Page 9 Group 00 General Table of Contents BACK HOME Pub No. TWME9502-00...
Page 10 GROUP 00 GENERAL MODEL CODING SYSTEM ..............2 POWER TRAIN TABLE ................3 CHASSIS NUMBER AND ENGINE NUMBER ........3 POWER TRAIN LABEL ................4 VEHICLE IDENTIFICATION NUMBER ..........4 PRECAUTIONS FOR MAINTENANCE OPERATION ......6 TABLE OF STANDARD TIGHTENING TORQUES ......18 CONNECTOR CONFIGURATION CHART ..........
Page 11 MODEL CODING SYSTEM Equipment Model Code Equipment name Model description Code description Engine 4 - 0 With turbocharger  Stands for automobile These are omitted in the   Remodeling sequence Service Manual Version number Series number Stands for diesel engine No.
Page 12 POWER TRAIN TABLE/CHASSIS NUMBER AND ENGINE NUMBER POWER TRAIN TABLE Final reduc- Engine Clutch Transmission Propeller Rear axle Model tion and model model model shaft model gear ratio M050S5 FH211C, E, G, 6D34T2 C5M33 R040T D040H 6.875/1.000 H, J 4.111 G.V.W.
Page 13 J W 6 C C C 1 G 4 5 7 8 9 F G Country Japan Make Mitsubishi Fuso Vehicle type Incomplete Vehicle Gross vehicle weight/Brake system 7258 to 8845 kg {16001 to 19500 lbs} /Air over hydraulic Line...
Page 14 M E M O 00-5...
Page 15 PRECAUTIONS FOR MAINTENANCE OPERATION In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condition, what the customer’s demand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure.
Page 16 When tilting the cab, be sure to insert the safety pin into the cab stay so that the cab stay remains locked and is not released when the cab is tilted. 14193 Pay special attention to safety when removing or installing heavy items such as engines, transmissions and axles.
Page 17 Replace oil seals, packing, O-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts. 00015 On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rota- tion, fatigue, clogging and any other possible defect.
Page 18 Put alignment marks on part combinations before disassembly and ar- range the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where performance and appearance will not be affected. Cover the area left open after removal of parts to keep it free from dust. CAUTION–...
Page 19 PRECAUTIONS FOR MAINTENANCE OPERATION Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic control unit. 00021 Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark.
Page 20 • Disconnect the negative terminals of batteries. • Disconnect connections between the cab harness wires and the chas- sis harness wires. 10639 To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 volt.
Page 21 PRECAUTIONS FOR MAINTENANCE OPERATION Measurement procedures using connectors • Test with connectors engaged (continuity through circuit obtained) < Waterproof connector > Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector.
Page 22 Connector inspection procedures • Visual inspection Check for loose connection and poor engagement. 02591 Check if harnesses are broken by pulling gently around the terminals. 02592 Check for a decrease in contact pressure between the male and female terminals. 02593 Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles.
Page 23 PRECAUTIONS FOR MAINTENANCE OPERATION Inspection procedures for blown fuses Remove fuse B and measure resistance between the loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0 Ω, a short has occurred between the Ω...
Page 24 • Do not splash water over the alternator. If water is directly splashed over the alternator, individual compo- nents will be short-circuited and might be destroyed. 05165 • Do not short-circuit terminal B and terminal L while running the alternator. If the terminals are short-circuited while the alternator is running, the diode trio might be destroyed.
Page 25 PRECAUTIONS FOR MAINTENANCE OPERATION Measures for temporary faults Temporary faults often occur under certain conditions. So identifying those conditions helps to find possible causes. To find the conditions under which temporary faults occurred, you need to reproduce the faults after interviewing customers in detail about actual driving condi- tions, weather, frequency of occurence and fault phenomena.
Page 26 M E M O 00-17...
Page 27 TABLE OF STANDARD TIGHTENING TORQUES • Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise specified. • Threads and contact seats shall be dry. • Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the bolt shall apply.
Page 28 Hex-head Nut Unit : N·m {lbf.ft, kgf·m} Strength classification Repre- sentation Diameter symbol Coarse screw Standard screw Coarse screw Standard screw 2 to 3 4 to 6 — — {1.4 to 2.2, 0.2 to 0.3} {2.9 to 4.3, 0.4 to 0.6} 4 to 6 7 to 11 —...
Page 29 TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flair nut for general purpose Unit : N·m {lbf.ft, kgf·m} Pipe diameter ø4.76 mm {0.19 in.} ø6.35 mm {0.25 in.} ø8 mm {0.31 in.} ø10 mm {0.39 in.} ø12 mm {0.47 in.} ø15 mm {0.59 in.} Tightening torque 17 {12, 1.7}...
Page 30 M E M O 00-21...
Page 31 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AA 1 A AA 2 A AA 2 B AA 3 A AA 3 B AA 4 A AA 4 B AA 6 A 00-22...
Page 32 Model Connection (Number shows number of pins) AA 6 B AA 8 A AA10A AA12A AB 1 A AB 2 A AB 3 A AB 4 A AB 6 A 00-23...
Page 33 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AC 1 A AC 2 A AC 3 A AC 4 A AD 1 A AD 2 A AE 2 A AE 3 A AE 5 A 00-24...
Page 34 Model Connection (Number shows number of pins) AE 7 A AE 9 A AE11A AE13A AE15A AE16A (White, Gray, Black) AE16B (Green) AE16C (Blue) AE17A 00-25...
Page 35 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AG16A AG20A AH10A AH12A AH18A 00-26...
Page 36 Model (Number shows number Connection of pins) AH18B AH22A (AH26A) AH22 AH24A AH26A AH26A (AH22) 00-27...
Page 37 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AJ 2 A AJ 4 A AJ 8 A AJ10A AJ12A 00-28...
Page 38 Model (Number shows number Connection of pins) AJ16A 00-29...
Page 39 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AJ20A AK 2 A AK 3 A AK 4 A AK 6 A 00-30...
Page 40 Model Connection (Number shows number of pins) AK 8 A AK10A AK14A AK18A AK20A 00-31...
