GENERAL INFORMATION 0A-1

SECTION 0

GENERAL INFORMATION

CONTENTS
SUBJECT PAGE

General Information .............................................................................................................................................. 0A

Maintenance and Lubrication .............................................................................................................................. 0B

SECTION 0A

GENERAL INFORMATION
CONTENTS
SUBJECT PAGE

Handling Electrostatic Discharge (ESD) Sensitive Parts ............................................................................ 0A- 2

Model Reference ..............................................................................................................................................0A- 2
VIN (Vehicle Identification Number) and Weight Rating Plate..................................................................... 0A- 2
GVWR (Gross Vehicle Weight Rating) .......................................................................................................... 0A- 3
Service Parts Identification Label ................................................................................................................. 0A- 3
Regular Production Options (RPO) Code List ............................................................................................. 0A- 4
Engine Serial Number ..................................................................................................................................... 0A- 5
Graphic Symbols ............................................................................................................................................ 0A- 5
Action Symbols ............................................................................................................................................... 0A- 5
Emergency Starting a Vehicle Due to a Discharged Battery ....................................................................... 0A- 5
Towing Procedure ........................................................................................................................................... 0A- 6
Vehicle Lifting Points ..................................................................................................................................... 0A- 7
Abbreviations Charts ...................................................................................................................................... 0A- 8
Essential Service Tools .................................................................................................................................. 0A-10
0A-2 GENERAL INFORMATION

HANDLING ELECTROSTATIC DISCHARGE

Crew cab model
(ESD) SENSITIVE PARTS

When handling an electronic part that has an ESD

MODEL
sensitive sticker (figure 1), the service technician
should follow these guidelines to reduce any
possible electrostatic charge build-up on the
service technicians body and the electronic part in NPR
the dealership: NQR
1. Do not open the package until it is time to install
the part.
2. Avoid touching the electrical terminals of the
part.
3. Before removing the part from its package,
ground the package to a known good ground on Figure 3. Model Reference (Crew Cab Model)
the vehicle.
VIN (VEHICLE IDENTIFICATION NUMBER)
4. Always touch a known good ground before
AND WEIGHT RATING PLATE
handling the part. This should be repeated
while handling the part and more frequently
The VlN and Weight Rating Plate (figure 4) lists
after sliding across the seat, sitting down from a
the manufacturer, gross vehicle weight for the
standing position or walking a distance.
vehicle, maximum front end weight at ground,
maximum rear end weight at ground, and the VlN
(vehicle identification number). This plate is
attached to the inner face of the cab side panel on
the driver side.
The vehicle identification number is a legal
identifier of your vehicle. It not only appears on the
VlN plate, but also on the Vehicle Certificates of
Title and Registration. The vehicle identification
number specifically identifies a vehicle by code.
Figure 5 displays the codes and descriptions for the
model covered in this manual.

Figure 1. Electrostatic Discharge Symbol

MODEL REFERENCE

The models covered in this manual are referred to

as a NPR, NQR.

Single cab model

MODEL

NPR
NQR
Figure 4. VIN Weight Rating Plate

Figure 2. Model Reference (Single Cab Model)

 GENERAL INFORMATION 0A-3

Cab Type Code Model Year Code

GVWR and Engine
Brake System Code
Series Chassis Check Plant
Identifiers Code Type Code Digit Code Sequential Numbers

J A L B 4 B 1 4 * Y 7 0 0 0 0 0 1

Code Description Code Plant Location

J Japanese Built 7 Fujisawa

Code Model Year

Code Description
X 1999
A Isuzu Motors
Y 2000
8 Isuzu Motors
1 2001
2 2002
Code Description
B Chevrolet Incomplete Code Description
D GMC Incomplete 4 Isuzu 4HE1-TCS
L Isuzu Incomplete 5 Isuzu 4HE1-TCN

Code Description
Code Description 1 42
B 10001 - 14000 lbs.
C 14001 - 16000 lbs.
E 16001 - 19500 lbs. Code Description
Hydraulic Brake System B Steel Tilt Cab
67.8 inch BBC*
Code Series J Non Tilt Cab
4 NPR/NPR HD 109 inch BBC*
5 NQR
*: Bumper to Back of Cab

Figure 5. VIN Chart

GVWR (GROSS VEHICLE WEIGHT

RATING)

The GVWR is the weight of a vehicle plus the

weight of a vehicles load. For the gross vehicle
weight rating and the gross vehicle combined
weight rating, refer to Model Explanation (figure 2).
For the gross vehicle weight rating range refer to
the VlN Chart (figure 5).

SERVICE PARTS IDENTIFICATION LABEL

The Service Parts Identification label (figure 6)

lists major components and their part numbers plus
vehicle options and their codes. The information on
the label was printed at the factory; therefore, it
represents only the equipment on the vehicle when
it was shipped from the factory. Always refer to this Figure 6. Service Parts Identification Label
label when ordering replacement service parts.
(Refer to the NOTICE on the label.)
The service parts identification label is attached
to the inner face of the cab side panel on the
Passenger side.
0A-4 GENERAL INFORMATION

REGULAR PRODUCTION
OPTIONS (RPO) CODE LIST

The RPO list (figure 7) contains RPOs available

on this model. Also, refer to the Service Parts
Identification label (figure 6) for a list of the RPOs Note; F=Front
R=Rear
used on each specific vehicle.
w/=With

OPTION OPTION OPTION OPTION

CODE DESCRIPTION CODE DESCRIPTION
100 INTERIOR-TRIM COLOR COMBI.(IN WHITE) RNJ AUTOMATIC TRANSMISSION 4-SPEED (AISIN)
153 INTERIOR-TRIM COLOR COMBI.(GRAY) RNL MANUAL TRANSMISSION-5 SPEED (MXA-5C)
729 BODY COLOR CODE-ARC WHITE (W301-P801) M11 SHIFT-FLOOR (REMOTE)
730 BODY COLOR CODE-ADRIATIC BLUE V66 POWER TAKE OFF-PROVISIONS FOR
(B302-P801) NL7 FUEL TANK-125L, 33GAL
800 BODY COLOR CODE-IN WHITE 6HU FUEL SEDIMENTER-WITH HEATER
979 BODY COLOR CODE-HEILING MAYERS GREEN N33 STEERING COLUMN-TILT TYPE
D94 PAINT-TOUCH-UP, ONE COLOR (WITH TELESCOPIC)
VG1 WAX-PROTECTIVE UNDERBODY N40 STEERING-POWER
RWC CANADIAN EQUIPMENT ASQ F/TIRE215/85R16-E, R/TIRE215/85R16-E
6SH BUDGET PACKAGE F&R/DISC 16X6K-127 w/DOT MARK
7VH OFFICE DEPOT PACKAGE WHITE DISC, (BS BRAND, R187)
YL3 FRIGID ZONE KIT AVE F&R/TIRE 225/70R19.5
6JJ DEALER INSTALLATION OPTION F&R/DISC 19.5X6.00-127, WHITE
6FM US TERRITORY (FT HIGHWAY, RR MUD & SNOW)
RQF GVWR CLASS-3 (10001-14000 LBS) AVU F&R/TIRE 225/70R19.5
RQG GVWR CLASS-4 (14001-16000 LBS) F&R/DISC 19.5X6.00-127, WHITE
RQH GVWR CLASS-5 (16001-19500 LBS) (FT & RR HIGHWAY)
7NQ VEHICLE CATEGORY-NQR AVZ F&R/TIRE 225/70R19.5 (FOR BUDGET)
6FZ FENDER COVER F&R/DISC 19.5X6.00-127, WHITE
RWZ CAB-TILT, MANUAL (FT & RR MUD & SNOW)
EK7 MARK-VEHICLE NAME AZF F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
6JS SEAT BELT EXTENSION F&R/DISC 16X6K-128 w/DOT MARK
D20 SUNVISOR-CO-DRIVER SIDE WHITE DISC (ALL SEASON)
C41 HEATER & DEFROSTER 9YY F/TIRE 215/85R16-E, R/TIRE 215/85R16-E JU019
C60 AIR CONDITIONER-MANUAL CONTROL F&R/DISC 16X6K-127 w/DOT MARK
C55 VENTILATOR-ROOF WHITE DISC
V92 TRAILER PROVISIONS 9YZ F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
F59 STABILIZER SHAFT-FRONT F&R/DISC 16X6K-127 w/DOT MARK
G73 AXLE REAR-HEAVY DUTY WHITE DISC, FOR BUDGET
6CP AXLE REAR-HEAVY DUTY VAR.2 9ZB F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
GT5 FINAL DRIVE GEAR RATIO-4.100 (41/10) F&R/DISC 16X6K-127 w/DOT MARK
HC6 FINAL DRIVE GEAR RATIO-4.556 (41/9) WHITE DISC (ALL SEASON)
R40 FINAL DRIVE GEAR RATIO-5.375 (43/8) 9ZC F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
R41 FINAL DRIVE GEAR RATIO-5.857 (41/7) F&R/DISC 16X6K-127 w/DOT MARK
7QQ BRAKE SYSTEM-HYDRO BRAKE BOOSTER WHITE DISC FOR BUDGET (ALL SEASON)
NF8 EXHAUST-BRAKE 9ZD F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
J52 BRAKES-FT DISK, MULTIPLE PISTON F&R/DISC 16X6K-127 w/DOT MARK
6PH BRAKE-WHEEL LOCK CONTROL, (L.S.P.V) WHITE DISC, (RR ALL SEASON)
JE5 ANTI LOCK BRAKE SYSTEM 9ZV F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
RLY ENGINE-DIESEL 4CYL L 4.8L (4HE1) F&R/DISC 16X6K-127 w/DOT MARK, WHITE
EE2 GOVERNOR-ENGINE, WITH HIGH ALTITUDE US DISC (ALL SEASON, US GOODYEAR)
COMPENSATOR R46 SPARE TIRE & DISC WHEEL VAR.1
K51 TURBO CHARGER 7NC SPARE TIRE & DISC WHEEL-LESS
KJ3 AIR INTAKE SYSTEM; RR VERTICAL P10 CARRIER-SPARE WHEEL (TRUCK)
6PL INTERCOOLER U01 LAMPS-FIVE, ROOF MARKER
7QV ENGINE POWER N-SPEC 6GZ RADIO-AM/FM STEREO ETR 2-SPEAKERS
8AA LONG LIFE COOLANT (50%) 6VL AM/FM w/CASSETTE 2SP 31N-1
6HT HEATER-OIL PAN U73 ANTENNA
K05 HEATER-ENGINE BLOCK 7FK SPEAKER OPTION: 2-SPEAKER
RNC MANUAL TRANSMISSION-6 SPEED (MBP-6P) C13 WIPER-WITH INTERMITTENT

Figure 7. Regular Production Option List


ENGINE SERIAL NUMBER
The engine serial number is machined on the left
side of the engine just above the oil pan.
GRAPHIC SYMBOLS
Graphic symbols are used on some controls and
displays on the vehicle (figure 8). Many of these
symbols are used internationally.
CLEARANCE
LIGHTS
Figure 8. International Symbols
ACTION SYMBOLS
In this manual, much of the general narrative has
been replaced with step-by- step procedures and
the addition of Action Symbols. To improve
readability and to provide emphasis where
necessary, the following symbols are used in the
manual.
...Remove or Disconnect
...Install or Connect
GENERAL INFORMATION 0A-5
...Disassemble
...Assemble
...Clean
...Inspect
...Measure
...Adjust
...Tighten to specified torque
...Important
EMERGENCY STARTING A VEHICLE DUE
TO DISCHARGED BATTERY
If your vehicle will not start due to a discharged
battery, it can often be started by using energy from
another batterya procedure called jump starting.
This vehicle has a 12volt starting system and a
negative ground electrical system. Be sure that the
other vehicle also has a 12volt starting system, and
that it is the negative (black ) terminal which is
grounded (attached to the engine block, chassis or
frame rail). Its owners manual may give you that
information. DO NOT TRY TO JUMP START IF
YOU ARE UNSURE OF THE OTHER VEHICLES
VOLTAGE OR GROUND (OR IF THE OTHER
VEHICLES VOLTAGE AND GROUND ARE
DIFFERENT FROM YOUR VEHICLE).
Some diesel engine vehicles have more than one
battery because of higher torque required to start a
diesel engine. This procedure can be used to start
a single battery vehicle from any of the diesel
vehicles batteries. However, it may not be possible
to start a diesel engine from a single battery in
another vehicle, at low temperatures.
NOTICE: Never tow the vehicle to start, because
the surge forward when the engine starts could
cause a collision with the tow vehicle. Also, this
vehicle has 12volt batteries. Be sure the vehicle or
equipment used to jump start your engine is also
a 12volt Use of any other system may damage the
vehicles electrical components.
0A-6 GENERAL INFORMATION

Jump Starting Instructions

CAUTION: Batteries produce explosive gases,
contain corrosive acid, and supply levels of
electrical current high enough to cause burns.
Therefore, to reduce the risk of personal injury
when working near a battery:
Always shield your eyes and avoid leaning
over a battery whenever possible.
Do not expose a battery to open flames or
sparks.
Be sure any batteries that have filler caps are
properly filled with fluid.
Do not allow battery acid to contact eyes or
skin. Flush any contacted area with water
immediately and thoroughly, and get medical
help.
Follow each step in the jump starting
instructions.
1. Position the vehicle with the good (charged) Figure 9. Jump Starting Diagram
battery so that the booster (jumper) cables will TOWING PROCEDURE
reach but never let the vehicles touch. Also, be
sure the booster cables to be used do not have Proper equipment must be used to prevent
loose or missing insulation. damage to vehicles during any towing. State
2. In both vehicles: (provincial in Canada) and local laws that apply to
Turn off the engine control switch and all vehicles in tow must be followed.
lights and accessories except the hazard Vehicles should not be towed at speeds in excess
flasher or any lights needed for the work area. of 55 mph (90 km/h).
Apply the parking brake firmly, and shift the Connect to the main structural parts of the
automatic transmission to Park or manual vehicle.
transmission to Neutral. DO NOT attach to bumpers, tow hooks or
3. Make sure the cable clamps do not touch any brackets.
other metal parts. Clamp one end of the first Use only equipment designed for this purpose.
booster cable to the positive +terminal on one Follow the instructions of the wrecker
battery, and the other end to the positive manufacturer.
terminal on the other battery. Never connect + A safety chain system must be used.
to (figure 9). The procedures below must be followed when
4. Clamp one end of the second cable to the towing, to prevent possible damage.
negative terminal of the good (charged) Front End Towing
battery and the final connection (to any solid, (Front Wheels Off The Ground)
stationary metallic object) on the engine at least
Before Towing
450 mm (18 in) from the discharged battery; or
To prepare a disabled vehicle for front end towing
the frame rail, chassis or some other well-
with front wheels raised off the ground, the
grounded point, if the battery is mounted
following steps are necessary:
outside the engine compartment. Make sure the
Block the rear wheels of the disabled vehicle.
cables are not on or near pulleys, fans, or other
Manual Transmission Models
parts that will move when the engine is started.
Shift into neutral position.
5. Start the engine of the vehicle with the good
If there is damage or suspected damage to the
(charged) battery and run the engine at a
transmission, disconnect the propeller shafts at
moderate speed for several minutes. Then, start
the rear axle.
the engine of the vehicle that has the
Secure the propeller shafts to the frame or
discharged battery.
crossmember.
6. Remove the jumper cables by reversing the
Automatic Transmission Models
above installation sequence exactly. While
Disconnect the propeller shafts at the rear axle.
removing each clamp, take care that it does not
Secure the propeller shafts to the frame or
touch any other metal while the other end
crossmember.
remains attached.
NOTICE: Never tow the vehicle with propeller

shafts is connected, as this may cause damage to
the automatic transmission.
Provide wood blocking to prevent towing chain
and bar from contacting the bumper.
If there is damage or suspected damage to the
rear axle, remove the axle shafts. Cover the hub
openings to prevent the loss of lubricant or entry
of dirt or foreign objects.
After Towing
Block the rear wheels and install the axle and
propeller shafts if removed.
Apply the parking brake before disconnecting
from the towing vehicle.
Check and fill rear axle with oil if required.
Front End Towing
(All Wheels On The Ground)
Before Towing
Your vehicle may be towed on all wheels provided
the steering is operable. Remember that power
steering and brakes will not power assist. There
must be a tow bar installed between the towing
vehicle and the disabled vehicle.
To prepare a disabled vehicle for front end towing
with all wheels on the ground, the following steps
are necessary:
Block the rear wheels of the disabled vehicle.
Manual Transmission Models
Shift into neutral position.
If there is damage or suspected damage to the
transmission, disconnect the propeller shafts at
the rear axle.
Secure the propeller shafts to the frame or
crossmember.
Automatic Transmission Models
Disconnect the propeller shafts at the rear axle.
Secure the propeller shafts to the frame or
crossmember.
NOTICE: Never tow the vehicle with propeller
shafts connected, as this may cause damage to
the automatic transmission.
Provide wood blocking to prevent towing chain
and bar from contacting the bumper.
If there is damage or suspected damage to the
rear axle, remove the axle shafts. Cover the hub
openings to prevent the loss of lubricant or entry
of dirt or foreign objects.
After Towing
Block the rear wheels and install the axle and
propeller shafts if removed.
Apply the parking brake before disconnecting
from the towing vehicle.
Check and fill rear axle with oil if required.
Rear End Towing
When towing a vehicle with rear wheels raised,
secure the steering wheel to maintain straight-
GENERAL INFORMATION 0A-7
ahead position. Make certain that the front axle is
not loaded above the front axle Gross Axle Weight
Rating (GAWR) as indicated on the vehicles VIN
and Weight Rating Plate.
Special Towing Instructions
1. All state and local laws regarding such items as
warning signals, night illumination, speed, etc.,
must be followed.
2. Safety chains must be used.
3. No vehicle should ever be towed at over 55
mph (90 km/h).
4. Loose or protruding parts of damaged vehicles
should be secured prior to moving.
5. A safety chain system completely independent
of the primary lifting and towing attachment
must be used.
6. Operators should not go under a vehicle that is
being lifted by the towing equipment unless the
vehicle is adequately supported by safety
stands.
7. No towing operation that for any reason
jeopardizes the safety of the wrecker operator
or any bystanders or other motorists should be
attempted.
VEHICLE LIFTING POINTS
Figure 10 shows the jack stand placement points.
CAUTION: To help avoid personal injury when a
vehicle is on a jackstand, provide additional
support for the vehicle at the opposite end from
which components are being removed. This will
reduce the possibility of the vehicle falling off of
the stand.
= Indicates Area
for Jackstand
Placement, etc.
Figure 10. Vehicle Lifting Points
0A-8 GENERAL INFORMATION

ABBREVIATIONS CHARTS
For abbreviations of emission system, refer to the section 6E.

LIST OF AUTOMOTIVE ABBRIVIATIONS WHICH MAY BE USED IN THIS MANUAL

A Ampere (s) DVM Digital Voltmeter (10 meg.)
ABS Antilock Brake System DVOM Digital Volt Ohmmeter
AC Alternating Current EBCM Electronic Brake Control Module
A/C Air Conditioning ECM Engine Control Module
ACCEL Accelerator ECT Engine Coolant Temperature
ACC Accessary EEPROM Electronically Erasable Programmable
ACL Air Cleaner Read Only Memory
Adj Adjust EGR Exhaust Gas Recirculation
A/F Air Fuel Ratio EI Electronic Ignition
AIR Secondary Air Injection System ESD Electrostatic Discharge
Alt Altitude ETR Electronically Tuned Receiver
AMP Ampere (s) EVAP Evaporation Emission
ANT Antenna Exh Exhaust
ASM Assembly F Degrees Fahrenheit
A/T Automatic Transmission Fed Federal (All States Except Calif.)
ATDC After Top Dead Center FF Front Drive Front Engine
ATF Automatic Transmission Fluid FICD Fast Idle Control Device
Auth Authority FL Fusible Link
Auto Automatic Front Left
BARO Barometric Pressure FLW Fusible Link Wire
Bat Battery FP Fuel Pump
B+ Battery Positive Voltage FR Front Right
Bbl Barrel FRT Front
BHP Brake Horsepower ft Foot
BPT Back Pressure Transducer FWD Front Wheel Drive
BTDC Before Top Dead Center 4 4, 4WD Four Wheel Drive
C Degrees Celsuis 4 A/T Four Speed Automatic Transmission
CAC Charge Air Cooler Gal Gallon (3.785 )
Calif California GEN Generator
cc Cubic Centimeter GND Ground
CID Cubic Inch Deplacement Gov Governor
CKP Crankshaft Position g Gram
CKT Circuit Harn Harness
CL Closed Loop HBB Hydraulic Brake Booster
CLCC Closed Loop Carburetor Control HC Hydrocarbons
CMP Camshaft Position HD Heavy Duty
CO Carbon Monoxide Hg Hydrargyrum (Mercury)
Coax Coaxial HiAlt High Altitude
Conn Connector HO2S Heated Oxygen Sensor
Conv Coverter HU Hydraulic Unit
Cu.In. Cubic Inch HVAC Heater-Vent-Air Conditioning
CV Constant Velocity IAC Idle Air Control
DI Distributor Ignition IAT Intake Air Temperature
Diff Differential IC Integrated Circuit
Dist Distributor ID Identification
DLC Data Link Connector Inside Diameter
DOHC Double (or Dual) Overhead Camshaft IGN Ignition
DRL Daytime Running Light Int Intake
DTC Diagnostic Trouble Code IP Instrument Panel
DTM Diagnostic Test Mode IPC Instrument Panel Cluster
DTT Diagnostic Test Terminal ISC Idle Speed Control
 GENERAL INFORMATION 0A-9

