ASSEMBLY 6.3.1 ROCKER ARM 6.3.2 INTAKE AND EXHAUST VALVES UUVW298A S76W2O2A Pull out the snap ring (1) at the end from the rocker Remove the valve collet (1) with screw driver while arm assembly and disassemble the plain washer (2), pushing down the valve spring retainer with a ring rocker arm (3), rocker arm support (4), rocker arm...
Page 109: Injection Nozzle
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3.3 INJECTION NOZZLE Fix the nozzle nut and unscrew it to remove it. S76W2O5A Remove the valve stem seal (1). S76W2O6A Install in the reverse order of removal. Remove the nozzle holder (1), adjusting washer (2), When installing the valve, apply oil to the valve nozzle spring (3), push rod (4), distance piece (5), stem and install in the cylinder head.
Page 110: Piston Assembly
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3.4 PISTON ASSEMBLY S76W2O7A S76W2O9A Remove the piston rings (1) using a removal tool. The cutout of expander (A) of the oil ring should face the opposite side of the oil ring end gap (B), Take out the piston pin springs (2) using pliers and and the end gaps of the second ring and oil ring remove the piston pin (3).
Page 111: Thermostat
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3.5 THERMOSTAT S76W2P0A UUVW2A5A Remove the two thermostat cover bolts (M8,1) from the coolant ﬂ ange. S76W2P1A The mark (A) of the connecting rod on the top should be aligned with the bottom portion. Install UUVW2A6A the connecting rod with the piston so that it faces the injection pump along with the arrow mark (B) on...
Page 112: Water Pump
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3.6 WATER PUMP ● OPENING TEMPERATURE OF THERMOSTAT VALVE T46W2F2A UUVW2A7A Suspend the thermostat in the water by a string. While heating the water slowly, read the tempera- tures when the valve starts to open and when the valve opens for approx.
Page 113: Main Bearing Case Assembly
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3.7 MAIN BEARING CASE ASSEMBLY IMPORTANT • If the main bearing case is installed incorrectly, its oil transfer holes are not aligned with the holes of the cylinder block which can cause engine stall. 5.
Page 114: Njection Pump Gear Assembly
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.3.8 INJECTION PUMP GEAR ASSEMBLY 6.3.9 ENGINE OIL RELIEF VALVE (FUEL CAMSHAFT GEAR) S76W2Q3A Pull out the snap ring (1) and remove the injection pump gear assembly. This assembly is forcibly pressed into the shaft, so a special device may be used for its disassembly.
Page 115: Cylinder Head Gasket Replacement
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.4 CYLINDER HEAD GASKET REPLACEMENT Park the vehicle on level ground, apply the parking brake, stop the engine and open the coolant drain cock to drain the coolant. (See 6.1 “Engine assem- bly removal.”) UUVW2B2A Unscrew the alternator bracket mounting bolt to remove the alternator bracket (1).
Page 116 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY CAUTION • When installing the engine again, adjust the valve clearance after installing the rocker arm assembly. (See 5.7.1 “Clearance adjustment.”) • For the cylinder head bolt installation, refer to 6.2.1. “Cylinder head.” UUVW2B5A Unscrew the cylinder head bolts (1) in the correct removal order.
Page 117: Gear Case Disassembly And Reassembly (Gear Case Gasket, Crankshaft Oil Seal And Oil Pump Replacement)
ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY 6.5 GEAR CASE DISASSEMBLY AND REASSEMBLY (GEAR CASE GASKET, CRANKSHAFT OIL SEAL AND OIL PUMP REPLACEMENT) Park the vehicle on level ground, apply the parking brake, stop the engine and disconnect the negative battery cable. UUVW2C1A Unscrew the fuel tank ﬁ...
Page 118 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW2C3A UUVW2C5A Unscrew the two air cleaner mounting bolts (M8, Undo the coolant hose band to disconnect the 1) and two intake duct mounting nuts (M8, 2) using coolant hose (1). Then, disconnect the engine stop the 12 mm spanner to remove the air cleaner as- solenoid connector (2) and accelerator wire (3) and sembly.
Page 119 ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW2C7A UUVW2G1A Remove the crankshaft pulley using a puller. Replace the oil seal (1), O-ring (2) and gear case gasket (3) with new ones as necessary. When replacing the gear case gasket, apply Three Bon 1215 or equivalent to the both mating surfaces of the gasket before installation.
Page 120: Engine Exploded View
ENGINE - ENGINE EXPLODED VIEW 7. ENGINE EXPLODED VIEW 7.1 E010 CYLINDER BLOCK UUVW2D1A COMPONENTS (1) TOTAL CYLINDER BLOCK ASSY (9) PIN (17) GASKET, OIL PUMP (2) PLUG (10) PIN, PIPE (18) BOLT (3) PLUG (11) O RING (19) GEAR, OIL PUMP DRIVE (4) PLUG (12) COVER (20) KEY...
Page 121: E020 Oil Pan
ENGINE - ENGINE EXPLODED VIEW 7.2 E020 OIL PAN UUVW2D2A COMPONENTS (1) OIL PAN ASSY (5) BOLT (9) GUIDE (2) PLUG (6) FILTER1 OIL (10) GUIDE, OIL GAUGE (3) WASHER, SEAL (7) O RING (11) PACKING (4) GASKET, OIL PAN (8) FLANGE BOLT WITH PIN (12) GAUGE, OIL SUUV-W00 Apr.
Page 122: E030 Cylinder Head
ENGINE - ENGINE EXPLODED VIEW 7.3 E030 CYLINDER HEAD UUVW2D3A COMPONENTS (1) TOTAL CYLINDER HEAD ASSY (7) COMBUSTION CHAMBER (13) STUD (2) CAP, SEALING (8) BOLT, HEAD (14) NUT, FLANGE (3) PLUG (9) GASKET, HEAD (15) WASHER, SPRING (4) PLUG (10) HOLDER, ENGINE (16) STUD (5) GUIDE, INLET VALVE...
Page 123: E040 Gear Case
ENGINE - ENGINE EXPLODED VIEW 7.4 E040 GEAR CASE UUVW2D4A COMPONENTS (1) GEAR CASE ASSY (17) SPRING (33) WASHER, SPRING (2) GEAR CASE (18) SEAT, VALVE (34) CLAMP, HOSE (3) PLUG (19) STEEL BALL (35) WATER PUMP ASSY (4) O RING (20) O RING (36) MAIN BODY, WATER PUMP (5) GASKET, GEAR CASE...
Page 124: E050 Main Bearing Case
ENGINE - ENGINE EXPLODED VIEW 7.5 E050 MAIN BEARING CASE UUVW2D5A COMPONENTS (1) BEARING CASE ASSY (7) BOLT, FLANGE (13) MAIN BEARING 2 CASE ASSY (2) BOLT, BEARING CASE1 (8) BOLT, FLANGE (14) BOLT, BEARING CASE1 (3) METAL, CRANKSHAFT (9) SEAL, OIL (15) SIDE METAL2 (4) GASKET, BEARING (10) MAIN BEARING 1 CASE ASSY...
Page 125: E080 Valve Rocker Arm
ENGINE - ENGINE EXPLODED VIEW 7.6 E080 VALVE ROCKER ARM UUVW2D6A COMPONENTS (1) VALVE, INLET (7) ROCKER ARM ALL ASSY (13) ROCKER ARM (2) VALVE, EXHAUST (8) SHAFT, ROCKER ARM (14) SCREW, ADJUSTING (3) SPRING, VALVE (9) BRACKET, ROCKET ARM (15) NUT, ADJUSTING (4) RETAINER, VALVE SPRING (10) WASHER...
Page 126: E090 Cylinder Head Cover
ENGINE - ENGINE EXPLODED VIEW 7.7 E090 CYLINDER HEAD COVER UUVW2D7A COMPONENTS (1) CYLINDER HEAD COVER ASSY (5) O RING (9) BAND (2) COVER, CYLINDER HEAD (6) OIL PROTECTOR (10) BOLT, HEAD COVER (3) CONNECTOR, AIR BREATHER (7) GASKET, HEAD COVER (11) STUD (4) PLUG, OIL FILLER (8) AIR BREATHER...
Page 127: E100 Camshaft
ENGINE - ENGINE EXPLODED VIEW 7.8 E100 CAMSHAFT UUVW2D8A COMPONENTS (1) TAPPET (6) STOPPER, CAMSHAFT (11) COLLAR1 (2) ROD, PUSH (7) CIR CLIP, EXTERNAL (12) COLLAR2 (3) CAMSHAFT ASSY (8) BOLT (13) CIR-CLIP (4) GEAR, CAMSHAFT (9) GEAR IDLE ASSY (14) SHAFT GEAR, IDLE (5) KEY (10) BUSH, IDLE GEAR...
Page 128: E110 Piston & Crank Shaft
ENGINE - ENGINE EXPLODED VIEW 7.9 E110 PISTON & CRANK SHAFT UUVW2D9A COMPONENTS (1) PISTON & PIN ASSY (7) PISTON OIL RING ASSY (13) CRANK SHAFT ASSY (2) PISTON (8) CIR-CLIP (14) GEAR, CRANK SHAFT (3) PIN, PISTON (9) CON ROD ASSEMBLY (15) KEY (4) RING, PISTON ASSY (10) BUSH, PISTON PIN...
Page 129: E120 Flywheel
ENGINE - ENGINE EXPLODED VIEW 7.10 E120 FLYWHEEL UUVW2E1A COMPONENTS (1) FLYWHEEL ASSY (5) STUD (9) GASKET (2) GEAR, RING (6) NUT (10) STARTER ASSY (3) BOLT (7) WASHER, SPRING (11) BOLT (4) PLATE-REAR END (8) FLANGE BOLT WITH PIN SUUV-W00 Apr.
Page 130: E130 Nozzle, Holder
ENGINE - ENGINE EXPLODED VIEW 7.11 E130 NOZZLE, HOLDER UUVW2E2A COMPONENTS (1) HOLDER,NOZZLE 1 ASSY (7) TUBE3, INJECTION (13) PLAIN WASHER (2) GASKET (8) CLAMP1, TUBE (14) CORD, GLOW PLUG (3) HEAT SHIELD (9) CLAMP, TUBE (15) HOSE, OVER FLOW (4) GASKET (10) SCREW (16) BAND...
Page 131: E140 Fuel Camshaft
ENGINE - ENGINE EXPLODED VIEW 7.12 E140 FUEL CAMSHAFT UUVW2E3A COMPONENTS (1) INJECTION PUMP ASSY (12) BEARING, BALL (23) HOSE1, FUEL (2) SHIM, INJECTION PUMP (13) KEY (24) STUD (3) SHIM (14) CIR CLIP, EXTERNAL (25) NUT (4) SHIM10, INJECTION PUMP (15) GOVERNOR SLEEVE ASSY (26) WASHER, SPRING (5) SHIM3, INJECTION PUMP...
Page 132: E150 Speed Control Plate
ENGINE - ENGINE EXPLODED VIEW 7.13 E150 SPEED CONTROL PLATE UUVW2E4A COMPONENTS (1) ADJUSTING BOLT (7) LEVER, SPEED CONTROL (13) BOLT, FLANGE (2) NUT (8) PLATE, SPEED CONTROL (14) NUT, FLANGE (3) GASKET (9) GASKET, SPEED CONTROL PLATE (15) SCREW, ADJUSTING (4) NUT, CAP (10) SPRING (16) NUT...
Page 133: E160 Engine Stop Lever
ENGINE - ENGINE EXPLODED VIEW 7.14 E160 ENGINE STOP LEVER UUVW2E5A COMPONENTS (1) START SPRING (9) PACKING (17) NUT, FLANGE (2) SHAFT, IDLE ADJUST (10) CAP (18) COVER,INJECTION PUMP (3) BUSH (11) COVER, ENGINE STOP LEVER (19) GASKET (4) IDLE ADJUSTMENT BODY (12) GASKET, SPEED CONTROL PLATE (20) BOLT, FLANGE (5) IDEL ADJUSTING BOLT...
Page 134: E170 Governor
ENGINE - ENGINE EXPLODED VIEW 7.15 E170 GOVERNOR UUVW2E6A COMPONENTS (1) GOVERNOR LEVER ASSY (3) BOLT (5) SPRING, GOVERNOR2 (2) LEVER ASSY (4) SPRING1, GOVERNOR SUUV-W00 Apr. 2011...
Page 135: E190 Water Hose
ENGINE - ENGINE EXPLODED VIEW 7.16 E190 WATER HOSE UUVW2E7A COMPONENTS (1) FLANGE, WATER (7) HOSE, WATER PUMP (13) BOLT (2) WATER FLANGE GASKET (8) BAND (14) THERMOSTAT COVER ASSY (3) BOLT (9) THERMOSTAT ASSY (15) COVER, WATER HOSE (4) STUD (10) GASKET (16) BOLT (5) NUT, FLANGE...
Page 136: E200 Dynamo
ENGINE - ENGINE EXPLODED VIEW 7.17 E200 DYNAMO UUVW2E8A COMPONENTS (1) ALTERNATOR ASSY (7) BOLT (13) PULLEY, FAN DRIVING (2) SUPPORT2, ANTERNATOR (8) WASHER, PLAIN (14) KEY (3) SUPPORT3, ALTERNATOR (9) COOLING FAN (15) NUT, CRANKSHAFT (4) SPACER (10) WASHER BOLT (16) FAN BELT (5) BOLT, FLANGE (11) COLLAR,FAN...
Page 137: E220 Mainfold
ENGINE - ENGINE EXPLODED VIEW 7.18 E220 MAINFOLD UUVW2E9A COMPONENTS (1) MANIFOLD,INLET (6) BOLT (11) WASHER, SPRING (2) BOLT, SCREW (7) BOLT (12) PLATE,HEAT (3) CONNECTOR, AIR BREATHER (8) MANIFOLD, EXHAUST (13) BOLT (4) GASKET / INLET MANIFOLD (9) GASKET, EXHAUST MANIFOLD (14) WASHER, PLAIN (5) BOLT (10) NUT...
Page 138 MEMO...
Page 139 CHAPTER 4 TABLE OF CONTENTS 1. SPECIFICATIONS ........4-2 5. DISASSEMBLY, SERVICE AND ASSEMBLY ..........4-11 1.1 General speciﬁ cations ......4-2 5.1 CVT disassembly ......... 4-11 1.2 Tightening torque ........4-2 5.2 CVT assembly ........4-13 1.3 Sealant and adhesive ......4-2 5.3 Drive pulley assembly components 2.
Page 140: Specifications
CVT - SPECIFICATIONS 1. SPECIFICATIONS 1.1 GENERAL SPECIFICATIONS Item Speciﬁ cation Type Constant variable, belt Pulley speed reduction ratio (drive : driven) 0.68 : 1 Speciﬁ cation 29 mm (1.142 in.) Belt width Allowable limit 24 mm (0.945 in.) Distance between center of two pulleys (Shaft distance) 327.15 mm (12.8799 in.) Drive pulley Centrifugal force reactive type variable pulley...