Page 41 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AK20B AK22A AK22B AL 1 A AL 2 A 00-32...
Page 42 Model Connection (Number shows number of pins) AL 2 B AL 3 A AL 3 B AL 3 C AL 3 D AL 3 E 00-33...
Page 43 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AL 4 A AL 4 B AL 6 A AL 6 B AL 8 A AL 8 B 00-34...
Page 44 Model Connection (Number shows number of pins) AM 2 A AM 2 B AM 2 C AM 4 A AM 4 B AM 6 A AM 6 B AM 8 A AM 8 B 00-35...
Page 45 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AM10A AN 1 A AN 2 A AN 3 A AN 4 A AN 4 B AN 6 A AN 6 B AN 8 A 00-36...
Page 46 Model (Number shows number Connection of pins) AN 8 B AP 1 A AP 1 B AP 2 A AP 2 B AP 2 C AQ 3 A AQ 3 B AQ13A 00-37...
Page 47 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AQ15A AQ20A AR 2 A AR 2 B AR 2 C AR 2 D AR 2 E AR 2 F 00-38...
Page 48 Model (Number shows number Connection of pins) AR 3 A AS 1 A AS 2 A AS 2 B AT 4 A AU 6 A AU 8 A AU10A 00-39...
Page 49 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) AU12A AU13A AU16A AV 1 A AV 2 A AW 1 A AW 1 B AW 2 A AX 4 A 00-40...
Page 50 Model Connection (Number shows number of pins) AY 2 A AZ 2 A BA 3 A BB 2 A BB 3 A BC 3 A BD 8 A BE 6 A BF12A 00-41...
Page 51 CONNECTOR CONFIGURATION CHART Model Connection (Number shows number of pins) BG16A BH 4 A BJ 9 A BL 2 A BM 2 A BM 2 B BM 2 C BN 1 A 00-42...
Page 52 BACK HOME...
Page 53 Group 01 Maintenance Schedule ' 98 Minor Change Table of Contents BACK HOME Pub No. TWME9502-201...
Page 54 MAINTENANCE SCHEDULE HOW TO READ THE MAINTENANCE SCHEDULE TABLES..01- 2 MAINTENANCE SCHEDULE TABLES ........... 01- 3 MAINTENANCE OPERATIONS ............01- 7 01- 7 • Replacement of Oil Filter ................01- 8 • Replacement of Fuel Filter ................ 01- 9 •...
Page 55 HOW TO READ THE MAINTENANCE SCHEDULE TABLES Example Table : *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance (2) Inspection interval Inspection and...
Page 56 MAINTENANCE SCHEDULE TABLES *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks...
Page 57 MAINTENANCE SCHEDULE TABLES *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks...
Page 58 *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks maintenance ×...
Page 59 MAINTENANCE SCHEDULE TABLES *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks...
Page 60 MAINTENANCE OPERATIONS This section explains simple maintenance procedures. See the relevant Group in this manual for further details. Replacement of Oil Filter - Lubricant Location Points of application Specified lubricant Quantity Inside oil filter Engine oil Approximately 1 L {1.1 qts} Gasket area of oil filter with thin application Engine oil As required...
Page 61 MAINTENANCE OPERATIONS Replacement of Fuel Filter - Lubricant Location Points of application Specified lubricant Quantity Gasket contact surfaces of fuel filter and fuel filter head Engine oil As required 0 Special tools Unit : mm {in.} Location Tool name and shape Part No.
Page 62 Draining of Water Separator Condensation Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Drain plug 3 to 4 {2.2 to 2.9, 0.3 to 0.4} — Visually inspect the water separator before driving. When float 1 reaches red line A, drain the condensation as follows: •...
Page 63 MAINTENANCE OPERATIONS Bleeding of Air from Fuel Line Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Air vent plug 7.8 to 12 {5.8 to 8.7, 0.8 to 1.2} — WARNING– • Fuel ignites easily. Do not get it near flame or heat. •...
Page 64 Adjustment of V-Belt Tension Newly installed V-belts can stretch during their initial running-in period. To prevent this from becoming a problem, run the engine for several minutes after installing the V-belt, then readjust. Perform this cycle several times. WARNING– You must take special precautions to prevent the engine from rotating while a V-belt is being inspected or adjusted.
Page 65 MAINTENANCE OPERATIONS Use of special tool belt tension gauge • Set upper O-ring G of 0 belt tension gauge to 98 N·m {72 lbf.ft, 10 kgf·m} (push load) on graduation H. • Set lower O-ring J of 0 belt tension gauge to graduation K (maximum flex of belt).
Page 66 Cleaning and Replacement of Air Cleaner Element [Removal] Remove wing nut 1 to remove element 2. [Installation] Install element 2 securely. 02208 [Cleaning] • Blow compressed air of 685 kPa {100 lbf/in , 7 kgf/cm } or less through air cleaner element 2 from the inside. •...
Page 67 MAINTENANCE OPERATIONS Inspection of Clutch Pedal Free Play Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Clutch pedal free play 37 to 52 {1.46 to 2.05} — Adjust or replace [Confirmation] Push clutch pedal 1 with your hand and measure the amount of move- ment A (free play) until you meet resistance.
Page 68 Air pressure Tire air pressure should be checked before the vehicle is driven, while the tires are still cool. Air Pressure Tire Size kPa {Psi, kgf/cm 215/75R 17.5 124/123L 700 {100, 7.00} CAUTION– • Make certain that there is no difference in the air pressure be- 00592 tween the inner and outer rear tires.
Page 69 MAINTENANCE OPERATIONS Removing tires • Jacking up point • For front wheels : Front axle bottom A < Front wheel > • For rear wheels : Rear axle tube bottom B WARNING– • The jack should be placed on flat, solid ground, and should not 02476 be used to raise the vehicle higher than necessary.
Page 70 Mounting tires • To prevent wheel nuts 2, 4 and hub bolt 6 from becoming loose and to prevent mounting parts (tire assemblies 3, 5 and hub 7) from being damaged, remove rust, dust, additional coatings of paint, and foreign particles from the following areas: F : Hub bolt thread area G : Wheel mounting surface of hub...