J/B Junction Block QWS Quick Warming-up System

kg Kilograms REF Reference
km Kilometers RF Right Front
km/h Kilometer per Hour RFI Radio Frequency Interference
kPa KiloPascals RH Right Hand
KS Knock sensor RL Rear Left
kV Kilovolts (Thousands of Volts) RPM Revolutions per Minute
kW Kilowatts RPS Revolution per Second
L Liter RPM Sensor Engine Speed Sensor
lbft Foot Pounds RPO Regular Production Option
lbin Inch Pounds RR Right Rear
LF Left Front RS Right Side
LH Left Hand RTV Room Temperature Vulcanizing
LR Left Rear RWAL Rear Wheel Antilock Brake
LS Left Side RWD Rear Wheel Drive
LWB Long Wheel Base SAE Society of Automotive Engineers
L-4 In-line Four Cylinder Engine Sec Secondary
MAF Mass Air Flow SFI Sequential Multiport Fuel Injection
MAN Manual SI System International
MAP Manifold Absolute Pressure SIR Supplemental Inflatable Restraint System
Max Maximum SOHC Single Overhead Camshaft
MC Mixture Control Sol Solenoid
MFI Multiport Fuel Injection SPEC Specification
MIL Malfunction Indicator Lamp Speedo Speedometer
Min Minimum SRS Supplemental Restraint System
mm Millimeter ST Start
MPG Miles per Gallon Scan Tool
MPH Miles per Hour Sw Switch
M/T Manual Transmission/Transaxle SWB Short Wheel Base
MV Millivolt SYN Synchronize
NA Natural Aspirated Tach Tachometer
NC Normally Closed TB Throttle Body
Nm Newton Meter TBI Throttle Body Fuel Injection
NO Normally Open TCC Torque Converter Clutch
NOx Nitrogen, Oxides of TCM Transmission Control Module
OBD On-Board Diagnostic TDC Top Dead Center
OD Outside Diameter Term Terminal
O/D Over Drive TEMP Temperaure
OHC Overhead Camshaft TP Throttle Position
OL Open Loop TRANS Transmission
O2 Oxygen TURBO Tubocharger
O2S Oxygen Sensor TVRS Television & Radio Suppression
PAIR Pulsed Secondary Air Injection System TVV Thermal Vacuum Valve
P/B Power Brakes TWC Three Way Catalytic Converter
PCM Powertrain Control Module 3 A/T Three Speed Automatic Transmission
PCV Positive Crankcase Ventilation 2WD Two Wheel Drive
PRESS Pressure 4 2 Two Wheel Drive
PROM Programmable Read Only Memory U-joint Universal Joint
PNP Park/Neutral Position V Volt (s)
P/S Power Steering VAC Vacuum
PSI Pounds per Square Inch VDC Volts DC
PSP Power Steering Pressure VIN Vehicle Identification Number
Pt. Pint = 1/8 gallon 0.473125 VRRRE Vehicle Refrigerant Recovery and
Pri Primary Recycling Equipment
PWM Pulse Width Modulate V-ref ECM Reference Voltage
Qt Quart = 1/4 gallon 0.94625 VSS Variable Swirl System
0A-10 GENERAL INFORMATION

ABBREVIATIONS CHARTS (Continued)

VSS Vehicle Speed Sensor w/b Wheel Base

VSV Vacuum Switching Valve W/L Warning Light
V-6 Six Cylinder V Engine w/o Without
W Watt (s) WOT Wide Open Throttle
w/ With WSS Wheel Speed Sensor

ESSENTIAL SERVICE TOOLS

Essential service tools that are shown in this

service manual that have tool product numbers
beginning with J are available for worldwide
distribution from:
Kent-Moore
SPX Corporation
29784 Little Mack
ROSEVILLE,MI 48066-2298
1-800-328-6657
Mon.-Fri. 8:00 p.m. EST
Telex: 244040 KMTR UR
FAX-313-578-7375
 MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Lubrication Detail Information ....................................................................................................................... 0B- 1
Engine Oil and Viscosity Recommendations............................................................................................ 0B- 1
Maintenance Schedule ................................................................................................................................... 0B- 3
Explanation of Complete Vehicle Maintenance Schedule ........................................................................... 0B- 6
Normal Vehicle Use ..................................................................................................................................... 0B- 6
Owner Safety and Routine Maintenance ...................................................................................................... 0B- 9
Noise Emission Control ................................................................................................................................. 0B-10
Noise Control System.................................................................................................................................. 0B-10
Tampering with Noise Control System Prohibited ................................................................................... 0B-10
Recommended Fluids and Lubricants........................................................................................................... 0B-11
Lubrication Chart ............................................................................................................................................ 0B-12
Specifications .................................................................................................................................................. 0B-13
Capacities ..................................................................................................................................................... 0B-13
Mintenace Item ............................................................................................................................................. 0B-13
Fastener Torques......................................................................................................................................... 0B-13

LUBRICATION DETAIL INFORMATION

ENGINE OIL AND VISCOSITY
RECOMMENDATIONS
The oil industry markets various types of engine
oil under certain service designation and
specification numbers.
The selection of a reliable supplier and close
attention to the oil and filter element change
recommendations can provide satisfactory
lubrication and longer life for the engine.
Using the proper engine oil and following the
recommended oil change intervals is your best
assurance of continued reliability and performance
from your vehicles engine.
Engine oil containers are labeled with various
APl(American Petroleum Institute) designations of
quality. Be sure the oil you use has the API
designation CD, either alone or shown with other
designations such as SF/CD. Oils which are not
labeled CD should not be used. For example, do
not use oils labeled only SA, SB, SC, SD, SE,
CA, CB, CC, or oils with a combination of any of
these letterssuch as SE/CC, as this may cause
engine damage.
DO NOT USE SYNTHETIC OILS.
Diesel Engine Oil Viscosities
Viscosity numbers make up a classification of
lubricants in terms of fluidity or viscosity, but with
no reference to any other characteristics or
properties.
0B-2 MAINTENANCE AND LUBRICATION
DO NOT USE SYNTHETIC OILS
Figure 1. Oil Viscosity Chart
Where cold weather starting is a problem,oil and
coolant system heaters,as well as proper fuel
selection, will be helpful. However, if these are not
available, lighter viscosity oils may be used only to
facilitate starting. Do not use starting aids in the air
intake system. Such aids can cause immediate
engine damage.
The engine oil viscosity specification depends on
the temperature of the engine oil at the time of
starting the engine. Viscosity recommendations for
various starting temperatures are shown in the
Viscosity Chart.
When choosing an oil, consider the range of
temperature your vehicle will operate in before the
next oil change. Then, select the recommended oil
viscosity from the chart (figure 1).
Diesel Break-In Oils And Additives
The use of proprietary blends of supplementary
additives or concentrates such as engine oil
supplements, break-in oils, tune-up compounds,
friction reducing compounds, etc., is not
recommended in lubricating oils of the diesel
engine in these vehicles.
Change Intervals
The oil and oil filter change intervals for the
engine are based on the use of CD-quality oil and
high quality filters. Using oil other than CD-
quality, or not changing the oil and filter often
enough could reduce engine life. Damage to
engines due to improper maintenance or use of
incorrect oil quality and/or viscosity is not covered
by the warranty.
 MAINTENANCE SCHEDULE FOR NPR, NQR/W-Series

Interval (kilometers) Service Intervals

10 400
20 800
31 200
41 600
52 000
62 400
72 800
83 200
93 600
104 000
114 400
124 800
135 200
145 600
156 000
166 400
Months or Miles
(kilometers)
whichever
comes first
Interval (Miles)

6,500
13,000
19,500
26,000
32,500
39,000
45,500
52,000
58,500
65,000
71,500
78,000
84,500
91,000
97,500
104,000

No. Item

01 Engine Noise Check I I I I I I I I I I I I I I I I *

02 Idle Speed I I I

03 Valve Lash A A

04 Injection Timing I I

05 Injector C I
06 Engine Oil & Oil Filter R R R R R R R R R R R R R R R R or every 12 months

07 Fuel Filter (Single Cab Model) R R R R R R R R or every 12 months

Main Fuel Filter (Crew Cab Model) R R R R R R R R
MAINTENANCE SCHEDULE

8 or every 12 months
Fuel Filter / Water Separator (Crew Cab Model) Every 12,000 miles (19,000 kilometers)
09 Air Cleaner Filter R R R R or every 12 months
0
10 Air Intake system (Duct, Hose & Clamps) I I I I

11 Drive Belt I R or every 12 months

12 Engine Bolt Torque I I
13 Rotate Tires R R R R R R R R R R R R R R R R

(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate
* Initial Torque check at 650 miles is required. (C): Clean
MAINTENANCE AND LUBRICATION 0B-3
 MAINTENANCE SCHEDULE FOR NPR, NQR/W-Series (CONT.)

Interval (kilometers) Service Intervals

10 400
20 800
31 200
41 600
52 000
62 400
72 800
83 200
93 600
104 000
114 400
124 800
135 200
145 600
156 000
166 400
Months or Miles
(kilometers)
whichever
comes first
Interval (Miles)

6,500
13,000
19,500
26,000
32,500
39,000
45,500
52,000
58,500
65,000
71,500
78,000
84,500
91,000
97,500
104,000

No. Item

14 Engine Cooling System I I I I I I I I I I I I I I I I or every 12 months

0B-4 MAINTENANCE AND LUBRICATION

15 Engine Coolant R R R R or every 24 months

16 Exhaust System I I I I I I I I I I I I I I I I
17 Fuel Line System I I I I I I I I or every 12 months
18 Brake Lining and Pad for Wear I I I I I I I I I I I I I I I I
19 Brake Drum and Rotor for Wear and Damage I I I I or every 12 months
20 Brake Fluid I I I I R I I I I R I I I I R I or every 12 months
21 Hydraulic Brake Booster Fluid R R R or every 24 months
22 Brake Line LSV and Hoses I I I I or every 12 months
MAINTENANCE SCHEDULE (CONT.)

23 Clutch Pedal Free Travel I I I I I I I I or every 12 months

24 Manual Transmission Oil I I R I I R I I R I I R I I R I or every 12 months
25 Automatic Transmission Fluid I I I R I I I R I I I R I I I R or every 12 months

(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate
 MAINTENANCE SCHEDULE FOR NPR, NQR/W-Series (CONT.)

Interval (kilometers) Service Intervals

10 400
20 800
31 200
41 600
52 000
62 400
72 800
83 200
93 600
104 000
114 400
124 800
135 200
145 600
156 000
166 400
Months or Miles
(kilometers)
whichever
comes first
Interval (Miles)

6,500
13,000
19,500
26,000
32,500
39,000
45,500
52,000
58,500
65,000
71,500
78,000
84,500
91,000
97,500
104,000

No. Item

26 Automatic Transmission Filter R R R R or every 24 months

27 Differential Gear Oil I I I R I I I R I I I R I I I R or every 24 months
28 Power Steering Fluid R R R or every 12 months
29 Steering Gear Box Torque T T T T or every 12 months
30 Propeller Shaft Flange Torque I T T T T T T T T or every 12 months
31 Leaf Spring U-Bolt Torque* T T T T T T T T
32 Wheel Nut Torque* T T T T T T T T T T T T T T T T
33 King Pin L L L L L L L L L L L L L L L L or every 12 months
34 Propeller shaft L L L L L L L L or every 12 months
MAINTENANCE SCHEDULE (CONT.)

35 Wheel Bearing Grease R R R or every 12 months

36 Rear Spring Pins L L L L L L L L L L L L L L L L

(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate
* Initial Torque check at 650 miles is required.
MAINTENANCE AND LUBRICATION 0B-5
0B-6 MAINTENANCE AND LUBRICATION

EXPLANATION OF COMPLETE VEHICLE

MAINTENANCE SCHEDULE
The following is a brief explanation of the service
listed in the preceding Complete Vehicle
Maintenance Schedule.
NORMAL VEHICLE USE
The vehicle maintenance instructions in the
Maintenance Schedule are based on the
assumption that the vehicle will be used as
designed:
to carry passengers and cargo within the
limitations specified on the tire placard.
to be driven on reasonable road surfaces within
legal operating limits.
to be driven on a daily basis, as a general rule,
for at least several miles/kilometers.
to be driven on proper fuel (See Owners Manual;
Diesel Fuel Requirement.).
Unusual operating conditions will require more
frequent vehicle maintenance, as specified in the
following section.
1. ENGINE NOISEThese components have an
effect on the control of noise emissions.
2. IDLE SPEED Check and adjust the engine
idle speed on the first 6,500 miles (10,400 km)
and every 52,000 miles (83,200 km).
Adjustments must be made with test equipment
known to be accurate.

Engine (Every 6,500 miles or 10,400 km) Inspection sound absorption materials for tears, broken out
sections or attachment. Repair or replace as necessary.

Cooling system (Every 13,000 miles or Inspection fan, shroud and radiator for attachment, tears or
20,800 km) cleanliness. Repair or replace as necessary.

Air intake system (Every 26,000 miles or Inspect all ducts, hoses and intake silencers for leaks or
41,600 km) chafing.Repair or replace as necessary.

Exhaust system (Every 6,500 miles or Inspect silencer, pipes, gaskets, clamps and mounting for
10,400 km) exhaust gas leaks or Iooseness. Repair or replace as
necessary.

Cab (Every 6,500 miles or 10,400 km) Inspect sound absorption materials for tears, broken out
sections or attachment. Repair or replace as necessary.

3. VALVE LASH Incorrect valve clearance will occurs first.

result in increased engine noise and lower
engine output, thereby adversely affecting
engine performance. Retorque rocker shaft
bracket nuts before checking and adjusting
valve clearance. Check and adjust valve
clearance at every 52,000 miles (83,200 km).
4. INJECTION TIMING Incorrect injection
timing could result in increased exhaust
emission or smoke emission, or lower engine
output.
Check and adjust injection timing every 52,000
miles (83,200 km).
5. INJECTOR Check spray condition at every
52,000 miles (83,200 km).
6. ENGINE OIL AND OIL FILTER Change at
interval noted below depending upon driving
conditions.
NORMAL SERVICE Change every 6,500
miles (10,400 km) or 12 months whichever
SEVERE SERVICE Change every 3,600
miles (5,760 km) or 3 months if the vehicle is
often driven under one or more of these
conditions (a) driving in dusty areas, (b)
frequent idling or idling for long periods, (c)
driving four miles (6 km) or less in freezing
weather, or other short trips in cold weather,
where engine dose not thoroughly warm up.
Change oil and filter soon after driving in a
dust storm.
7. FUEL FILTER (SINGLE CAB MODEL)
Replace filter at every 13,000 miles (20,800 km)
or 12 months whichever occurs first, or more
frequently if clogged. Drain water from the water
separator every 6,500 miles (10,400 km).
8. FUEL FILTER / WATER SEPARATOR (CREW
CAB MODEL) Replace main filter near the
engine at every 13,000 miles (20,800 km) or 12
months whichever occurs first, or more

frequently if clogged. Replace filter beneath rear
left seat at every 12,000 miles (19,000 km) or
12 months whichever occurs first, or more
frequently if clogged. Drain water from the water
separator as same frequency as filter under rear
left seat.
9. AIR CLEANER FILTER Replace the engine
air cleaner filter under normal operations every
26,000 miles (41,600 km). Operation of vehicle
in dusty areas will necessitate more frequent
filter replacement.
10. AIR INTAKE SYSTEM Check if air cleaner
hoses and ducts are connected and correctly
installed every 26,000 miles (41,600 km).
11. DRIVE BELT Check belt driving the fan,
generator at every 52,000 miles (83,200 km).
Look for cracks, fraying, wear, and proper
tension.
Replace at every 104,000 miles (166,400 km).
12. ENGINE BOLT TORQUE Loosened bolts
result in lower engine output. Check and adjust
manifold mounting, and injection nozzle to
correct torque every 52,000 miles (83,200 km).
Specified tightening torque
INTAKE/EXHAUST, MANIFOLDS 18/34 Nm
(13/25 lbft)
INJECTOR 19 Nm
(14 lbft)
13. ROTATE TIRES To equalize wear, rotate
tires and adjust tire pressures at every 6,500
miles (10,400 km).
Figure 2. Rotate Tires
MAINTENANCE AND LUBRICATION 0B-7
14. ENGINE COOLING SYSTEM At 12 months
or 6,500 miles (10,400 km) intervals, rinse
radiator cap and filler neck with clean water,
pressure test system and radiator cap for proper
pressure holding capacity, tighten hose clamps
and inspect condition of all cooling and heater
hoses. Replace hoses if cracked, swollen or
otherwise deteriorated.
Also each 12 months or 6,500 miles (10,400
km), clean exterior of radiator core and if
necessary, drain, flush and refill the engine
cooling system with a new engine coolant
solution as described in the Owners Manual.
15. ENGINE COOLING Every 24 months or
26,000 miles (41,600 km), drain the engine
coolant by opening the drain cock at the bottom
of the radiator core, flush and refill the engine
cooling system with a new engine coolant
solution.
16. EXHAUST SYSTEM Check the complete
exhaust system at every 6,500 miles (10,400
km). Check body areas near the exhaust
system.
Look for broken, damaged, missing, or out-of
position parts. Also inspect for open seams,
holes, loose connections, or other conditions
which could cause heat build-up in the floor
pan, which could let exhaust fumes seep into
the passenger compartment. Dust or water in
the cabin may indicate a leak in the area.
Needed repairs should be made at once.
17. FUEL LINE SYSTEM Inspect the fuel tank,
cap and lines for damage at every 13,000 miles
(20,800 km). Inspect fuel cap for correct sealing
ability and indications of physical damage.
Replace any damaged or malfunctioning parts.
18. BRAKE LINING AND PAD FOR WEAR
Check drum brake lining and disc brake pad for
wear or cracks at every 6,500 miles (10,400
km). Check brakes (including parking brake)
more often if conditions and habits result in
frequent braking.
Front disc brake have built-in wear indicators
which are designed to make a high pitched
squeal or cricket-like warning sound when the
brake pads are worn to the point where new
pads are needed.
When the vehicle is in motion, the sound may
be constant or it may come and go. Pressing
the brake pedal firmly may cause the sound to
stop.
Have the brake linings or the brake pads
replaced, if these conditions exist.
Failure to do so can result in expensive damage
to the brake system or a serious accident.
19. BRAKE DRUM AND ROTOR FOR WEAR AND
DAMAGE Check brake drums (rear and
parking) and rotor (front) for wear or damage at
0B-8 MAINTENANCE AND LUBRICATION

every 26,000 mile (41,600 km) or 12 months

whichever occurs first.
20. BRAKE FLUID Check the brake fluid level in
the brake fluid reservoir every 6,500 miles
(10,400 km).
21. HYDRAULIC BRAKE BOOSTER FLUID
Replace power steering fluid every 24 months
or 32,500 miles (52,000 km), whichever occurs
first.
22. BRAKE LINE, LSV AND HOSES Check
lines and hoses for proper hook-up, binding,
leaks, cracks, chafing, etc. every 26,000 miles
(41,600 km). Any questionable parts should be
replaced or repaired at once. When rubbing or
wear is noted on lines or hoses, the cause must
be corrected at once. Figure 3(a). Dipstick of the ATF Level
23. CLUTCH PEDAL CONTROL Check lines (Crew Cab Model)
and hoses for proper hook-up, binding, leaks,
cracks, chafing, etc. at every 13,000 miles
(20,800 km). Any questionable parts should be
replaced or repaired.
24. MANUAL TRANSMISSION OIL Replace
lubricant at every 19,500 miles (31,200 km).
Check lubricant level at every 6,500 miles
(10,400 km), and add lubricant to level of filler
hole if necessary.
25. AUTOMATIC TRANSMISSION FLUID (ATF)
Check the ATF at each engine oil change and
replace fluid every 26,000 miles (41,600 km).
To check the fluid level, first set the parking
brake, then start the engine in P position.
With the regular brakes applied, move the
selector through all the gear position, ending
Figure 3(b). ATF Level Check
with P. You must check the ATF level with the
engine running at slow idle and the truck must If it felt cool, about room temperature, the
be on a level surface. level should be in the C range.
If it felt warm, about normal operating
NOTICE: If you have driven for a prolonged temperature of 158 to 176 F(70 to 80C),
period of time or in city traffic in hot weather, the level should be in the H range.
wait until the fluid cools down (Approx. 30 26. AUTOMATIC TRANSMISSION FLUID FILTER
minutes) before checking ATF level. Replace filter at every 26,000miles
(41,600Km)
Remove the dipstick located at the left rear 27. DIFFERENTIAL GEAR OIL Replace
side of the engine (Single cab model). Remove lubricant at every 26,000 miles (41,600 km).
the dipstick located beneath the panel for the Check lubricant level at every 6,500 miles
inspection (Crew cab model). Carefully touch (10,400 km) or every 12 months, and add
the wet end of the dipstick to find out if the ATF lubricant to within 0 to 10 mm (0 to 0.4 in) of
is cool, warm or hot. Wipe it clean and push it bottom edge of the filler hole if necessary.
back in until the cap seats. Pull out the dipstick
and read the ATF level.