Page 141: Structure And Operating Principle
CVT - STRUCTURE AND OPERATING PRINCIPLE 2. STRUCTURE AND OPERATING PRINCIPLE 2.1 STRUCTURE OF CVT (CONTINUOUSLY VARIABLE TRANSMISSION) Adaptor CVT drive pulley Transmission 6204 6205 CVT driven pulley 20x24x13 6204R 25x29x13 25x29x13 6204 6204 6305R 6305R T2610-22661 03014-50820 UUVW301A SUUV-W00 Apr. 2011...
Page 142: Operating Principle
CVT - STRUCTURE AND OPERATING PRINCIPLE 2.2 OPERATING PRINCIPLE UUVW2F2A The CVT (Continuously Variable Transmission) equipped in this vehicle has the driving pulley (1) and driven pulley (2) that are connected with the belt (3). This transmission can change steplessly through speed ratios between maxi- mum 3.55:1 and minimum 0.68:1 by changing the effective diameter of the belt for the driving and driven pulleys.
Page 143 CVT - STRUCTURE AND OPERATING PRINCIPLE Driven pulley Drive pulley ※ For the driving pulley, the flange (8) and shaft (9) shown in blue rotate engaged to the engine flywheel while the flange (4) and centrifugal pendulum (1) shown in red rotate sliding on the shaft (9) in the axial direction as one unit. Driven pulley Drive pulley ※...
Page 144 CVT - STRUCTURE AND OPERATING PRINCIPLE Tension Relaxation Drive pulley Driven pulley : Belt rotating direction Relaxation : Belt moving direction Tension Drive pulley Driven pulley UUVW317A CVT operation under load (example: uphill road) - (C) CVT operation under reverse load (example: downhill road) - (D) When the vehicle starts to drive uphill while driving on When driving from an uphill to a downhill road, the load the level road with maximum speed, without load, the...
Page 145: Principle Of Cooling System For Cvt
CVT - STRUCTURE AND OPERATING PRINCIPLE 2.3 PRINCIPLE OF COOLING SYSTEM FOR CVT Air ﬂ ow UUVW313A UUVW335A The drive pulley is equipped with the cooling fan which Then, the negative pressure is generated on the center rotates in the CVT case to draw ambient air in with the of the fan.
Page 146: Troubleshooting
CVT - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Cause Service • Cracked or abnormally worn • Visually check and replace belt the belt. Abnormal noise from belt in CVT • Changed distance between • Adjust it with the shaft dis shafts tance setting jig again. •...
Page 147: Inspection And Adjustment
CVT - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 ADJUSTING DISTANCE BETWEEN SHAFTS FOR PULLEYS REMARK When the distance between the shafts and offset val- ues are uncertain during the inspection of the CVT or • Shafts & offset measuring jig (without adapter installation of the engine or gear box, perform the fol- attached) lowing procedures to measure the distance between...
Page 148: Check And Replacement For Cvt Belt
CVT - INSPECTION AND ADJUSTMENT 4.2 CHECK AND REPLACEMENT FOR CVT BELT REMARK How to change the clutch button UUVW336A Measure the width of the CVT belt(1). Replace it with a new one if it has been used for more than UUVW337A 800 hours or its width is 1 in.
Page 149: Disassembly, Service And Assembly
CVT - DISASSEMBLY, SERVICE AND ASSEMBLY 5. DISASSEMBLY, SERVICE AND ASSEMBLY 5.1 CVT DISASSEMBLY Park the vehicle on level ground, apply the parking brake and stop the engine. Lift the rear cargo bed and support it with the sup- port. UUVW2G4A Undo the clamps for the CVT case intake hose (1) and disconnect the intake hose.
Page 150 CVT - DISASSEMBLY, SERVICE AND ASSEMBLY IMPORTANT • Apply LOCTITE #242 or equivalent to the mounting bolts of CVT drive and driven pulleys before installing them. REMARK • REMOVAL TOOL FOR CVT DRIVE PULLEY Part number : UCVT-P10 UUVW339A UUVW241A 9 /16 -18 UUVW240A Unscrew the CVT drive pulley mounting bolt (1)
Page 151: Cvt Assembly
CVT - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 CVT ASSEMBLY UUVW452A UUVW455A Loosen the body mounting bolts of the engine front Tighten the mounting bolts for the gear box and en- bracket (1) and engine rear bracket (2). gine bracket as well as the 8 inner cover mounting bolts.
Page 152 CVT - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW341A UUVW342A 6. Apply LOCTITE #242 or equivalent to the driven 7. Install the outer CVT cover and tighten its mounting pulley mounting bolt and tighten it completely. bolt. 8. Make sure that all mounting bolts for the engine Driven pulley mounting bolt (1) and CVT are installed properly.
Page 153: Drive Pulley Assembly Components Disassembly And Assembly
CVT - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3 DRIVE PULLEY ASSEMBLY COMPONENTS DISASSEMBLY AND ASSEMBLY UUVW343A UUVW345A UUVW344A UUVW346A Unscrew the impeller cover ﬁ xing bolt(1) of drive pulley Fix the shaft (A) of ﬁ xing pulley assembly and turn the assembly to disassemble the impeller cover(2), pulley spider assembly part (B) to remove and then remove body(4) and spring(3).
Page 154 UUVW347A UUVW350A 3. Remove the upper and lower covers (1) from the 4. Unscrew the centrifugal lever fixing bolt(1) from spider assembly, and remove the washers (2), sliding pulley assembly and remove the centrifugal spacer (3) and pin (4) in order. Then, remove the lever(2), thrust washer(3) and lock nut(4).
Page 155: Driven Pulley Assembly Components Disassembly And Assembly
5.4 DRIVEN PULLEY ASSEMBLY COMPONENTS DISASSEMBLY AND ASSEMBLY CAUTION When reassembling the drive pulley assembly (driving part CVT assembly), tighten the impel- ler cover bolt to the diagonal direction gradu- ally by turns. Apply the adhesive equivalent LOCTITE #271 to the following screw thread. •...
Page 156: Components For Cvt
CVT - COMPONENTS 6. COMPONENTS FOR CVT 6.1 U060A CVT UUVW471B COMPONENTS (1) CVT, PRIMARY (5) ARM. CAM (9) SCREW (2) CVT, SECONDARY (6) SPIDER KIT (10) SCREW, SET (3) BELT, DRIVE (7) FRICTION SPRING (11) BUTTON KIT (4) BOLT (8) FAN (12) SPRING SUUV-W00 Apr.
Page 157: U0287A Clutch Cover
CVT - COMPONENTS 6.2 U0287A CLUTCH COVER UUVW353A COMPONENTS (1) ADAPTOR, CVT DRIVE (7) WASHER, SPRING (13) BOLT, FLANGE (2) BOLT, FLANGE (8) BOLT, CVT DRIVE (14) AIR BAFFLING BOX ASSY (3) CLUTCH COVER ASSY - INNER (9) PLUG (15) BOLT, FLANGE (4) BOLT, FLANGE (10) BOLT (16) CLMAP, HOSE...
Page 158 MEMO...
Page 159 TRANSMISSION CHAPTER 5 TABLE OF CONTENTS 1. SPECIFICATIONS ........5-2 5. DISASSEMBLY, SERVICE AND ASSEMBLY ..........5-13 1.1 General speciﬁ cations ......5-2 5.1 Transmission removal ......5-13 1.2 Tightening torque ........5-2 5.2 Transmission components disassembly 1.3 Sealant and adhesive ......5-3 and assembly ........
Page 160: Specifications
TRANSMISSION - SPECIFICATIONS 1. SPECIFICATIONS 1.1 GENERAL SPECIFICATIONS Item Speciﬁ cation Gears Low speed, high speed, neutral and reverse 0.9 ℓ / 0.24 u.s gal SAE gear oil #90 or DAEDONG UTF55 Transmission ﬂ uid Shell Donax -TD Exxonmobil Mobilﬂ uid 423 or 424 Tractran UTH Rotating ratio for front/rear wheels 1.008 / 1...
Page 161: Sealant And Adhesive
TRANSMISSION - SPECIFICATIONS 1.3 SEALANT AND ADHESIVE Applied position Purpose Speciﬁ cation Bearing holder mounting screw for 10 spiral Prevention of looseness LOCTITE #242 or equivalent bevel pinion shaft Mating surface of transmission case and cover Prevention of oil leakage Three Bond 1206D or equivalent Mating surface of transmission case and front Prevention of oil leakage...
Page 162: Structure And Operating Principle
TRANSMISSION - STRUCTURE AND OPERATING PRINCIPLE 2. STRUCTURE AND OPERATING PRINCIPLE 2.1 TRANSMISSION STRUCTURE 6204 6205 20x24x13 6204 25x29x13 25x29x13 6204R 46T 34T UUVW401A SUUV-W00 Apr. 2011...
Page 163: Speed Control System
TRANSMISSION - STRUCTURE AND OPERATING PRINCIPLE 2.2 SPEED CONTROL SYSTEM 6204 6205 20x24x13 25x29x13 25x29x13 6204 6204R Forward(High) Forward(High) Forward(High) Reverse Reverse Reverse Forward(Low) Forward(Low) Forward(Low) 6204 6305R 6305R T2610-22661 03014-50820 UUVW402A The shaft 1 (1), which is the CVT driven shaft, is LOW-SPEED FORWARD DRIVING equipped with and rotates with the 15 gear (2), 17 Shaft 1 (driven shaft) →...
Page 164: Shift System
TRANSMISSION - STRUCTURE AND OPERATING PRINCIPLE 2.3 SHIFT SYSTEM UUVW405A 6204 6205 6204R 20x24x13 6204 25x29x13 25x29x13 46T 34T UUVW474A UUVW475 A The shift system of this transmission is equipped with The detent disc (11) is installed to the splined section the fork rod (9) and shift drum (7).
Page 165: Wheel Drive System
TRANSMISSION - STRUCTURE AND OPERATING PRINCIPLE 2.4 WHEEL DRIVE SYSTEM Front wheel drive FWD ON T8101-75520 FWD OFF 6204 34150-2156-1 6305 6305R T2610-22661 T8101-75520 03014-50820 Rear wheel drive UUVW403A The 46 gear is installed to the countershaft (shaft 2) FRONT WHEEL DRIVE of the speed control system and it drives the 52 gear 52 gear →...
Page 166: Troubleshooting
TRANSMISSION - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Cause Service • Excessive oil • Adjust the oil level. • Loose bolt • Retighten the bolt. Oil leakage • Damaged oil seal, O-ring or gasket • Replace the damaged parts. • Cracked transmission housing •...
Page 167: Inspection And Adjustment
TRANSMISSION - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 BACKLASH OF 10 SPIRAL BEVEL PINION SHAFT AND 31 BEVEL GEAR T8101-75520 T8101-75520 6204 6305 34150-2156-1 6305R T2610-22661 UUVW406A T8101-75520 03014-50820 Set the rear wheel drive shaft as it is installed to the 10 spiral bevel pinion shaft and 31 bevel gear as shown in the ﬁ...
Page 168: Tooth Contact Of Spiral Bevel Gear
TRANSMISSION - INSPECTION AND ADJUSTMENT 4.2 TOOTH CONTACT OF SPIRAL BEVEL GEAR A. TOE CONTACT T8101-75520 6204 6305 34150-2156-1 T46W819A 6305R T2610-22661 T8101-75520 If the center of the contact mark is too close to the toe 03014-50820 of the tooth, push back the pinion shaft and push in the ring gear to the pinion direction so that the back lash is UUVW476A maintained.
Page 169: Air Gap Of Vehicle Speed Sensor
TRANSMISSION - INSPECTION AND ADJUSTMENT 4.3 AIR GAP OF VEHICLE SPEED SENSOR C. DEEP CONTACT T8101-75520 6204 34150-2156-1 6305 6305R T2610-22661 T46W821A T8101-75520 If the contact mark is on the bottom of the ring gear 03014-50820 teeth, push the ring gear away from the pinion and push the pinion into the ring gear (if necessary) to UUVW408A maintain the backlash.
Page 170: Shift Cable Length
TRANSMISSION - INSPECTION AND ADJUSTMENT 4.4 SHIFT CABLE LENGTH 4.5 FRONT WHEEL DRIVE CABLE LENGTH UUVW503A UUVW507A UUVW504A UUVW508A Put the shift lever to the "N" position. Then, adjust Set the differential lock lever to the "UNLOCK" po- the length of the section A of the gear selector ca- sition.
Page 171: Disassembly, Service And Assembly
TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY 5. DISASSEMBLY, SERVICE AND ASSEMBLY 5.1 TRANSMISSION REMOVAL UUVW412A UUVW409A Park the vehicle on ﬁ rm and level ground, stop the engine and apply the parking brake. Then, raise the cargo bed and support it. Remove the CVT.
Page 172: Transmission Components Disassembly And Assembly
TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 TRANSMISSION COMPONENTS DISASSEMBLY AND ASSEMBLY UUVW415A UUVW417A UUVW416A UUVW418A Set the transmission case assembly in a stable Unscrew the transmission case cover mounting bolts place and undo the drain plug (1) with the 22 mm (1) (M8, 10 EA) using the 12 mm socket wrench to socket wrench to drain the transmission ﬂ...
Page 173 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW433A Remove the ball bearing (1) from the spiral bevel pinion shaft on the transmission cover side to re- move the 52 gear (2). UUVW446A On the transmission case cover side, pull the drive shaft (1), driven shaft (2), shift guide lever (3), fork (4) and fork rod (5) to the front of the case to re- move them as an assembly.
Page 174 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW447A Disconnect the shift guide lever (1) and pull out Remove the driven shaft 30 gear assembly (A). the fork rod (2). Then, remove the forks (4) while Then, remove the silent chain (18 links) (5). setting the clutch dogs (3) on both sides adhered together.
Page 175 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY REMARK CAUTION UUVW449A UUVW451A • When installing the fork, its longer bosses (A) • The 46 gear (1) (A) cannot be removed from the should be in the splined direction. driven shaft assembly; it is shrink-fitted with heat.
Page 176: Axle Drive Shaft Disassembly And Assembly
TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3 AXLE DRIVE SHAFT DISASSEMBLY AND ASSEMBLY UUVW421A UUVW424A UUVW422A UUVW425A Unscrew the front wheel drive cover mounting bolts Disconnect the silent chain and disassemble the (1), (M8, 8 EA) using the 12 mm socket wrench to rear wheel drive shaft and front wheel drive shaft.
Page 177 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW426A When assembling the rear wheel drive shaft, ﬁ t the 31 bevel gear (1), 22 sprocket (2), snap ring (3), spacer (4) and ball bearing (5) to the splined side of the rear wheel drive shaft. Then, tap in the ball bearing (6) from the other side.
Page 178 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW428A UUVW429A When assembling the front wheel drive shaft, tap in the ball bearing (1) to the splined side. Then, ﬁ t the fork (2), needle bearing (3), needle bearing (3), 19 sprocket (4), thrust washer (5) and ball bearing (6) to the other side in order.
Page 179 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY Unscrew the ball bearing holder mounting screws (1) (M8, 4 EA) to remove the holder (2). Mounting screw (M8) tightening torque .... 7.8 ~ 15.7 Nm 0.8 ~ 1.6 kgf-m 5.8 ~ 11.5 lb-ft CAUTION •...