Page 71 MAINTENANCE OPERATIONS • Tighten the nuts in the order as illustrated, tightening each nut two or three times. To finish, tighten each nut at the specified torque. WARNING– Always use the specified torque when tightening the wheel nuts. If the wheel nuts are not tightened properly, the wheels could come loose while the vehicle is being driven, which could result in life threatening accidents or the truck being disabled.
Page 72 Tire rotation Tires wear differently, according to the location where they are mounted. To make this wear uniform and prolong the life of your tires, they should be rotated every 10000 km (6000 miles) in the rotation order shown below: •...
Page 73 MAINTENANCE OPERATIONS Inspection of Brake Pedal Free Play Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Free play of brake pedal 10 to 15 {0.39 to 0.59} — Adjust [Inspection] Check if brake pedal free play A confirms to the standard valve with starter switch OFF.
Page 74 Inspection of Brake Lining Thickness Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Thickness of brake lining — 5 {0.20} Replace (Wear limit at side step) NOTE Be sure to inspect at two points for each wheel per side. •...
Page 75 MAINTENANCE OPERATIONS Visual inspection • If terminal A is corroded, scrub off the corrosion from it using a wire brush. • If cracks or defects are found on the battery, replace it since the cracks or defects can cause liquid spills. CAUTION–...
Page 76 Charging • Although, as a rule, charging of the battery should be done with the battery removed from the vehicle, if you have to charge the battery while it is on the vehicle, make sure that you stop the engine and disconnect the battery cable ë. •...
Page 77 MAINTENANCE OPERATIONS Fuse F18 to 34 F1 to 17 12983 1 Main high-current fuse 2 High-current fuse box 3 Fuse box CAUTION– • If a fuse blows, make sure you identify and remedy the cause, then replace the fuse. • Make sure that you replace the fuse with one having the same rating. •...
Page 78 Main high-current fuse Fuse Main load Capacity — High-current fuse box 120 A High-current fuse box Fuse Main load Capacity Fuse box (F1 to F4) 50 A Fuse box (F5 to F8, F11) 40 A Brake booster (Hydraulic booster) 50 A Starter switch (Terminal B) 50 A Glow relay...
Page 79 LUBRICATION *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items Time of inspection and maintenance Inspection interval Inspection and Lubrication procedures Remarks maintenance ×...
Page 80 Engine Oil Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Oil pan drain plug 69 {51, 7} — [Inspection] • Pull out dipstick 1, wipe off the oil with a cloth. • Reinsert dipstick 1, then pull it out carefully. •...
Page 81 LUBRICATION [Replacement] °C Since engine oil greatly influences the performance, the life expectancy, °F and the ability to start the engine, use only oil of the specified grade and S A E 1 0 W – 3 0 viscosity. The chart illustrates the relationship between oil viscosity and the ambi- S A E 2 0 W –...
Page 82 Clutch Fluid (Brake Fluid) Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Air bleeder 25 to 34 {18 to 25, 2.5 to 3.5} — - Fluid Location Points of application Specified fluid Quantity Fluid tank Brake fluid...
Page 83 LUBRICATION [Replacement] • Attach vinyl pipe 3 to air bleeder 2 of the clutch power cylinder. • Loosen air bleeder 2 and depress clutch pedal 4 several times to drain brake fluid completely. 11772 • Supply new brake fluid to the “MAX” level of fluid tank 1. Depress clutch pedal 4 repeatedly until the old brake fluid discharged from vinyl pipe 3 is replaced by the new brake fluid.
Page 84 Manual Transmission Gear Oil Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Inspection plug 69±15 {51±11, 7±1.5} — Drain plug 69±15 {51±11, 7±1.5} — - Sealant Location Points of application Specified sealant Quantity Thread area of inspection plug THREEBOND 1105D...
Page 85 LUBRICATION Automatic Transmission Fluid and Oil Filter Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Drain plug 20 to 27 {15 to 20, 2.05 to 2.75} — Dipstick guide connector 125 to 135 {91 to 100, 12.55 to 13.76} —...
Page 86 [Replacement] • Park the vehicle on level ground, chock the wheels and shift the range selector lever to the N position. • Place a container under oil pan 3, remove drain plug 4 and drain the fluid. WARNING– Take care because the fluid temperature immediately after the engine has stopped is very high.
Page 87 LUBRICATION • Remove oil filter 12 (for oil cooler) by turning it counterclockwise. • Lightly coat gasket C with the fluid before installing oil filter 12. Then tighten the oil filter. 14157 • Supply fluid through dipstick guide 2. CAUTION– Make sure that dirt and foreign particles do not become mixed in with the fluid when it is added.
Page 88 Rear Axle Gear Oil Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Inspection plug 98 to 115 {72 to 87, 10 to 12} — Drain plug 98 to 115 {72 to 87, 10 to 12} —...
Page 89 LUBRICATION Power Steering Fluid Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Oil pipe 66.69±12.75 {49±9.4, 6.8±1.3} — - Fluid Location Points of application Specified fluid Quantity Between Power steering oil tank Automatic transmission fluid "MAX"...
Page 90 [Supply] • Supply fluid into power steering oil tank 1 up to filler cap 2. • With the engine stopped, jack up the front wheels and turn the steer- ing wheel fully left and right repeatedly. When the fluid level has dropped, add fluid to maintain the fluid level within range A.
Page 91 LUBRICATION Brake Fluid Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Air bleeder 7.8 to 12 {5.8 to 8.5, 0.8 to 1.2} — - Fluid Location Points of application Specified fluid Quantity Fluid tank Brake fluid As required...
Page 92 [Inspection and replenishment] • Inspect the level of the brake fluid in fluid tank 1. It should fall between the “MAX” and “MIN” levels. • If it is below the “MIN” level, remove the cap from fluid tank 1, then supply the specified brake fluid until the level comes up to the “MAX”...