Figure 4. Differential Gear Oil Level
28. POWER STEERING FLUID Replace power
steering fluid every 24 months or 32,500 miles
(52,000 km), whichever occurs first.
29. STEERING GEAR BOX TORQUE Retighten
the fixing bolts of the steering gear box to the
specified torque at every 26,000 miles (41,600
km).
Specified tightening torque
STEERING GEAR BOX 102 Nm
(75 lbft)
30. PROPELLER SHAFT FLANGE TORQUE
Check the fixing bolts of propeller shaft flange
for looseness or damage at first 6,500 miles
(10,400 km). Retighten the fixing bolts to the
specified torque at every 13,000 miles (20,800
km).
Specified tightening torque
PROPELLER SHAFT FLANGE 102 Nm
(75 lbft)
OWNER SAFETY AND ROUTINE MAINTENANCE
Listed below are vehicle checks which should be
made periodically by either the owner or a qualified
technician to ensure proper performance and safety
of the vehicle.
For your safety and that of others, any of the
safety-related components that may have been
damaged in an accident should be checked and
necessary repairs performed before operating
the vehicle.
At the minimum, these routine checks should be
made every 6 months or 6,000 miles (10,000 km),
whichever comes first. Whenever repairs are
necessary, have them completed before operating
the vehicle.
A PARKING BRAKE Park on a fairly steep hill
and hold the vehicle with the parking brake
only. This checks holding ability.
MAINTENANCE AND LUBRICATION 0B-9
31. LEAF SPRING U-BOLT TORQUE Tighten
the U-Bolt nuts to the specified torque at 650
miles (1,050 km), 6,500 miles (10,400 km) and
thereafter each 13,000 miles (20,800 km).
Specified tightening torque
LEAF SPRING U-BOLT Front 127 Nm
(94 lbft)
Rear 177 Nm
(130 lbft)
32. WHEEL NUT TORQUE Check tire for
excessive or abnormal wear, or damage. Also
check tire inflation pressures and adjust. Be
sure wheels are not bent or cracked and that
wheel nuts have been tightened to the specified
torque at 650 miles (1,050 km) and then every
6,500 mile (10,400 km). Refer to Section 3 for
the specified torque.
Specified tightening torque
Front and Rear wheel 440 Nm
(325 lbft)
33. KING PIN Lubricate the grease fitting on the
king pins at 12 months or 6,500 miles (10,400
km) whichever occurs first.
34. PROPELLER SHAFT Lubricate the grease
fitting on each universal joint and spline
coupling at 12 months or 13,000 miles (20,800
km) whichever occurs first.
35. WHEEL BEARING GREASE Clean and
repack front wheel bearings at every brake
relining or 32,500 miles (52,000 km) whichever
comes first.
36. REAR SPRING PINS Lubricate the grease
fitting on the rear spring pins every 6,500 miles
(10,400 km).
Before checking item (B), be sure to have enough
room around the vehicle. Then firmly apply both the
parking brake and the regular brake.
Do not use the accelerator pedal. If the engine
starts, be ready to turn off the ignition/engine
control switch at once. Take these precautions
because the vehicle could move without warning
and possibly cause personal injury or property
damage.
B STARTER SAFETY SWITCH (AUTOMATIC
TRANSMISSION) Check by trying to start
the engine in each gear. The starter should
crank only with selector in position P or N.
C TRANSMISSION SHIFT INDICATOR
(AUTOMATIC TRANSMISSION) Check that
the indicator points to the gear chosen.
D STEERING Be alert for any changes in
 0B-10 MAINTENANCE AND LUBRICATION
steering action. An inspection or service is
needed when the steering wheel is harder to
turn or has too much free play, or when there
are strange sounds when turning or parking.
E WHEEL ALIGNMENT, BALANCE, AND TIRES
Check tires for abnormal wear or damage.
Also, check for damaged wheels. A pull to the
right or left on a straight and level road may
show the need for a wheel alignment. A
vibration of the steering wheel or seat at normal
highway speeds may mean a wheel balancing is
needed. Check tire pressure when the tires are
cold, at least monthly, and whenever the
vehicle is serviced. (Include the spare, if
equipped.)
Inspect the tire for any cuts or punctures if
frequent tire inflation is needed.
F BRAKES Be alert for the low vacuum
warning light or for the tone alarm, or changes
in braking action, such as repeated pulling to
one side, unusual sounds when braking or
increased brake pedal travel. Check regularly
that the brake fluid reservoir is properly filled
and check for fluid leaks. Any of these
conditions could indicate the need for brake
system inspection and/or service.
G EXHAUST SYSTEM Be alert for any
changes in the sound of the exhaust system or
exhaust oder. These are signs the system may
be leaking. Have it checked and/or repaired at
once.
H WINDSHIELD WIPERS AND WASHERS
Check operation and condition of the wiper
blades. Check the flow and aim of the washer
spray.
I DEFROSTER Turn the control lever to
Defrost and the fan lever to 4. Then check T UNDERBODY Corrosive materials used for
the airflow from the ducts at the inside base of
the windshield. The engine must be running at
this time.
J REARVIEW MIRRORS AND SUN VISORS
Check that friction joints hold mirrors and sun
visors in place.
K HORN Sound the horn periodically to be sure
it works.
L LAP-SHOULDER BELTS Check seat belt
system (including webbing, buckles, latch
plates, and anchors) for proper operation, and
NOISE EMISSION CONTROL
NOISE CONTROL SYSTEM
The following information relates to compliance
with Federal noise emission standards for vehicles
with a Gross Vehicle Weight Rating (GVWR) of
more than 10,000 lb (4,536 kg). The Maintenance
Schedule provides information on maintaining the
for damage.
M SEAT ADJUSTERS When adjusting a
manual seat, be sure seat adjusters latch by
pushing the seat forward and backward.
Do not attempt to adjust the seat when the
vehicle is in motion.
N LAMPS Check panel lighting, warning lamps,
indicator lamps, and interior lamps. On the
outside, check: license plate lamps, side marker
lamps, reflectors on outside mirrors, headlamps,
parking lamps, identification and clearance
lamps, taillights, brake lamps, turn signals,
backup lamps, and hazard warning flashers.
Have headlamp aim checked at once if beams
seem improperly aimed.
O GLASS, MIRRORS, LIGHTS AND/OR
REFLECTORS CONDITION Look for broken,
scratched, dirty or damaged glass, mirrors,
lamps or reflectors that could reduce the view or
visibility, or cause injury. Replace, clean or
repair promptly.
P DOOR LATCHES Check that doors close,
latch, and lock tightly. Check for broken,
damaged or missing parts that might prevent
tight latching.
Q TILT CAB Be sure the tilt lever is raised and
the lock pin is inserted in the lever bracket.
R FLUID LEAKS Check for fuel, water, oil, or
other fluid leaks by looking at the surface
beneath the vehicle after it has been parked for
a while. If you notice diesel fumes or fluid at any
time, have the cause found and corrected at
once.
S SPARE AND JACK Check that spare tire
assembly and jack equipment (if equipped) are
securely stowed at all times.
ice removal, snow removal, and dust control
can collect on the underbody. If these materials
are not removed, accelerated corrosion (rust)
can occur on underbody parts such as fuel
lines, frame, floor pan, and exhaust system. At
least every spring, flush these materials from
the underbody with plain water. Thoroughly
clean the underbody where mud and debris can
accumulate. Sediment packed in closed areas
of the frame should be loosened before being
flushed.
noise control system to minimize wear of the noise
emission control system during the life of the
vehicle. The noise control system warranty is given
in the vehicle Warranty Folder.
These standards apply only to vehicles sold in the
United States.
 MAINTENANCE AND LUBRICATION 0B-11

TAMPERING WITH NOISE CONTROL Engine

SYSTEM PROHIBITED
Federal law prohibits the following acts or the
causing thereof:
1. The removal or rendering inoperative by any
person other than for purposes of maintenance,
repair or replacement of any device or element
of design incorporated in any new vehicle for
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser or while it is
in use.
2. The use of the vehicle after such device or
element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute
tampering are acts listed below.
Insulation
Removal of noise shields or underhood insulation.
Removal of engine speed governor, if so
equipped,or rendering inoperative so as to allow
engine speed to exceed manufacturer
specifications.
Fan and Drive
Removal of fan clutch, if so equipped, or
rendering clutch inoperative.
Removal of fan shroud, if so equipped.
Air Intake
Removal of air cleaner silencer.
Reversing air cleaner cover.
Exhaust
Removal of muffler and/or resonator.
Removal of exhaust pipes and exhaust pipe
clamps.

RECOMMENDED FLUIDS AND LUBRICANTS

USAGE
Engine Oil
Manual Transmission Oil
Automatic Transmission Fluid
Power Steering Fluid
Hydro Boost Brake Fluid
Rear Axle
Chassis Lubricant
Battery Terminals
Clutch and Brake Fluid
Cab-Door Hinges and
Latches Lubricant
Engine Coolant
Windshield Washer Solvent
Propeller Shaft, Universal
Joints and Sliding Sleeve
Lubricant
Propeller Shaft Center Bearing,
Wheel Hub Bearing Lubricant
FLUIDS/LUBRICANTS
SG/CE, SF/CD, SE/CD, CD Engine Oil
SAE 5W-30 SF below 32 C (90 F) or
SAE 40 engine oil above 32 C (90 F)
ATF Dexron-III
Multi-purpose gear oil SAE90 GL-5
Multi-purpose grease with high temperature, good quality, lithium soap,
extreme pressure grease
Petroleum Jelly
Brake fluid DOT 3 or equivalent
A semi-fluid grease having extreme pressure properties and
containing zinc oxide (Lubricant or equivalent)
Mixture of water and high quality ethylene glycol base type antifreeze
conforming to GM Spec. 6038-M or equivalent.
Washer Solvent
NLGI #1 or #2 multi-purpose type grease
NLGI #2 or #3
0B-12 MAINTENANCE AND LUBRICATION

LUBRICATION CHART

GREASE POINTS REMARKS

2. King Pins 4 fittings

3. Propeller Shaft Universal Joints, 5 fittings
Sliding Sleeve and Center
Bearing
4. Rear Spring Pins 2 fittings

GREASE POINTS CHART

Figure 5. Grease Points Chart

 MAINTENANCE AND LUBRICATION 0B-13

SPECIFICATIONS
CAPACITIES

Engine Crankcase
This capacity is for a normal refill and it is an approximate amount. Keep the level as close as possible to
the full mark without overfilling. Do not operate with the level below the low mark.
4HE1-TC......................................................................................................................................13 (3.4 gal)
This figure includes the full-flow oil filter, which should be changed at each oil change.

Engine Cooling System

Capacity.......................................................................................................................................14 (3.7 gal)
Thermostat ...................................................................................................................82, 85 C (180, 185 F)
Radiator Pressure Cap .......................................................................................................103 kPa (15.46 psi)

Fuel Tank
The fuel tank capacity is stated on a metal plate attached to the fuel tank body. Only fill the tank to 95
percent of its capacity. This will allow for fuel expansion.

Transmission
Manual Transmission Oil...............................................................................................NPR; 3.2 ( 6.8 pints)
NQR; 5.3 (11.2 pints)
Automatic Transmission Fluid...............................................................................................13.5 (28.5 pints)

Rear Axle
Capacity .................................................................................................................................9.7 (20.5 pints)

MAINTENANCE ITEM

Air Cleaner (DONALDSON EGB10-8107) Filter............ISUZU Part No. 8-94430-250-0 GM Part No. 94430250
Engine Oil Filter Cartridge ............................................ISUZU Part No. 8-97148-270-0 GM Part No. 97148270
Fuel Filter Cartridge ......................................ISUZU Part No. 1-13240-074-1 or -079-1 GM Part No. 94414796

FASTENER TORQUES

Intake Manifold Nut and Bolts ............................................................................................ 18 Nm ( 13 ftlbs)

Exhaust Manifold Nut and Bolts ......................................................................................... 34 Nm ( 25 ftlbs)
Injector .......................................................................................1st 10 Nm (7 ftlbs), 2nd 19 Nm ( 14 ftlbs)
Steering Gear Box Fixing Nuts and Bolts ...........................................................................102 Nm ( 75 ftlbs)
Propeller Shaft Flange Nuts ...............................................................................................102 Nm ( 75 ftlbs)
Leaf Spring U-Bolt Nuts ............................................................................................Front 127 Nm ( 94 ftlbs)
Rear 177 Nm (130 ftlbs)
Wheel Nuts ........................................................................................................................440 Nm (325 ftlbs)
0B-14 MAINTENANCE AND LUBRICATION

MEMO
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 HEATING AND VENTILATION 1A-1

SECTION 1

HEATING AND AIR CONDITIONING

CONTENTS
SUBJECT PAGE

Heating and Ventilation ..........................................................................................See 1999-2001 Service Manual

Air Conditioning......................................................................................................See 1999-2001 Service Manual
1A-2 HEATING AND VENTILATION

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 FRAME AND BODY MOUNTS 2A-1

SECTION 2

FRAME AND CAB

CONTENTS
SUBJECT PAGE

Frame and Body Mounts ..................................................................................... See 1999-2001 Service Manual

Cab Maintenance ................................................................................................... See 1999-2001 Service Manual
Sheet Metal ............................................................................................................. See 1999-2001 Service Manual
2A-2 FRAME AND BODY MOUNTS

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 FRONT END ALIGNMENT 3A-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES

CONTENTS
SUBJECT PAGE

Front End Alignment.............................................................................................. See 1999-2001 Service Manual

Steering Linkage .................................................................................................... See 1999-2001 Service Manual
Power Steering .................................................................................................................................................... 3B3
Steering Column..................................................................................................... See 1999-2001 Service Manual
Front Axle and Suspension................................................................................... See 1999-2001 Service Manual
Rear Suspension .................................................................................................... See 1999-2001 Service Manual
Wheels and Tires.................................................................................................... See 1999-2001 Service Manual
 POWER STEERING 3B3-1

SECTION 3B3

POWER STEERING
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Description ............................................................................................................. See 1999-2001 Service Manual
Diagnosis of Power Steering System .................................................................. See 1999-2001 Service Manual
Power Steering System Test............................................................................. See 1999-2001 Service Manual
Power Steering System On-Vehicle Service ....................................................... See 1999-2001 Service Manual
Maintenance ....................................................................................................... See 1999-2001 Service Manual
Power Steering Fluid and Filter Service .......................................................... See 1999-2001 Service Manual
Steering Wheel Free Play ............................................................................................................................ 3B3-2
Steering Gear Replacement .............................................................................. See 1999-2001 Service Manual
Steering Gear Adjustment ................................................................................ See 1999-2001 Service Manual
Hydraulic Pump Replacement ......................................................................... See 1999-2001 Service Manual
Tandem Hydraulic Pump Assembly Replacement ......................................... See 1999-2001 Service Manual
Bleeding the Hydraulic System ........................................................................ See 1999-2001 Service Manual
Hydraulic System Flushing............................................................................... See 1999-2001 Service Manual
Power Steering Gear Unit Repair ......................................................................... See 1999-2001 Service Manual
Removal of Major Sub-assemblies From Power Steering Gear Unit ............ See 1999-2001 Service Manual
Cleaning, Inspection and Repair ...................................................................... See 1999-2001 Service Manual
Assembling Major Sub-assemblies into Power Steering Gear Unit.............. See 1999-2001 Service Manual
Hydraulic Pump Unit Repair ................................................................................. See 1999-2001 Service Manual
Tandem Hydraulic Pump Unit Repair................................................................... See 1999-2001 Service Manual
Specifications......................................................................................................... See 1999-2001 Service Manual
Fastener Torques .............................................................................................. See 1999-2001 Service Manual
Special Tools.......................................................................................................... See 1999-2001 Service Manual

DESCRIPTION
Vehicles covered by this manual are equipped
with power steering as standard equipment.
An integral steering gear is used. In an integral
steering gear, the power cylinder and control valve
are integrated into the steering gear. No separate
power cylinder is necessary.
A vane-type hydraulic pump with remote reservoir
is used. The hydraulic pump is gear driven.
The power steering fluid reservoir is equipped
with a screen and fluid filter to help keep the
system fluid clean.
3B3-2 POWER STEERING

STEERING WHEEL FREE PLAY

Preparation
Remove the Front grille.
Refer to page 2C-1 of the 1999-2001 Service
Manual.
Remove the Headlight assembly and related
parts.
Refer to page 8-72 of the 1999-2001 Service
Manual.

Inspect

1. Check the amount of the steering wheel play by

turning the wheel in both directions until the
tires begin to move with the front wheels
properly in the straight ahead position.
NOTE:
If the vehicle is equipped with a power
steering unit, the wheel free play should be
checked with the engine running.
Steering wheel free play 10-50mm (0.4-2.0 in)
2. Also check the steering wheel for play and
looseness in mount by moving it back and forth
and sideways. While driving check for hard-
steering, shimmy and tendency of steering to
pull to one side.

Adjust

1. Align the front wheels properly in the straight

ahead position.
2. Loosen the lock nut on the adjusting screw of
the steering unit.
3. Turn the adjust screw clockwise to decrease
free play or counter- clockwise to increase.
4. After check of specified free play, tighten the
lock nut to specified torque.

Tighten

Lock nut to 69N.m (51 Ib ft).

440L200001
3A-2 FRONT END ALIGNMENT

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 REAR AXLE 4A1-1

SECTION 4

REAR AXLE AND PROPELLER SHAFT

CONTENTS
SUBJECT PAGE

Rear Axle ............................................................................................................... See 1999-2001 Service Manual

Propeller Shaft ...................................................................................................... See 1999-2001 Service Manual
4A1-2 REAR AXLE

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 HYDRAULIC BRAKES 5A-1

SECTION 5

BRAKES
CONTENTS
SUBJECT PAGE
Hydraulic Brakes ..................................................................................................................................................5A
Vacuum Booster Brake System .............................................................................See 1999-2001 Service Manual
Hydraulic Booster Brake System ........................................................................................................................5A2
Hydraulic Foundation Brakes.................................................................................See 1999-2001 Service Manual
Anti-lock Brake System (ABS)................................................................................See 1999-2001 Service Manual
Parking Brakes.........................................................................................................See 1999-2001 Service Manual

SECTION 5A

HYDRAULIC BRAKES
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Introduction .............................................................................................................See 1999-2001 Service Manual
Description ..........................................................................................................See 1999-2001 Service Manual
Hydraulic Brake Fluid .........................................................................................See 1999-2001 Service Manual
Brake System Diagnosis ........................................................................................See 1999-2001 Service Manual
Road Testing Brakes ..........................................................................................See 1999-2001 Service Manual
Brake System Diagnosis Chart..........................................................................See 1999-2001 Service Manual
Brake Lining Diagnosis Chart............................................................................See 1999-2001 Service Manual
Brake Drum Diagnosis Chart ............................................................................See 1999-2001 Service Manual
Front Disc Brake Diagnosis Chart.....................................................................See 1999-2001 Service Manual
Inspection and Repair ...........................................................................................See 1999-2001 Service Manual
System Inspection ..............................................................................................See 1999-2001 Service Manual
Contamination of Brake System........................................................................See 1999-2001 Service Manual
Flushing Brake System ......................................................................................See 1999-2001 Service Manual
Bleeding Brakes..................................................................................................See 1999-2001 Service Manual
Load-Sensing Proportioning Valve (LSPV) Adjustment ...........................................................................5A- 2
Brake Lines..........................................................................................................See 1999-2001 Service Manual
Brake Fluid Reservoir ........................................................................................See 1999-2001 Service Manual
Load-Sensing Proportioning Valve (LSPV) .....................................................See 1999-2001 Service Manual
Master Cylinder ...................................................................................................See 1999-2001 Service Manual
Brake Pressure Metering Valve .........................................................................See 1999-2001 Service Manual
Specifications..........................................................................................................See 1999-2001 Service Manual
Fastener Torques ...............................................................................................See 1999-2001 Service Manual
Special Tools...........................................................................................................See 1999-2001 Service Manual
5A-2 HYDRAULIC BRAKES

LOAD-SENSING PROPORTIONING VALVE
(LSPV) ADJUSTMENT
This adjustment should be performed with the
battery voltage applied to the valve.
1. Adjust the specified rear axle weight by loading
the rear body as according to the chart values
by model description.
3. Loosen the nut (6) and raise the valve assembly
(7) all the way. Then lower the valve assembly
gradualily and tighten the nut (6) lamp (1) turns
on. If the miniature lamp (1) goes out as the nut
(6) is tightened, lower the valve assembly (7)
slightly with the nut loosened, then retighten the
nut (6).

GVWR Wheel Rear Axle

Model
(Ibs) Base(in) Weight kg(lb)
109 1200(2,650)
132.5 1000(2,210)
NPR 12,000
150 900(1,990)
176 900(1,990)
109 1500(3,310)
132.5 1400(3,090)
NPR 14,500
150 1300(2,870)
176 1300(2,870)
109 1400(3,090)
132.5 1300(2,870)
NQR 17,950
150 1150(2,540)
176 1150(2,540) Figure 5. Load-Sensing Proportioning Valve
Adjustment-1

2. Connect a miniature lamp (1) and a battery (2)
as shown below between the valve bracket (3)
and linkage (4). This is done to locate the point
where the piston in the valve assembly comes
in contact with the linkage.
4. Depress the linkage (4) near the valve assembly
slightly downward with finger (test pressure :4.9-
7.8N (1.1-1.7lb)) and check to see if the
miniature lamp (1) goes out.
Lamp goes out : OK Adjustment is completed.
Lamp remains on : NG

Repeat adjustment operation outlined

under paragraph 3.
Excessive force is exerted on linkage
by piston (8) within the valve assembly.

Figure 4. Miniature Lamp Wiring

Note:
As the linkage is coated with insulation material,
turn the clip (5) with 2 or 3 turns to break
insulation.
 HYDRAULIC BRAKES 5A-3

5. Inspection of brake fluid pressure (Reference

value)

1) Adjust the rear axle weight as specified

under the paragraph 1.
2) Install the pressure gauge on the bleeder
screws on the front and rear brakes.
3) Depress the brake pedal and obtain the
pressure gauge reading. The brake fluid
pressure is normal if the pressure of fluid
within the rear wheel cylinders is within
the range of 5,030590kPa (72997psi)
when pressure of fluid within the front
wheel cylinders reaches 7,850kPa
(1,138psi).

Important
Figure 6. Load-Sensing Proportioning Valve The brake pedal should be depressed gradually
Adjustment-2 until specified pressure is reached without
pumping or adjusting foot pressure.
Note:
Adjustment can also be made by means of nuts
(9) and (10) on shackle at rear axle case side.
However, shackle nut is not normally used for
adjustment as it is for making fine adjustment.

Figure 6-1. Load-Sensing Proportioning Valve

Adjustment-3
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-1

SECTION 5A2

HYDRAULIC BOOSTER BRAKE SYSTEM

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
General Description................................................................................................See 1999-2001 Service Manual
Booster Assembly ..............................................................................................See 1999-2001 Service Manual
Fluid and Fluid Handling ....................................................................................See 1999-2001 Service Manual
Flushing The Hydraulic Booster System..........................................................See 1999-2001 Service Manual
System Outline....................................................................................................See 1999-2001 Service Manual
Hydraulic Booster Troubleshooting......................................................................See 1999-2001 Service Manual
Notes ....................................................................................................................See 1999-2001 Service Manual
Supply Parts Replacement.................................................................................See 1999-2001 Service Manual
On-Vehicle Service .................................................................................................See 1999-2001 Service Manual
Accumulator and O-Ring Replacement ............................................................See 1999-2001 Service Manual
Hydraulic Booster Replacement........................................................................See 1999-2001 Service Manual
Clevis and Lock Nut Replacement ....................................................................See 1999-2001 Service Manual
Guard Replacement ............................................................................................See 1999-2001 Service Manual
Brake Pedal Replacement ..................................................................................See 1999-2001 Service Manual
Brake Pedal Adjustment.....................................................................................See 1999-2001 Service Manual
Hydraulic Booster Brake Fluid and Filter ...................................................................................................5A2-1
Specifications..........................................................................................................See 1999-2001 Service Manual
Fastener Torques................................................................................................See 1999-2001 Service Manual
5A2-2 HYDRAULIC BOOSTER BRAKE SYSTEM

4
1

5
9
6

1. Cover
2. Cap
3. Filter
4. Fluid Reservoir
5. Hose (Single Cab)
6. Hose (Crew Cab)
7. Tubing (Hydraulic Pump Brake Booster
8. Hose (Reservoir Brake Booster)
9. Hydraulic Pump
331L200001

Figure 1. Hydraulic Booster Brake Fluid Reservoir

HYDRAULIC BOOSTER BRAKE

FLUID AND FILTER

1. Remove the cover (1) and cap (2) (figure1). 5. Disconnect the reservoir hose (5) single cab, (6)
2. Remove the filter (3). crew cab at the reservoir.
3. Clean the filter (3) in clean solvent. Then blow Drain the fluid reservoir (4).
the filter dry with compressed air.
4. Raise the vehicle until the tires are off the floor.
Support the frame with stands.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-3

6. Connect the reservoir hose. 8. Fill and bleed the hydraulic system.
DO NOT START ENGINE Refer to page 5A2-7 of the 1999-2001 Service
7. Install the filter (3). Manual.
9. Install the cap (2) and cover (1).
 ENGINE 6A-1

SECTION 6

ENGINE

CONTENTS
SUBJECT PAGE

Engine ....................................................................................................................................................................6A
Isuzu Engine..........................................................................................................................................................6A6
Cooling System.....................................................................................................................................................6B1
Radiator .................................................................................................................................................................6B2
Fan ........................................................................................................................................................................6B3
Fuel System...........................................................................................................................................................6C1
Fuel Injection System ...........................................................................................................................................6C3
Engine Electrical...............................................................................................SEE 1999-2001 SERVICE MANUAL
Emission and Electrical Diagnosis .................................................................SEE 1999-2001 SERVICE MANUAL
Exhaust..............................................................................................................SEE 1999-2001 SERVICE MANUAL

SECTION 6A

ENGINE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

Engine Replacement.........................................................................................................................................6A- 2
Engine Mountings............................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Maintenance .................................................................................................SEE 1999-2001 SERVICE MANUAL
Front Engine Mount Replacement..............................................................SEE 1999-2001 SERVICE MANUAL
Rear Engine Mount Replacement ..............................................................SEE 1999-2001 SERVICE MANUAL
Exhaust Brake System ....................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Operation ......................................................................................................SEE 1999-2001 SERVICE MANUAL
Diagnosis of Exhaust Brake ...........................................................................SEE 1999-2001 SERVICE MANUAL
Exhaust Brake On-Vehicle Service ................................................................SEE 1999-2001 SERVICE MANUAL
Component Locations .................................................................................SEE 1999-2001 SERVICE MANUAL
Magnetic Valve Replacement......................................................................SEE 1999-2001 SERVICE MANUAL
Vacuum Chamber Replacement .................................................................SEE 1999-2001 SERVICE MANUAL
Exhaust Brake Valve Replacement ...........................................................SEE 1999-2001 SERVICE MANUAL
6A-2 ENGINE

Throttle Position Sensor Replacement......................................................SEE 1999-2001 SERVICE MANUAL

Clutch Switch Replacement........................................................................SEE 1999-2001 SERVICE MANUAL
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL
Fastener Torques.........................................................................................SEE 1999-2001 SERVICE MANUAL

ENGINE REPLACEMENT

6. Air intake pipe (6) from the turbocharger and

Remove or Disconnect (Figures 1-12)
the air cleaner (figure 3).
1. Battery negative cable (1) at the battery (figure
1).
Main feed wire (5) at the starter solenoid (figure
2).