Page 180: Gear Shift System Disassembly And Assembly
TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY 5.4 GEAR SHIFT SYSTEM DISASSEMBLY AND ASSEMBLY UUVW419A UUVW420A Unscrew the shift cover mounting bolts (1) (M6, 5 EA) and shift lever mounting nut (2) (M8, 1 EA) using the 10 mm and 12 mm spanners and socket wrenches to remove the shift cover. UUVW437A Remove the shift disc (1), spacer (2), 16 gear (3), spring (4), lock arm (5), shaft (6), 33 gear (7) and O-ring (8) from the shift cover side.
Page 181 TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW439A UUVW441A When reassembling these components, insert the Install the lock arm (1) and spring (2) to the shaft. 16 gear (1) to the shift guide lever and set the 33 Apply a sufﬁ cient amount of grease to the shift gear gear (2) to the shaft with the gear boss toward the installing area before installing the shift cover.
Page 182: Front Wheel Drive System Disassembly And Assembly
TRANSMISSION - DISASSEMBLY, SERVICE AND ASSEMBLY 5.5 FRONT WHEEL DRIVE SYSTEM DISASSEMBLY AND ASSEMBLY REMARK UUVW430A UUVW432A • When installing the front wheel drive lever and spring, make sure the mark "4WD" and spring hook groove face upward. UUVW431A When necessary, remove the shift arm (6) and front wheel drive lock fork (7) by unscrewing the front wheel drive lever mounting nut (1) (M10, 1 EA), removing the shift arm (2) and spring (3) and then...
Page 183: Components
TRANSMISSION - COMPONENTS 6. COMPONENTS 6.1 U120A TRANSMISSION CASE UUVW462A COMPONENTS (1) TRANMISSION ASSY (7) BOLT (13) WASHER, SEAL (2) MISSION CASE (8) PIN, STRAIGHT (14) PLUG (3) COVER, TRANSMISSION CASE (9) COVER, SHIFT (15) CONNECTOR, AIR BREATHER (4) BOLT (10) BOLT (16) HOSE, OVER FLOW (5) PIN, STRAIGHT...
Page 184: U130A Shaft 1
TRANSMISSION - COMPONENTS 6.2 U130A SHAFT 1 6204 6205 20x24x13 6204R 25x29x13 25x29x13 6204 UUVW464A UUVW463A COMPONENTS (1) SHAFT (9) 26T, SPROCKET (17) BEARING, NEEDLE (2) SHAFT (10) BEARING, NEEDLE (18) GEAR 46 (3) GEAR 31 (11) COLLAR, THRUST (19) BEARING, BALL (4) BEARING, BALL (12) SNAP RING (20) BEARING, BALL...
Page 185: U140A Bevel Pinion Gear
TRANSMISSION - COMPONENTS 6.3 U140A BEVEL PINION GEAR 20x24x13 25x29x13 25x29x13 6204 6204R 6204 6305R 6305R T2610-22661 03014-50820 UUVW466 A UUVW465A COMPONENTS (1) SPIRAL BEVEL GEAR ASSEMBLY (7) BEARING, BALL (13) GEAR 52 (2) SHAFT, 10 BEVEL PINION (8) SHIM 0.1 (14) SCREW (3) BEVEL GEAR, 31 (9) SHIM 0.2...
Page 186: U150A Shaft 2
TRANSMISSION - COMPONENTS 6.4 U150A SHAFT 2 20x24x13 25x29x13 25x29x13 6204 6204R FWD ON T8101-75520 6305 34150-2156-1 6305R T2610-22661 T8101-75520 03014-50820 UUVW468A UUVW469A UUVW467A COMPONENTS (1) SHAFT, FRONT DRIVE (12) ARM, SHIFT(FRONT) (23) COLLAR (34) O RING (2) SHIFT, FRONT DRIVE (13) PIN, SPRING (24) BEARING, BALL (35) GEAR 16...
Page 187: U160A Propeller Shaft
TRANSMISSION - COMPONENTS 6.5 U160A PROPELLER SHAFT UUVW470A COMPONENTS (1) PROPELLER SHAFT ASSY, FR (3) PROPELLER SHAFT ASSY, RR (2) PIN, SPRING (4) PIN, SPRING SUUV-W00 Apr. 2011...
Page 188 MEMO...
Page 189 CHASSIS CHAPTER 6 TABLE OF CONTENTS 1. SPECIFICATIONS ........6-2 4. COMPONENTS ........6-13 1.1 Tire ............6-2 4.1 U030A Accelerator pedal ...... 6-13 4.2 U0912A Hood ........6-14 2. INSPECTION AND ADJUSTMENT ..6-3 4.3 U0200A Structure ......... 6-15 2.1 Installation direction of front/rear tires ..
Page 190: Specifications
CHASSIS - SPECIFICATIONS 1. SPECIFICATIONS 1.1 TIRE Item Standard Speciﬁ cation Front 25 x 10 - 12 (6PR) 12 psi (0.84 kgf/cm², 82.7 kPa) Standard tire inﬂ ation pressure Rear 25 x 11 -12 (6PR) 18 psi (1.26 kgf/cm², 124.0 kPa) Front Flange nut (M10) 39.2 ~ 45.1 Nm...
Page 191: Inspection And Adjustment
CHASSIS - INSPECTION AND ADJUSTMENT 2. INSPECTION AND ADJUSTMENT 2.1 INSTALLATION DIRECTION OF FRONT/REAR TIRES Rear wheel Rear wheel outer direction outer direction UUVW501A Front wheel Front wheel outer direction outer direction UUVW502A SUUV-W00 Apr. 2011...
Page 192: Routes For Various Cables
CHASSIS - INSPECTION AND ADJUSTMENT 2.2 ROUTES FOR VARIOUS CABLES 2.2.1 DIFFERENTIAL LOCK CABLE 2.2.2 SHIFT SELECTOR CABLE UUVW510B UUVW514B UUVW511B UUVW515B UUVW512B UUVW516B UUVW513B UUVW517B SUUV-W00 Apr. 2011...
Page 193: Front Wheel Drive Cable
CHASSIS - INSPECTION AND ADJUSTMENT 2.2.3 FRONT WHEEL DRIVE CABLE 2.2.4 PARKING BRAKE CABLE UUVW518B UUVW521B UUVW519B UUVW522B UUVW520B UUVW523B SUUV-W00 Apr. 2011...
Page 194: Accelerator Pedal Cable
CHASSIS - INSPECTION AND ADJUSTMENT / DISASSEMBLY, SERVICE AND ASSEMBLY 3. DISASSEMBLY, SERVICE AND ASSEMBLY 3.1 CARGO BED REMOVAL 2.2.5 ACCELERATOR PEDAL CABLE UUVW524A UUVW528A Park the vehicle on level ground, apply the parking brake and stop the engine. UUVW526B UUVW2G6A UUVW527B UUVW530A...
Page 195: Seat And Fender Removal
CHASSIS - DISASSEMBLY, SERVICE AND ASSEMBLY 3.2 SEAT AND FENDER REMOVAL UUVW571A UUVW533A Lift the cargo bed and remove the mounting pins (1) from both sides. Then, pull out the cargo bed support pole connecting pin (2) and remove the gas cylinder ﬁ...
Page 196 CHASSIS - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW535A UUVW537A UUVW536A UUVW538A Unscrew the left and right cover mounting screws (1) for the middle fender to remove the covers. UUVW539A Remove the seat by pulling it up in the front. Then, unscrew the seatback assembly mounting screws UUVW532A (1) to remove the seatback assembly.
Page 197: Hood, Panel, Fl Oor And Radiator Removal
CHASSIS - DISASSEMBLY, SERVICE AND ASSEMBLY 3.3 HOOD, PANEL, FLOOR AND RADIATOR REMOVAL UUVW561A UUVW543A Disconnect the headlamp connector (1) and un- screw the hood mounting bolts (2) on the left and right to remove the hood. UUVW544A 3. Unscrew the panel mounting screws (1) (LH/RH) from the hood side.
Page 198 CHASSIS - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW546A UUVW549A UUVW550A 7. Unscrew the left and right cover mounting screws (1) for the middle fender to remove the covers (LH/RH). UUVW547A 5. Unscrew the brake pedal hinge mounting bolt (1) and pull out the rod connecting pin (2). Then, remove the UUVW551A brake pedal (3) through the hole.
Page 199: Hand Throttle Disassembly
CHASSIS - DISASSEMBLY, SERVICE AND ASSEMBLY 3.4 HAND THROTTLE DISASSEMBLY UUVW552A UUVW573A Remove the seat(1). Lift the cargo bed and secure it. UUVW553A 9. If necessary, unscrew the front grill (lower) mounting UUVW567A screw and open the drain cock (1) to drain the coolant. Unscrew the mounting bolts (1) for the accelerator Then, disconnect the coolant hose and electric motor connector and unscrew the radiator mounting bolts (2)
Page 200 CHASSIS - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW566A Unscrew the accelerator lever mounting double nut and remove the nut (1), plain washer (2), plate spring (3), bracket (4), brake lining (5) and accel- erator lever (6). Assemble in reverse order of disassembly. IMPORTANT •...
Page 201: Components
CHASSIS - COMPONENTS 4. COMPONENTS 4.1 U030A ACCELERATOR PEDAL UUVW554A COMPONENTS (1) ARM ASSY, ACCEL PEDAL (6) SPRING, ACCEL PEDAL (11) ACCEL PEDAL CABLE (2) FOOT, ACCEL PEDAL (7) BRKT, ACCEL PEDAL MTG (12) CLAMP (3) PIN, HEAD (8) SPRING (13) BOLT, FLANGE (4) PIN, SNAP (9) WASHER, PLAIN...
Page 202: U0912A Hood
CHASSIS - COMPONENTS 4.2 U0912A HOOD UUVW574A COMPONENTS (1) HOOD ASSY(GREEN) (9) PLATE, FIXED (17) PIN, SPLIT (2) HOOD(GREEN) (10) TAPPING SCREW (18) BOLT, WASHER (3) HOOD HINGE LH ASSY (11) STRAP,HOOD LATCH (19) NUT, FLANGE (4) HOOD HINGE RH ASSY (12) BOLT, FLANGE (20) HOOD LINER (5) TAPPING SCREW...
Page 203: U0200A Structure
CHASSIS - COMPONENTS 4.3 U0200A STRUCTURE UUVW575A COMPONENTS (1) STRUCTURE ASSY (9) SCREW (BLACK) (16) FLANGE BOLT (2) STEERING COVER ASSY (10) STAY ROD BRKT (17) SUPPORT FLOOR FRAME ASSY (3) BOLT (11) NUT, FLANGE (18) RUBBER, CUSHION (4) NUT, FLANGE (12) NOISE PLATE (19) BOLT (5) BOLT, FLANGE...
Page 204: U630A Lever
CHASSIS - COMPONENTS 4.4 U630A LEVER UUVW557A COMPONENTS (1) SELECTOR SHIFT LEVER ASSY (19) NUT (37) KNOB ASSY, DIFF LOCK (2) LOWER ARM ASSY, SELECTOR (20) 4WD LEVER ASSY (38) BOLT, SCREW (3) BUSHING, SHIFT LEVER (21) GRIP (39) TUBE, LOCK LEVER (4) SPRING, SHIFT LEVER RETURN (22) BOLT,SCREW (40) SPRING, ROD...
Page 205: U0900A Molding
CHASSIS - COMPONENTS 4.5 U0900A MOLDING UUVW576A COMPONENTS (1) FENDER, FR LH (8) PANEL WHEEL WELL, LH (15) OIL CHECK COVER ASSY (2) FENDER, FR RH (9) PANEL WHEEL WELL, RH (16) BOLT (3) FENDER MIDDLE OUTER, LH (10) MAIN FLOOR ASSY FR (17) PARKING LEVER COVER (4) COVER, BATTERY (11) NUT, SPRING...
Page 206: U670A Engine Mounting
CHASSIS - COMPONENTS 4.6 U670A ENGINE MOUNTING UUVW559A COMPONENTS (1) ENGINE MOUNTING FRONT BRACKET ASSY (15) TM MOUNTING BRACKET ASSY, FR (2) ENGINE MOUNTING FRONT BRACKET ASSY (16) WASHER BOLT (3) DAMPER, ROLL MOUNTING (17) BRACKET, TM MOUNTING REAR (4) REAMER BOLT, FLANGE (18) BOLT (5) NUT (19) WASHER, PLAIN...
Page 207: U0922A Deck
CHASSIS - COMPONENTS 4.7 U0922A DECK UUVW577A COMPONENTS (1) DECK ASSY(BLACK) (8) PIN, SPLIT (15) NUT, FLANGE (2) DECK UNDER BUMPER (9) PIN, SNAP (16) FENDER (3) TAILGATE ASSY(BLACK) (10) DECK POLE COVER (17) FLANGE BOLT (4) TAILGATE HINGE BRACKET(BLACK) (11) REAMER BOLT, FLANGE (18) FLANGE NUT (5) BOLT, WASHER...
Page 208: U1000A Gas Cylinder
CHASSIS - COMPONENTS 4.8 U1000A GAS CYLINDER UUVW578A COMPONENTS (1) BRKT, GAS SPRING (6) COLLAR, GAS SPRING (11) JOINT PIN (2) BOLT, FLANGE (7) BOLT (12) WASHER, PLAIN (3) NUT (8) WASHER, PLAIN (13) PIN, SNAP (4) BRACKET, STOPPER (9) NUT, FLANGE (5) BOLT, FLANGE (10) GAS SPRING SUUV-W00 Apr.
Page 209: U0225A Rops
CHASSIS - COMPONENTS 4.9 U0225A ROPS UUVW579A COMPONENTS (1) FRAME FRONT ASSY (6) BOLT (11) NUT (2) REAR FRAME ASSY (7) WASHER (12) BOLT (3) FRAME MIDDLE (8) BOLT (13) BOLT, WASHER (4) BOLT (9) WASHER (14) BOLT, FLANGE (5) FLANGE NUT (10) WASHER,SPRING (15) CLAM, WIRE SUUV-W00 Apr.
Page 210: U0811A Seat
CHASSIS - COMPONENTS 4.10 U0811A SEAT UUVW580A COMPONENTS (1) SEAT CUSHION ASSY (5) BUCKLE (9) BOLT (2) SEAT BACK ASSY (6) SEAT BELT ASS'Y (10) NUT (3) FLANGE BOLT (7) BUCKLE (11) SEAT RUBBER MOUNT (4) SEAT BELT ASSY(3PT) (8) SAFETY BELT(CTR) SUUV-W00 Apr.
Page 211 REAR AXLE CHAPTER 7 TABLE OF CONTENTS 1. SPECIFICATIONS ........7-2 5. DISASSEMBLY, SERVICE AND ASSEMBLY ........... 7-14 1.1 Rear axle case oil ........7-2 5.1 Rear axle case removal 1.2 Tightening torque ........7-2 (Rear axle disassembly) ....... 7-14 1.3 Suspension ...........