Page 93 LUBRICATION • Maintaining a supply of new brake fluid up to the “MAX” level of fluid tank 1, depress brake pedal 3 repeatedly until the old brake fluid of the brake system is replaced with new fluid. • Carry out air bleeding of the brake system. “MAX”...
Page 94 M E M O 01-41...
Page 95 LUBRICATION Greasing Various Areas of Chassis Carefully clean away all dust and dirt from the grease nipples, and use the specified type of grease. The areas to be greased are shown in the following illustration. 27678 02244 02245 02246 02243 02247 02248 00360...
Page 96 Door hinge 01518 01-43...
Page 97 Table of Contents BACK HOME...
Page 98 MAINTENANCE SCHEDULE HOW TO READ THE MAINTENANCE SCHEDULE TABLES....2 MAINTENANCE SCHEDULE TABLES ..........3 MAINTENANCE OPERATIONS ............. 7 • Replacement of Oil Filter ................... • Replacement of Fuel Filter ................. • Draining of Water Separator Condensation ............. • Cleaning of Fuel Feed Pump Gauze Filter ............•...
Page 99 HOW TO READ THE MAINTENANCE SCHEDULE TABLES Example Table : *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance (2) Inspection interval Inspection and...
Page 100 MAINTENANCE SCHEDULE TABLES *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks...
Page 101 MAINTENANCE SCHEDULE TABLES *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks...
Page 102 *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks maintenance ×...
Page 103 MAINTENANCE SCHEDULE TABLES *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items : Noise control items Time of inspection and maintenance Inspection interval Inspection and Working procedures Remarks...
Page 104 MAINTENANCE OPERATIONS This section explains simple maintenance procedures. See the relevant Group in this manual for further details. Replacement of Oil Filter - Lubricant Location Points of application Kinds Quantity Inside oil filter Engine oil Approximately 1 L {1.1 qts} Gasket area of oil filter with thin application Engine oil As required...
Page 105 MAINTENANCE OPERATIONS Replacement of Fuel Filter - Lubricant Location Points of application Kinds Quantity Gasket contact surfaces of fuel filter and fuel filter head Engine oil As required 0 Special tools Unit : mm {in.} Location Tool name and shape Part No.
Page 106 Draining of Water Separator Condensation Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Drain plug 2.9 to 3.9 {2.2 to 2.9, 0.3 to 0.4} — Visually inspect the water separator before driving. When float 1 reaches red line A, drain the condensation as follows: •...
Page 107 MAINTENANCE OPERATIONS Bleeding of Air from Fuel Line Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Air vent plug 7.8 to 12 {5.8 to 8.7, 0.8 to 1.2} — WARNING– • Fuel ignites easily. Do not get it near flame or heat. •...
Page 108 Adjustment of V-Belt Tension Newly installed V-belts can stretch during their initial running-in period. To prevent this from becoming a problem, run the engine for several minutes after installing the V-belt, then readjust. Perform this cycle several times. WARNING– You must take special precautions to prevent the engine from rotating while a V-belt is being inspected or adjusted.
Page 109 MAINTENANCE OPERATIONS Use of special tool belt tension gauge • Set upper O-ring G of 0 belt tension gauge to 98 N·m {72 lbf.ft, 10 kgf·m} (push load) on graduation H. • Set lower O-ring J of 0 belt tension gauge to graduation K (maximum flex of belt).
Page 110 Cleaning and Replacement of Air Cleaner Element [Removal] Remove wing nut 1 to remove element 2. [Installation] Install element 2 securely. 02208 [Cleaning] • Blow compressed air of 685 kPa {100 lbf/in , 7 kgf/cm } or less through air cleaner element 2 from the inside. •...
Page 111 MAINTENANCE OPERATIONS Inspection of Clutch Pedal Free Play Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Clutch pedal free play 32 to 44 {1.26 to 1.73} — Adjust or replace [Confirmation] Push clutch pedal 1 with your hand and measure the amount of move- ment A (free play) until you meet resistance.
Page 112 Air pressure Tire air pressure should be checked before the vehicle is driven, while the tires are still cool. Air Pressure Tire Size kPa {Psi, kgf/cm 215/75R 17.5 124/123L 700 {100, 7.00} CAUTION– • Make certain that there is no difference in the air pressure be- 00592 tween the inner and outer rear tires.
Page 113 MAINTENANCE OPERATIONS Removing tires • Jacking up point • For front wheels : Front axle bottom A < Front wheel > • For rear wheels : Rear axle tube bottom B WARNING– • The jack should be placed on flat, solid ground, and should not 02476 be used to raise the vehicle higher than necessary.
Page 114 Mounting tires • To prevent wheel nuts 2, 4 and hub bolt 6 from becoming loose and to prevent mounting parts (tire assemblies 3, 5 and hub 7) from being damaged, remove rust, dust, additional coatings of paint, and foreign particles from the following areas: F : Hub bolt thread area G : Wheel mounting surface of hub...
Page 115 MAINTENANCE OPERATIONS • Tighten the nuts in the order as illustrated, tightening each nut two or three times. To finish, tighten each nut at the specified torque. WARNING– Always use the specified torque when tightening the wheel nuts. If the wheel nuts are not tightened properly, the wheels could come loose while the vehicle is being driven, which could result in life threatening accidents or the truck being disabled.
Page 116 Tire rotation Tires wear differently, according to the location where they are mounted. To make this wear uniform and prolong the life of your tires, they should be rotated every 10000 km (6000 miles) in the rotation order shown below: •...
Page 117 MAINTENANCE OPERATIONS Inspection of Brake Lining Thickness Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy Thickness of brake lining — 5 {0.20} Replace (Wear limit at side step) NOTE Be sure to inspect at two points for each wheel per side. •...
Page 118 Visual inspection • If terminal A is corroded, scrub off the corrosion from it using a wire brush. • If cracks or defects are found on the battery, replace it since the cracks or defects can cause liquid spills. CAUTION– Make sure you grease the ê...