2
6. Air Intake Pipe
1 For 12 Volt
Figure 3. Air Intake Pipe to Turbocharger
1. Battery Negative Cable Attachment
2. Battery Positive Cable
7. Air intake pipe (9) with connecting hoses (10),
(11) from the turbocharger (8) and the charge
Figure 1. Battery Cable Identification air cooler (12) (figure 4).

10
5

4
9 11 12
8. Turbocharger
4. Solenoid Wire 9. Air Inlet Pipe
5. Main Feed Wire 10. Connecting Hose
11. Connecting Hose
Figure 2. Wiring at Starter 12. Charge Air Cooler
2. Cab floor cover. Refer to STEEL CREW CAB Figure 4. Air Inlet Pipe Attachment
(SEC. 10E).
3. Rear floor engine cover and rear engine cover
assembly. Important
4. Drain the coolant from the drain cock at the
bottom rear of the radiator. Tape the inlet opening of the turbocharger to
5. Engine oil from the oil pan plug. prevent entry of foreign material.
 ENGINE 6A-3

8. Air intake pipe (13) with connecting hoses (14) 13. Generator electrical wire harness (19) (figure 7).
from the intake manifold and the charge air
cooler (12) (figure 5).

18. Generator
14 13 14 19. Generator Electrical Wire
13. Air Inlet Pipe
14. Connecting Hose Figure 7. Wiring and Generator

Figure 5. Intake Manifold Pipe Attachment
9. Radiator upper hose and lower hose.
10. Heater hoses.
11. Vacuum hoses (16) at the vacuum pump (15).
12. Loosen the generator adjusting bolts (17)
(figure 6).
14. Driver belts for air conditioning condenser,
generator, and water pump.
15. Air conditioning condenser (20). Do not
disconnect the hoses from the condenser
(figure 8).
16. Air conditioning condenser bracket.

20

15. Vacuum Pump

16. Vacuum Hose 20. A/C Compressor
17. Generator Adjusting Bracket
Figure 8. Air Conditioner (A/C) Compressor
Figure 6. Vacuum Hose Attachment at Vacuum Removed
Pump
17. Fan and fan clutch from the fan clutch plate.
Refer to FAN (SEC. 6B3).
18. Fuel filter and fuel filter bracket from cylinder
head. Refer to FUEL INJECTION SYSTEM
(SEC. 6C3).
6A-4 ENGINE
19. Accelerator cable and engine stop cable. Refer
to FUEL SYSTEM (SEC. 6C1).
20. Accelerator cable bracket.
21. Power steering pipe bracket and turbocharger
oil feed pipe bracket from the flywheel housing.
22. Power steering pump. Do not disconnect the
hoses from the power steering pump. Refer to
POWER STEERING (SEC. 3B3).
23. Power steering pump bracket.
24. EGR pipe from EGR valve and exhaust
manifold.
25. Turbocharger water return pipe and feed pipe.
26. Turbocharger oil return pipe and feed pipe.
27. Exhaust brake unit assembly (22) (figure 9).
28. Front exhaust pipe (23) (figure 9).
20
22 23
20. Vacuum Chamber
22. Exhaust Brake Unit Assembly
23. Front Exhaust Pipe
Figure 9. Exhaust Brake
29. Exhaust manifold with turbocharger.
30. Fuel lines at the frame near the injection pump.
Refer to FUEL SYSTEM (SEC. 6C1).
31. Fuel shutoff cable at the injection pump and at
the support bracket. Refer to FUEL SYSTEM
(SEC. 6C3).
32. Starter motor harness from the starter motor.
33. Starter motor.
34. Propeller shaft. Refer to MANUAL
TRANSMISSION (SEC. 7B).
35. Transmission shift cable and parking brake from
transmission. Refer to AUTOMATIC
TRANSMISSION (SEC. 7A).
36. Speedometer cable from transmission.
37. Automatic transmission (A/T) oil cooler from
transmission (A/T only). Refer to AUTOMATIC
TRANSMISSION (SEC. 7A).
38. ATF level guide tube.
39. Electrical wiring harness with bracket and
connector.
40. Set jack beneath the engine and transmission.
Secure the engine and transmission to the jack
with wire.
41. Turn the steering wheel fully to one side. This
moves the tie rod forward to provide additional
working space.
42. Transmission bracket (33) from cross member
(figure 12).
43. Engine mount insulator (24) bolts from engine
mounting cross member (figure 11).
44. Engine mounting cross member from Chassis
frame.
45. Use the jack to lower the engine / transmission
assembly.
 ENGINE 6A-5

24. Engine Mount Insulator

26. Engine Mount Bracket

Figure 11. Front Engine Mount

28. Crossmember
29. Engine Mount Insulators
30. Side Supports
31. Upper Mount Assembly
32. Transmission Cover
33. Bracket

Figure 12. Transmission Mount

6A-6 ENGINE
Install or Connect (Figures 1-12)
NOTICE: See NOTICE on page 6A-1 of this
section for steps 7, 8, 9 and 10.
1. Turn the steering wheel fully to on side. This
moves the tie rod forward to provide additional
working space.
2. Position the engine / transmission assembly
underneath the vehicle with the jack. Use the
jack to raise the engine / transmission assembly
in to the installed position.
3. Engine mounting cross member to
Chassisframe.
4. Engine mount insulator (24) to engine mounting
cross member (figure 11).
Tighten
The engine mount insulator bolts to 75 Nm
(55 lbft).
5. Transmission bracket (33) to cross member
(figure 12).
Tighten
The bracket to cross member nuts to 69 Nm
(51 lbft).
6. Electrical wiring harness with bracket and
connector.
7. ATF level guide tube.
8. Automatic transmission (A/T) oil cooler to
transmission. Refer to AUTOMATIC
TRANSMISSION (SEC. 7A).
9. Propeller shaft. Refer to MANUAL
TRANSMISSION (SEC. 7B).
10. Speedometer cable to transmission.
11. Transmission shift cable and parking brake to
transmission. Refer to AUTOMATIC
TRANSMISSION (SEC. 7A).
12. Propeller shaft. Refer to MANUAL
TRANSMISSION (SEC. 7B).
13. Starter motor
14. Starter motor harness to the starter motor.
15. Fuel lines at the frame near the injection pump.
Refer to FUEL SYSTEM (SEC. 6C1).
16. Exhaust manifold with turbocharger.
Tighten
The exhaust manifold with turbocharger.
To cylinder head to 34 Nm (25 lbft).
17. Front exhaust pipe (23) (figure 9).
18. Exhaust brake unit assembly (22) (figure 9).
Refer to EXHAUST (SEC. 6F).
19. Turbocharger oil return pipe and feed pipe.
20. Turbocharger water return pipe and feed pipe.
21. EGR pipe to EGR valve and exhaust manifold.
22. Power steering pump bracket.
23. Power steering pump. Refer to POWER
STEERING (SEC. 3B3).
24. Power steering pipe bracket and turbocharger
oil feed pipe bracket to the flywheel housing.
25. Accelerator cable bracket.
26. Accelerator cable and engine stop cable. Refer
to FUEL SYSTEM (SEC. 6C1).
27. Fuel filter and fuel filter bracket to cylinder
head.
28. Fan and fan clutch to the fan clutch plate. Refer
to FAN (SEC. 6B3).
29. Air conditioning condenser bracket.
30. Air conditioning condenser (20) (figure 8).
31. Air conditioning condenser, generator, and
water pump belts.
32. Generator adjusting (17) (figure 6).
33. Generator electrical wiring harness (19) (figure 7).
34. Vacuum hoses (16) at the vacuum pump (15)
(figure 6).
35. Heater hoses.
36. Radiator upper hose and lower hose.
37. Air intake pipe (13) with connecting hoses (14)
to the intake manifold and the charge air cooler
(figure 5).
38. Air intake pipe (9) with connecting hoses (10),
(11) to the charge air cooler (12) and the
turbocharger (8) (figure 4).
39. Air intake pipe (6) to the turbocharger and the
air cleaner (figure 3).
40. Be sure the oil pan plug is tight. Install 13 liters
(3 gal) of engine oil. Refer to MAINTENANCE
AND LUBRICATION (SEC. 0B).
41. Close the radiator drain cock. Fill the coolant as
described in COOLING SYSTEM (SEC. 6B1).
42. Rear floor engine cover and rear engine cover
assembly.
43. Cab floor cover. Refer to STEEL CREW CAB
(SEC. 10E).
44. Check the automatic transmission fluid level
and replenish as necessary (automatic
transmission only). Refer to AUTOMATIC
TRANSMISSION (SEC. 7A).
45. Connect the main feed wire (5) at the starter,
and the battery negative (1) cable at the battery
(figures 1 and 2).
 ISUZU ENGINE 6A6-1

SECTION 6A6

ISUZU ENGINE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
General Information.........................................................................................SEE 1999-2001 SERVICE MANUAL
Statement on cleanliness and care ............................................................SEE 1999-2001 SERVICE MANUAL
Description .......................................................................................................SEE 1999-2001 SERVICE MANUAL
Lubrication system ......................................................................................SEE 1999-2001 SERVICE MANUAL
Diagnosis of Isuzu diesel engine ...................................................................SEE 1999-2001 SERVICE MANUAL
Engine will not turn over .............................................................................SEE 1999-2001 SERVICE MANUAL
Engine turns over slowly but does not start .............................................SEE 1999-2001 SERVICE MANUAL
Engine cranks normally but does not start ...............................................SEE 1999-2001 SERVICE MANUAL
Engine cranks normally but is difficult to start.........................................SEE 1999-2001 SERVICE MANUAL
Inconsistent idle speed (Engine Lopes).................................................SEE 1999-2001 SERVICE MANUAL
Engine misses at idle ..................................................................................SEE 1999-2001 SERVICE MANUAL
Engine misses at high speeds....................................................................SEE 1999-2001 SERVICE MANUAL
Engine misses at all speeds .......................................................................SEE 1999-2001 SERVICE MANUAL
Engine misses on one cylinder ..................................................................SEE 1999-2001 SERVICE MANUAL
Lack of power or performance ...................................................................SEE 1999-2001 SERVICE MANUAL
Excessive exhaust smoke...........................................................................SEE 1999-2001 SERVICE MANUAL
Engine fails to reach operating temperature.............................................SEE 1999-2001 SERVICE MANUAL
Engine overheats .........................................................................................SEE 1999-2001 SERVICE MANUAL
Low oil pressure ..........................................................................................SEE 1999-2001 SERVICE MANUAL
High oil pressure..........................................................................................SEE 1999-2001 SERVICE MANUAL
Burned, sticking or broken valves .............................................................SEE 1999-2001 SERVICE MANUAL
Excessive fuel consumption.......................................................................SEE 1999-2001 SERVICE MANUAL
Excessive oil consumption.........................................................................SEE 1999-2001 SERVICE MANUAL
Engine noises...............................................................................................SEE 1999-2001 SERVICE MANUAL
Compression check.....................................................................................SEE 1999-2001 SERVICE MANUAL
Maintenance .....................................................................................................SEE 1999-2001 SERVICE MANUAL
Valve adjustment .........................................................................................SEE 1999-2001 SERVICE MANUAL
Turbocharger maintenance.........................................................................SEE 1999-2001 SERVICE MANUAL
Changing the engine oil and oil filter.........................................................SEE 1999-2001 SERVICE MANUAL
Isuzu Engine On-Vehicle Service ...................................................................SEE 1999-2001 SERVICE MANUAL
Statement on cleanliness and care ............................................................SEE 1999-2001 SERVICE MANUAL
Air intake manifold and exhaust manifold with turbocharger .................................................................6A6- 3
Charge air pipe replacement.......................................................................................................................6A6- 4
Intake manifold replacement ......................................................................................................................6A6- 4
Turbocharger replacement .........................................................................................................................6A6- 4
Exhaust manifold replacement...................................................................................................................6A6- 7
Cylinder head cover replacement ..............................................................................................................6A6- 8
Valve stem seal and components replacement ........................................SEE 1999-2001 SERVICE MANUAL
6A6-2 ISUZU ENGINE

Valve train component replacement ..........................................................SEE 1999-2001 SERVICE MANUAL

Glow plug replacement ...............................................................................................................................6A6- 8
Cylinder head replacement .........................................................................................................................6A6- 9
Valve seat grinding ......................................................................................SEE 1999-2001 SERVICE MANUAL
Valve grinding ..............................................................................................SEE 1999-2001 SERVICE MANUAL
Valve guide replacement.............................................................................SEE 1999-2001 SERVICE MANUAL
Valve seat replacement ...............................................................................SEE 1999-2001 SERVICE MANUAL
Valve lapping ...............................................................................................SEE 1999-2001 SERVICE MANUAL
Cylinder head gasket selection ..................................................................SEE 1999-2001 SERVICE MANUAL
Piston and connecting rod replacement ..................................................................................................6A6-15
Piston and liner grade selection................................................................................................................6A6-20
Cylinder liner replacement..........................................................................SEE 1999-2001 SERVICE MANUAL
Cylinder liner grade selection.....................................................................SEE 1999-2001 SERVICE MANUAL
Piston pin bushing replacement ................................................................SEE 1999-2001 SERVICE MANUAL
Vibration damper replacement ..................................................................................................................6A6-23
Oil pump replacement .................................................................................SEE 1999-2001 SERVICE MANUAL
Bypass valve ................................................................................................SEE 1999-2001 SERVICE MANUAL
Timing gear replacement ...........................................................................................................................6A6-24
Camshaft replacement ...............................................................................................................................6A6-30
Flywheel replacement..................................................................................SEE 1999-2001 SERVICE MANUAL
Flywheel housing replacement..................................................................................................................6A6-34
Crankshaft front oil seal replacement.......................................................................................................6A6-37
Crankshaft rear oil seal replacement .........................................................SEE 1999-2001 SERVICE MANUAL
Power steering pump replacement ............................................................SEE 1999-2001 SERVICE MANUAL
Oil pan replacement.....................................................................................SEE 1999-2001 SERVICE MANUAL
Crankshaft and main bearing replacement ...............................................SEE 1999-2001 SERVICE MANUAL
Crankshaft gear replacement .....................................................................SEE 1999-2001 SERVICE MANUAL
Oil jet replacement.......................................................................................SEE 1999-2001 SERVICE MANUAL
Oil cooler replacement ...............................................................................................................................6A6-40
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL
Engine main specifications.........................................................................SEE 1999-2001 SERVICE MANUAL
Fastener torques..........................................................................................SEE 1999-2001 SERVICE MANUAL
Engine mechanical data ..............................................................................SEE 1999-2001 SERVICE MANUAL
Special tools.....................................................................................................SEE 1999-2001 SERVICE MANUAL
 ISUZU ENGINE 6A6-3

AIR INTAKE MANIFOLD AND EXHAUST MINFOLD WITH TURBOCHARGER

11. Intake Manifold

11a. EGR case
12. Nut
13. Bolt
14. Gasket
15. Nut
16. Exhaust Adapter
19. Turbocharger
20. Gasket
21. Exhaust Manifold
22. Heat shield
23. Bolt
23a. Nut
24. Gasket
25. Cylinder Head

Figure 9. Manifolds, Turbocharger and Components

6A6-4
CHARGE AIR PIPE REPLACEMENT
Refer to Statement on Cleanliness and Care
previously in this section.
Remove or Disconnect (Figure 9)
Remove the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Remove the rear floor engine cover and rear engine
cover assembly.
1. Connecting hoses clamps.
2. Connecting hoses.
3. Bracket bolts and washers and charge air pipe
from turbocharger to charge air cooler.
4. Clamps.
5. Connecting hose.
6. Bracket accelerator cable.
7. Bracket engine stop cable and vacuum hose.
8. Engine harness connector.
9. Charge air pipe from charge air cooler to intake
manifold.
Inspect
Hoses for deterioration, or damage.
Charge air pipes for damage.
Install or Connect (Figure 9)
1. Charge air pipe from charge air cooler.
2. Engine harness connector.
3. Bracket engine stop cable and vacuum hose.
4. Bracket accelerator cable.
5. Connecting hose.
6. Clamps.
7. Charge air pipe from turbocharger to charge air
cooler and bracket bolts.
8. Connecting hoses.
9. Clamps.
Install the rear floor engine cover and rear engine
cover assembly.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
INTAKE MANIFOLD REPLACEMENT
Remove or Disconnect
Remove the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Remove the rear floor engine cover and rear engine
cover assembly.
1. Injection nozzle cover.
2. Vacuum hose from intake manifold.
3. Vacuum hoses EGR valve and throttle valve.
4. EGR pipe.
5. Charge air pipe connection hose.
6. Injection pipes.
7. Bolts and nuts for fixing intake manifold.
8. Intake manifold with gasket.
9. EGR case.
Install or Connect (Figure 9)
1. EGR case with liquide gasket.
2. Intake manifold with gasket.
Tighten
Nuts (12) and bolt, a little at a time, to 19 Nm
(14 lbft).
3. Injection pipes.
Tighten
Fuel injector line nuts to 29 Nm (22 lbft).
4. Charge air pipe connection hose.
5. Vacuum hoses EGR valve and throttle valve.
6. Vacuum hose to intake manifold from injection
pump.
7. Injection nozzle cover.
Install the rear floor engine cover and rear engine
cover assembly.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
TURBOCHARGER REPLACEMENT
Refer to Statement on Cleanliness and Care
previously in this section.
Remove or Disconnect
(Figures 9, 11, 12 and 13)
Remove the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Remove the rear floor engine cover and rear engine
cover assembly.
1. Turbocharger air inlet pipe (310) (figure 11).
2. Connecting hose.
3. Heat shield (22) bolt (figure 9).
4. Water feed (300) (figure 12) and drain lines.
5. Oil feed line (280) (figure 11).
6. Oil drain line (290) (figure 12).
7. Exhaust pipe to exhaust adapter Nuts.
8. Exhaust adapter (16) to exhaust manifold bolts
(17) (figures 9 and 13).
9. Turbocharger to exhaust manifold nuts (18)
(figures 13).
10. Turbocharger (19) (figure 9).
11. Exhaust adapter (16) (figures 9 and 13).
 6A6-5

280 19

310

Figure 11a. Radial Clearance Measurement

19. Turbocharger.
280. Oil Supply Line. Measure
310. Air Inlet Pipe. Play in axial clearance.
Moving the rotor in the axial clearance, measure
Figure 11. Turbocharger Oil Feed Line Attachment the play by a dial gage.
Measure the play at several points while letting
Inspect (Figure 9) the rotor revolve.
Attach the turbocharger and dial gage firmly.
Turbocharger (19) housing for cracks or Service limit is 0.090 mm (0.0035 in). If
damage. excessive, replace the turbocharger.
Gasket surfaces for damage.
Seals and gaskets for damage.
Turbine and compressor blades for damage or
carbon deposit.
Air and exhaust exit openings for oil or wetness.
For grinding or roughness when spinning
turbine and compressor wheels by hand.
For evidence of turbine or compressor blades
contacting the shroud or housing. If any of the
above conditions exist, the turbocharger must
be replaced or repaired by an authorized repair
facility.

Measure

Play in radial clearance. Figure 11b. Axial Clearance Measurement

Moving the rotor in the radial clearance, measure
the play by a dial gage.
Measure the play at several points while letting
the rotor revolve.
Use only the flat dial gage attachment. Do not use
the pointed one.
Attach the turbocharger and dial gage firmly.
Service limit is 0.140 mm (0.0055 in). If
excessive, replace the turbocharger.
Operation of waist gate
Disconnect hose from waist gate acutuator ,
and install pressure gauge as shown in the
figure.
With the engine stopped, operate the pressure
gauge pump to apply pressure to the waist gate
for check the waist gate function.
6A6-6

280 19 300

290

Figure 11c. Measurement 19. Turbocharger.

280. Oil Supply Line.
Oil leakage check 290. Oil Drain Line.
1. Remove the charge air pipe connecting 300. Water Feed Line.
hose to the compressor side of the turbo-
charger. Figure 12. Turbocharger Oil Lines Attachment
2. Clean the area around the compressor
wheel.
3. Remove the blow-by hose.
4. Start the engine and let idle. Rev the engine
and hold at wide open throttle (WOT) for five
seconds, then release and let idle for five
seconds. Repeat this cycle for a total of five
times, then let the engine idle steady for five
minutes.
5. Shut off the engine.
6. Check the compressor area for an oil
leakage.

Important

A leaking of oil indicates a possible defective

turbocharger. If mist or spray is present,
16. Exhaust Adapter
however, this is normal and is NOT indicative
17. Exhaust Adapter Bolts
of a turbocharger problem.
18. Turbocharger to Manifold Nuts
7. If the turbocharger is suspect any problem,
Figure 13. Turbocharger Mounting Attachment
refer to the turbocharger replacement
procedures in this section.
Install or Connect (Figures 9, 11, 12 and 13)

1. Exhaust adapter (16) to turbocharger (19).

2. New gasket (20) and turbocharger (19) to
exhaust manifold (21) (figure 9).

Tighten

Nuts (18) to 25 Nm (18 lbft) (figure 13).

3. Exhaust adapter (16) to exhaust manifold (21)

(figure 13).