Page 212: Specifications
REAR AXLE - SPECIFICATIONS 1. SPECIFICATIONS 1.1 REAR AXLE CASE OIL Type Capacity Remarks SAE gear oil #90 or DAEDONG : UTF55 Exxon : Mobil Fluid 423 or 424 0.8ℓ / 0.2 u.s gal : Tractran UTH Shell : DONAX-TD Rear wheel drive universal joint Grease: NLGL grade No.2 or equivalent Sufﬁ...
Page 213: Structure And Function
REAR AXLE - STRUCTURE AND FUNCTION 2. STRUCTURE AND FUNCTION 2.1 STRUCTURE OF REAR AXLE SECTION T2185-43861 Differential lock OFF Differential lock ON 4T-32009X 37300-2817-2 UUVW601A COMPONENTS (1) 10 spiral bevel pinion (4) 37 spiral bevel gear (2) Rear wheel drive shaft assembly (RH) (5) Rear wheel drive shaft assembly (LH) (3) Rear differential assembly (6) Differential shift...
Page 214: Rear Axle Power Transfer Diagram
REAR AXLE - STRUCTURE AND FUNCTION 2.2 REAR AXLE POWER TRANSFER DIAGRAM 6304 6205 6205 6205 19 HEX 6305 6204 UUVW680A SUUV-W00 Apr. 2011...
Page 215 REAR AXLE - STRUCTURE AND FUNCTION T2185-43861 Differential lock OFF Differential lock ON 4T-32009X 37300-2817-2 UUVW602A As power is transferred through the rear propeller shaft from the transmission case, this power drives the 37 spiral bevel gear (2) through the 10 spiral bevel pinion (1) resulting in deceleration. Then, this power is transferred to the differential case (3), differential pinion (4), differential side gear (5) and rear wheel drive shaft (6) in order to drive the rear wheels.
Page 216: Operating Principle Of Differential System
REAR AXLE - STRUCTURE AND FUNCTION 2.3 OPERATING PRINCIPLE OF DIFFERENTIAL SYSTEM In this case, both racks refer to the differential side gears and the pinion refers to the differential pinion. Also, the force that pulls up the pinion is the rotating force of the ring gear.
Page 217: Operating Principle Of Differential Lock System
REAR AXLE - STRUCTURE AND FUNCTION 2.4 OPERATING PRINCIPLE OF DIFFERENTIAL LOCK SYSTEM T2185-43861 Differential lock OFF Differential lock ON 4T-32009X 37300-2817-2 UUVW603A The differential lock system is to solve such problems as described on the previous page. When the differential lock lever is operated, the differential lever (1) in the ﬁ gure rotates and the rotating shift arm (2) moves the differential fork (3) which then moves the differential shift (4) to lock the differential system.
Page 218: Troubleshooting
REAR AXLE - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Cause Service • Check the differential lock links, Impossible to disengage differen- • Insufﬁ ciently lubricated links for differen- differential lock lever and shift for tial lock system tial lock or improperly adjusted cable deformation or breakage and ad- just or replace them if necessary.
Page 219: Inspection And Adjustment
REAR AXLE - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 DIFFERENTIAL SYSTEM ASSEMBLY BACKLASH ADJUSTMENT UUVW604A UUVW605A Set the lever-type dial gauge as shown in the ﬁ gure 3. Set the lever-type dial gauge as shown in the ﬁ gure and measure the backlash while turning the dif- and set the sensor to contact with the splined sec- ferential pinion gently with the contact pin touched...
Page 220 REAR AXLE - INSPECTION AND ADJUSTMENT 6. The total amount of the shims in the section (1) and TURNING TORQUE ADJUSTMENT (2) should never be changed. Shim type: 0.1 mm (0.0039 in.) 0.2 mm (0.0079 in.) 0.4 mm (0.0157 in.) 0.8 mm (0.0315 in.) Standard shim 1.0 mm (0.0394 in.) 1.2 mm (0.0472 in.)
Page 221 REAR AXLE - INSPECTION AND ADJUSTMENT TOOTH CONTACT CHECK REMARK • The pre-load of the taper roller bearing, that T2185-43861 supports the spiral bevel pinion shaft, can be adjusted by tightening its mounting nut. (Refer to the diagram in this chapter.) The standard pre- load is deﬁ...
Page 222 REAR AXLE - INSPECTION AND ADJUSTMENT • HEEL CONTACT CONTACT CHECK AND SHIM ADJUSTMENT Ring gear : Spiral bevel gear T2185-43861 T85W615A If the contact mark is close to the heel of the ring gear teeth, decrease the shims (A) on the ring gear side, increase the amount of shims (B) to push the ring gear (2) away from the pinion (1) and increase the amount of shims (C) so that the backlash is maintained.
Page 223 REAR AXLE - INSPECTION AND ADJUSTMENT 2. Differential case, cover and differential side gear CLEARANCE CHECK UUVW612A UUVW610A UUVW613A UUVW611A Differential pinion and differential pinion shaft a. Measure the I.D. of the differential pinion and O.D. of the differential pinion shaft. b.
Page 224: Differential Lock Cable Length
REAR AXLE - INSPECTION AND ADJUSTMENT / DISASSEMBLY, SERVICE AND ASSEMBLY 5. DISASSEMBLY, SERVICE AND ASSEMBLY 4.2 DIFFERENTIAL LOCK CABLE LENGTH 5.1 REAR AXLE CASE REMOVAL (REAR AXLE DISASSEMBLY) Park the vehicle on ﬁ rm and level ground, stop the engine and apply the parking brake.
Page 225 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW617A UUVW684A • Pull out the rear cargo bed frame mounting snap pin (1) Disconnect the brake ﬂ uid hose (1) and remove the and remove the pins (2) on both sides. upper/lower rear arm mounting bolts (2) (M10, 2 EA) and strut assembly mounting bolt (3) (M8, 1 EA) using the 14 mm and 12 mm spanners.
Page 226 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY IMPORTANT UUVW622A UUVW624A • The splined end of the CV joint is equipped with Disconnect the bleeder hose (1) and differential the inner-extensible snap ring. When removing lock cable (2) and unscrew the mounting bolts (3) the CV joint, apply impact to the CV joint gently (M10, 4 EA) with the 14 mm socket wrench to re- with a lever to remove it.
Page 227: Rear Axle Case Disassembly And Assembly
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 REAR AXLE CASE DISASSEMBLY AND ASSEMBLY UUVW625A UUVW627A Unscrew the rear axle case mounting bracket bolts (1) (M10, 13 EA) using the 14 mm socket wrench to remove the brackets (LH/RH). IMPORTANT UUVW628A Pull out the differential lock shifter (1) and unscrew the rear axle case mounting bolts (2) (M8, 7 EA)
Page 228 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW630A UUVW633A Unfold the tab part of the shift arm shaft tongue washer (1) and remove the shift arm shaft (3) and shift hook (4) by pulling the shift arm shaft. Be careful not to miss the O-ring and check its con- dition.
Page 229 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW635A When removing the outer wheels of the taper roller Assemble in the reverse order of disassembly. bearings from the rear axle case and rear axle case cover, keep the adjusting shims (1) in a safe place IMPORTANT so that they can be ﬁ...
Page 230: Rear Differential System Disassembly And Assembly
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3 REAR DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY UUVW636A UUVW637A Unscrew the differential case mounting bolts (1) (M10, 8 EA) to remove the side gear cover (2), spiral bevel gear (3) and differential case (4) in order. ( If necessary, remove the taper roller bearings (LH/RH).) UUVW639A Pull out the spring pins (1) from the differential case and tap the differential pinion shaft (2) to remove...
Page 231 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY ▶ ASSEMBLY IMPORTANT UUVW640A UUVW642A Put the differential washer (1) into the differential case. Then, install the differential side gear (2). S76W668A • Make sure that the washer protrusion of the differential pinion is seated to the groove of the differential case.
Page 232: Rear Axle Replacement
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.4 REAR AXLE REPLACEMENT UUVW644A UUVW646A Insert the differential washer (1) into the side gear Unscrew the brake caliper mounting bolts (1) (M8, cover and install the side gear (2). Then, ﬁ t this as- 2 EA) to remove the brake caliper (2).
Page 233: Cv Joint Boot Replacement
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.5 CV JOINT BOOT REPLACEMENT UUVW686A UUVW651A Unscrew the rear arm upper/lower mounting bolts Remove the rubber bellows band from the rear axle (1) (M10, 2 EA) and strut assembly mounting bolt (2) assembly.
Page 234 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW654A UUVW657A When installing the band, align the band with the boot mounting groove, nip the protrusion, pull the outer band and hook the band to the hook. UUVW658A Pull out the snap ring (1). Then, remove the ball joint guide (2), case (3), ball (4) and rubber bellows (5) in order.
Page 235 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 참고 REMARK IMPORTANT • • • • • • • • • • UUVW624A • UUVW681A • When installing the rear axle drive shaft to the • Only the CV joint (1) on the differential case side rear axle case, be careful not to miss the O-ring can be removed.
Page 236: Suspension Assembly Removal
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.6 SUSPENSION ASSEMBLY REMOVAL UUVW660A UUVW663A Unscrew the strut mounting bolts (1) (M8, 2 EA) with When assembling the rear suspension, tighten the 14 mm and 12 mm spanners and remove the each tightening section to the specified torque. ①.
Page 237: Rear Carrier Replacement
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.7 REAR CARRIER REPLACEMENT UUVW664A UUVW686A Set a hydraulic jack under the rear frame as a sup- Remove the upper/lower rear arm mounting bolts (1) port and remove the rear wheels. and carrier assembly mounting bolt (2). UUVW665A UUVW688A Unscrew the brake caliper mounting bolts (1) to remove...
Page 238: Rear Propeller Shaft Replacement
REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.8 REAR PROPELLER SHAFT REPLACEMENT Park the vehicle on level ground, apply the parking brake and stop the engine. UUVW673A Loosen the left and right mounting bolts (1) (M8, 4 EA) for the stabilizer. UUVW689A Raise and support the cargo bed.
Page 239 REAR AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY Assemble in the reverse order of disassembly. When assembling the components, tighten the brake disc mounting bolts first to install the disc. Then, ﬁ t the spring pin to secure the propeller shaft. REMARK UUVW675A •...
Page 240: Components
REAR AXLE - COMPONENTS 6. COMPONENTS 6.1 U200A REAR AXLE DRIVE SHAFT UUVW676A COMPONENTS (1) DRIVE SHAFT ASSY, RR-LH (5) DRIVE SHAFT ASSY, RR-RH (2) BOOT REPAIR KIT FRT O/B (W/ GREASE) (6) WASHER, PLAIN (3) BOOT REPAIR KIT FRT I/B (W/ GREASE) (7) PIN, SPLIT (4) NUT SUUV-W00 Apr.
Page 241: U210A Rear Differential System
REAR AXLE - COMPONENTS 6.2 U210A REAR DIFFERENTIAL SYSTEM UUVW677A COMPONENTS (1) REAR AXLE CASE ASSY (20) WASHER, DIFF.3 (39) SHIM (2) CASE, REAR AXLE (21) WASHER, DIFF. (40) SHIM(1.2) (3) COVER, REAR AXLE CASE (22) WASHER, DIFF. (41) BEARING, TAPER ROLLER (4) O RING (23) PINION (42) SHIM 0.6...
Page 242: U680A Rear Differential
REAR AXLE - COMPONENTS 6.3 U680A REAR DIFFERENTIAL UUVW678A COMPONENTS (1) REAR DIFF BRACKET ASSY, RH (4) BUSHING, CENTERING (7) BOLT (2) OIL SEAL(38*54*9.5) (5) NUT (3) REAR DIFF BRACKET ASSY, RH (6) BOLT SUUV-W00 Apr. 2011...
Page 243: U0510A Rear Suspension
REAR AXLE - COMPONENTS 6.4 U0510A REAR SUSPENSION 18 19 UUVW690A COMPONENTS (1) STRUT ASSY, RR (14) WASHER, SPRING (29) BOLT, UPR ARM MTG TO CARRIER (M10X110) (2) STRUT ASSY, RR (15) ARM ASSY-UPR-RR (30) BOLT, LWR ARM MTG TO CARRIER (3) SPRG SEAT, UPR RR (16) BUSHING, ARM (M10X135)
Page 244 MEMO...
Page 245 BRAKE CHAPTER 8 TABLE OF CONTENTS 1. SPECIFICATIONS ........8-2 5. DISASSEMBLY, SERVICE AND ASSEMBLY ..........8-9 1.1 General speciﬁ cations ......8-2 5.1 Rear wheel brake removal 1.2 Tightening torque ........8-2 (brake pad and disc replacement) ..8-9 2.
Page 246: Specifications
BRAKE - SPECIFICATIONS 1. SPECIFICATIONS 1.1 GENERAL SPECIFICATIONS Item Speciﬁ cation Remarks Hydraulically operated pedal type Brake type caliper disc Brake pedal free play 15 ~ 20 mm (0.59 ~ 0.79 in.) Speciﬁ cation for new component: Allowable min. brake disc thickness 3.5 mm (0.318 in.) 4.0 mm (0.157 in.) Speciﬁ...
Page 247: Structure And Function
BRAKE - STRUCTURE AND FUNCTION 2. STRUCTURE AND FUNCTION 2.1 FRONT AND REAR WHEEL BRAKES UUVW701A Piston UUVW743A When the brake pedal (1) is depressed, the master cylinder rod (2) pushes the master cylinder piston to deliver the brake ﬂ uid in the slave cylinder to each wheels. This brake ﬂ...
Page 248: Parking Brake
BRAKE - STRUCTURE AND FUNCTION 2.2 PARKING BRAKE Cam plate UUVW751A UUVW752A Operation Braking force generated UUVW744B When the parking brake lever is pulled up, the cam lever (3) is rotated by the cable. The cam lever and bracket (4) are equipped with the steel ball pockets and the steel ball is seated in center in a normal state as shown in the ﬁ...
Page 249: Troubleshooting
BRAKE - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Cause Solution • Replace the part. • Excessively worn brake disc or pad Vehicle pulls to one side • Replace the part. when depressing the brake • Damaged brake link • Check and replace the tube line. pedal •...
Page 250: Inspection And Adjustment
BRAKE - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 BRAKE DISC THICKNESS 4.2 BRAKE DISC RUNOUT UUVW703A UUVW704A Measure the thickness of the front/rear brake discs Set a dial gauge on top of the lower arm of the rear with a micrometer.
Page 251: Caliper Pad Clearance And Thickness
BRAKE - INSPECTION AND ADJUSTMENT 4.3 CALIPER PAD CLEARANCE AND THICKNESS 4.4 BRAKE LAMP SWITCH INSTALLATION CLEARANCE (OPTIONAL) UUVW705A UUVW710A When installing the brake lamp switch, release the brake pedal and set the distance from the brake lamp switch contact to the pressing plate with the plate fully pressed to be within 1 mm.