Page 119 MAINTENANCE OPERATIONS Charging • Although, as a rule, charging of the battery should be done with the battery removed from the vehicle, if you have to charge the battery while it is on the vehicle, make sure that you stop the engine and disconnect the battery cable ë. •...
Page 120 M E M O 01-23...
Page 121 MAINTENANCE OPERATIONS Fuse F18 to 34 F1 to 17 12983 1 Main high-current fuse 2 High-current fuse box 3 Fuse box CAUTION– • If a fuse blows, make sure you identify and remedy the cause, then replace the fuse. • Make sure that you replace the fuse with one having the same rating. •...
Page 122 Main high-current fuse Fuse Main load Capacity — High-current fuse box 120 A High-current fuse box Fuse Main load Capacity Fuse box (F1 to F4) 50 A Fuse box (F5 to F8) 50 A Fuse box (F9 to F12) 40 A Starter switch (Terminal B) 40 A Glow relay...
Page 123 LUBRICATION *1 : 30000 km/18000 miles or 6 months, whichever occurs first. *2 : 60000 km/36000 miles or 12 months, whichever occurs first. : Exhaust emission items Time of inspection and maintenance Inspection interval Inspection and Lubrication procedures Remarks maintenance ×...
Page 124 Engine Oil Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Oil pan drain plug 69 {51, 7} — [Inspection] • Pull out dipstick 1, wipe off the oil with a cloth. • Reinsert dipstick 1, then pull it out carefully. •...
Page 125 LUBRICATION [Replacement] °C Since engine oil greatly influences the performance, the life expectancy, °F and the ability to start the engine, use only oil of the specified grade and S A E 1 0 W – 3 0 viscosity. The chart illustrates the relationship between oil viscosity and the ambi- S A E 2 0 W –...
Page 126 Clutch Fluid (Brake Fluid) Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Air bleeder 25 to 34 {18 to 25, 2.5 to 3.5} — - Fluid Location Points of application Kinds Quantity Fluid tank Brake fluid As required...
Page 127 LUBRICATION • Supply new brake fluid to the “MAX” level of fluid tank 1. Depress clutch pedal 4 repeatedly until the old brake fluid discharged from vinyl pipe 3 is replaced by the new brake fluid. NOTE Carry out this operation maintaining the brake fluid level in fluid tank 1 between “MAX”...
Page 128 Manual Transmission Gear Oil Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Inspection plug 69±15 {51±11, 7±1.5} — Drain plug 69±15 {51±11, 7±1.5} — - Sealant Location Points of application Kinds Quantity Thread area of inspection plug THREEBOND 1105D As required...
Page 129 LUBRICATION Automatic Transmission Fluid and Oil Filter Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Drain plug 20 to 27 {15 to 20, 2.05 to 2.75} — Dipstick guide connector 125 to 135 {91 to 100, 12.55 to 13.76} —...
Page 130 [Replacement] • Park the vehicle on level ground, chock the wheels and shift the range selector lever to the N position. • Place a container under oil pan 3, remove drain plug 4 and drain the fluid. WARNING– Take care because the fluid temperature immediately after the engine has stopped is very high.
Page 131 LUBRICATION • Remove oil filter 12 (for oil cooler) by turning it counterclockwise. • Lightly coat gasket C with the fluid before installing oil filter 12. Then tighten the oil filter. 14157 • Supply fluid through dipstick guide 2. CAUTION– Make sure that dirt and foreign particles do not become mixed in with the fluid when it is added.
Page 132 Rear Axle Gear Oil Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Inspection plug 98 to 115 {72 to 87, 10 to 12} — Drain plug 98 to 115 {72 to 87, 10 to 12} —...
Page 133 LUBRICATION Power Steering Fluid Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Oil pipe 66.69±12.75 {49±9.4, 6.8±1.3} — - Fluid Location Points of application Kinds Quantity Between Power steering oil tank Automatic transmission fluid end and F (DEXRON or DEXRON II type) on filler...
Page 134 [Supply] • Pour fluid into power steering oil tank 1 up to the inner port of strainer • With the engine stopped, jack up the front wheels and turn the steer- ing wheel fully left and right repeatedly. When the fluid level has dropped, add fluid to maintain the fluid level within range A.
Page 135 LUBRICATION Brake Fluid Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks — Air bleeder (Airmaster) 6.9 to 12.7 {5.1 to 9.4, 0.7 to 1.3} — — Air bleeder (Wheel brake) 7.8 to 12 {5.8 to 8.5, 0.8 to 1.2} —...
Page 136 [Inspection and replenishment] Inspect the level of the brake fluid in fluid tank 1. It should fall between the “L” and “H” levels. If it is below the “L” level, remove cap 2 from the fluid tank, then supply the specified brake fluid until the level comes up to the “H”...
Page 137 LUBRICATION • Loosen air bleeders 1 and depress brake pedal 2 several times to drain brake fluid completely. 12548 • Maintaining a supply of new brake fluid up to the “H” level of fluid tank 3, depress the brake pedal repeatedly until the old brake fluid of the brake system is replaced with new fluid.
Page 138 • Depress brake pedal 3 slowly a few times, and with the brake pedal depressed, loosen air bleeder 2 to drain brake fluid containing air. • Tighten air bleeder 2, and release brake pedal 3. • Repeat this service procedure until air is no longer present in the fluid being drained.
Page 139 LUBRICATION Greasing Various Areas of Chassis Carefully clean away all dust and dirt from the grease nipples, and use the specified type of grease. The areas to be greased are shown in the following illustration. 02195 02244 02245 02246 02243 02247 02248 00360...
Page 140 Door hinge 01518 01-43...
Page 141 Group 10 Removal and Installation of Engine Table of Contents BACK HOME Pub No. TWME9502-10...
Page 142 GROUP 10 REMOVAL AND INSTALLATION OF ENGINE REMOVAL AND INSTALLATION OF ENGINE • Charge and Discharge of Engine Coolant, Removal and Installation of Hoses ..............• Removal and Installation of Engine Related Parts .......... • Removal and Installation of Engine ..............10-1...