Tighten
Bolts (17) to 25 Nm (18 lbft).
4. New gasket and exhaust pipe to exhaust
adapter (16) (figure 9).
Tighten
Nuts (15) to 37 Nm (27 lbft).
5. Turbocharger oil drain line (290) (figure 12).
Tighten
Bolts to 9 Nm (6 lbft) turbocharger side.
Bolts to 22 Nm (15 lbft) cyl. block side.
6. Turbocharger oil supply line (280) to
turbocharger (19) (figure 12).
Tighten
Fitting (280) to 27 Nm (20 lbin).
7. Water supply and drain lines (300) (figure 12).
Tighten
Fitting (300) to 41 Nm (30 lbft).
8. Heat shield (22) to exhaust adapter (16) (figure
9).
9. Charge air pipe connecting hoses and clamps
to turbocharger (19) (figure 9).
10. Air inlet pipe (310) to turbocharger (19) (figure
11).
Remove the rear floor engine cover and rear
engine cover assembly.
Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
6A6-7
EXHAUST MANIFOLD REPLACEMENT
Remove or Disconnect (Figure 9)
Disconnect the battery negative cable.
Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
engine cover assembly.
1. Turbocharger (19) refer to the turbocharger
replacement in this section.
2. Exhaust manifold Bolts (23), nuts (23a) and
washers.
3. Exhaust manifold (21).
4. Gaskets (24).
Inspect (Figure 9)
Exhaust manifold (21) and cylinder head (25) for
cracks or damage to gasket surfaces.
Install or Connect (Figures 9, 16)
1. Gaskets (24) as shown in figures 9.
2. Exhaust manifold (21).
3. Washers nuts (23a) and bolts (23) as shown in
figure 9.
Tighten
Nuts and bolts, a little at a time, in the
sequence shown in figure 16, to 34 Nm (25
lbft).
Figure 16. Exhaust Manifold Bolt Torquing
Sequence
4. Turbocharger (19) refer to the turbocharger
replacement in this section.
5. Heat shield (22).
Install the rear floor engine cover and rear engine
cover assembly.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
6A6-8

CYLINDER HEAD COVER REPLACEMENT Cylinder Head Cover Nut and Bolt Torque:
18 Nm (13 lbft)
Remove or Disconnect (Figures 17)

Disconnect the battery negative cable.

Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
engine cover assembly.

1. Injection nozzle cover.

2. Bolt (33), nut (34) and oil cap (35) (figure 17).
3. Cylinder head cover (36).
4. Gasket (37).

Figure 104. Cylinder Head cover

3. Injection nozzle cover.

33. Bolt Install the rear floor engine cover and rear engine
34. Nut cover assembly.
35. Oil Cap Install the cab floor cover. Refer to STEEL CREW
36. Cylinder Head Cover CAB (SEC. 10E).
37. Gasket Connect the battery negative cable.

Figure 17. Cylinder Head Cover Assembly GLOW PLUG REPLACEMENT

Remove or Disconnect (Figure 25)
Clean (Figure 17)
Disconnect the battery negative cable.
All sludge and dirt from cylinder head cover (36). Remove the cab floor cover. Refer to STEEL
The gasket (37). CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
Inspect (Figure 17) engine cover assembly.
Cylinder head cover (36) for damage.
1. Glow plug wire (58).
Install or Connect (Figure 17) 2. Glow plug connector nuts (59).
3. Glow plug connector (57).
1. Gasket (37). 4. Glow plug (56). Use a deep socket.
2. Cylinder head cover (36) to cylinder head.

Tighten

Tighten the cylinder head cover nuts and bolts

to the specified torque in the numerical order
shown in the illustration.
 6A6-9

Install or Connect (Figure 25) CYLINDER HEAD REPLACEMENT

1. Glow plug (56). Refer to Statement on Cleanliness and Care in

this section.
Tighten
Tools Required:
Glow plug (56) to 23 Nm (17 lbft). J-43287 Valve Spring Compressor
J-43283 Valve Guide Remove and Installer
2. Glow plug connector (57). J-43284 Valve Stem Seal Installer
3. Glow plug connector nuts.(59)
Remove or Disconnect (Figures 27 and 28)
Tighten
Disconnect the battery negative cable.
Glow plug connector nuts(59) to Remove the cab floor cover. Refer to STEEL
1.2 Nm (0.88 lbft). CREW CAB (SEC. 10E).
4. Glow plug wire (58). Remove the rear floor engine cover and rear
engine cover assembly.
Install the rear floor engine cover and rear engine
cover assembly. 1. Drain engine coolant at lower rear of radiator
Install the cab floor cover. Refer to STEEL CREW trough drain valve.
CAB (SEC. 10E). Refer to RADIATOR (SEC. 6B2).
Connect the battery negative cable. 2. Radiator upper hose at thermostat housing.
Refer to RADIATOR (SEC. 6B2).
3. Water pump bypass hose at thermostat
59 housing.
4. Heater hose return.
5. Injection nozzle cover.
6. Turbocharger refer to the turbocharger
replacement.
7. Front exhaust pipe from exhaust manifold.
8. Injection pipes.
58 Important
* Plug the delivery valve holder ports and
injector holder ports with caps to prevent entry
of the foreign material.
9. Fuel pipes, gaskets from the fuel filter and fuel
56
filter.
57 10. Injector leak off pipe and gasket.
56. Glow Plug 11. Fan guide bracket.
57. Glow Plug Connector 12. Engine harness connectors.
58. Glow Plug Wire 13. Glow plug harness connector(58) (Figure 25).
59. Glow Plug Connector nots 14. A/C compressor and bracket.
15. EGR pipe.
Figure 25. Glow Plug Replacement
6A6-10

69
70
71

72
75
74

69. Valve cap

73 70. Split collar
71. Spring upper seat
72. Valve spring
73. Intake and exhaust valve
74. Valve stem Seal
75. Spring lower seat

Figure 27. Cylinder Head and Components

16. Charge air hose and pipe from the intake

manifold.
17. Cylinder cover refer to the cylinder head cover
replacement.
18. Rocker arm and shaft assembly refer to the
valve train component replacement.
19. Camshaft assembly.
20. Cylinder head bolts (Figure 28).
* Loosen the cylinder head bolts in numerical
order a little at a time.
21. Cylinder head assembly.
22. Cylinder head gasket.

Figure 28. Cylinder Head Bolt Loosening

Sequence
 6A6-11

Disassemble (Figure 9, 27, 29) Inspect

1. Injectors and gasket Cylinder head for cracks, damaged threaded

2. Glow plugs parts, etc.
3. Exhaust manifold and gasket. Cylinder head gasket surface for damage.
4. Intake manifold with gasket. Valves for warping, pitting, etc.
5. EGR case.
6. Fuel filter bracket. Measure (Figures 27 and 30-37)
7. C/box bracket.
Cylinder head gasket surface for warpage. Use
8. Engine hanger
a straightedge and feeler gage as shown in
9. Water outlet pipe from front of cylinder head.
figure 30. Check in six different directions, as
10. Thermostats.
shown. If the cylinder head is warped more than
11. Valve caps from top of valve stem.
0.05 mm (0.0020 in), it must be replaced.
12. Use J-43287 to remove the valve spring and
Cylinder head cannot be machined.
relation parts.
13. Split colors.
14. Upper spring seat.
15. Valve springs.
16. Valve stem seal.
17. Lower spring seal.
18. Valves.
If the valves are to be reinstalled, mark their
installation position each valve with the cylinder
number from which it was removed.
19. Sealing cap for idle gear C.
20. Bolt with thrust washer.
21. Idle gear C with shaft.

352

14. Cylinder Head

A. Straight Edge
B. Feeler Gage
352. J-43287 C. Check in Six Directions

Figure 29. Compressing Valve Spring Figure 30. Checking Cylinder Head Distortion

Inspection and repair Valve installed depth (figure 31). Production

depth is 0.701.20 mm (0.0270.046 in). If
Clean more than 2.5 mm (0.100 in), replace the valve
(73) or valve seat (76) as required.
All carbon from valve ports.
Valve guide bore of dirt and carbon.
Valve stems and heads. Do not use a wire
wheel.
All traces of old gaskets from cylinder head and
block.
6A6-12

14. Cylinder Head

73. Valve 73. Valve
76. Valve Seat 77. Valve Guide
A. Valve Installed Depth A. Dial Indicator

Figure 31. Measuring Valve Installed Depth
Valve stem diameter, as shown in figure 32.
Check in three places, as shown. Check against
Specifications at the end of this section.
Figure 33. Measuring Valve Stem to Guide
Clearance
Valve springs for length and straightness.
Check against Specifications at the end of this
section.
Check length with vernier calipers (figure 34).
Check amount of inclination from vertical with
a square on a surface plate, as sown in figure
35.

Figure 32. Measuring Valve Stem Diameter

Valve guide (77) inside diameter, using an

inside micrometer. Check against
Specifications at the end of this section.
Valve guide to valve stem clearance (figure 33).
Locate a dial indicator as shown. Figure 34. Measuring Valve Spring Length
Hold the valve on its seat.
Move the valve stem from side to side to
obtain the clearance reading. Check against
Specifications at the end of this section.
 6A6-13

4. Find the maximum value (Tmax) of the average

Cylinder head gasket grade selection
of each cylinder. (piston projection)
procedure
5. Based on the Tmax obtained, select a gasket of
1. Clean thoroughly the top faces of the piston the appropriate grade.
head and the cylinder body.
2. Use the dial gauge to measure the piston head Cylinder Head Gasket Selection mm (in)
projection. Take measurements at two location
Gasket Grade Tmax Gasket Thickness
for each cylinder.
The measurement points of the piston head and 0.479 - 0.559 1.70
A
the reference point of the cylinder body are (0.0189 - 0.0220) (0.0669)
shown in the illustration. 0.559 - 0.629 1.75
B
(0.0220 - 0.0248) (0.0689)
0.629 - 0.709 1.80
C
(0.0248 - 0.0280) (0.0708)

Figure 42a. Measurement of Piston

projection

Measurement points : Points G1 and G2 of the

piston head
Reference point : Point R on the top face of
the cylinder body Figure 42c. Location of Cylinder Head Gasket
Grade

Point R Install or Connect (Figures 27 and 43-45)

1. Cylinder head gasket.

Install the cylinder head gasket with its PART
NUMBER mark facing up and toward the left
50

of the engine.
70

Point G2
20

1
00

Point G1

Figure 42b. Measurement Points

3. For each cylinder, calculate the average value

(T) of the piston projection.
Figure 43. Head Gasket Marking
6A6-14
2. Cylinder head assembly.
3. Cylinder head bolts.
Apply grease containing molybdenum
disulfide to all head bolts.
Tighten (Figures 44 and 45)
Cylinder head bolts in three stages, as
outlined below. (For sequence number 1-18)
Stage 1: Tighten all head bolts to 98 Nm (72
lbft) using the tightening sequence shown
figure 44.
Stage 2: Tighten all head bolts to 147 Nm
(108 lbft) using the tightening sequence
shown figure 44.
Stage 3: Refer to figure 45. Make punch mark
on the bolt heads, as shown.
Then, make a second punch mark on the
cylinder head, 3060 degrees clockwise from
the first mark, as shown. Then, tighten all
head bolts 3060 degrees, using the
tightening sequence shown in figure 44.
The sequence number 19 and 20 are
tightened to 38 Nm (28 lbft).
Figure 44. Head Bolt Tightening Sequence
A. Reference Punch Mark on Bolt
B. Reference Punch Mark on Cylinder Head
Figure 45. Anglar Tightening Method for
Cylinder Head Bolts
4. Camshaft assembly refer to the camshaft
replacement.
5. Rocker arm and shaft assembly refer to the
valve train component.
6. Adjust for valve clearance.
Refer to the maintenance: valve adjustment.
7. Cylinder head cover refer to the cylinder head
cover replacement.
8. Charge air hose and pipe to the intake manifold.
9. EGR pipe.
10. A/C compressor and bracket.
11. Glow plug connector refer to the glow plug
replacement.
12. Engine harness connectors.
13. Fan guide bracket.
14. Injector leak off pipe and gasket.
15. Fuel pipes, gaskets to the fuel filter and fuel
filter.
16. Injector pipes.
17. Front exhaust pipe to exhaust manifold.
18. Turbocharger refer to the turbocharger
replacement.
19. Injection nozzle cover.
20. Heater hose return.
21. Water pump bypass hose.
22. Radiator upper hose. Refer to RADIATOR
(SEC. 6B2).
23. Engine coolant.
Fill the radiator with the proper quantity and
grade of engine coolant.
Install the rear floor engine cover and rear engine
cover.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
 6A6-15

PISTON AND CONNECTING ROD

REPLACEMENT Disassemble (Figures 46, 48 and 59)

1. Rings (75, 76, 77 and 78), using a ring

Refer to Statement on Cleanliness and Care
expander (figure 48).
previously mentioned in this section.
2. Snap rings (79).
Remove or Disconnect (Figures 46 and 47) 3. Piston pin (84).

Engine refer to the engine replacement (SEC. 6A). Clean (Figure 46)

Piston (80) and rings (75, 76, 77 and 78) in

1. Cylinder head assembly refer to the cylinder
solvent.
head replacement.
Do not use wire brush the piston.
2. Oil level gauge tube with dip stick.
Liner (89) bore with a solvent soaked cloth
3. Oil pan.
(figure 59).
4. Oil strainer.
Piston (80) ring grooves.
5. Oil jets
6. Connecting cap bolts (83).
7. Connecting rod cap (82) with bearing (87).
8. Piston (80) with connecting rod (81). If the
piston is to be reused, mark the cylinder number
on it so it can be returned to the proper cylinder
as assembly. Be sure to keep the connecting
rod cap (82), connecting rod (81) and
connecting rod bearing inserts (86 and 87)
together as a matched set. Numbers are
stamped on the connecting rod and cap to help
keep the parts together (figure 47).
6A6-16

75. Compression 1st Ring

76. Compression 2nd Ring
75
77. Compression 3rd Ring 76
78. Oil Control Ring 77
78
79. Snap Ring
80. Piston
81. Connecting Rod 84 79
82. Connecting Rod Cap
83. Bolt
84. Piston Pin
80
86. Upper Connecting Rod Bearing
87. Lower Connecting Rod Bearing
88. Connecting Rod Bearing Set

79
81

86 82
88
87
83

Figure 46. Piston, Connecting Rod and Components

Inspect (Figure 46)

Piston (80) for cracks and scoring.

Liner (89) for scratches, cracks and scoring
(figure 59).
Connecting rod (81) and connecting rod cap
(82) for cracks, damage etc.
Connecting rod bearing (86 and 87) for scoring.
Connecting rod bearing (86 and 87) tension
(figure 53). Moderate finger pressure should be
needed to push the bearing inserts into place. If
the inserts fit loosely, they should be replaced.
Connecting rod journal on the crankshaft for 81. Connecting Rod
scoring or other damage. 82. Connecting Rod Cap
A. Connecting Rod Markings
(2 Means #2 Rod)

Figure 47. Connecting Rod Markings

 6A6-17

75 76
77 A. Piston Ring
78 80. Piston

Figure 49. Measuring Piston Ring to Groove

80 Clearance

75. Compression 1st Ring

76. Compression 2nd Ring
77. Compression 3rd Ring
78. Oil Control Ring
80. Piston

Figure 48. Removing or Installing Piston Rings

Measure

Piston Ring to Piston Ring Groove Clearance

(Figure 49)
The clearance should be as specified in
Specifications at the end of this section.
A. Piston Ring
Piston Ring End Gap (Figure 50)
The gap should be as specified in specifications Figure 50. Measuring Piston Ring End Gap
at the end of this section.

Piston Pin Hole Inside Diameter (Figure 51)

The hole should measure 40.00440.012
(1.57491.5752 in).

Piston Pin Diameter (Figure 52)

Measure in three places as shown. The
production diameter is 39.99540.000 mm
(1.57461.5748 in).

Figure 51. Measuring Piston Pin Hole Diameter

6A6-18
Piston Pin to Piston Pin Hole Clearance
(Figures 51 and 52)
Subtract the piston pin diameter from the piston
pin hole diameter to obtain the clearance.The
proper clearance is 0.0040.017 mm
(0.000160.00067 in).
Connecting Rod Small End Bushing Inside
Diameter (Figure 54)
The correct diameter is 40.01240.022 mm
(1.57521.5756 in).
Piston Pin to Connecting Small End Bushing
Clearance
Subtract the piston pin diameter from bushing
inside diameter to obtain the clearance.The
standard clearance is 0.0120.027 mm
(0.00050.0011 in).The service limit is 0.05 mm
(0.002 in).
84. Piston Pin
Figure 52. Measuring Piston Pin Diameter
Figure 53. Checking Connecting Rod Bearing
Tension
Figure 54. Measuring Piston Pin Bushing Inside
Diameter
Crankpin Diameter (Figure 55)
Measure in two places and in the horizontal and
vertical, as shown. The crankpin should measure
72.92072.922mm (2.79792.7980 in).
Important
If the crankshaft is worn, it should be
replaced. It cannot be reground. Undersize
bearings are not available. This is becaus of
the special tufftriding hardening process that
has been applied to it.
Crankpin to Connecting Rod Bearing Clearance
(Figure 46)
Method 1 of measuring procedure.
Apply molybdenum disulfide grease to the threads
of the bolts (83).
Install the connecting rod cap (82), connecting
rod bearing insert (86 and 87) and bolts (83).
Tighten
Bolts (83) to
1st stage 39 Nm (29 lbft),
2nd stage 60 degrees and
3rd stage 30 degrees.
Measure the connecting rod bearing (88) inside
diameter, using an inside micrometer (figure 56).
Subtract the crankpin diameter from the
connecting rod bearing inside diameter to obtain
the clearance. The production clearance is 0.036
0.077 mm (0.0014 0.0030 in).The service limit
is 0.10 mm (0.004 in).
Remove the bolts (83).
Remove the connecting rod cap (82) and
bearings (86 and 87).
 6A6-19

2. A piece of plastigage the length of the bearing

(parallel to the crankshaft) on the journal (figure
68). Do not turn the crankshaft with the gaging
plastic installed.

Figure 55. Measuring the Crankpin

A. Place Gaging Plastic

Parallel to Crankshaft

Figure 68. Placing the Gaging Plastic on the

Crankpin

3. Install the connecting rod cap (82) with the

Figure 56. Measuring the Connecting Rod
Bearing Inside Diameter
lower bearing insert (87). Be sure the numbers
on the connecting rod (81) and connecting rod
cap align.
Apply molybdenum disulfide grease to the
threads of the bolts (83).
4. Install the Bolts (83).

Method 2 of measuring procedure Tighten

(Figures 46 and 68~70)
The simplest, most accurate way to measure Bolts (83) to
connecting rod bearing clearance is with the use of 1st stage 39 Nm (29 lbft),
plastigage. This wax-like material compresses 2nd stage 60 degrees and
evenly between the bearing and journal surfaces 3rd stage 30 degrees.
without damaging them. Proceed as follows. 5. Remove the bolts (83).
6. Remove the connecting rod cap (82).
Clean The gaging plastic will be found sticking
either to the crankpin or lower bearing
All oil from the crankpin and the bearing inserts insert (87). Do not remove it at this time.
(86 and 87).
1. Install the connecting rod (81) with the upper
bearing insert (86) to the crankpin.

Important

If a bearing is being fitted to an out-of-round

crankpin, be sure to fit to the maximum diameter
of the crankpin. If the bearing is fitted to the
minimum diameter and the crankpin is
excessively out-of-round, interference between
the bearing and the crankpin will result in rapid
bearing failure.
6A6-20

Figure 57. Liner and Piston Grade Marking

A. Measure Widest Point of Gaging Method 1

Plastic With Graduated Scale The cylinder block deck has been marked during
production to indicate both the correct liner and
Figure 69. Measuring the Gaging Plastic piston sizes. The liner grade (i.e. 1, 2, 3) is
indicated in permanent ink (figure 57) .
Gaging plastic at its widest point, using the The piston grade is indicated (i.e. A, B, C, D) by a
scale at the gaging plastic envelope (figure metal stamping. This information is for reference to
69). select the piston service grades.
If the clearance exceeds specifications, select In the case of a questionable liner marking use
a new, correct size connecting rod bearing the next method for correct liner selection.
and remeasure the clearance.
Connecting Rod Bearing Selection Table
Conbination of Bearing Grades
Connecting Bearing Oil Clearance
rod Grade Grade mm(in)
A Green 0.0360.077 (0.00140.0030)
B Yellow 0.0360.077 (0.00140.0030)

Connecting Rod Grade Measurement mm(in)

A 77.98577.992 (3.0703-3.0705)
B 77.99378.000 (3.0706-3.0709)
Do not attempt to use shims or file the bearing
to obtain the needed clearance.
If clearance cannot be brought to within Figure 58. Measuring the Cylinder Bore
specifications, replace the crankshaft. The
crankshaft cannot be reground. Undersize Method 2
bearings are not available. In order to select the correct liner for each
Remove the gaging plastic. cylinder bore, six measurements must be
taken(figure 58).
Piston and Liner Grade Selection These measurements are then averaged as
The cylinder inner diameter grade and the piston follows:
service grade are supplied two grades. The service
grade AX for the production grade A and B, and the 1+2+3+4+5+6
service grade CX for the production grade C and D. Diameter Average =
6
There are two methods by whitch liners can be
selected.
 6A6-21

Cylinder Liner and Piston Service Grade

Production Cylinder liner innner Service Piston outer Liner to piston
grade diameter mm (in) grade diameter mm (in) clearance mm (in)

110.066 110.075 109.944 109.959 0.107 0.131

A and B AX
(4.3333 4.3337) (4.3285 4.3291) (0.0042 0.0052)

110.076 110.085 109.960 109.975 0.101 0.125

C and D CX
(4.3337 4.3340) (4.3291 4.3297) (0.0040 0.0049)

4. Oil control ring expander to the piston (80).

Assemble and Install or Connect
(Figures 46, 48, 49, and 64-70)
Heat the piston (80) in an oven, if necessary, to
ease insertion of the piston pin (84).
1. Piston (80) to the connecting rod (81). Align the
piston and connecting rod as shown in figure
64.
Lubricate the piston pin (84) with engine oil.
2. Piston pin (84).
3. Snap rings (79). Rotate the snap rings in their
grooves to be sure they are fully seated.
5. Oil control ring (78). Use a ring installing tool
(figure 48).
6. Compression 3rd ring (77). Use a ring installing
tool.
7. Compression 2nd ring (76). Use a ring installing
tool.
8. Compression 1st ring (75). Use a ring installing
tool. The marked 1st ring has 1N, 2nd and 3rd
rings have N) face of the ring must face up
(figure 65).
Locate the ring end gaps as shown in figure
66.