Page 252: Parking Brake Wire Installation (Length Adjustment)
BRAKE - INSPECTION AND ADJUSTMENT 4.6 BRAKE PEDAL FREE PLAY 4.5 PARKING BRAKE WIRE INSTALLATION (LENGTH ADJUSTMENT) UUVW711A UUVW712A Connect the parking brake cable to the caliper. Adjust the free play while pressing the brake pedal with a hand gently. Pull the parking brake lever fully until a clicking Proper free play: 15 ~ 20 mm (0.59 ~ 0.79 in.) sound is heard for 7 to 8 times and secure the ad-...
Page 253: Disassembly, Service And Assembly
BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY 5. DISASSEMBLY, SERVICE AND ASSEMBLY 5.1 REAR WHEEL BRAKE REMOVAL (BRAKE PAD AND DISC REPLACEMENT) UUVW754A UUVW720A Unscrew the brake caliper mounting bolts (1) (M8, 2 EA) to remove the brake caliper (2) from the brake disc assembly (3).
Page 254 BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW722A UUVW725A If necessary, pull out the guide forward and remove the spring. UUVW723A Unscrew the hexagon screws (1) from the brake caliper and remove the mounting screws (2) using UUVW726A the 6 mm hex. wrench. For assembly, insert the spring (2) into the caliper body (1), ﬁ...
Page 255: Front Wheel Brake Removal (Brake Pad And Disc Replacement)
BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 FRONT WHEEL BRAKE REMOVAL (BRAKE PAD AND DISC REPLACEMENT) IMPORTANT UUVW755A UUVW727A • When connecting the brake hose to the caliper, insert the copper washers (1) to the both ends and tighten it to the speciﬁ ed torque. The copper washers should be replaced with new ones during sassembly.
Page 256: Brake Master Cylinder Disassembly
BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3 BRAKE MASTER CYLINDER DISASSEMBLY UUVW729A UUVW730A Unscrew the front/rear brake fluid pipe connector Unscrew the screw (1) and tap the brake ﬂ uid res- nuts (1). Then, unscrew the mounting bolts (2) (M8, ervoir upward to remove it.
Page 257: Bleeding Brake Line
BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.4 BLEEDING BRAKE LINE IMPORTANT • When connecting the brake pipe, place its connector section to the mounting surface, tighten its nut to the specified torque with an open end wrench. Speciﬁ ed torque for nut ....16.0 ~ 21.0 Nm 1.6 ~ 2.1 kgf-m 11.8 ~ 15.4 lb-ft...
Page 258 BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW716A When the brake ﬂ uid is drained through the bleed- ing pipe, there are air bubbles in the ﬂ uid. Drain the brake fluid until there is no bubbles. Then, tighten the bleeding pipe and close the cap (1). Bleed the front and rear brakes with the same proce- dures.
Page 259: Parking Brake Disassembly And Assembly (Parking Brake Pad Replacement)
BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.5 PARKING BRAKE DISASSEMBLY AND ASSEMBLY (PARKING BRAKE PAD REPLACEMENT) UUVW757A Assemble in the reverse order of disassembly. UUVW758A Unscrew the parking brake caliper mounting nuts (1) UUVW759A (M10, 2 EA) to remove the bracket (2), ball (3), cam lever (4), support plates (5), pad (6), spring (7) and •...
Page 260 BRAKE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW760A UUVW762A • Fit the other pad (1) to the bolts and place the sup- • Fit the bracket (1) to the bolts and tighten the nuts (2). port plates (2) as a ﬁ gure. IMPORTANT UUVW761A UUVW705A...
Page 261: Components
BRAKE - COMPONENTS 6. COMPONENTS 6.1 U300A FRONT BRAKE 3 = 5 + A + B 15 = 17 + A + B UUVW740A COMPONENTS (1) CALIPER ASSY, LH (14) PAD, COMP (27) BOLT(M10x1.25), HUB (40) TUBE, FRT BRAKE RH (2) PAD, COMP (15) CARRIER ASSY DIFF (28) DISC, BRAKE FRT...
Page 262: U0431A Packing Backe
BRAKE - COMPONENTS 6.2 U0431A PARKING BRAKE UUVW763A COMPONENTS (1) PARKING BRAKE ASSY (5) PIN, SNAP (9) CALIPER ASSY, PARK BRAKE (2) BOLT, WASHER (6) CLAMP (10) PAD, PARKING BRAKE (3) CABLE ASSY-PARKING (7) BOLT, FLANGE (11) DISK, PACKING BRAKE (4) JOINT PIN (8) NUT, FLANGE (12) BOLT, FLANGE...
Page 263 FRONT AXLE CHAPTER 9 TABLE OF CONTENTS 1. SPECIFICATIONS ........9-2 5. DISASSEMBLY, SERVICE AND ASSEMBLY ........... 9-13 1.1 General speciﬁ cations ......9-2 5.1 CV joint removal ........9-13 1.2 Tightening torque ........9-3 5.2 CV joint boot replacement ....9-15 1.3 Sealant and adhesive ......
Page 264: Specifications
FRONT AXLE - SPECIFICATIONS 1. SPECIFICATIONS 1.1 GENERAL SPECIFICATIONS Item Speciﬁ cations Remarks SAE gear oil #90 or DAEDONG UTF55 Exxon Mobil ﬂ uid 423/424 Tractran UTH Shell DONAX-TD Grease NLGL grade No.2 or equivalent Lower section of hub strut 0.5 ℓ...
Page 265: Tightening Torque
FRONT AXLE - SPECIFICATIONS 1.2 TIGHTENING TORQUE Position Size Tightening torque 39.2 ~ 45.1 Nm Front wheel mounting nut 4.0 ~ 4.6 kgf-m 28.8 ~ 33.1 lb-ft 54.0 ~ 61.0 Nm Slotted tie rod end nut 5.4 ~ 6.1 kgf-m 38.9 ~ 43.9 lb-ft 21.0 Nm Upper strut mounting nut...
Page 266: Structure And Function
FRONT AXLE - STRUCTURE AND FUNCTION 2. STRUCTURE AND FUNCTION 2.1 FRONT AXLE POWER TRANSFER DIAGRAM 6205 6304 6205 6205 19 HEX 6305 6204 UUVW801A SUUV-W00 Apr. 2011...
Page 267 FRONT AXLE - STRUCTURE AND FUNCTION 23x21x1.0 23x21x1.0 6005 6005 6010 6010 38440-4424-0 UUVW802A • As the power is transferred from the transmission through the front propeller shaft, it is passed to the differential case through the 8 bevel pinion shaft and 34 bevel gear. Then, the internal bevel gear is rotated by the rotating differential case and the power is transferred to the front wheel drive shaft, which is connected to the differential side gear, in order to drive the front wheels.
Page 268: Lsd (Limited Slip Device)
FRONT AXLE - STRUCTURE AND FUNCTION 2.2 LSD (LIMITED SLIP DEVICE) 23x21x1.0 23x21x1.0 6005 6005 6010 6010 38440-4424-0 UUVW803A The rear axle is equipped with the manual differential lock as a dog clutch while the front axle is equipped with the automatic LSD (Limited Slip Differential).
Page 269: Troubleshooting
FRONT AXLE - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Cause Solution • Uneven tire pressure • Adjust Front wheels wander to • Improperly adjusted toe-in (improper wheel alignment) • Adjust right or left • Loose tie rod end • Tighten • Broken drive shaft •...
Page 270: Inspection And Adjustment
FRONT AXLE - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 TOE-IN ADJUSTMENT 4.2 TURNING TORQUE OF 8 BEVEL PINION SHAFT UUVW804A After tying the pinion shaft with a string, measure the load by pulling the string down with a pull scale. Load of pull scale ..
Page 271: Backlash Of Differential Pinion And Differential Side Gear
FRONT AXLE - INSPECTION AND ADJUSTMENT 4.3 BACKLASH OF DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR REMARK • The pre-load of the taper roller bearing, that supports the spiral bevel pinion shaft, can be adjusted by tightening its mounting nut. (Refer to the diagram in this chapter.) The standard pre- load is deﬁ...
Page 272: Backlash Of 8 Bevel Pinion Shaft And 34 Bevel Gear
FRONT AXLE - INSPECTION AND ADJUSTMENT 4.4 BACKLASH OF 8 BEVEL PINION SHAFT AND 34 BEVEL GEAR 4. Replace the collars (4) and (5) installed to the front and rear sides of the shaft if the 8 spiral bevel pin- ion shaft (6) should be moved.
Page 273: Tooth Contact Of Spiral Bevel Gear
FRONT AXLE - INSPECTION AND ADJUSTMENT 4.5 TOOTH CONTACT OF SPIRAL BEVEL GEAR INSPECTION ADJUSTMENT A. TOE CONTACT Ring gear (34 Spiral bevel gear) 23x21x1.0 23x21x1.0 6005 6005 6010 6010 T46W819A If the center of the contact mark is too close to the toe of the tooth, push back the pinion shaft and push in the ring gear to the pinion direction so that the back lash is maintained.
Page 274: Differential System Clearance Check
FRONT AXLE - INSPECTION AND ADJUSTMENT 4.6 DIFFERENTIAL SYSTEM CLEARANCE CHECK 4.6.1 DIFFERENTIAL PINION AND DIFFERENTIAL PINION SHAFT C. DEEP CONTACT T46W821A If the contact mark is deep into the ring gear teeth, push the ring gear away from the pinion. If necessary, UUVW809A push the pinion toward the ring gear to maintain the backlash.
Page 275: Differential Case, Spiral Bevel Gear
FRONT AXLE - INSPECTION AND ADJUSTMENT / DISASSEMBLY, SERVICE AND ASSEMBLY 4.6.2 DIFFERENTIAL CASE, SPIRAL BEVEL GEAR 5. DISASSEMBLY, SERVICE AND ASSEMBLY AND DIFFERENTIAL SIDE GEAR 5.1 CV JOINT REMOVAL Oil ﬁ lling plug Oil drain plug UUVW811A UUVW814A Park the vehicle on ﬁ rm and level ground, stop the en- gine and apply the parking brake.
Page 276 FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW874A UUVW875A Unscrew the brake caliper (1) mounting bolts (M8, 2 EA) Remove the slotted nut (1) and split pin under the tie to remove the brake caliper. rod end mounting bolt as well as the slotted nut (2) and split pin under the front knuckle mounting bolt to separate the tie rod end and lower arm.
Page 277: Cv Joint Boot Replacement
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 CV JOINT BOOT REPLACEMENT UUVW821A UUVW823A Remove the O-ring (1) and snap ring (2) from the front axle drive shaft assembly. Then, tap the bearing hold- er to remove the ball bearing (3) and bearing holder (4). UUVW822A Unscrew the front axle drive shaft bearing holder mounting bolts (1) (M8, 3 EA) using the 12 mm socket...
Page 278 FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY IMPORTANT If necessary, pull out the snap ring and remove the ball joint guide, case, ball and rubber bellows in order. • During installation, make sure that the larger (Refer to "Rear axle drive shaft disassembly" in this opening of the CV joint (3) cup is inserted into the chapter.) housing (4) ﬁ...
Page 279: Front Differential Case Removal
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3 FRONT DIFFERENTIAL CASE REMOVAL IMPORTANT Remove the front wheels. Then, remove the front axle drive shaft assemblies (LH/RH). (For the removal pro- cedures, refer to "5.1 Front axle disassembly.") IMPORTANT UUVW831A • During assembly, set the spring length "A"...
Page 280 FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW834A UUVW837A Unscrew the radiator drain cock to drain the coolant (referring to "Engine removal" in chapter 2). Then, undo the coolant hose connecting clamp to disconnect the coolant hose, and disconnect the cooling fan mo- tor connector (1).
Page 281: Front Differential Case Disassembly And Assembly
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.4 FRONT DIFFERENTIAL CASE DISASSEMBLY AND ASSEMBLY UUVW839A UUVW841A Unscrew the front differential case mounting bolts (1) (M10, 7 EA) with the 14 mm socket wrench. Bolt speciﬁ ed torque ..39.2 ~ 44.1 Nm 4.0 ~ 4.5 kgf-m 28.8 ~ 32.4 lb-ft UUVW842A...
Page 282: Differential System Disassembly And Assembly
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.5 DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY 5.5.1 DIFFERENTIAL SYSTEM DISASSEMBLY UUVW843A UUVW845A Remove the clutch assembly (1) from the front differ- ential assembly. UUVW846A Unscrew the spiral bevel gear mounting bolts (1) (M8, UUVW844A 6 EA) with the 12 mm socket wrench and remove the Remove the ball bearing (1) from the front differential...
Page 283: Differential System Assembly
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.5.2 DIFFERENTIAL SYSTEM ASSEMBLY UUVW848A UUVW851A Fit the straight pin (1) and knock pin (2) into the spiral Insert the differential washer (1) and side gear (2) into bevel gear. the spiral bevel gear. UUVW849A UUVW852A Insert the differential washer (1) and side gear (2) into...
Page 284: Lsd Disassembly And Assembly
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.6 LSD DISASSEMBLY AND ASSEMBLY UUVW853A UUVW855A Tap the ball bearings (1) onto the front and back. Take out the snap ring (1). IMPORTANT UUVW854A UUVW856A • When installing the snap ring to the clutch Tap the clutch assembly into the case with a rubber hammer.
Page 285: Front Axle Knuckle Assembly Disassembly And Assembly (Front Knuckle Replacement)
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.7 FRONT AXLE KNUCKLE ASSEMBLY DISASSEMBLY AND ASSEMBLY (FRONT KNUCKLE REPLACEMENT) UUVW857A UUVW879A Remove the spring seating plate (2), spring (3), spring seating plate (4), clutch discs (5), clutch plates (6) and case (7) in order. Assemble in the reverse order of disassembly.
Page 286 FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW861A UUVW864A Unscrew the mounting nut (9) with the 19 mm spanner Unscrew the ball joint bracket mounting screws and and remove the spring seat (10), spring (11) and bum- separate the bracket (15) and ball joint (16). per stopper (12).
Page 287 FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW865A Assemble in the reverse order of disassembly. UUVW866A Place and install the front wheel shock absorber onto the knuckle. Then, tighten the mounting nut (1) to set the spring length "A" to be 328 ± 3 mm. SUUV-W00 Apr.
Page 288: Propeller Shaft(Front Universal Joint) Replacement
FRONT AXLE - DISASSEMBLY, SERVICE AND ASSEMBLY 5.8 PROPELLER SHAFT(FRONT UNIVERSAL JOINT) REPLACEMENT UUVW867A Remove the propeller shaft mounting spring pin (1) on the front axle case side by tapping it. UUVW868A Pull the propeller shaft toward the transmission to separate it from the front axle case.
Page 289: Components
FRONT AXLE - COMPONENTS 6. COMPONENTS 6.1 U100A FRONT AXLE DRIVE UUVW869A COMPONENTS (1) FRONT DRIVE SHAFT, LH (7) O RING (13) BEARING,BALL (2) BOOT REPAIR KIT FRT O/B (8) FRONT DRIVE SHAFT, RH (14) O RING (W/ GREASE) (9) BOOT REPAIR KIT FRT O/B (15) WASHER BOLT (3) BOOT REPAIR KIT FRT I/B (W/ GREASE)
Page 290: U110A Front Diff. Case
FRONT AXLE - COMPONENTS 6.2 U110A FRONT DIFF. CASE UUVW870A COMPONENTS (1) FRONT AXLE CASE ASSY (19) GEAR, DIFF. SIDE (37) BEVEL PINION SHAFT 8 (2) CASE, FRONT AXLE (20) SHIM 0.8 (38) COLLAR (3) COVER, FRONT CASE (21) SHIM 1.0 (39) COLLAR (4) BOLT (22) SHIM 1.2...