Page 143 REMOVAL AND INSTALLATION OF ENGINE Charge and Discharge of Engine Coolant, Removal and Installation of Hoses 13258 13257 13259 13260 10-2...
Page 144 Work before removal and after installation Õ P10-3 Removal sequence 1 Battery cable ë 2 Pressure cap (Surge tank) 3 Radiator drain plug ^ Gr 14 4 Crankcase drain plug ^ Gr 14 5 Transmission assembly ^ Gr 22, 23 6 Air hose ^ Gr 14 7 Suction hose ^ Gr 14 8 Supply hose ^ Gr 14...
Page 145 REMOVAL AND INSTALLATION OF ENGINE Removal and Installation of Engine Related Parts 10 12 13261 13262 10-4...
Page 146 Removal sequence 1 Supply hose ^ Gr 14 2 Inlet hose ^ Gr 14 3 Heater hose ^ Gr 55B 4 Air intake hose ^ Gr 15 5 Outlet hose ^ Gr 14 6 Air intake hose ^ Gr 15 7 Intercooler ^ Gr 15 8 Radiator ^ Gr 14 9 Air intake hose ^ Gr 15...
Page 147 REMOVAL AND INSTALLATION OF ENGINE Removal and Installation of Engine 11723 11724 11725 Removal sequence 1 Bolt 2 Nut 3 Engine assembly WARNING– When you lift engine assembly 3, you must use lifting gear that is strong enough to lift the mass of the engine (approximately 550 kg {1210 lb}).
Page 148 Service procedure Removal of engine assembly • Hook lifting gear B to two hangers A on engine assembly 3 and lift the engine using crane C until the lifting gear becomes taut. • Make sure that wiring and hoses are disconnected. 13263 •...
Page 149 Group 11 Engine Table of Contents BACK HOME Pub No. TWME9502-11...
Page 150 GROUP 11 ENGINE SPECIFICATIONS .................. 2 STRUCTURE AND OPERATION ............3 TROUBLESHOOTING ................6 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE • Inspection of Engine Compression ..............• Inspection and Adjustment of Valve Clearance ..........CYLINDER HEAD AND VALVE MECHANISM ........10 TIMING GEAR ..................
Page 151 SPECIFICATIONS Item Specifications Engine model 6D34T2 Type 6-cylinder in-line, water-cooled 4-cycle diesel Combustion chamber type Direct injection type Valve mechanism Overhead valve (OHV) type Maximum output HP/rpm 175/2900 (SAE Gross) Maximum torque lbs.ft/rpm 325/2000 (SAE Gross) Bore×stroke mm {in.} ø104×115 {4.09×4.53} Total displacement {cu.
Page 152 STRUCTURE AND OPERATION Engine Body 12384 1 Rocker arm 9 Piston 2 Valve spring 10 Connecting rod 3 Camshaft 11 Timing gear 4 Cylinder sleeve 12 Tappet 5 Cylinder head 13 Inlet valve 6 Flywheel 14 Push rod 7 Crankshaft 8 Exhaust valve A : Direction of rotation 11-3...
Page 153 STRUCTURE AND OPERATION Connecting Rod 1 Connecting rod bushing 2 Connecting rod 3 Connecting rod cap 4 Connecting rod bolt 5 Upper connecting rod bearing 6 Lower connecting rod bearing A : Alignment mark B : Mass mark (A, B, C, D, E, F, G) 03141 Piston A : Stamped mass...
Page 154 Timing Gear 1 Camshaft gear 2 Injection pump gear 3 Crankshaft gear 4 Oil pump gear 5 Idler gear 6 Idler shaft 7 Idler bushing 8 Bolt 9 Thrust plate 10 Power steering oil pump gear A : Oil hole Alignment marks “1”, “2”, “3”...
Page 155 TROUBLESHOOTING Symptoms Remarks Possible causes ^ Gr 12 Oil viscosity unsuitable Fuel incorrect or unsuitable Valve clearance faulty Head gasket faulty Valve and valve seat worn, and carbon deposits Valve spring fatigued Piston ring worn or damaged Piston ring grooves worn or damaged ^ Gr 13 Injection timing faulty ^ Gr 13...
Page 156 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Inspection of Engine Compression Service standards Location Maintenance item Standard value Limit Remedy Engine Each cylinder (200 rpm) 2550 kPa {370 lbf/in , 26 kgf/cm 1960 kPa Inspect Compression {285 lbf/in 20 kg/cm — Pressure difference between each —...
Page 157 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE • Remove fuse 2 for the fuel-cut motor from fuse box 1 inside the cab to prevent the fuel from being injected when the engine is cranked by the starter. 12000 • Remove all the injection nozzles. ^ Gr 13 •...
Page 158 Inspection and Adjustment of Valve Clearance Service standards Unit : mm {in.} Location Maintenance item Standard value Limit Remedy — Valve clearance (When engine is cold) 0.4 {0.016} — Adjust Inspect and adjust the valve clearance while the engine is cold in the following way.
Page 159 CYLINDER HEAD AND VALVE MECHANISM Disassembly sequence 1 Oil filler cap 2 Rocker cover gasket 3 Rocker cover 4 Cylinder head bolt 5 Rocker and bracket assembly 2 Ù Õ P11-14 6 Push rod 7 Cylinder head and valve assembly Õ P11-16 4 Ê...
Page 160 0 Special tools Location Tool name and shape Part No. Application Socket wrench MH061560 Installation of cylinder head and valve assembly 01984 Tappet extractor MH063329 Removal of tappet 03320 Service procedure Push rod deflection If the measured value is higher than the limit, replace push rod 6. 01948 Cylinder head and valve assembly [Removal]...
Page 161 CYLINDER HEAD AND VALVE MECHANISM [Installation] • Center punch the heads of cylinder head bolts 4 before installation. CAUTION– À À À À À À À If there are already three center-punch marks, replace the cylinder head bolt with a new one. •...
Page 162 Cylinder head gasket “UP” [Removal] CAUTION– Be careful not to scratch the cylinder head or crankcase * when you remove cylinder head gasket 8. [Installation] • Install cylinder head gasket 8 onto crankcase * in the direction as illustrated. 12411 CAUTION–...