Marked Side Up
75

76

77
78

75. Compression 1st Ring

76. Compression 2nd Ring
77. Compression 3rd Ring
78. Oil Control Ring
A. Front Mark
B. Emboss dots Figure 65. Installing the Piston Rings
80. Piston
81. Connecting Rod
82. Connecting Rod Cap

Figure 64. Aligning the Piston and Connecting

Rod
6A6-22

75
76
78

FRONT
MARK

77
B B A
75. Compression 1st Ring
76. Compression 2nd Ring
77. Compression 3rd Ring
78. Oil Control Ring
A. Oil Ring Expander
B. 45 degrees

Figure 66. Piston Ring End Gap Locations

9. Upper connecting rod bearing insert (86) to the 80. Piston

connecting rod (81) (Figure 46). A. Front Mark
10. Lower connecting rod bearing insert (87) to the B. Front of Engine
connecting rod cap (82). C. Piston Ring Compressor
11. Piston (80) and connecting rod (81) assembly to
the proper liner. Figure 67. Installing the Piston
Lubricate the piston (80) and connecting rod
bearing with engine oil. 12. Connecting rod cap (82) with the lower bearing
Without disturbing the ring end gap locations, insert to the connecting rod (81). The numbers
install the piston ring compressor tool over the on the connecting rod and connecting rod cap
piston. must align (figure 47).
Push the piston into place (figure 67). Make Apply molybdenum disulfide grease to the
the front marks face the front of the engine, threads of the connecting rod cap bolts (83).
as shown. 13. Bolts (83).

Tighten

Bolts (83) in three stages, as follows:

Stage 1: Tighten both bolts to 39 Nm (29
lbft).
Stage 2: Refer to figure 70. Make a punch
mark on the bolt heads, as shown. Then make
a second punch mark on the connecting rod
cap, 60 degrees clockwise from the first mark.
Tighten both bolts 60 degrees (until the punch
marks align).
Stage 3: Make a punch mark on the bolt
heads, as shown. Then make a second punch
mark on the connecting rod cap 30 degrees
clockwise from the first mark.
Tighten both bolts 30 degrees.

A. Reference Punch Mark on Bolt
B. Reference Punch Mark on
Connecting Rod Cap
Figure 70. Anglar tightening Method for
Connecting Rod Bolts
14. Oil jet to 21 Nm (15 lbft).
15. Oil strainer with o-ring to 31 Nm (23 lbft).
16. Oil level gauge tube with dip stick
17. Cylinder head assembly refer to the cylinder
head replacement.
Engine refer to the engine replacement (SEC. 6A).
VIBRATION DAMPER REPLACEMENT
Remove or Disconnect (Figure 71)
Disconnect the battery negative cable.
Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
engine cover assembly.
1. Three stay for fan shroud.
2. Cooling fan (2) (figure 4, SEC. 6B3).
3. Loosen the generator adjusting plate bolt and
remove the drive belts.
4. Loosen the A/C compressor drive belt tensioner
and remove the drive belt. Refer to AIR
CONDITIONING (SEC. 1B).
5. Damper bolts (93).
6. Vibration damper (90).
6A6-23
93 91 90
90. Vibration Damper
91. Pulley
93. Bolt
Figure 71. Crankshaft Damper and Pulley
Install or Connect (Figure 71)
1. Vibration damper (90).
2. Lubricate the bolt (93) threads with engine oil.
3. Bolts (93).
Tighten
Bolts (93) to 200 Nm (147 lbft).
4. Routine the drive belts.
5. Adjust the generator drive belts to push the belt
8 - 12 mm (0.3150 - 0.4724in) with 98 Nm (22
lbft).
6. Adjust the A/C compressor drive belt tensioner
to push the belt 16 - 20 mm (0.6300 - 0.7874 in)
with 98 Nm (22 lbft).
7. Cooling fan (2) (figure 4, SEC. 6B3).
8. Stay for fan shroud (figure 1, SEC. 6B2).
Install the rear floor engine cover and rear engine
cover assembly.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
6A6-24 ISUZU ENGINE

TIMING GEAR REPLACEMENT

161. Camshaft bearing cap 171. Clutch pressure plate 167. Power steering pump idle gear
162. Camshaft bearing upper assembly cover
160. Camshaft assembly 172. Driven plate 166. Power steering pump idle gear
163. Camshaft bearing lower 164. Injection pump assembly 165. Flywheel housing
63. Cylinder head gasket 173. Flywheel 168. Idle gear A
174. Camshaft 134. Oil pan 169. Idle gear B
159. Oil pipe 170. Idle gear B shaft

Figure 79. Timing Gear Replacement

 ISUZU ENGINE 6A6-25

Befor removal the timing gears, measure the

following items

1. Idle gear backlash measurement.

Measure (Figure 86a)

1-1. Set a dial indicator to the timing gear to be

measured.
Hold both the gear to be checked and the
adjoining gear stationary.
1-2. Move the gear to be checked right and left as
far as possible. Take the dial indicator reading.

Timing Gear Backlash Gear to Gear: Figure 86b. Idler Gear End Play
Standard: 0.100.17 mm (0.00390.0067 in)
Limit: 0.30 mm (0.012 in)
Remove or Disconnect

Preparation
Engine refer to the engine replacement (SEC. 6A).

1. Injection nozzle cover.

2. Front exhaust pipe.
3. Cylinder head cover refer tot the cylinder head
cover replacement.
4. Rocker arm shaft assembly refer to the valve
train and component replacement.
5. Camshaft assembly(174) refer to the camshaft
replacement.

Figure 86a. Timing Gear Backlash Measurement

2. Idler Gear End Play

Measure (Figure 86b)

Insert a feeler gauge between the idler gear and

the thrust collar to measure the gap and determine
the idler gear end play.
If the measured value exceeds the specified limit,
the thrust collar must be replaced.

Idler Gear End Play:

Standard: 0.0580.115 mm (0.0020.005 in) Figure 80. Camshaft
Limit: 0.2 mm (0.008 in)
6. Clutch assembly for M/T(170, 171) refer to the
Section 7C.
7. Flywheel for M/T(169) or Flywheel and flexible
plate(172) for A/T.
6A6-26 ISUZU ENGINE

13. Power steering idle gear bolt with thrust collar.

14. Power steering pump idle gear.

Figure 84a. Flywheel (M/T) & (A/T)

8. Oil pipe (159).

9. Engine control wires. Figure 85. Power Steering Pump Gear

15. Oil pan (134) refer to the oil pan replacement.

16. RH and LH stiffeners.
17. Rubber spacer.
18. Flywheel housing (165) refer to the flywheel
housing replacement.
19. Rear oil seal slinger.
20. Oil seal refer to the rear oil seal replacement.
21. Idle gear A fixing bolt with thrust collar.
22. Idle gear A.
23. Idle gear B fixing bolt with thrust collar.
24. Idle gear B.
25. Idle gear B shaft fixing three bolts with idle gear
B shaft.

Figure 83. Engine Control Wires

10. Injection pump assembly(164).

Figure 86. Idle Gear

Inspection and Repair

1. Idler Gear Shart Outside Diameter

Measure (Figure 87)

Figure 83a. Injection Pump Assembly Use a micrometer to measure the idler gear shaft
outside diameter.
11. Power steering pump from front side of flywheel
If the measured value is less than the specified
housing.
limit, the idler gear must be replaced.
12. Power steering pump idle gear cover from
flywheel housing.
 ISUZU ENGINE 6A6-27

Idler Gear Shaft (A, B) Outside Diameter:

Install or Connect
Standard: 29.95929.980 mm (1.17951.1803 in)
Limit: 29.80 mm (1.1732 in) 1. Idle gear B shaft with bolts to cylinder block.
Tighten bolts to 31 Nm (23 Ibft).
Apply the engine oil to the idle gear shaft after
installation.

Figure 87. Idler Gear Shaft Outside Diameter

Idler Gear (A, B) Inside Diameter
Measure (Figure 87a)
Use an inside dial indicator or an inside
micrometer to measure the idler gear inside
diameter.
Figure 88. Idler Gear B Sahft
2. Idle gear B.
3. Idle gear B fixing bolt with thrust collar.
Tighten bolt to 110 Nm (81 lbft)

Idler Gear Inside Diameter:

Standard: 30.00030.021 mm (1.18111.1819 in)
Limit: 30.100 mm (1.1850 in)

If the clearance between the idler gear shaft

outside diameter and the idler gear inside diameter
exceeds the limit, the idler gear must be replaced.

Idler Gear Shaft and Idler Gear Clearance:

Standard: 0.0200.062 mm(0.00080.0024 in)
Limit: 0.200 mm (0.0079 in)

Figure 88a. Idle Gear B

4. Turn crankshaft to align No1 piston at TDC.

5. Idle gear A shaft to cylinder block.
6. Idle gear A.
Align the crankshaft gear with the engagement
mark of the idle gear and install the idle gear A.
(Figure 88b)
7. Idle gear A fixing bolt with thrust collar.
Tighten bolt 133 Nm (98 lbft).

Figure 87a. Idler Gear Inside Diameter

6A6-28 ISUZU ENGINE

Figure 88b. Timing Gear Alignment

8. Flywheel housing refer to the flywheel housing

replacement.
9. Crankshaft rear oil seal refer to the crankshaft
rear oil seal replacement.
10. RH and LH stiffeners refer to the flywheel
housing replacement.
12. Oil pan refer to the oil pan replacement.
13. Power steering idle gear with collar and bolt.
Tighten bolt to 133 Nm (98 lbft).

Figure 89d. Power Steering Pump Idle Gear and Shaft

14. Power steering idle gear cover to flywheel

housing.
Tighten bolt to 19 Nm (14 lbft)

Figure 89c. Power Steering Pump Idle Gear

Figure 89e. Power Steering Pump Cover

 ISUZU ENGINE 6A6-29

15. Injection pump assembly refer to the injection

pump replacement.

Figure 83a. Injection Pump Assembly

16. Engine control wire.

17. Oil pipe.
18. Flywheel for M/T or flywheel and flexible plate
for A/T refer to the flywheel replacement.

Figure 84a. Flywheel (M/T) & (A/T)

19. Clutch assembly for M/T refer to the Section 7C.

20. Camshaft assembly(174) refer to the camshaft
replacement.
21. Rocker arm shaft assembly refer to the valve
train and component replacement.
22. Cylinder head cover refer tot the cylinder head
cover replacement.
23. Front exhaust pipe.
24. Injection nozzle pipe cover.
25. Charged air pipe and hose to turbocharger.
26. Charged air pipe and hose to intake manifold.
27. Fill coolant and engine oil.
Engine refer to the engine replacement (SEC. 6A).
6A6-30 ISUZU ENGINE

CAMSHAFT REPLACEMENT

174. Camshaft
175. Washer
176. Camshaft Gear
177. Bolt
179. Key

Remove or Disconnect

Disconnect the battery negative cable.

Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
engine cover assembly.

1. Injection nozzle cover.

2. EGR pipe between exhaust manifold and EGR
valve.
3. cylinder head cover refer to the cylinder head
cover replacement.
4. Before remove the rocker shaft assembly and 6A17-1.tif

camshaft assembly measure the camshaft end

play. Use a thickness gauge to measure the
end play between the camshaft gear and the
camshaft bracket.
If the measured value exceeds the service limit,
the camshaft gear or camshaft must be
replaced.
The production end play is 0.085 - 0.205 mm
(0.0033 - 0.0081 in), the service limit is 0.25
mm (0.0098 in)
5. Rocker arm shaft assembly refer to the valve
train and component replacement.
6. Camshaft bracket bolt and bracket.
7. Camshaft with camshaft gear.
8. Camshaft fixing bolt.
9. Separate the camshaft and camshaft gear.
10. Sealing cap.
11. Idle gear C fixing bolt with thrust collar.
12. Idle gear C shaft.
13. Idle gear C.

Inspection and Repair

Inspect

Camshaft (174) lobes and bearing journals for

pitting, galling, or scratches.
Camshaft gear (176) for chipped or broken
teeth.
 ISUZU ENGINE 6A6-31

Measure

1. Camshaft (174) runout (Figure 87f). Replace the

camshaft if the runout is more than 0.05 mm
(0.002 in).
2. Camshaft (174) journal diameter using a
micrometer (Figure 87c). Measure in two
places, as shown.
The production diameter is 39.95039.975 mm
(1.57281.5738 in). The service limit is 39.850
mm (1.569 in).

Figure 87f. Measuring Camshaft Runout

174. Camshaft
A. Camshaft Journal
B. Camshaft Lobe

Figure 87c. Measuring the Camshaft Journal

3. Camshaft bearing inside diameter (Figure 87e).

The correct measurement is 40.00040.037
mm (1.57481.5763 in).
4. Camshaft (174) journal to camshaft bearing
clearance.
Subtract the camshaft journal diameter from
the camshaft bearing inside diameter to obtain
the clearance.
The production clearance is 0.0250.087 mm
(0.00100.0034 in). The service limit is 0.15
mm (0.006 in).

Figure 87e. Measuring the Camshaft

Bearing Inside Diameter
6A6-32 ISUZU ENGINE
5. Cam height.
Measure the cam height A with a micrometer.
If the measured value is less than 53.6 mm
(2.110) in), the camshaft must be replaced.
174. Camshaft
Figure 87d. Measuring Camshaft Lobe Lift
Install or Connect
1. Idle gear C with oil groove face to cylinder
head.
2. Apply engine oil to idle gear C shaft and install
to cylinder head.
3. Idle gear C fixing bolt with thrust collar. Tighten
bolt to 95 Nm (70 lbft).
4. Apply loctite to sealing cap and install to
cylinder head as shown in the illustration.
5. Install the camshaft gear with align the key
groove of the camshaft gear to the camshaft
dowel pin on the camshaft.
6. Camshaft gear fixing bolt with washer to 142
N.m (105 lbft).
7. Camshaft bearing lower to the cylinder head.
8. Camshaft assembly.
8-1. Turn the crankshaft in the direction of normal
rotation until the timing mark on the
crankshaft damper pulley is aligned with the
TDC notched line.
8-2. Apply engine oil to the camshaft journal and
the camshaft bearing surfaces before
installation.
8-3. Carefully align the camshaft gear "I" mark and
the cylinder head upper face shown in the
illustration.

Figure 98. Camshaft Gear Alignment Mark
9. Camshaft bracket with upper bearing.
Install
Install the bracket with the bracket head mark
(arrow) facing forward.
Apply a coat of engine oil to the bracket bolt
and stud threads.
Figure 98a. Camshaft Bearing Upper
Tighten
Tighten the bracket bolts to the specified
torque. (Figure 99)
Tighten bracket bolt to 27 Nm (20 lbft).
Figure 99. Camshaft Bracket Bolts
ISUZU ENGINE 6A6-33
10. Rocker arm shaft assembly refer to the valve
train and component replacement.
Caution:
Take sufficient care not to let valve caps fall into
the gear.
Figure 100. Valve Cap
11. Adjust the valve clearance refer to the valve
adjustment in maintenance.
Valve Clearance:
At cold: 0.4 mm (0.016 in)
Figure 103. Valve Clearance
12. Cylinder head cover refer to the cylinder head
cover replacement.
13. EGR pipe.
14. Injection nozzle cover.
Install the rear floor engine cover and rear engine
cover assembly.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
6A6-34 ISUZU ENGINE

FLYWHEEL HOUSING REPLACEMENT Install or Connect

Tool required
J-43285 Slinger puller 1. Apply the recommended liquid gasket (Three
Bond 1141E) or its equivalent to the shaded
Remove or Disconnect areas shown in the illustration.
Disconnect the battery negative cable.
Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
engine cover assembly.

1. Transmission (M/T or A/M).

2. EGR pipe.
3. Power steering pump.
4. Oil pipe with oil pipe clamps.
5. Breather hose from C/box with clamp.
6. RH and LH stiffeners.
7. Insulater from lower portion of the flywheel
housing.
8. Oil pan refer to the oil pan replacement. Figure 89. Smearing Area for Liquid Gasket
9. Flywheel refer to the flywheel replacement.
10. Power steering pump idle gear cover. 2. Align the cylinder body knock pins with the
11. Power steering pump idle gear. flywheel housing knock pin holes.
12. Set J-43285 Slinger puller to remove the
crankshaft rear oil seal. Tighten

Tighten the flywheel housing bolts to the

specified torque shown in the illustration.

Flywheel Housing Bolt Torque (Figure 89a)

: 96 Nm (71 Ibft)
: 48 Nm (35 Ibft)
: 48 Nm (35 Ibft)
: 48 Nm (35 Ibft)
: 38 Nm (28 Ibft)

Tighten the bolts marked with or

from the injection pump side, and those with
from the cylinder body side.
13. Flywheel housing fixing bolts.
14. Flywheel housing.

Inspection and Repair

1. Visual check for damage on the flywheel

housing.
2. Replace the flywheel housing, if find any
damage.

Clean

1. Carefully wipe any foreign material from the

cylinder body rear face.
2. Liquid gasket from flywheel housing.
Figure 89a. Flywheel Housing Bolts
 ISUZU ENGINE 6A6-35

4. Power Steering Pump Idle Gear (Figure 89c,

89d)
1) Apply the engine oil to the idle gear shaft.
2) Install the idle gear shaft 1 with the idle
gear 2 to the cylinder body A portion as
shown in the illustration.

Figure 89e. Power Steering Pump Cover

6. Oil Pan.
1) Apply a 3 mm (0.1 inch) bead of
recommended liquid gasket (Three Bond
1207C) or its equivalent to the shaded areas
shown in the illustration.
Figure 89d. Power Steering Pump Idle Gear and Shaft

Figure 89c. Power Steering Pump Idle Gear

Tighten

Idle Gear Shaft Bolt Torque: 133 Nm (98 lbft)

5. Power steering Pump Idle Gear Cover (167)

(Figure 89e)
Install the gear cover with the O-ring.

Tighten

Gear Cover Bolt Torque: 19 Nm (14 lbft)

Tighten oil pan bolts and nuts to the specified

torque in the numerical order.
marks are located on nut positions.

Oil pan bolts and nuts torque.

24 Nm (17 lbft) for numerical order 1 - 22 and
numerical order 24 - 26.
18 Nm (13 lbft) for numerical order 23.
6A6-36 ISUZU ENGINE

020LY00001

7. Insulator 10. Crankshaft rear oil seal refer to the crankshaft

Use stiffener bolt to tighten together with the rear oil seal replacement.
stiffener. 11. Flywheel refer to the flywheel replacement.
12. Breather hose with clamp to flywheel housing.
13. Oil pipe with pipe clamps.
14. Power steering pump refer to the power
steering pump replacement.
15. EGR pipe with gaskets.
Tighten three bolts and two nuts.
24 Nm (17 lbft) for bolt and 28 Nm (21 lbft)
for nut.
EGR pipe clamp bolt to 24 Nm (17 lbft).
16. Transmission.

Install the rear floor engine cover and rear engine

cover assembly.
Install the cab floor cover. Refer to STEEL CREW
020LY00007
CAB (SEC. 10E).
8. Stiffener LH. Connect the battery negative cable.
Tighten stiffener fixing bolts to 128 N.m (93
lbft) for star mark and 76 Nm (56 lbft) for
circle mark.

020LY00002

9. Stiffener RH.
Tighten stiffener fixing bolts to 48 Nm (35 lbft)
for black triangle mark and 76 Nm (56 lbft) for
square mark.
 ISUZU ENGINE 6A6-37

CRANKSHAFT FRONT OIL SEAL

REPLACEMENT
Tool required
J-43285 Slinger puller
J-43282 Oil seal setting tool kit

Oil Seal Setting Tool Kit Applicable

Part Name Stamp Slinger Oil Seal
Front-use adapter FT
Rear-use adapter RR ? ?
Front-use slinger sleeve FT
Rear-use slinger sleeve RR ? 6A3-87-3.tif

Front-use oil seal sleeve FT 13. Crankshaft front oil seal.

Rear-use oil seal sleeve RR ? Caution:
Center bolt ? ? Be careful not to damage the crankshaft front oil
seal contact surface during the removal
Adapter bolt ? ? procedure.
Collar RR ? ?

Preparation
Disconnect the battery negative cable.
Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Remove the rear floor engine cover and rear
engine cover assembly.
Drain the coolant.
Drain the engine oil.

Remove or Disconnect

1. Under cover (M/T model) 6A3-87-4.tif

2. Starter 14. Slinger.

3. Radiator upper hose Use J-43285 slinger puller to pull out slinger.
4. Coolant reserve tank hose or bypass hose.
5. Radiator lower hose
6. Charge air hose at charger air cooler both from
turbocharger and intake manifold.
7. Fan guide bracket at top of engine front and
lower of engine front.
8. Radiator (with fan guide)
9. Loosen generator adjust plate bolt and A/C
compressor belt tensioner.
10. Fan belts.
11. Fan assembly.
12. Damper pulley.
12-1. Use suitable crankshaft stopper to prevent
turning the crankshaft
12-2. Remove the damper pulley bolts. 6A3-88-1.tif
6A6-38 ISUZU ENGINE

Install or Connect

Note:
Be sure to replace the slinger and oil seal as
a set.
1. Slinger
Press in the slinger using oil seal setting tool kit
1-1. Insert the slinger 1 onto the end of adapter
2 and install the adapter on the crankshaft
front.

6A3-89-1.tif

2. Crankshaft front oil seal

Press in the oil seal using the front oil seal
setting tool kit.
2-1. Apply engine oil to the lip of the oil seal.
2-2. Remove the slinger sleeve and insert the
oil seal 5 onto the adapter 2.
2-3. Install the oil seal sleeve 6 and tighten the
center bolt until the sleeve comes to
contact the adapter stopper 7.
2-4. Remove the oil seal setting tool.
6A3-88-2.tif 2-5. Make sure of the measurements specified
1-2. Cover the sleeve 3 and tighten the bolt value in the illustration.
until the sleeve comes to contact the Specified value from front end of crankshaft.
adapter stopper. C = 31 0.3 mm (1.2205 0.0118 in)

6A3-88-3.tif 6A3-89-3.tif
1-3. Make sure of measurements specified
value as well as of slinger deflection.
Specified value from front end of crankshaft.
A = 40.5 0.3 mm (1.5945 0.0118 in)
B = 34 0.1 mm (1.3386 0.0039 in)

6A3-89-2.tif
 ISUZU ENGINE 6A6-39

3. Damper pulley Install the cab floor cover. Refer to STEEL CREW
Apply engine oil to thread and seat of damper CAB (SEC. 10E).
pulley bolt. Connect the battery negative cable.
Tighten damper pulley bolt to 100 N.m (148
lbft) OIL COOLER REPLACEMENT
Remove the crankshaft stopper.
Remove or Disconnect

Engine refer to the engine replacement (SEC. 6A).

1. Vacuum Hose
2. Oil Level Guide Tube
Remove the guide tube fixing bolt and pull out
the guide tube.
3. Intake Air Duct
4. Engine Stop Cable
Loosen the locking nut at the bracket and
disconnect engine stop cable from injection
pump stop lever.

6A3-89-4.tif

4. Fan assembly.
Tighten fan assembly fixing bolts to 24 N.m (17
lbft).
5. Routing the fan belts
6. Adjust the belt tension to 8 - 12 mm (0.3150 -
0.4724 in) for new belt and 10 - 14 mm (0.3937
- 0.5512 in) for reuses belt when apply 98 N (22
lb).

6A3-62-1.tif

5. Accelerator Control Cable

Loosen the locking nut at the bracket and
disconnect accelerator control cable from
injection pump control lever.