Page 291: U0500A Front Suspension
FRONT AXLE - COMPONENTS 6.3 U0500A FRONT SUSPENSION UUVW881A COMPONENTS (1) STRUT ASSY, FRT (13) KUNCKLE ASSY-FR-LH (25) BUSHING, ARM (2) NUT, STRUT TOP MTG (14) BRACKET, B/JOINT (26) BUSH (3) WASHER (15) BOLL JOINT ASSY, FR LWR (27) ARM-LWR-FR-RH (4) SPACER, RUBBER (16) BOLT (28) BOLT...
Page 292 MEMO...
Page 293 STEERING SYSTEM CHAPTER 10 TABLE OF CONTENTS 1. SPECIFICATIONS ......... 10-2 5. DISASSEMBLY, SERVICE AND ASSEMBLY ........... 10-8 1.1 Steering gearbox ........10-2 5.1 Steering gearbox removal ....10-8 1.2 Tightening torque ......... 10-2 5.2 Steering column removal and installation ...10-9 2.
Page 294: Specifications
STEERING SYSTEM - SPECIFICATIONS 1. SPECIFICATIONS 1.1 STEERING GEARBOX Item Speciﬁ cations Remarks Type Manual (rack & pinion) Distance from tie rod end to end (from center of ball) 934.8± 1.5 mm (36.803 ± 0.059 in.) 1 ~ 1.5 Nm Average turning torque (0.102 ~ 0.153 kgf-m, 0.735 ~ 1.102 lb-ft ) Rotating ratio (rack moving distance...
Page 295: Structure And Function
STEERING SYSTEM - STRUCTURE AND FUNCTION 2. STRUCTURE AND FUNCTION 2.1 OPERATING SYSTEM DIAGRAM UUVW901A • When the steering wheel (1) is turned, the steering Finally, the steering gearbox moves the tie rods (5) wheel shaft (2), that its splined part is engaged with and knuckles (6) to steer the wheels to the left or the steering wheel, rotates and this movement is right.
Page 296: Structure In Steering Gearbox
STEERING SYSTEM - STRUCTURE AND FUNCTION 2.2 STRUCTURE IN STEERING GEARBOX UUVW902A COMPONENTS (1) PINION SHAFT (3) RACK SUPPORT (5) PLUG (2) RACK (4) SPRING (6) GEARBOX BODY In the steering gearbox, the pinion is engaged with the rack. When the pinion rotates, the rack moves to the side in a linear motion.
Page 297: Steering Gearbox Components
STEERING SYSTEM - STRUCTURE AND FUNCTION 2.3 STEERING GEARBOX COMPONENTS UUVW903A COMPONENTS (1) PLUG (5) RACK (9) SPRING (2) OIL SEAL (6) RACK GUIDE (10) PLUG (3) PINION SHAFT (7) STEERING GEARBOX (4) BALL BEARING (8) RACK SUPPORT SUUV-W00 Apr. 2011...
Page 298: Troubleshooting
STEERING SYSTEM - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Cause Solution Vehicle pulls to right or left • Improper front tire size, inﬂ ation pressure or • Adjust the inﬂ ation pressure shape or replace the tires • Worn or damaged tie rod end •...
Page 299: Inspection And Adjustment
STEERING SYSTEM - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 TIE-ROD LENGTH ADJUSTMENT 4.2 TOE-IN ADJUSTMENT Adjust the toe-in so that the distance between the front of the front wheels is 2 ~ 8 mm (0.079 ~ 0.315 in.) shorter than the distance between the rear of the front wheels.
Page 300: Disassembly, Service And Assembly
STEERING SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5. DISASSEMBLY, SERVICE AND ASSEMBLY 5.1 STEERING GEARBOX REMOVAL UUVW904A UUVW907A Unscrew the steering column mounting bolt (1) (M8, Unfold the caulked part of the holder (1) and rotate the 1 EA). Then, unscrew the gearbox mounting bolts ball joint (2) to separate the left and right ball joint as- (2) (M8, 3 EA) and bracket mounting bolts (3) (M8, 2 semblies from the steering gearbox.
Page 301: Steering Column Removal And Installation
STEERING SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 STEERING COLUMN REMOVAL AND INSTALLATION UUVW910A UUVW561A Remove the cap (1) and pull out the pinion shaft (2). Open and support the hood, disconnect the headlamp connector (1) and unscrew the ratchet mounting bolts (2) (M8, 4 EA) to remove the hood.
Page 302 STEERING SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW916A UUVW918A UUVW919A Remove the steering wheel cap (1) and unscrew the wheel mounting nut (M12, 1 EA) using the 17 mm socket wrench to remove the steering wheel. Mounting nut tightening torque ....48.0 ~ 55.9 Nm 4.9 ~5.7 kgf-m 35.3 ~ 41.2 lb·ft REMARK...
Page 303 STEERING SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY UUVW922A UUVW923A Remove the steering column assembly by tapping the steering shaft (1) downward. Then, unscrew the steer- ing column mounting bolt (2) (M8, 1 EA) with the 13 mm spanner to remove the steering column. Install in the reverse order of removal.
Page 304: Components
STEERING SYSTEM - COMPONENTS 6. COMPONENTS 6.1 U250A STEERING UUVW925A COMPONENTS (1) STEERING GEAR BOX ASSY (11) BOLT (21) NUT (2) GEAR BOX, STEERING (12) BOLT (22) RUBBER, CUSHION (3) NUT (13) WASHER BOLT (23) WASHER (4) CLIP, A (14) BOLT (24) HANDLE (5) BOOT LH (15) WASHER, PLAIN...
Page 305 HYDRAULIC SYSTEM CHAPTER 11 TABLE OF CONTENTS 1. SPECIFICATIONS ........11-2 5.2 Auxiliary hydraulic valve, dumping valve and front block (relief valve) disassembly and assembly ........11-21 2. OPERATING PRINCIPLE .......11-3 5.2.1 Valve removal ......11-21 2.1 Hydraulic component layout ....11-3 5.2.2 Auxiliary hydraulic valve 2.2 Hydraulic circuit ........
Page 306: Specifications
HYDRAULIC SYSTEM - SPECIFICATIONS 1. SPECIFICATIONS Item Speciﬁ cations Remarks Operating oil Daedong UTF55 Exxon Mobilﬂ uid 423 or 424 BP Tractran UTH Shell DONAX-TD 15.0 ℓ (3.96 u.s.gal.) Oil tank capacity 22.5 ℓ/min (5.94 u.s.gal./min) Gear pump capacity 10 cc/rev Gear pump discharge ﬂ...
Page 307: Operating Principle
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2. OPERATING PRINCIPLE 2.1 HYDRAULIC COMPONENT LAYOUT Supply line Return line UUVWB08A COMPONENTS (1) GEAR PUMP (3) DUMPING VALVE (5) DUMPING CYLINDER (2) OIL TANK (4) AUXILIARY HYDRAULIC VALVE SUUV-W00 Apr. 2011...
Page 308 HYDRAULIC SYSTEM - OPERATING PRINCIPLE UUVWB01A SUUV-W00 Apr. 2011...
Page 309: Hydraulic Circuit
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.2 HYDRAULIC CIRCUIT How to calculate hydraulic capacity: 10 cc/rev x 2800 rpm x 0.5x = 22.5 ℓ/min 1000 Cargo Bed Lift Cylinder Single Rod Double Acting Cylinder ID : Φ40mm Where; Rod ID : Φ25mm 0.5 : Fuel cam shaft speed ratio Stroke : 195mm 29 : Pump dive gear...
Page 310: Hydraulic Line
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.3 HYDRAULIC LINE 2.3.1 DUMPING OPERATION HYDRAULIC OIL FLOW DIAGRAM • As the gear pump (1) pushes out the hydraulic oil, the hy- draulic oil flows to the front block under the dumping valve (3). Then, it passes through the dumping valve and auxiliary hydraulic valve (if equipped) and then flows...
Page 311 HYDRAULIC SYSTEM - OPERATING PRINCIPLE CIRCUIT Cargo Bed Lift Cylinder End Cover Single Rod Double Acting Cylinder ID : Φ40mm Rod ID : Φ25mm Stroke : 195mm Detent Floating Valve ∅ 2.0 Front Block Relief Valve 155 kgf/cm 22.5lpm Gear Pump 10cc/rev Oil Tank 15 liter UUVWB03A...
Page 312: External Hydraulic Oil Operation
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.3.2 EXTERNAL HYDRAULIC OIL OPERATION HYDRAULIC OIL FLOW DIAGRAM UUVWB10A (1) GEAR PUMP (4) AUXILIARY HYDRAULIC VALVE (2) OIL TANK (5) HYDRAULIC HOSE P (3) FRONT BLOCK ASSEMBLY (6) QUICK COUPLER (PARKER) SUUV-W00 Apr. 2011...
Page 313 HYDRAULIC SYSTEM - OPERATING PRINCIPLE CIRCUIT Relief Valve 155 kgf/cm UUVWB04A UUVWB75B SUUV-W00 Apr. 2011...
Page 314: Gear Pump
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.4 GEAR PUMP MOUNTING LOCATION AND STRUCTURE UUVWB35A UUVWB36A UUVWB28A (1) REAR COVER (3) DRIVE GEAR SHAFT (5) SEAL BLOCK (2) SEAL BLOCK (4) DRIVEN GEAR (6) CASE SUUV-W00 Apr. 2011...
Page 315 HYDRAULIC SYSTEM - OPERATING PRINCIPLE Oil ﬂ ow (from oil tank) Oil supply (to valve) UUVWB11A • The hydraulic pump is driven by the fuel camshaft • The hydraulic pump is always driven as long as the in the engine. The fuel camshaft rotates at half engine is running to draw the oil from the oil tank speed of the engine.
Page 316: Dumping Cylinder
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.5 DUMPING CYLINDER MOUNTING LOCATION AND STRUCTURE UUVWB43A UUVWB34A UUVWB44A (1) TUBE (4) PISTON (7) O RING (2) ROD (5) SPRING WASHER (8) PISTON PACKING (3) HEAD COVER (6) NUT (9) WEAR RING The dumping cylinder is a double acting single-rod cylinder. Its rod outside diameter is 25mm (0.984 in.), its inside diameter is 40mm (1.57 in.), its outside diameter is 50mm (1.97 in.) and its stroke is 195mm (7.68 in.).
Page 317 HYDRAULIC SYSTEM - OPERATING PRINCIPLE STROKE 195 ± 1.0 ± 1.5 UUVWB13A (1) Head cover (3) Dust seal (5) O RING (7) Wear ring (2) DU bush (4) Rod seal (6) Piston packing (8) O RING ∅ 2.0 Oriﬁ ce Check valve UUVWB76A The hydraulic line on the lifting side of the dumping...
Page 318: Front Block (Dumping Valve)
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.6 FRONT BLOCK (DUMPING VALVE) MOUNTING LOCATION ANDSTRUCTURE UUVWB45A UUVWB37A FRONT BLOCK UUVWB46A (1) BODY (3) POPPET (5) COVER (2) SPOOL (4) SPRING SUUV-W00 Apr. 2011...
Page 319 HYDRAULIC SYSTEM - OPERATING PRINCIPLE DUMPING VALVE UUVWB47A (1) BODY (6) INTERNAL SPRING (11) ADAPTER (2) PLUG (7) EXTERNAL SPRING (12) DETENT HOUSING (3) SPOOL ASSEMBLY (8) ADJUSTING SCREW (13) BELLOWS (4) BALL (9) ADJUSTING NUT (14) LEVER (5) DETENT BALL (10) MOUNTING NUT (15) PIN UUVWB77A...
Page 320: Auxiliary Hydraulic Valve
HYDRAULIC SYSTEM - OPERATING PRINCIPLE 2.7 AUXILIARY HYDRAULIC VALVE MOUNTING LOCATION AND STRUCTURE UUVWB48A UUVWB38A UUVWB49A (1) BODY (4) SPRING (7) MOUNTING NUT (10) ADJUSTING NUT (2) PLUG (5) BALL (8) DETENT HOUSING (11) LEVER (3) SPOOL ASSEMBLY (6) DETENT BALL (9) ADJUSTING SCREW (12) PIN SUUV-W00 Apr.
Page 321 HYDRAULIC SYSTEM - OPERATING PRINCIPLE Supply port Return port UUVWB78B Even though the auxiliary hydraulic valve is a single acting type valve, it is equipped with one outlet port and one return port, which is distinct from the single acting valve in the tractor.
Page 322: Troubleshooting
HYDRAULIC SYSTEM - TROUBLESHOOTING 3. TROUBLESHOOTING Symptom Possible cause Remedy • Faulty hydraulic pump • Replace • Broken control valve or incorrect installation • Inspect or replace Impossible to extend dumping cylin- • Faulty relief valve • Inspect or replace der or slow extending speed •...
Page 323: Inspection And Adjustment
HYDRAULIC SYSTEM - INSPECTION AND ADJUSTMENT 4. INSPECTION AND ADJUSTMENT 4.1 MAIN RELIEF VALVE PRESSURE CAUTION Place the selector shift lever in the neutral posi- tion, start the engine and speed up the engine to its • Make sure to check the oil level and add oil if maximum.
Page 324: Disassembly, Service And Assembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5. DISASSEMBLY, SERVICE AND ASSEMBLY 5.1 GEAR PUMP DISASSEMBLY AND ASSEMBLY 5.1.1 GEAR PUMP REMOVAL 5.1.2 GEAR PUMP DISASSEMBLY Park the vehicle on level ground and apply the parking brake. Lift the cargo bed using the dumping operation le- ver and stop the engine.
Page 325: Auxiliary Hydraulic Valve, Dumping Valve And Front Block (Relief Valve) Disassembly And Assembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2 AUXILIARY HYDRAULIC VALVE, DUMPING VALVE AND FRONT BLOCK (RELIEF VALVE) DISASSEMBLY AND ASSEMBLY 5.2.1 VALVE REMOVAL Park the vehicle on level ground, stop the engine and apply the parking brake. UUVWB17A Remove the rear cover (1), seal block (2), drive gear shaft (3), driven gear (4), seal block (5) and UUVWB21A case (6) in order.
Page 326 HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY CAUTION REMARK • When disassembling or assembling the hydraulic valve or cover, be careful not to damage the O-ring and make sure to apply a sufficient amount of oil to the surface of the O-ring before installation.
Page 327: Auxiliary Hydraulic Valve Disassembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2.2 AUXILIARY HYDRAULIC VALVE DISASSEMBLY UUVWB24A UUVWB26A Unscrew the detent housing mounting nut (1) and remove the detent housing (2), ball (3) and spring (4). UUVWB25A Unscrew the adjusting nut (1) and remove the ad- justing screw (3) with the detent ball (2).