Page 163 CYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly Disassembly sequence 1 Set bolt 2 Rocker shaft bracket 3 Rocker assembly 4 Rocker bushing 5 Lock nut 6 Adjusting screw 7 Rocker 8 Rocker shaft spring 9 Rocker shaft Assembly sequence Follow the disassembly sequence in re- verse.
Page 164 Service procedure Rocker bushing and rocker shaft [Inspection] If the clearance is higher than the limit, replace the faulty parts. 01952 Rocker bushing [Removal] 06009 [Press-fitting] • Align oil hole A of rocker bushing 4 with oil hole B of rocker 7. •...
Page 165 CYLINDER HEAD AND VALVE MECHANISM Cylinder Head and Valve Assembly Disassembly sequence 1 Valve cap 2 Valve cotter 3 Upper retainer 4 Outer valve spring 11 Ê 5 Inner valve spring 12 Ê 6 Valve stem seal Ù15 7 Inlet valve Ù14 8 Exhaust valve 9 Nut...
Page 166 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) Outer valve Without load 66.1 {2.60} 63.0 {2.48} Replace spring Installed load 273±12 N 230 N {52 lbf, Replace (Installed length 47.25 {1.86}) {62±2.6 lbf, 27.9±1.2 kgf} 23.7 kgf} Tilt...
Page 167 CYLINDER HEAD AND VALVE MECHANISM 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Valve lifter 30091-08500 Removal and installation of valve cotter ø47 {1.85} 03265 ø9 Valve stem seal MH061293 Installation of valve stem ø28 {0.35} {1.10}...
Page 168 Service procedure Valve cotter [Removal] Remove valve cotter 2 making sure that valve springs 4, 5 are squarely and evenly pressed down by 0 valve lifter. [Installation] Follow the removal procedure in reverse. CAUTION– Be sure not to press down on valve springs 4, 5 too hard because 03252 this would cause upper retainer 3 to contact valve stem seal 6 and damage it.
Page 169 CYLINDER HEAD AND VALVE MECHANISM (2) Valve seat angle and valve margin If the measured value is higher than the limit, correct or replace valves 7, 8. 7, 8 Valve seat angle Valve margin 02264 [Correction] NOTE • Be sure to keep the grinding work as light as possible. •...
Page 170 78OP Valve and valve seat [Inspection] • Apply red lead evenly to entire surface A of valve seats 19, 20 that contact valves 7, 8. • Fit valves 7, 8 to valve seats 19, 20 and tap once without rotating. NOTE Be sure to carry out inspection under the condition that valves 7, 8 and all parts of valve guides 17, 18 are normal.
Page 171 CYLINDER HEAD AND VALVE MECHANISM Valve seat [Inspection] 7, 8 19, 20 (1) Valve seat width If the measured value is higher than the limit, replace valve seats 19, A : Valve seat width NOTE Be sure to lap and fit valves 7, 8 and valve seats 19, 20 after 01975 correction or replacement.
Page 172 [Installation] • Make sure that the diameter of valve seat hole of cylinder head 23 conforms to the standard value. E : Inlet valve seat hole diameter F : Exhaust valve seat hole diameter +0.025 +0.025 ø46 ø39 +0.00098 +0.00098 {1.81 in.} {1.54...
Page 173 TIMING GEAR Ê18 Ù - 20 12575 Ê 14 - - Ê 1 Ê Ù Ù 12543 Inspection before disassembly Õ P11-26 Disassembly sequence *1 : Crankshaft gear Õ P11-52 12 Idler gear assembly 1 Nut *2 : Oil pump gear ^ Gr 12 2 Taper cone 13 Idler gear bushing *3 : Camshaft gear Õ...
Page 174 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) — Backlash of Idler gear assembly and crankshaft 0.07 to 0.15 {0.0023 to 0.0059} 0.3 {0.012} Replace gears gear Idler gear assembly and camshaft 0.07 to 0.17 {0.0023 to 0.0067} 0.3 {0.012} gear...
Page 175 TIMING GEAR Service procedure Inspection before disassembly (1) Backlash of each gear Measure three or more locations on the pairing gears and if the measurements are higher than the limit, replace the faulty parts. 12576 (2) End play of idler gear If the measured value is higher than the limit, replace the faulty parts.
Page 176 Installation of thrust plate A : Chamfered side 03536 Installation of idler gear assembly Install idler gear assembly 12 by matching alignment marks “1”, “2”, “3” on the gears that engage with those on the assembly. *1 : Crankshaft gear *2 : Camshaft gear *3 : Air compressor gear NOTE...
Page 177 CAMSHAFT 7 Ù Ê 12638 Disassembly sequence 6 Thrust plate 11 Sealing cap 1 Bolt 7 Key 12 No.4 camshaft bushing 2 Camshaft assembly 8 Camshaft 13 No.3 camshaft bushing 3 Bolt 9 No.1 camshaft bushing 4 Washer * : Crankcase Õ P11-52 10 No.2 camshaft bushing 5 Camshaft gear Ù...
Page 178 - Lubricant Location Points of application Kinds Quantity Thread area of bolt Engine oil As required 9, 10 Inner surface of camshaft bushing Engine oil As required 12, 13 0 Special tools Unit : mm {in.} Location Tool name and shape Part No.
Page 179 CAMSHAFT [Installation] • Before installing camshaft assembly 2, measure the end play be- tween thrust plate 6 and camshaft 8. • If the measured value is higher than the limit, replace the faulty parts. • Install the camshaft assembly by matching the alignment mark on camshaft gear 5 with the alignment mark on the idler gear.
Page 180 Inspection of camshaft (1) Difference between long diameter and short diameter If the measured value is lower than the limit, replace camshaft 8. NOTE Measure at point A, as illustrated, because the cam is tapered. B : Long diameter 7.5 mm 7.5 mm {0.30 in.} {0.30 in.}...