Page 328 HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY UUVWB82A Unscrew the plug (1) and pull out the spool (2). IMPORTANT • During disassembly and assembly, be careful not to damage the O-ring. If it is not intact, replace with a new one and apply a sufﬁ cient amount of oil on the new one before installation.
Page 329 HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY ● ASSEMBLY UUVWB32A UUVWB30A Fit the tool into the hole of the lever (1) as shown When installing the detent ball, insert the spring into in the ﬁ gure to ﬁ x the spool in position. Then, tap the spool, apply grease to the balls (1) and insert the detent housing with a hammer to screw it to the them to the three holes of the spool.
Page 330: Dumping Valve Disassembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2.3 DUMPING VALVE DISASSEMBLY UUVWB50A UUVWB53A Pull out the lever ﬁ xing pin (1) and pull up the lever (2) to remove it with the bellows (3). UUVWB51A Unscrew the adjusting nut (1) and remove the ad- justing screw (3) with the detent ball (2).
Page 331 HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY ● ASSEMBLY UUVWB59A UUVWB62A When installing the detent ball, apply grease to the Insert the springs (double) (1) into the spool as three balls (1) and insert them to the three holes of shown in the ﬁ...
Page 332 HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY REMARK UUVWB65A UUVWB68A • Turning the adjusting screw (1) counterclockwise Push the top of the detent ball with a tool to pass it increases the spool moving range, resulting through the three balls in the spool. Then, tighten in more oil flow and increase in the cargo bed the detent housing completely.
Page 333: Front Block (Relief Valve) Disassembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.2.4 FRONT BLOCK (RELIEF VALVE) DISASSEMBLY REMARK UUVWB55A UUVWB58A • Adjust the relief valve pressure by unscrewing Unscrew the plug (1) on the relief adjusting screw. the adjusting nut (1) and turning the adjusting screw (2).
Page 334: Dumping Cylinder Disassembly And Assembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3 DUMPING CYLINDER DISASSEMBLY AND ASSEMBLY 5.3.1 DUMPING CYLINDER REMOVAL Park the vehicle on level ground and apply the parking brake. Lift the cargo bed using the dumping operation le- ver and stop the engine. Place the support between the cargo bed and frame so that the cargo bed does not fall down ac- cidentally.
Page 335: Dumping Cylinder Disassembly
HYDRAULIC SYSTEM - DISASSEMBLY, SERVICE AND ASSEMBLY 5.3.2 DUMPING CYLINDER DISASSEMBLY IMPORTANT UUVWB71A UUVWB74A • When installing the head cover, check the condition of the O-ring (1). If it is not intact, replace with a new one and apply a sufficient amount of oil on the new one before installation.
Page 336: Exploded View
HYDRAULIC SYSTEM - EXPLODED VIEW 6. EXPLODED VIEW 6.1 U1300A HYDRAULIC DUMPING 24 27 86 85 87 30 31 UUVWB05A COMPONENTS (1) TANK, HYD ASSY (32) ELBOW (63) CONNECTOR A (2) NUT (33) BLOCK ASSY, FR (64) LEVER 1 (3) BUSHING - RADIATOR (34) DETENT FLOATING VALVE (65) PIN, SNAP (4) WASHER, SEAL...
Page 337: U1310A Auxiliary Hydraulic Valve
HYDRAULIC SYSTEM - EXPLODED VIEW 6.2 U1310A AUXILIARY HYDRAULIC VALVE UUVWB06A COMPONENTS (1) DU SECTIONAL VALVE (6) NUT (11) CAP (2) ADAPTOR, CONTROL VALVE (7) COUPLER,SELF-SEALING,AC,1-1/4 (12) GRIP (3) PIN, SPRING (8) CONNECTOR B (13) CABLE (4) PIN, SNAP (9) CONNECTOR C (14) WASHER, PLAIN (5) BOLT (10) LEVER 2...
Page 338 MEMO...
Page 339 ELECTRIC SYSTEM CHAPTER 12 TABLE OF CONTENTS 1. SPECIFICATION ........12-3 5.4 Slow-blow fuse ........12-21 5.5 Glow plug ........... 12-21 2. CIRCUIT DIAGRAM ......12-4 5.6 Engine stop solenoid ......12-22 2.1 Color code of wire ........ 12-4 5.7 Parking brake switch ......12-23 2.2 Cross section of wire ......
Page 340 TABLE OF CONTENTS 6. WIRING CONFIGURATION ....12-48 8. EXPLODED VIEW FOR THE COMPONENTS ........12-66 6.1 Wiring diagram ........12-48 8.1 U500A Light ..........12-66 7. DIAGNOSIS AND TROUBLESHOOTING ... 12-49 8.2 U510A Electrical system 1 ......12-67 7.1 General troubleshooting ..... 12-49 8.3 U620A Electrical system 2 ......
Page 341: Specification
ELECTRIC SYSTEM - SPECIFICATION 1. SPECIFICATION Item Speciﬁ cation 12V, 80AH °C : 630CCA Cold Cranking Ampere at -18 Battery Reserve capacity : 135 minutes L x W x H = 259 x 172 x 240mm 12V, 1.7kW, Overall lengt : 240mm Start motor Pinion : spur, Module 3, 9 teeth 12V, 50A...
Page 342: Circuit Diagram
ELECTRIC SYSTEM - CIRCUIT DIAGRAM 2. CIRCUIT DIAGRAM 2.1 COLOR CODE OF WIRE Code Color Code Color Code Color Black Brown/Red Black/Yellow Blue Red/White Light Green/Red White Yellow/Red Light Green/White Brown Yellow/White Black/Blue Green White/Yellow Blue/White Yellow Green/White Black/White Light Green Red/Black Black/Red Gray...
Page 343: Symbols For Electric Components
ELECTRIC SYSTEM - CIRCUIT DIAGRAM 2.3 SYMBOLS FOR ELECTRIC COMPONENTS Symbol Description Symbol Description Single bulb Fuse Lamp Slow-blow fuse Double bulb Diode Motor Zener-diode Switch (Normally Open Type) (Light Emitting Diode) Switch (Normally Close Type) Compressor Photo Diode Ground (Wire) N.P.N Transistor Ground (Chassis) P.N.P Transistor...
Page 345 ELECTRIC SYSTEM - CIRCUIT DIAGRAM 2.4 OVERALL CIRCUIT DIAGRAM 3.0RW 3.0RW 3.0RW 3.0RW 3.0RW 3.0RB 5.0R 3.0R 3.0R 0.5R 5.0R 5.0R 5.0R 5.0R 0.5Br 0.85RB 0.85Gr 1.25Lg ASS'Y COMBI-METER FLASHER STARTER COMBINATION SWITCH SWITCH UNIT STARTER 0.85LY RELAY HAZARD FOG LAMP WORK LAMP (40A) SWITCH...
Page 346 ELECTRIC SYSTEM - LOCATION OF ELECTRICAL DEVICES 3. LOCATION OF ELECTRICAL DEVICES UUVWA01B SUUV-W00 Apr. 2011...
Page 347: Operating Principle
ELECTRIC SYSTEM - OPERATING PRINCIPLE 4. OPERATING PRINCIPLE 4.1 WHEN THE KEY SWITCH IS TURNED TO “ON” POSITION - The power is supplied to display unit, holding coil of stop solenoid, IC regulator of alternator, combination switch, engine oil pressure sensor, dash board. POWER GROUND 3.0RW...
Page 348 ELECTRIC SYSTEM - OPERATING PRINCIPLE POWER GROUND 5.0R 3.0RW STARTER SWITCH ASS'Y COMBI-METER SLOW BLOW FUSE BATTERY ALTERNATOR 0.5P 0.85RW UUVWAA3A - Power supplied to the combi-meter ﬂ ows through the - Power supplied to the engine oil pressure sensor charge warning lamp and diode on through to ground (engine oil switch) will turn on the engine oil pressure in the alternator to turn the charge warning lamp...
Page 349: Preheating And Post Heating
ELECTRIC SYSTEM - OPERATING PRINCIPLE 4.2 PREHEATING AND POST HEATING 3.0RW POWER GROUND 5.0R 5.0R 5.0R MANUAL GLOW START SIGNAL TO STOP PREHEATING OR START POST HEATING STARTER SWITCH ASS'Y COMBI-METER 0.85LY 0.5LY SLOW BLOW FUSE DISPLAY UNIT GLOW RELAY BATTERY (70A) TEMP...
Page 350: When The Key Switch Is Turned To "Start" Position
ELECTRIC SYSTEM - OPERATING PRINCIPLE 4.3 WHEN THE KEY SWITCH IS TURNED TO “START” POSITION POWER GROUND 5.0R 3.0RW 5.0R STARTER SWITCH 0.85LY DIODE 0.85BY ASS'Y COMBI-METER STARTER 0.5BL MOTOR BATTERY UUVWAA5A - The start signal from key switch activates start relay to engage start motor. However the start relay can not be acti- vated when the negative line of start signal is open by the neutral switch which is mounted on the gear shift lever.
Page 351: Fan Motor Operation
ELECTRIC SYSTEM - OPERATING PRINCIPLE 4.4 FAN MOTOR OPERATION POWER GROUND 5.0R 3.0RW 3.0RW STARTER SWITCH FAN MOTOR RELAY SLOW BLOW DISPLAY 0.85RW FUSE UNIT FAN MOTOR BATTERY TEMP SENSOR UUVWAA6A - When the key is in the “ON” position, the display unit controls radiator cooling fan motor in accordance with coolant temperature.
Page 352: Right After The Engine Starts
ELECTRIC SYSTEM - OPERATING PRINCIPLE 4.5 RIGHT AFTER THE ENGINE STARTS POWER GROUND 3.0RW 3.0RW 0.5R 5.0R 0.85RW SLOW BLOW FUSE DISPLAY UNIT BATTERY 0.85RW ALTERNATOR 0.5P 0.85RW UUVWAA7A - The generator starts generating to supply the 13.5~14V to diode and charge warning lamp. However, the current can not ﬂ...
Page 353: When The Key Switch Is In "Off" Position (Horn And Turn Signal Operation)
ELECTRIC SYSTEM - OPERATING PRINCIPLE 4.6 WHEN THE KEY SWITCH IS IN “OFF” POSITION (HORN AND TURN SIGNAL OPERATION) POWER GROUND 5.0R 1.25Lg FLASHER UNIT HAZARD SWITCH SLOW BLOW FUSE FRONT COMBINATION FRONT COMBINATION LAMP(L) LAMP(R) HORN BATTERY UUVWAA8A - The engine stop solenoid will return by the return spring to block the fuel supply as the power on the holding coil of stop solenoid is eliminated.
Page 354: Electrical Components
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5. ELECTRICAL COMPONENTS 5.1 DISPLAY UNIT 6. Stop solenoid pull-coil operation: When the ignition switch is turned to the “ON” posi- tion to start the engine, the display unit operates the pull coil (32 A) for 1 second to pull the stop so- lenoid.
Page 355: External Wiring Diagram For Display Unit
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.1.1 EXTERNAL WIRING DIAGRAM FOR DISPLAY UNIT KEY ON PREHEATER RELAY KEY G GLOW PLUG KEY ST (HOUR) UUVWA76B DISPLAY UNIT CONNECTOR DESCRIPTION Signal key on + 12V Preheat lamp output Alternator charge signal input Key switch ST input Manual preheat signal input Preheat relay output...
Page 356: Cooling Fan Motor
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.2 COOLING FAN MOTOR FAN MOTOR TEST UUVWA07A The cooling fan motor is installed on the back of the radiator under the hood. Blue (L) Black (B) MOTOR SPECIFICATIONS Power 100W ± 10% (Max) Rated speed 2060 rpm ±...
Page 357 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS REMOVAL UUVWA08A UUVWA10A 1. Unscrew the radiator cover mounting bolts (1) (M6, 2 EA) using the 10 mm socket wrench to remove the cover assembly (2). UUVWA11A 3. Turn the connector (1) to disconnect it. Then, un- screw the cooling fan motor mounting screws (2) to remove the cooling fan motor (3).
Page 358: Headlamp
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.3 HEADLAMP The headlamps are attached to the left and right of the hood. REMOVAL UUVWA15A 3. Pull out the bulb. UUVWA12A REMARK HEADLAMP BULB REPLACEMENT 1. Open the hood and disconnect the headlamp connector. UUVWA13A 1.
Page 359: Slow-Blow Fuse
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.4 SLOW-BLOW FUSE 5.5 GLOW PLUG UUVWA18A UUVWA19A The slow-blow fuse is attached on the frame under The glow plug is installed in the engine cylinder the seat. head. Capacity : 60A The glow plugs are used to warm the air in the com- If the slow-blow fuse is blown, all electric systems in bustion chamber before the engine is started.
Page 360: Engine Stop Solenoid
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.6 ENGINE STOP SOLENOID UUVWA20A UUVWA84A • Circuit test: Disconnect the glow plug connector and connect the positive test lead to the wiring connector termi- nal (red with black stripe) and negative test lead to the body.
Page 361: Parking Brake Switch
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.7 PARKING BRAKE SWITCH • The voltage should be measured when turning the key switch to ON position when the wiring connec- tor is installed. UUVWA21A The parking brake switch is installed to the front of the parking brake lever on the left side from the driver's seat.
Page 362: Safety Start Switch
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.8 SAFETY START SWITCH CONTINUITY TEST UUVWA22A UUVWA96A Tester's measuring point Range Remarks Result Red lead Black lead No. 1 No. 2 Switch Continuity connector connector Released (beeping) Continuity No. 1 No. 2 Switch No continuity connector connector Pushed...
Page 363: Engine Oil Pressure Switch
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.9 ENGINE OIL PRESSURE SWITCH 5.10 COOLANT TEMPERATURE SENSOR UUVWA23A UUVWA24A The engine oil pressure switch is installed on the The coolant temperature sensor is installed on the cylinder block. coolant ﬂ ange. If the engine oil pressure drops below 0.5 ± 0.1 kg/cm It is not recommended to measure the resistence of (7 psi ±...
Page 364 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS Temp. (°C) 15° 30° 60° Remarks To display Preheating Approx. Approx. Approx. or fan unit input 3.2 V 2.5 V 1.4 V operation (VDC) To instru- ment cluster Approx. Approx. Approx. Temp. gauge input operation 10 V 10 V 10 V...
Page 365: Fuel Sender
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.11 FUEL SENDER 2. SENSOR FOR PRE-HEATING AND FAN MOTOR. • Resistance Temp. - 40 - 20 (°C) Resis- 15.48 2.45 tance (48.14) (5.790) (1.148) ± 1.35 ± 0.14 (kΩ) Temp. (°C) UUVWA25A Resis- 0.1471 tance (0.5865) (0.3222) (0.1884) (0.1163)
Page 366: Alternator
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.12 ALTERNATOR UUVWA97A UUVWA26A Disconnect the fuel sender connector and disassemble There are some components, such as headlamp, start the fuel sender to measure its resistance. motor, engine stop solenoid and glow plugs, which need a lot of electricity. The alternator supplies power to such components and charges the battery which Tester's measuring point Tester...
Page 367 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS ● PERFORMANCE CURVE OF ALTERNATOR TEST As shown in the performance curve below, the alterna- tor does not generate the power until its speed reaches 1,200 rpm. This minimum revolution speed is called "Cut In Speed".
Page 368: Speed Sensor
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.13 SPEED SENSOR TEST UUVWA27A UUVWAB3A The vehicle speed sensor is attached to the side of 1. Connect the positive test lead to the pin No. 4 and the transmission case. the negative test lead to the pin No. 13 of the in- strument cluster connector and measure the VDC.
Page 369 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS REMARK REMARK SPEED SIGNAL OUTPUT FROM DISPLAY UNIT SPEED SIGNAL OUTPUT FROM SPEED SENSOR Average Average - 0.3 UUVWAB7A • The output voltage from speed sensor is shown UUVWAB6A in the graph above. However, it is hard to read •...
Page 370: Key Switch
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.14 KEY SWITCH 2. KEY SWITCH TEST UUVWA28A UUVWA99A The key switch is installed on the right side of the Disconnect the key switch from the wiring harness con- steering wheel. nector. Use an ohmmeter (Ω) to test the switch. 1.
Page 371: Combination Switch
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.15 COMBINATION SWITCH UUVWA29A The combination switch is installed on the left side from the steering wheel on the main instrument panel. Six switch positions: • • Turn signal lamp (LH) • Tail/Head lamp • Turn signal lamp (RH) (low beam) •...
Page 372 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS Lever operation Lever operation Lever operation Wiring color Wiring color Wiring color Term. position Term. position Term. position T46WB49D SUUV-W00 Apr. 2011...
Page 373: Flasher Unit (Optional)
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.16 FLASHER UNIT (OPTIONAL) 5.17 ENGINE STOP RELAY (5P) UUVWA30A UUVWA31A The ﬂ asher unit is attached to the relay bracket un- The engine stop relay is attached to the relay der the hood. bracket under the hood. This relay is used as power supply to the pull coil of the engine stop solenoid.
Page 374: Preheat Relay (4P)
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.18 PREHEAT RELAY (4P) UUVWAA1A UUVWA32A The preheat relay is attached to the relay bracket Tester Tester's measuring point under the hood. Result selector Red lead Black lead The preheat relay is used to activate the glow plugs. Approx.
Page 375 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS UUVWAA2A Tester Tester's measuring point Result selector Red lead Black lead Approx. 84.6 Ω Relay 85 Relay 86 Resi s tance Relay 30 Relay 87 No continuity ※ When measuring the resistance with a tester, it is OK to switch the leads (red and black).
Page 376: Instrument Panel
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.19 INSTRUMENT PANEL ● COMPONENTS AND LOCATIONS Front view UUVWA33A SYMBOL Appearance FUEL BEAM Name TURN/L TURN/R CHARGE GLOW NEUTRAL PARKING Lamp 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W Color Amber Blue Green Green Amber Green...
Page 377 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS ● CIRCUIT DIAGRAM OF INSTRUMENT PANEL CIRCUIT NAME CONNECTOR ILL(+) TEMP - U TURN/L TEMP GND TURN/R GLOW SPEED - U HIGH/BEAM HOUR - U IGN + ILL(+) BRAKE CHARGE NEUTRAL BRAKE FUEL WARNING CHARGE NEUTRAL FUEL GLOW...
Page 378 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS ● GAUGES AND INDICATORS Speedometer and hour meter Fuel gauge UUVWA39A UUVWA37A This indicates the vehicle speed and is operated by the The fuel gauge’s pointer is operated by variable input speed sensor signal. voltage. The input voltage depends on the resistance of the fuel 1.
Page 379 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS Engine coolant temperature gauge Turn signal indicating lamps (LH, RH) The turn signal lamp indicator comes on the instrument panel when operating the turn signal lamp switch. Tester's measuring point Tester Operation Result selector Red lead Black lead Connector, Connector,...
Page 380 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS Preheat indicator Parking brake indicator This comes on when you hold the key switch in the “HEAT” This indicator indicates the ON and OFF status of the position. parking brake. When the parking brake is applied, this indicator comes on.
Page 381 ELECTRIC SYSTEM - ELECTRICAL COMPONENTS Charge warning lamp This lamp comes on when turning the key switch to "ON" position and goes off when the alternator is turn- ing by the engine. If this lamp comes on while driving, the charging sys- tem is malfunctioning.
Page 382: Start Relay (5P)
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.20 START RELAY (5P) 5.21 FAN MOTOR RELAY (5P) UUVWA42A UUVWA43A The start relay is attached to the relay bracket un- The start relay is attached to the relay bracket un- der the hood. der the hood. This relay supplies the magnet coil of the start motor with power when the key switch is turned to the "ST"...
Page 383: Twin Relay (High/Low Beam)
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.22 TWIN RELAY (HIGH/LOW BEAM) 5.23 TWIN RELAY (WORK/FOG LAMP) (OPTIONAL) UUVWA44A UUVWA45A The twin relay (high/low beam) is attached to the The twin relay (work/fog lamp) is attached to the relay bracket under the hood. relay bracket under the hood.
Page 384: Power Outlet
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.24 POWER OUTLET 5.25 FUSE BOX UUVWA46A UUVWA47A The power outlet (12 V) is installed to the lower The fuse box is attached to the relay bracket under side on the center of the main instrument panel. the hood.
Page 385: Brake Lamp Switch (Optional)
ELECTRIC SYSTEM - ELECTRICAL COMPONENTS 5.26 BRAKE LAMP SWITCH (OPTIONAL) REMARK • Body grounds UUVWA48A UUVWA50A UUVWA49A The brake lamp switch is attached to the main UUVWA51A bracket under the hood. The brake switch turns on the brake lamps of the tail lamps on the rear cargo bed when the brake pedal is depressed.
Page 386: Wiring Configuration
ELECTRIC SYSTEM - WIRING CONFIGURATION 6. WIRING CONFIGURATION 6.1 WIRING DIAGRAM UUVWA54A SUUV-W00 Apr. 2011...
Page 387: Diagnosis And Troubleshooting
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7. DIAGNOSIS AND TROUBLESHOOTING 7.1 GENERAL TROUBLESHOOTING 7.1.1 BATTERY ● CAUSES OF BATTERY EXPIRATION The causes for battery failure can be divided into the following three causes: 1. Overly discharged The speciﬁ c gravity of electrolyte is too low and the terminal voltage is not measurable.
Page 388: Wiring
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.1.2 WIRING ● CAUSES FOR BLOWN FUSE The negative battery cable should be disconnected if there is any possibility of short circuit when installing There are three causes for blown fuse which can be or removing the wiring and electric components.
Page 389 ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING ● GROUND TEST The ground connection is critical for the electric and electronic circuits' operation. It is often exposed to sev- eral factors for corrosion such as humidity and dust. Corrosion produces unnecessary resistance and this re- sistance can affect the circuit operation.
Page 390: General
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.1.3 GENERAL ● OVERVIEW Sometime, a problem may be difﬁ cult to reproduce. If this is the case, the conditions during failure may need to be reproduced. The following is how to re- produce conditions that can cause electrical prob- lems.
Page 391 ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING WIRE CONTACT CHECK Tap it gently. Shake it gently. Bend it gently. T46WB30A LOOSE PRONG CHECK WIRE SEIZING CHECK As the connector is installed and re- moved repeatedly, the aperture of contact spring can be bent.
Page 392 ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING ● DAMAGE BY HEAT ● FAULT BY MOISTURE If the problem in the tractor occurred in hot weather, A fault may occur only in high humidity condition, rainy the inspector should check the conditions affected by season or snow.
Page 393: Troubleshooting
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2 TROUBLESHOOTING 7.2.1 WHEN THE ENGINE CANNOT BE STARTED Check point Check item (method) Remarks 1. Battery voltage - Measure the voltage between battery (+) and (-) terminals us- ing a tester. - Result: 11.8 ~ 12.9 V However, the voltage may be over this range if it is measured imme- diately after turning the engine off.
Page 394 ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING Check point Check item (method) Remarks 6. Fuse - Check No. 1 and 2 fuses for open circuit. (If it has a open circuit, replace it with new one with rated capacity.) UUVWA56B 7. Engine stop solenoid 1.
Page 395: When The System Is Not Charged
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.2 WHEN THE SYSTEM IS NOT CHARGED Check point Check item (method) Remarks 1. Fuse - Check the fuse No. 2 for open circuit. (If it has a open circuit, replace it with new one with rated capacity.) UUVWA57B 2.
Page 396: Check The Charge Warning Lamp For Malfunction
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.3 CHECK THE CHARGE WARNING LAMP FOR MALFUNCTION. Normal operating condition Before starting the engine (key switch in "ON" posi- tion): Charge warning lamp ON After starting the engine: Charge warning lamp OFF Check point Check item (method) Remarks 1.
Page 397: When The System Is Not Preheated Manually
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.4 WHEN THE SYSTEM IS NOT PREHEATED MANUALLY Check point Check item (method) Remarks 1. Preheat relay 1. Connecting 12 V to the No. 85 and 86 terminals with the key ON : No. 87 and 30 terminals connected (closed circuit) 2.
Page 398: When The System Is Not Preheated Automatically
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.5 WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY Check point Check item (method) Remarks 1. Check the battery - Measure the voltage between battery (+) voltage and (-) terminals using a tester - Result: 11.8 ~ 12.9 V However, the voltage may be over this range if it is measured immediately after turning the engine off.
Page 399 ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING Check point Check item (method) Remarks 6. Fuse 1. Check method - Fuse 3 for open circuit - If it has a open circuit, replace it with new one with rated capacity (5A). (Fuse No.3) UUVWA63B 7.
Page 400: When High And Low Beams Cannot Be Operated
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.6 WHEN HIGH AND LOW BEAMS CANNOT BE OPERATED Check point Check item (method) Remarks 1. Fuse - Check fuse engagement. - Fuse for open circuit : Fuse 5 (15 A) UUVWA60B 2. Combination switch - Check the low beam for proper connection.
Page 401: Speedometer Operation With The Engine Running
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.7 SPEEDOMETER OPERATION WITH THE ENGINE RUNNING Check point Check item (method) Remarks 1. Fuse - Check fuse engagement. - Fuse 3 for open circuit, rated capacity: 5 A - Fuse 9 for open circuit, rated capacity: 5 A UUVWA61B 2.
Page 402: Fuel Gauge Operation
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.8 FUEL GAUGE OPERATION Check point Check item (method) Remarks 1. Fuse - Check fuse engagement. - Fuse 9 for open circuit Rated capacity: 5 A UUVWA62B 2. Fuel sender Measure the resistance between two terminals of fuel sender con- nector after disconnecting wiring and connector.
Page 403: Hour Meter Operation
ELECTRIC SYSTEM - DIAGNOSIS AND TROUBLESHOOTING 7.2.9 HOUR METER OPERATION Check point Check item (method) Remarks 1. Fuse - Check fuse engagement. - Fuse 3 for open circuit Rated capacity: 5 A UUVWA63B 2. Operating power of regula- - Measure the voltage between tor (with key switch "ON") No.
Page 404: Exploded View For The Components
ELECTRIC SYSTEM - EXPLODED VIEW FOR THE COMPONENTS 8. EXPLODED VIEW FOR THE COMPONENTS 8.1 U500A LIGHT UUVWA64A COMPONENTS (1) HEADLIGHT, BEZEL, FR LH (6) HEADLIGHT, BEZEL, FR RH (2) HEADLIGHT, BEZEL, RR LH (7) HEADLIGHT, BEZEL, RR RH (3) HEADLIGHT, LH (8) HEADLIGHT, RH (4) BULB (9) BULB...
Page 405 ELECTRIC SYSTEM - EXPLODED VIEW FOR THE COMPONENTS 8.2 U510A ELECTRICAL SYSTEM 1 UUVWA65A COMPONENTS (1) INSTRUMENT CLUSTER ASSY (6) COMBINATION SWITCH ASSY (11) SWITCH, SAFETY START (2) BULB 12V 3W (7) SWITCH, STARTER (12) WASHER, PLAIN (3) BULB 14V 3W (8) SOCKET (13) NUT (4) BULB 14V 1.4W...
Page 406 ELECTRIC SYSTEM - EXPLODED VIEW FOR THE COMPONENTS 8.3 U620A ELECTRICAL SYSTEM 2 UUVWAB8A COMPONENTS (1) FUSE BOX ASSY (10) RELAY 5P (19) DIODE, 2P (2) FUSE 5A (11) ACCESSORY RELAY ASSY (20) WASHER, SPRING (3) FUSE 10A (12) BOLT, FLANGE (21) BOLT, FLANGE (4) FUSE 15A (13) DISPLAY UNIT...
Page 407 INDEX CHAPTER 13...
Page 408 INDEX Check and replacement for CVT belt ....4-10 Accelerator pedal cable ........6-6 Check the charge warning lamp for malfunction..12-58 Adjusting distance between shafts for pulleys ..4-9 Checking and adjusting the injection timing ..3-35 Air cleaner ............3-30 Circuit diagram ..........
Page 409 INDEX U0500A Front suspension ......9-29 system) ............11-20 Connecting rods ..........3-12 Disassembly, service and assembly(Engine) ... 3-52 Coolant temperature sensor ......12-25 Disassembly, service and assembly(CVT) ..4-11 Cooling fan motor ........... 12-18 Disassembly, service and assembly (Transmission) ..........5-13 Cooling system ..........
Page 410 INDEX E190 Water hose ........... 3-97 Front wheel brake removal(brake pad and disc replacement) ............ 8-11 E200 Dynamo ..........3-98 Front wheel drive cable length ......5-12 E220 Mainfold..........3-99 Front wheel drive cable ........6-5 Engine identiﬁ cation .......... 3-3 Front wheel drive system disassembly and Engine oil ﬂ...
Page 411 INDEX Headlamp ............12-20 Main relief valve pressure....... 11-19 Hood, panel, ﬂ oor and radiator removal ..... 6-9 Maintenance schedule chart......2-10 Hour meter operation........12-65 Maintenance ............. 2-10 How to install spring pin and snap ring ..... 2-18 Measuring the piston compression pressure ..3-34 Hydraulic circuit ..........
Page 412 INDEX Piston ring end gap.......... 3-43 Sealant and adhesive(Front axle)....... 9-3 Piston rings ............3-7 Seat and fender removal ........6-7 Piston, ﬂ ywheel and crankshaft ......3-66 Serial number ............. 2-3 Pistons ..............3-8 Service speciﬁ cations ......... 3-6 Power outlet............
Page 413 INDEX Stud ..............2-14 Turning torque of 8 bevel pinion shaft ....9-8 Suspension ............7-2 Twin relay (high/low beam) ......12-45 Suspension assembly removal ......7-26 Twin relay (work/fog lamp) (optional)....12-45 Symbols for electric components...... 12-5 Unit conversion table ........2-19 The location of safety decal ........
Page 414 MEMO...
Page 416 1451 Marvin Gri n Road, Augusta, GA 30906 (800) 241-5855 I Fax (706) 796-4540 I www.ezgo.com e-mail: ezgo@textron.com I ©2011 E-Z-GO Division of Textron Inc.