Page 181 CAMSHAFT • For press-fitting, mount guide B to 0 camshaft bushing installer and 9, 10, 12, 13 extractor. • Install camshaft bushings 9, 10, 12, 13 in descending order, from No.4 to No.1. • Install No.4 camshaft bushing 12 from the rear end of the engine, and No.3 to No.1 camshaft bushings 9, 10, 13 from the front end of the engine.
Page 182 • For press-fitting of No.3 camshaft bushing 13, use tool K as illustrated. 200 mm {7.37 in.} 50 mm {1.97 in.} ø30 mm {1.18 in.} ø17.5 mm {0.69 in.} 07584 • Align oil holes L, M of No.1 camshaft bushing 9 in the direction as illustrated.
Page 183 PISTON, CONNECTING ROD AND CYLINDER SLEEVE - Ê1 12702 Disassembly sequence *1 : Crankshaft Õ P11-52 1 Bolt *2 : Crankcase Õ P11-52 2 Lower connecting rod bearing *3 : Oil pan ^ Gr 12 3 Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly Õ...
Page 184 Service standards Unit : mm {in.} Standard value Location Maintenance item Limit Remedy (Basic diameter in [ ]) — Extent of piston protrusion 0.43 to 0.69 {0.017 to 0.027} — Inspect — End play of connecting rod 0.15 to 0.45 {0.0059 to 0.018} 0.6 {0.024} Inspect 2, 4...
Page 185 PISTON, CONNECTING ROD AND CYLINDER SLEEVE 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Socket wrench MH061560 Installation of piston and connecting 01984 rod assembly : Piston guide clamp : MH061890 : Piston guide lever : MF061658 01981 Cylinder sleeve installer...
Page 186 Connecting rod bearing [Installation] Install connecting rod bearings 2, 4 by matching lugs A to the connecting rods. CAUTION– Be sure to distinguish between upper and lower connecting rod bearings 2, 4. The upper bearing has oil opening B while the lower bearing has no oil opening.
Page 187 PISTON, CONNECTING ROD AND CYLINDER SLEEVE Installation of piston and connecting rod assembly CAUTION– • Be sure to fit piston ring A in the correct position. Õ P11-46 • Be careful not to scratch or damage head B of the piston (a part of the combustion chamber).
Page 188 • Turn 0 socket wrench holder G counterclockwise and keep the spring in the wrench compressed. Socket Rod (for connection) 01991 • Set 0 socket wrench holder G so that the repercussive force of the spring presses rod K (for connection) against crankshaft *1. •...
Page 189 PISTON, CONNECTING ROD AND CYLINDER SLEEVE Cylinder sleeve [Removal] • Mount a boring machine on crankcase *2 and center. Centering must be done at the lower part of cylinder sleeve 6 which is less unevenly worn. • Bore until the thickness of cylinder sleeve 6 is approximately 0.5 mm {0.020 in.}.
Page 190 < If interference is sufficient > • Press-fit cylinder sleeve 6 into crankcase *2 from the chamfered end using 0 cylinder sleeve installer. NOTE Align the top of cylinder sleeve 6 with the top of crankcase *2 when press-fitting. • After press-fitting, make the inner diameter of cylinder sleeve 6 con- form to the standard value by honing the surface.
Page 191 PISTON, CONNECTING ROD AND CYLINDER SLEEVE Piston and Connecting Rod Assembly Disassembly sequence 1 Snap ring 2 Piston pin 3 Connecting rod bushing 4 Connecting rod 5 1st compression ring 6 2nd compression ring 7 Oil ring 8 Piston Assembly sequence Follow the disassembly sequence in re- verse.
Page 192 0 Special tools Unit : mm {in.} Location Tool name and shape Part No. Application Connecting rod bushing puller kit MH062225 Removal and installation of connecting rod bushing 02015 ø60 to 120 {2.36 to 4.72} 5 to 7 Piston ring tool MH060014 Removal and installation of piston ring 02013...
Page 193 PISTON, CONNECTING ROD AND CYLINDER SLEEVE [Press-fitting] • Apply engine oil to the exterior peripheral area of connecting rod bushing 3 and the inner area of the bushing fitting ring of connecting rod 4. • Fit collar F, connecting rod bushing 3 and collar D in puller C in the arrangement and direction as illustrated and mount them with nut G.
Page 194 Clearance between piston pin and piston If the clearance is higher than the limit, replace the faulty parts. 02016 Degree of bend or distortion of connecting rod • Mount connecting rod bushing 3 and piston pin 2 to connecting rod 4. 100 mm •...
Page 195 PISTON, CONNECTING ROD AND CYLINDER SLEEVE Piston ring and piston Piston ring [Removal] 02024 [Installation] • Install oil ring 8 so that split D and the butting joint of expander spring E come to the points as illustrated. “ ” •...
Page 196 (2) Clearance between piston ring and ring groove • If the measured value is higher than the limit, replace the faulty parts. • Measure using feeler gauge F, by pressing 1st compression ring 5 against piston 8 with straight edge G. NOTE •...
Page 197 FLYWHEEL 2 Ê - 2 Ê - 3 < Automatic transmission > < Manual transmission > 12719 Disassembly sequence 1 Flywheel housing adaptor 5 Flywheel adaptor 11 Rear oil seal < Automatic transmission > < Automatic transmission > 12 Flywheel housing 2 Bolt 6 Bearing 3 Plate <...
Page 198 Ê Tightening torque Unit : N·m {lbf.ft, kgf·m} Location Parts to be tightened Tightening torque Remarks Bolt (Flywheel mounting) 39 {29, 4} +45 - Lubricant and sealant Location Points of application Kinds Quantity Thread area of bolt Engine oil As required Lip area of rear oil seal Engine oil As required...
Page 199 FLYWHEEL Ring gear [Inspection] Check and see if there is any damage, wear or other fault, and if any fault is found, replace ring gear 8. [Removal] • Heat up ring gear 8 evenly using an acetylene torch. • Hammer the outer edge of ring gear 8 evenly until it drops off. 03352 [Installation] •...
Page 200 M E M O 11-51...

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