6A3-89-5.tif

7. Radiator (with fan guide).

Tighten radiator mounting bolt to 76 N.m (56
lbft).
8. Fan guide bracket at top of engine front and
lower of engine front.
9. Charge air hose at charger air cooler both to
turbocharger and intake manifold.
10. Radiator lower hose
6A3-62-3.tif
11. Coolant reserve tank hose or bypass hose.
6. Engine Control Cable
12. Radiator upper hose
7. Engine Control Lever
13. Starter
14. Under cover (M/T model)

Install the rear floor engine cover and rear engine

cover assembly.
6A6-40 ISUZU ENGINE

6A3-63-1.tif 6A3-65-1.tif

8. Oil Pipe 25. Oil Cooler Assembly

9. Fuel Return Hose 1) Remove the oil cooler bolts.
10. Fuel Feed Hose 2) Install a oil cooler fixing bolt to the oil cooler
Disconnect fuel hose from injection pump side replace hole as shown in the illustration, and
and take care not to spill and enter dust. tighten the bolt alternately a little at a time.
11. Nozzle Cover 26. O-Ring
12. Leak Off Pipe
13. Fuel Pipe
14. Positive Crankcase Ventilation (PCV) Hose
4HE1-TC
15. Water Bypass Hose
16. Injection Pipe
17. Injection pump Assembly
Above works refer to Section 6C Fuel System
in this manual.
18. Injection Pump Rubber Spacer
19. Air Conditioning (A/C) Drive Belt (If equipped
with A/C)
20. Idle Pulley Bracket (If equipped with A/C)
After removal of the A/C drive belt, remove the
three bracket fixing bolts. Then, remove the
050LY00003
bracket with the tensioner and the idler
attached.
Disassemble

1. Element fixing bolts

2. Element
3. O-Ring

6A3-63-2.tif

21. Heater Hose

22. Radiator Lower Hose
23. Heater Pipe
24. Water Suction Pipe 6A3-64-1.tif
 ISUZU ENGINE 6A6-41

3. Water Suction Pipe

Reassemble
3-1. Apply 2mm-3mm bead of the
1. O-Ring recommended liquid gasket (Three Bond
Apply a coat of engine oil to the O-rings and 1207C) or its equivalent on the groove of
install to the oil cooler. the water suction pipe fitting surface.
2. Element
3. Element fixing bolts to 20 Nm (14 lbft).

Install or Connect

1. O-Ring
2. Oil Cooler Assembly
2-1. Apply 2mm-3mm (0.08-0.1 in) bead of the
recommended liquid gasket (Three Bond
1207C) or its equivalent on the oil cooler
fitting surface.
2-2. Apply a coat of engine oil to the O-rings (2
pieces) and install the O-rings to the oil
cooler.
NOTE: 6A3-64-5.tif

Take care that the O-ring is not smeared with 3-2. Install the water suction pipe to the oil
liquid gasket. cooler.
Install the oil cooler within 7 minutes after Tighten fixing bolts to 24 Nm (17 lbft).
application of liquid gasket. NOTE: Install the water suction pipe
immediately after the installation of the oil
cooler for prevent into foreign material.
O-ring Liquid gasket O-ring
Judge
ment

OK OK NG
0.3mm 1mm

23mm More then 1mm

Application
condition

Liquid gasket

6A3-64-3.tif

2-3. Tighten the oil cooler bolts and nut to the

specified torque a little at a time in the 6A3-65-1.tif

sequence shown in the illustration. 4. Heater Pipe

Tighten the oil cooler bolts and nut to 24 4-1. Install the O-ring to the heater pipe.
Nm (17 lbft). 4-2. Install the heater pipe to the oil cooler.

13 9 4 1 5 10 14

12 15

16
8

7 3 2 6 11 17

050LY00002 6A6-65-2.tif
6A6-42 ISUZU ENGINE

5. Radiator Lower Hose 23. Accelerator Control Cable

6. Heater Hose 23-1. Check to see if the idling control knob is
7. Idle Pulley Bracket (If equipped with A/C) turned to the utmost limit to the left.
Tighten bracket bolt to 48 Nm (35 lbft). 23-2. Install the end tip of the cable to the
engine control lever.
23-3. With the outer cable pulled toward the
front of the vehicle, provide the engine
control wire and the inner cable with the
appropriate play. Then, fasten the clamp
with a nut.
23-4. Check to see if the control lever of the
injection pump is set at the idling positio
(with the lever attached to the stopper
bolt).
NOTE:
Refer TPS re-learning procedure on page
6C317.
6A3-65-4.tif

8. Adjust the drive belt tension to 8-12 mm

(0.3150-0.4724 in) for new belt and 10-14 mm
(0.3937-0.5512 in) for reuses belt when apply
98N (22 lb).
For A/C compressor drive belt to 16-20 mm
(0.6300-0.7874 in) for new belt and 18-22 mm
(0.7087-0.8661 in) for reuses belt when apply
98 N (22 lb).

Tighten

Locking nut to 27 Nm (20 lbft).

9. Injection Pump Rubber Spacer
6A3-67-2.tif
10. Injection Pump Assembly
24. Engine Stop Cable
11. Injection Pipe
24-1. Install the end tip of the cable to the
12. Water Bypass Hose
engine stop lever.
13. Positive Crankcase Ventilation (PCV) Hose
24-2. Pull the cable toward the rear of the
14. Fuel Pipe
vehicle, and fasten the clamp with a nut at
15. Leak Off Pipe
the position where the lever stops.
16. Nozzle Cover
17. Fuel Feed Hose
18. Fuel Return Hose
19. Air Bleeding
Above works refer to Section 6C Fuel System
in this manual.
20. Oil Pipe
21. Engine Control Lever Assembly
22. Engine Control Cable

6A3-67-4.tif

25. Intake Air Duct

26. Oil Lever Gauge Guide Tube
26-1. Install the O-rings to the guide tube lower
portion and insert the guide tube
completely to the cylinder body.
 ISUZU ENGINE 6A6-43

26-2. Tighten the guide tube bolt to 13 Nm (9.4

lbft).
27. Vacuum Hose
Pour coolant into radiator.
Connect battery ground cable.
Check engine oil level.
Start engine and check for oil and water
leakage carefully.

Engine refer to the engine replacement (SEC. 6A).

 COOLING SYSTEM 6B1-1

SECTION 6B1

COOLING SYSTEM
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Cooling System................................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Engine Coolant Recommendations ...........................................................SEE 1999-2001 SERVICE MANUAL
Corrosion Prevention ..................................................................................SEE 1999-2001 SERVICE MANUAL
Diagnosis of Cooling System .........................................................................SEE 1999-2001 SERVICE MANUAL
Operations and Maintenance..........................................................................SEE 1999-2001 SERVICE MANUAL
Cooling System Checks ..............................................................................SEE 1999-2001 SERVICE MANUAL
Cooling System Pressure Check................................................................SEE 1999-2001 SERVICE MANUAL
Radiator Maintenance..................................................................................SEE 1999-2001 SERVICE MANUAL
Draining and Filling the Cooling System...................................................SEE 1999-2001 SERVICE MANUAL
Cleaning the Cooling System .....................................................................SEE 1999-2001 SERVICE MANUAL
Flushing the Cooling System .....................................................................SEE 1999-2001 SERVICE MANUAL
Cold-Weather Operation..............................................................................SEE 1999-2001 SERVICE MANUAL
On-Vehicle Service: Cooling System Components .......................................................................................6B1-2
Engine Thermostat ......................................................................................................................................6B1-2
Engine Oil Cooler..........................................................................................................................................6B1-3
Water Pump Replacement............................................................................................................................6B1-5
Water Pump Unit Repair..............................................................................SEE 1999-2001 SERVICE MANUAL
Engine Warming-up System ...........................................................................SEE 1999-2001 SERVICE MANUAL
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL
Thermostat ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Fastener Torques.........................................................................................SEE 1999-2001 SERVICE MANUAL
Special Tools....................................................................................................SEE 1999-2001 SERVICE MANUAL
6B1-2 COOLING SYSTEM

ON-VEHICLE SERVICE: COOLING SYSTEM COMPONENTS

ENGINE THERMOSTAT

The thermostat consists of a restriction valve 1

controlled by a thermostatic element. The
restriction valve starts to open at a predetermined
temperature and continues to open as the engine 2
coolant temperature increases. To assure proper
cooling and engine warm up, it is important that the
correct thermostat be used.

Thermostat Replacement
Remove or Disconnect (Figure 3)

Disconnect the battery negative cable.

4
1. Partially drain the radiator.
2. Hose at thermostal cover to turbocharger.
3. Thermo sensor connecter.
4. Thermostat bolts (1) from the thermostat cover
(2).
5. Thermostats (3).
3 3b
Inspect
3a
The thermostat to be sure its in good condition. 1. Bolt
The following test should be done: 2. Thermostat Cover
Suspend the thermostat (3) and thermometer (6) in 3a. Thermostat with dual valves
water with the thermometer located close to the 3b. Thermostat with single valve
thermostat. Be sure the thermostat is placed on the 4. O-Ring
wood piece (8) inside the flask. Agitate the water
with a small rod. Apply heat (7) to the water and Figure 3. Thermostat Components
record both the temperature at which the
thermostat begins to open and the temperature at
which the thermostat is fully opened (figure 4).
Compare temperature readings taken in the test.
The valve opening temperature should be about
82~85C (180~185F). The full open temperature
should be about 95~100C (203~212F). For
details, refer to Specifications at the end of this
section.
 COOLING SYSTEM 6B1-3

ENGINE OIL COOLER

Oil is circulated through the radiator oil cooler,

through the oil filter, and into the engine main oil
passage.
If engine difficulties are encountered, or the
engine has stopped, foreign material may have
entered the oil cooler. The oil cooler, connecting
lines, and filter adapter assembly must be flushed
before the engine is put back into operation. The oil
cooler should be flushed in the following manner.
1. Remove oil cooler from the engine as outline in
Oil Cooler Replacement later in this section.
2. Back-flush oil cooler and lines using clean
solvent and compressed air.

Important

Do not exceed 690 kPa (100 psi) air pressure.

3. Remove all remaining cleaning solvent from the

3. Thermostat
system with compressed air.
6. Thermometer
4. Flush the system again, this time with engine
7. Heat
oil.
8. Wood Piece
5. Remove the filter adapter from the engine and
9. Rod
clean the adapter in solvent. Dry with
compressed air and flush thoroughly with
Figure 4. Testing the Thermostat
engine oil.
6. Remove the gasket from the engine block and
Important inspect the seal (0-ring) on the adapter for
damage or distortion. Install a new gasket in the
Do not attempt to repair the thermostat. If the engine block cavity and a new seal on the
thermostat does not function properly, replace adapter if needed.
with a new unit which has been checked as 7. Install adapter screws and a new oil filter.
described previously. 8. Test the flow of oil through the cooler before
connecting the oil lines. If the flow is not
Install or Connect (Figure 3)
restricted, connect the oil lines to the adapter. If
1. Thermostats (3). the flow is restricted, replace the radiator.
2. Thermostat cover (2). 9. Start the engine and check for leaks.

NOTICE: See NOTICE on page 6B1-1 of this Oil Cooler Replacement

section.
3. Bolts (1).
Tighten
Bolts to 24 Nm (17 lbft).
4. Thermo sensor connecter.
5. Hose at thermostat cover to turbocharger.
6. Upper radiator hose.
7. Fill the cooling system and run the engine.
Check for engine coolant leaks at thermostat
housing and at cover gasket.
Connect the battery negative cable.
(Figures 5 and 6)
Engine refer to the engine replacement (Section
6A).
1. Intake air duct (310) (figure 11, SEC. 6A6).
2. Accelerator cable injection pump side.
3. Remove the injection pump assembly. Refer to
DIESEL FUEL INJECTION (SEC. 6C3) in this
manual.
4. Oil cooler oil pipe.
5. Remove the oil cooler mounting bolts (14).
6. Remove the oil cooler element (10) and oil
cooler housing (15).
6B1-4 COOLING SYSTEM

14

10

15

10. Element
14. Oil Cooler Mounting Bolts
15. Oil Cooler Housing

Figure 5. Oil Cooler Assembly

7. Clean the all parts.

NOTICE: For steps 2, see NOTICE on page

6B1-1 of this section.

8. Install the oil cooler element (10) to oil cooler 13 9 4 1 5 10 14

housing (15) using new gaskets.
9. Install the oil cooler mounting bolts (14). Tighten 12 15
in numerical sequence as shown in figure 6.
16
Tighten 8

Oil cooler mounting bolts to 24 Nm (17 lbft). 7 3 2 6 11 17

10. Install the injection pump assembly. Refer to

DIESEL FUEL INJECTION (SEC. 6C3) in this
manual.
Engine refer to engine replacement (Section 6A)
Time the engine as described in DIESEL 050LY00002
FUEL INJECTION (SEC. 6C3) of this manual. Figure 6. Oil Cooler Mounting Bolts Tightening
Sequence
 COOLING SYSTEM 6B1-5

WATER PUMP REPLACEMENT Tighten

Remove or Disconnect (Figure 7) Water pump bolts to 24 Nm (17 lbft).
Disconnect the battery negative cable.
3. Hose water pump to cylinder head.
Remove the cab floor cover. Refer to STEEL
4. Radiator lower hose (2).
CREW CAB (SEC. 10E).
5. Water pump pully.
1. Drain engine coolant.
2. Stay bell-mouth upper. Tighten
3. Cooling fan (17) and fan clutch (16).
4. Generator adjusting bolt. Bolts (20) to 24 Nm (17 lbft).
5. Fan drive belt (21).
6. Water pump pully. 6. Fan drive belt (21).
7. Radiator lower hose (2). 7. Generator adjusting bolt.
8. Hose water pump to cylinder head. Refer to Drive Belts in FAN (SEC. 6B3) in
9. Water pump fixing bolts. this manual for adjustment procedure.
10. Water pump. 8. Fan clutch (16) and cooling fan (17).

Install or Connect (Figure 7) Tighten

NOTICE: For steps 2, 4 and 6 see NOTICE on Nuts (23) to 24 Nm (17 lbft).
page 6B1-1 of this section. 9. Stay bell-mouth upper.
10. Pour engine coolant.
1. Water pump. Install the cab floor cover. Refer to STEEL CREW
2. Pump bolts. CAB (SEC. 10E).
Connect the battery negative cable.

17
16

20

22 21
23

16. Cooling Fan Clutch

17. Cooling Fan
18. Nut
18 20. Bolt
21. Fan Belt
22. Spacer
23. Nut

Figure 7. Cooling System Components

 RADIATOR 6B2-1

SECTION 6B2

RADIATOR
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
On-Vehicle Service .........................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Radiator Maintenance..................................................................................SEE 1999-2001 SERVICE MANUAL
Radiator Replacement ..................................................................................................................................6B2-1
Eingine Coolant Recovery System..............................................................................................................6B2-2
Radiator Mountings .....................................................................................SEE 1999-2001 SERVICE MANUAL
Stabilizer Rods .............................................................................................SEE 1999-2001 SERVICE MANUAL
Shroud Replacement ....................................................................................................................................6B2-2
Pressure Cap................................................................................................SEE 1999-2001 SERVICE MANUAL
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL

RADIATOR REPLACEMENT 6. Stay radiator support (8).

7. Inter cooler assembly (9).
When oil cooler lines are removed, use an 8. Reserve tank hose (10).
approved container to catch the oil from the cooler 9. Air duct panel (11).
and lines. DO NOT reuse this oil. Refill any drained 10. Guide panel (12).
reservoirs to a recommended level with clean, new 11. Mount nut and cushion rubber (13).
fluid after radiator installation. 12. Radiator assembly (14).
After the radiator has been removed from the
vehicle, be sure to check the mounting supports, Install or Connect (Figure 1)
retainers, and brackets. If any of these components
1. Radiator assembly (14).
are deteriorated or worn, replace them immediately.
2. Mount nut and cushion rubber (13).
Remove or Disconnect (Figure 1) 3. Guide panel (12).
4. Air duct panel (11).
Disconnect the battery negative cable. 5. Reserve tank hose (10).
Remove the cab floor cover. Refer to STEEL 6. Inter cooler assembly (9).
CREW CAB (SEC. 10E). 7. Stay radiator support (8).
Drain the engine coolant. 8. Flexible hose (6, 7).
1. Lower and upper radiator hoses (1 and 2), clips 9. Fan shroud assembly (5).
or brackets attached to the radiator. 10. Rubber ring (4).
2. Heater hose bracket (3). 11. Heater hose bracket (3).
3. Rubber Ring (4), bell-mouth to shroud. 12. Lower and upper radiator hoses (1 and 2), clips
4. Fan shroud assembly (5). or brackets that were removed.
5. Flexible hose (6, 7), inter cooler LH & RH. Fill the system with new engine coolant as
6B2-2 RADIATOR

described in COOLING SYSTEM (SEC. 6B1)

of this manual. Then check the system for
leaks.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
ENGINE COOLANT RECOVERY SYSTEM
The engine coolant recovery system consists of a
reserve tank, cap, brackets, and hose. The engine
coolant level must be maintained between the MAX
and MIN markings on the tank.
SHROUD REPLACEMENT
A radiator shroud is attached to the rear of the
radiator and is designed to assist the fan in
directing airflow, through the radiator core. The
shroud also serves as a fan guard.
Inspect
The shroud for damage or deterioration. Check
for missing and loose fasteners. Replace the
shroud if it is damaged.

Remove or Disconnect (Figure 1)

Disconnect the battery negative cable.

Remove the cab floor cover. Refer to STEEL
Forward
CREW CAB (SEC. 10E).
Disconnect battery ground cables.
Partially drain the radiator.
1. Upper radiator hose (2).
MAX 2. Stay bell-mouth (figure 1).
3. Bell-mouth (figure 1).
4. Shroud fixing bolts.
MIN 5. Shroud assembly (5).
Coolant Reserve
Tank Install or Connect (Figure 1)

1. Shroud assembly (5).

2. Shroud fixing bolts.
3. Bell-mouth (figure 1).
4. Stay bell-mouth (figure 1).
5. Upper radiator hose (2).
901L200003 Install the cab floor cover. Refer to STEEL CREW
Figure 2. Reserve Tank CAB (SEC. 10E).
Connect the battery negative cable.
Remove or Disconnect (Figure 2)
Important
1. Battery ground cables.
Fill the radiator with new engine coolant.
Important Connect the battery cables. Start the engine
and check for leaks.
Drain the reserve tank.

2. Hose and clip.

3. Reserve tank.

Install or Connect (Figure 2)

1. Reserve tank.
2. Hose and clip.
3. Battery cables.

Important

Fill the reserve tank with new engine coolant.

Start the engine and check for leaks.
 FAN 6B3-1

SECTION 6B3

FAN
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Description .......................................................................................................SEE 1999-2001 SERVICE MANUAL
Fan.................................................................................................................SEE 1999-2001 SERVICE MANUAL
Automatic Fan Clutch..................................................................................SEE 1999-2001 SERVICE MANUAL
Diagnosis of Automatic Fan Clutch ...............................................................SEE 1999-2001 SERVICE MANUAL
On-Vehicle Service: Cooling Components.....................................................................................................6B3-2
Fan Replacement .........................................................................................................................................6B3-2
Fan Clutch Replacement .............................................................................................................................6B3-3
Fan Pulley Replacement...............................................................................................................................6B3-3
Fan Adjustment............................................................................................SEE 1999-2001 SERVICE MANUAL
On-Vehicle Service: Drive Belts .....................................................................SEE 1999-2001 SERVICE MANUAL
Diagnosis of Belts........................................................................................SEE 1999-2001 SERVICE MANUAL
Inspection and Replacement .....................................................................SEE 1999-2001 SERVICE MANUAL
Belt Tension Adjustment ............................................................................SEE 1999-2001 SERVICE MANUAL
Cleaning and Storage ..................................................................................SEE 1999-2001 SERVICE MANUAL
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL
Fastener Torques ......................................................................................6SEE 1999-2001 SERVICE MANUAL
Special Tools....................................................................................................SEE 1999-2001 SERVICE MANUAL
6B3-2 FAN

ON-VEHICLE SERVICE: COOLING COMPONENTS

FAN REPLACEMENT Remove or Disconnect (Figure 4)

CAUTION: Keep hands and clothing clear of Disconnect the battery negative cable.
moving fan blades. (Fan may run when the engine Remove the cab floor cover. Refer to STEEL
is off.) Blades are exposed and can cause CREW CAB (SEC. 10E).
personal injury. 1. Stay bell mouth upper.
2. Nuts (5).
3. Cooling fan (2).

2
1

4 7
5

1. Cooling Fan Clutch

2. Cooling Fan
3. Bolt; Fan to Clutch
4. Fan Clutch Plate
3 5. Nut; Plate to Clutch
6. Bolt; Plate to Water
Pump
7. Fan Belt

Figure 4. Cooling System Components

 FAN 6B3-3

Install or Connect (Figure 4) FAN PULLEY REPLACEMENT

1. Cooling fan (2). Remove or Disconnect (Figures 4 and 5)

Disconnect the battery negative cable.

NOTICE: See NOTICE on page 6B3-1 of this
section.
2. Nuts (5).
Tighten
Nuts (5) to 24 Nm (17 lbft).
3. Stay bell mouth upper.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
1. Generator adjusting bolt.
2. Fan belt (7).
3. Stay bell mouth upper.
4. Plate to clutch nuts (5).
5. Fan and clutch assembly.
6. Plate to water pump bolts (6).
7. Plate (4) and fan pulley (8) (figure 5).

FAN CLUTCH REPLACEMENT

Remove or Disconnect (Figure 4)

Disconnect the battery negative cable.

Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
1. Stay bell mouth upper.
2. Plate to clutch nuts (5).
3. Fan (2) and clutch (1) assembly.
4. Fan to clutch nuts (3).
5. Fan (2) from the fan clutch (1).
8. Fan Pulley
Install or Connect (Figure 4) 9. Water Pump

NOTICE: See NOTICE on page 6B3-1 of this Figure 5. Fan Pulley Replacement
section for steps 2 and 3.
Install or Connect (Figures 4 and 5)
1. Fan (2) to the fan clutch (1).
2. Fan to clutch nuts (3). NOTICE: For steps 2 and 4 see NOTICE on
page 6B3-1 of this section.
Tighten
1. Fan pulley (8) and fan clutch plate (4).
Nuts (3) to 9 Nm (78 lbin).
2. Plate to water pump bolts (6).
3. Fan (2) and fan clutch (1) assembly. Tighten
4. Plate to clutch nuts (5).
Bolts (6) to 24 Nm (17 lbft).
Tighten
3. Fan and clutch assembly.
Nuts (5) to 24 Nm (17 lbft).
4. Plate to clutch nuts (5).
5. Stay bell mouth upper. Tighten
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E). Nuts (5) to 24 Nm (17 lbft).
Connect the battery negative cable.
6B3-4 FAN

5. Stay bell mouth upper.

6. Drive belts (7).
7. Generator adjusting bolt.
Refer to Belt Tension Adjustment later in this
section.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
 FUEL SYSTEM 6C1-1

SECTION 6C1

FUEL SYSTEM
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Air Cleaner........................................................................................................................................................6C1- 2
Description ...................................................................................................................................................6C1- 2
Air Filter Replacement.................................................................................................................................6C1- 3
Air Filter Cleaning ........................................................................................SEE 1999-2001 SERVICE MANUAL
Fuel Filters........................................................................................................................................................6C1- 4
Description ...................................................................................................................................................6C1- 4
Draining the Pre-Fuel Filter.........................................................................................................................6C1- 4
Fuel Filter Replacement ..............................................................................SEE 1999-2001 SERVICE MANUAL
Accelerator Linkage and Hand Throttle.........................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Accelerator Linkage Adjustment ...............................................................SEE 1999-2001 SERVICE MANUAL
Hand Throttle Adjustment ..........................................................................SEE 1999-2001 SERVICE MANUAL
Adjustment of Accelerator Pedal Stopper Bolt........................................SEE 1999-2001 SERVICE MANUAL
Engine Stop Linkage .......................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Engine Stop Linkage Adjustment...............................................................SEE 1999-2001 SERVICE MANUAL
Fuel Tank ..........................................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
Fuel Tank Replacement...............................................................................SEE 1999-2001 SERVICE MANUAL
Fuel tank Unit Replacement .......................................................................SEE 1999-2001 SERVICE MANUAL
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL
Fastener Torques.........................................................................................SEE 1999-2001 SERVICE MANUAL
6C1-2 FUEL SYSTEM

AIR CLEANER

DESCRIPTION on dusty or sandy roads, the unit should be cleaned

The function of the air cleaner assembly is to
prevent dirt and water from entering the engine. Air
enters the air cleaner assembly and hits a helical
ramp that is around the air filter. This causes the air
to spin. Centrifugal force separates the dirt and
water from the intake air. A rubber ejector valve is
placed in the bottom of the assembly to eject dirt
and water from the air cleaner assembly.
Air cleaners should be inspected and serviced at
intervals listed in the Maintenance Schedule, or
more often under severe dust conditions.
Under adverse conditions or long periods of time
every day. Air cleaners on vehicles operating in
dust storm areas should be cleaned immediately
after such storms occur.
NOTICE: In addition to its function of filtering air
drawn into the engine, the air cleaner also acts as
a flame arrester in the event the engine backfires.
Because backfiring may cause fire in the engine
compartment, the air cleaner should be installed
at all times unless temporary removal is
necessary during repair or maintenance of the
vehicle.

1. Cover Wing Nut

2. End Cover
3. Air Filter
4. Air Cleaner Body
130LX00001

Figure 1. Air Cleaner Assembly

 FUEL SYSTEM 6C1-3

4. Air Cleaner Body

6. Air Intake
8. Engine Intake Hose
130L200001
Figure 2. Air Cleaner Assembly

AIR FILTER REPLACEMENT

Remove or Disconnect (Figure 1)

1. Cover wing nut (1).

2. End cover (2).
3. Air Filter (3).

Clean (Figure 3)

Wipe out the inside of the air cleaner assembly.

Wipe off the cover.

130LX00002

Figure 3. Cleaning the Air Cleaner Assembly

Inspect

The air filter with a light for tears or holes (figure

4).
Ejector valve.
6C1-4 FUEL SYSTEM

Install or Connect (Figures 1 and 2)

1. Air filter (3).

2. End cover (2).
3. Cover wing nut (1).

FUEL FILTERS

DESCRIPTION

The purpose of the fuel filters is to clean the fuel

of any dirt particles that can cause wear on the fuel
injector's sliding surface; and to separate any water
from the fuel, which is ever-present from the
condensation in the fuel tank. The pre-fuel filter
(water separator) is located between the fuel tank
and the injection pump (figure 6). The secondary
fuel filter is located between the fuel pump and the
injection pump (figure 7).

3. Fuel Lines
4. Fuel Filter
041LX00002

Figure 7. Fuel Filter

Pre-Fuel Filter
When the condensed water in the pre-fuel filter
2 (water separator) comes to the warning level
indicated on its plastic body, drain the fluid
immediately from the drain plug located bottom of
1. Vent Plug water separator.
2. Drain Plug
901L200006
Fuel Filter
Figure 6. Pre-Fuel Filter
The fuel filter is spin-on cartridge-type. The filter
should be replaced. Never try to clean it. For the
replacement interval refer to MAINTENANCE AND
LUBRICATION (SEC. 0B).

DRAINING THE PRE-FUEL FILTER

1. Loosen the vent plug (12) and drain plug (2) by

turning them counterclockwise (figures 6 and 8).
2. Drain approximately 0.1 liters (3.4 oz) of water.
3. Securely tighten the drain plug and air intake
plug.
4. Operate the primer pump on the fuel pump to
bleed the fuel system. Refer to FUEL
INJECTION SYSTEM (SEC. 6C3).
5. Start the engine and check to be sure no fuel is
leaking from the drain plug.
 FUEL INJECTION SYSTEM 6C3-1

SECTION 6C3

FUEL INJECTION SYSTEM

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Fuel Injection System ......................................................................................SEE 1999-2001 SERVICE MANUAL
Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL
System Operation ........................................................................................SEE 1999-2001 SERVICE MANUAL
Boost Compensator Function ....................................................................SEE 1999-2001 SERVICE MANUAL
Fuel Low Cut Function ................................................................................SEE 1999-2001 SERVICE MANUAL
Diagnosis of Fuel Injection System ...............................................................SEE 1999-2001 SERVICE MANUAL
Fuel Injector Test .........................................................................................SEE 1999-2001 SERVICE MANUAL
On-Vehicle Service .........................................................................................................................................6C3- 2
Fuel Pump....................................................................................................................................................6C3- 2
Fuel Pump Replacement ............................................................................................................................6C3- 2
Fuel Injector.................................................................................................................................................6C3- 2
Fuel Injection Pump Replacement ............................................................................................................6C3- 6
Bleeding the Fuel System ..........................................................................................................................6C3-10
Re-learning of the Throttle Position Sensor Voltage Procedure.............SEE 1999-2001 SERVICE MANUAL
Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL
Fastener Torques ........................................................................................SEE 1999-2001 SERVICE MANUAL
Emission Specifications..............................................................................SEE 1999-2001 SERVICE MANUAL
6C3-2 FUEL INJECTION SYSTEM

ON-VEHICLE SERVICE

FUEL PUMP
FUEL INJECTOR
The fuel pump is mounted on the side of the fuel
injection pump. A primer pump for fuel system CAUTION: Do not bend injection lines in any
bleeding is also located on top of the pump (figure shape or form to ease injector replacement.
6).
Remove or Disconnect (figure 7)
FUEL PUMP REPLACEMENT
Disconnect the battery negative cable.
Remove or Disconnect (Figure 6) Remove the cab floor cover. Refer to STEEL
CREW CAB (SEC. 10E).
Engine refer to the engine replacement (Section
Remove the rear floor engine cover and rear
6A).
engine cover assembly.
1. Fuel line from the fuel pump.
2. Mounting stud nuts.
1. Nozzle cover.
3. Fuel pump and gasket.
2. Fuel line fitting at the injector assembly (1).
Install or Connect (Figure 6) 3. Fuel return line bolt (16), gasket (15) and fitting.
4. Flange (14).
1. New gasket to the fuel pump. 5. Injector assembly (1) from the cylinder head.
2. Fuel pump to the side of injection pump. Cap the fuel lines.
3. Fuel line. Plug the hole in the cylinder head with a clean shop rag.
4. Bleed the fuel system. 6. Injector gasket (13).
Engine refer to the engine replacement (Section 7. Check injector opening pressure, spray pattern,
6A). chatter and oil leakage. Refer to FUEL
INJECTOR TEST in this service manual.

10
16
11

15

4
15

14

12 1

4. Fuel pump
10. Primer Pump
11. Fuel Bolt and Gaskets (Outlet) 1. Injection Assembly
12. Fuel Bolt and Gaskets (Inlet) 13. Injector Gasket
13
042LX00002 14. Flange
Figure 6. Fuel Pump 15. Fuel Return Line Gasket
16. Fuel Return Line Bolt
040LX00026
Figure 7. Injector Assembly
 FUEL INJECTION SYSTEM 6C3-3

CAUTION: Clean the injector holder mating

Disassemble (Figure 8) surface and both sides of the spacer with a
hardwood piese or a soft cloth.
1. Clamp the injector holder assembly into a vise.
Do not use a metal brush since scars on these
2. Injector retaining nut (43).
surfaces cause oil leakage.
3. Injector (45).
Carefully remove carbon residues sticking to
4. Spacer (46).
inside of the retaining nut with the appropriate
5. Spring seat (47).
scraper.
6. Injector spring (48).
Remove carbon residues and dirt on the seat
7. Shim (49).
surface, inside surface of the body sliding
8. Injector holder (44).
section, sac cone and spray hole inside of the
injector body using the cleaning tools (figures
9 and 10).

44

49

48

47 B. Scraper (J-39533)
040LX00019
46
Figure 9. Cleaning of Injector Sac Cone

45

43
43. Injector Retaining Nut
44. Injector Holder C. Scraper (J-39532)
45. Injector
040LX00020
46. Spacer Figure 10. Cleaning of Seat Section
47. Spring Seat
48. Injector Spring 2. Pull out the needle valve from the injector body
49. Shim and clean both of them to clean the injector.
First, Holding the needle by the stem only clean
040LX00027

Figure 8. Injector Assembly the shaft section and seat surface of the needle
valve using a hardwood dipped in oil or a clean
soft cloth (figure 11).
Clean (Figures 9, 10, 11 and 12) Clean the spray holes of the hole type injector
with the special cleaning needle contained in
Tool Required: the cleaning kit (figure 12). If a large amount of
J-39531 Injector Cleaning Kit carbon residue remains and the injector cannot
J-39532 Scraper be cleaned well enough, dip the injector in
J-39533 Scraper carbon cleaner, and repeat the cleaning
process.
1. Soak all parts other than the injector in a
cleaning oil and wipe off all excess residue with CAUTION: Never use sand paper, metal
a soft cloth or the like. Use the wire brush to scraper, or other abrasive materials to clean
clean excessively dirty parts. the injector body and needle valve.
6C3-4 FUEL INJECTION SYSTEM
040LX00021
Figure 11. Needle Seat Cleaning with a Wooden Piece
040LX00022
Figure 12. Spray Holes Cleaning
3. Wash all parts in a clean oil and place them on
a clean work table. For best results compressed
air should be applied to them after the oil
cleaning.
CAUTION: After cleaning, all parts must be
coated with a light oil to prevent rust.
Inspect (Figures 8 and 13)
The following items should be checked on all
parts (figure 8):
Abrasion, corrosion, impact marks, scars, breaks,
cracks, cavitation erosion, damages caused by
foreign material in the fuel, or excessive.
Replace any worn, corroded or damaged parts.
Injector slide test (Figure 13)
Dip the injector and needle in light oil and
assemble. Insert the needle all the way into the
body. Raise the needle 1/3 (one-third) of the way
out and release. The needle must slide all the
way back into the body by its own weight. If the
needle sticks, reclean and repeat the slide test.
Any injector that fails must be replaced.
040LX00023
Figure 13. Injector Slide test
Assemble (Figure 8)
CAUTION: New injector must be cleaned in a
solvent to remove protective coating. The
injector body and needle must always be
replaced as an assembly.
1. Clamp the injector holder to a vise.
2. Shim (49).
3. Injector spring (48).
4. Spring seat (47).
5. Spacer (46).
6. Injector (45).
7. Injector retaining nut (43).
Tighten
Retaining nut to 34 Nm (25 lbft).
8. Check injector opening pressure, spray pattern,
chatter and oil leakage. Refer to FUEL
INJECTION TEST in this service manual.
 FUEL INJECTION SYSTEM 6C3-5

Injector Opening Pressure Adjustment Install or Connect (Figure 7)

1. Check injector opening pressure. 1. New injector gasket (13).
The gage should read 21600 kPa (3130 psi). 2. Injector assembly (1).
2. If the injector opening pressure does not meet 3. Flange (14).
specification, disassemble the injector and
holder assembly and replace the shim with a Tighten
new one.
Use a thicker shim, if the pressure is lower Nuts to 19 Nm (14 lbft).
than the specification.
Use a thinner shim, if the pressure is higher 4. Gasket (15), fuel return line and bolt (16).
than the specification.
The shim is available in the following thickness. Tighten
1. 0.1 mm (0.00394 in) Fuel return line bolt to 13 Nm (113 lbin).
2. 0.2 mm (0.00787 in)
3. 0.3 mm (0.01181 in) 5. Fuel line.
4. 0.4 mm (0.01575 in)
5. 0.5 mm (0.01969 in) Tighten
6. 0.52 mm (0.02047 in)
7. 0.54 mm (0.02126 in) Fuel line sleeve nut to 29 Nm (22 lbft).
8. 0.56 mm (0.02205 in)
9. 0.58 mm (0.02283 in) Install the rear floor engine cover and engine
cover assembly.
Install the cab floor cover. Refer to STEEL CREW
CAB (SEC. 10E).
Connect the battery negative cable.
6C3-6 FUEL INJECTION SYSTEM

FUEL INJECTION PUMP REPLACEMENT 6. Engine Control Wire

7. Engine Control Lever
Remove or Disconnect (Figures 1416) 8. Oil Pipe
9. Fuel Return Hose
Preparation 10. Fuel Feed Hose
Engine refer to the engine replacement (Section Disconnect fuel hose from injection pump side
6A). and take care not to spill and enter dust.
1. Intake Air Duct 11. Nozzle Cover
2. Vacuum Hose 12. Leak-Off Pipe
3. Oil Level Guide Tube 13. Fuel Pipe
Remove the guide tube fixing bolt and pull out 14. Fuel Filter Assembly
the guide tube. 15. PCV Hose
4. Engine Stop Calbe (Figure 14) 16. Injection Pipe (Figure 16)
Loosen locking nut at bracket and disconnect. Loosen the injection pipe sleeve nuts 1.
Engine stop cable from injection pump stop Do not apply excessive force to the injection
lever. pipes 5.
Loosen the injection pipes clips 3.
Remove the injection pipe assembly.
Plug the delivery valve holder 2 ports and
nozzle holder 4 ports with caps to prevent
the entry of foreign material.

060LX00036

Figure 14. Engine Stop Cable

5. Accelerator Control Cable (Figure 15)

Loosen locking nut (6) at bracket and
disconnect accelerator control cable (3) from
injection pump control lever. 040LX00024
Figure 16. Injection Pipe

17. Injection Pump Assembly

1. Remove the injection pump bracket bolts
and the injection pump rear bracket bolts.
2. Then remove the injection pump assembly.

101LX00004

Figure 15. Accelerator Control Cable

 FUEL INJECTION SYSTEM 6C3-7

Install or Connect (Figures 1726)

1. Injection Pump Assembly

1) Turn the crankshaft until the timing mark on
the crankshaft damper pulley is aligned with
13 line.

Inspect

2) Check the No.1 cylinder intake and exhaust

valve rocker arms for any play.
If the No.1 cylinder intake and exhaust valve
rocker arms are depressed the No.4 piston
is at on the compression stroke.
Rotate the crankshaft one full turn (360
degrees) and realign the crankshaft damper
pulley timing mark with the 13 line.
(Figure 17) 085LX00001

Figure 18. Bracket Slit and Timer Slit

4) Install the injection pump assembly to the

cylinder body.

NOTICE: When the injection pump has a

poor gear engagement while installing the
assembly to the cylinder body, insert a
screwdriver into the slit on the time
peripheral with the pump bracket slit used
as a guide, and move it up and down to get
it into forcibly.

5) After mounting make sure the 13 mark is in

position through the check hole. (Figure 19)

020LX00009

Figure 17. TDC Mark and Crank Pulley Mark

NOTICE: BTDC 13 to be aligned with here

is an angle at which the injection pump is
installed, and has nothing to do with the
injection timing.

Remove the inspection hole plug from the

cylinder body.
Install the O-ring to the injection pump
bracket.
3) Align the injection pump bracket slit with the
timer slit. (Figure 18)

080LX00004
Figure 19. Timing Check Hole (13)

6) Lightly tighten nuts and bolts.

NOTICE: Check to see no play between

cylinder Body and injection pump.

7) Monut injection pump blacket and retighten

only the cylinder side of bolts.
6C3-8 FUEL INJECTION SYSTEM
8) Turn the crankshaft until the timing mark on
the crankshaft damper pulley is aligned with
8 position.
NOTICE: Position in its normal rotating
direction.
020LX00008
Figure 20. TDC Mark and Crank Pulley Mark
9) Adjust injection pump downward so that the
8 comes to position in the timing check
hole, (Figure 21 and Figure 22)
2. Fuel Injection Pipe
080LX00005
Figure 21. Timing Check Hole (8)
080LX00006
Figure 22. Timing Adjust
Tighten
10) Tighten bolts and nuts to the specified
torque.
Injection Pump Bracket Bolt and Nut to 48
Nm (35 Ibft).
11) Tighten the inspection hole plug to 95 Nm
(75 Ibft).
NOTICE: Be careful not to loosen the stud
nuts to excess. Too much loosening may
make a clearance between cylinder Body
and injection pump, which could put timing
out of order after retightening.
1) Install the injection pipe assembly and
temporarily tighten the injection pipe sleeve
nuts.
2) Set the clips in the prescribed position
shown in the illustration (Figure 23).
CAUTION: Make absolutely sure that the
clip is correctly positioned.
An improperly positioned clip will result in
injection pipe breakage and fuel pulsing
noise.
Tighten
Clip Screw to 3 Nm (26 Ibin)
Tighten
3) Tighten the injection pipe sleeve nuts to the
specified torque.
Injection Pipe Sleeve Nut to 29 Nm (22
Ibft)
 FUEL INJECTION SYSTEM 6C3-9

3. PCV Hose
4. Fuel Filter

Tighten

Fuel Filter Bracket Bolt to 34 Nm (25 Ibft)

5. Fuel Pipe (Figure 23)

Do not apply excessive force to the fuel pipe.

Tighten

Fuel Pipe Joint Bolt 1 to 41 Nm (30 Ibft)

Fuel Pipe Joint Bolt 2 to 22 Nm (16 Ibft)
Clip Screw to 4 Nm (35 Ibin)
Fuel Pipe Bracket Bolt to 18 Nm (13 Ibft)
040LX00025

Figure 24. Leak Off Pipe

7. Nozzle Cover
8. Fuel Feed Hose
9. Fuel Return Hose
10. Oil Pipe

Tighten

Oil Pipe Joint Bolt to 17 Nm (12 Ibft)

11. Engine Control Lever Assembly

Tighten

Engine Control Lever Bolt to 24 Nm (17 Ibft)

12. Engine Control Wire

042LX00001
Figure 23. Fuel Pipe Joint Bolt
6. Leak Off Pipe (Figure 24)
Tighten
Leak-Off Pipe Joint Bolt to 13 Nm (113 Ibin)
13. Accelerator Control Cable (Figure 25)
Check to see if the idling control knob is
turned to the extreme left.
Attach the tip end of the cable to the engine
control lever.
Pull the outer cable toward the front side of
the vehicle, and provide the engine control
wire and the inner cable with an appropriate
play before fastening the clamp with a nut.
Check to see if the injection pump control
lever is at the idling position (with the lever in
touch with the stopper bolt).
14. Engine Stop Cable (Figure 26)
Attach the end tip of the cable to the engine
stop lever.
Pull the cable toward the rear side of the
vehicle, and fasten the clamp with a nut at the
position where the lever stops.
6C3-10 FUEL INJECTION SYSTEM

BLEEDING THE FUEL SYSTEM

Anytime the fuel system is opened to the

atmosphere, outside air can enter. Air bubbles,
trapped in the fuel system, will cause the engine to
run poorly. After any service that requires opening
the fuel system has been performed, all trapped air
must be removed by bleeding the system (figure
27,28).
1. Loosen the vent plug.
2. Operate the priming pump. Pump the primer
pump until fuel flow is free of air bubbles.
3. Tighten the vent plug.

19

18
101LX00004

Figure 25. Accelerator Control Cable

15. Oil Level Gauge Guide Tube

1) Install the o-rings to the guide tube lower
portion and insert the guide tube completely
to the cylinder body.
2) Tighten the guide tube bolt to the specified
torque.

Tighten

Guide Tube Bolt to 13 Nm (113 Ibin) 18. Vent Plug

19. Priming Pump
901L200005
16. Vacuum Hose
Figure 27. Bleeding Fuel System
17. Intake Air Duct
Pour coolant into radiator. 4. After peeling the mat on the floor of the rear
Connect battery ground cable. cabin and removing the bolts of the panel for
Start engine and check for oil and fuel inspection, open the rear floor engine coner.
leakage carefully. Then, loosen the bleed bolt on the injection
pump.
5. Operate the priming pump. Pump the primer
pump until fuel flow is free of air bubbles.
6. Tighten the bleed bolt on the injection pump.
7. If the vehicle does not start, repeat the
procedure.

1/2 inch(13mm)
Ring wrench
(Boxhead wrench)
060LX00036
Caution plate
Figure 26. Engine Stop Cable
Bleed
bolt
Engine refer to the engine replacement (Section
6A).
Figure 28. Bleed bolt
 AUTOMATIC TRANSMISSION 7A1-1

SECTION 7

TRANSMISSION

CONTENTS
SUBJECT PAGE

Automatic Transmission ........................................................................................See 1999-2001 Service Manual

Manual Transmission (MXA)..................................................................................See 1999-2001 Service Manual
Manual Transmission (MBP)..................................................................................See 1999-2001 Service Manual
Clutch (For MXA Transmission) ............................................................................See 1999-2001 Service Manual
Clutch (For MBP Transmission) ............................................................................See 1999-2001 Service Manual
7A1-2 CONSTRUCTION AND FUNCTION

MEMO
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 CAB AND CHASSIS ELECTRICAL 8-1

SECTION 8

CAB AND CHASSIS ELECTRICAL

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound, will be called out. The
correct torque values must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
General Information.........................................................................................SEE 1999-2001 SERVICE MANUAL
Notes for Working on Electrical Items .......................................................SEE 1999-2001 SERVICE MANUAL
Symbols and Abbreviations........................................................................SEE 1999-2001 SERVICE MANUAL
Symbols....................................................................................................SEE 1999-2001 SERVICE MANUAL
Abbreviations...........................................................................................SEE 1999-2001 SERVICE MANUAL
Parts for Electrical Circuit...........................................................................SEE 1999-2001 SERVICE MANUAL
Wiring........................................................................................................SEE 1999-2001 SERVICE MANUAL
Fuse and Fusible Link .............................................................................SEE 1999-2001 SERVICE MANUAL
Relay .........................................................................................................SEE 1999-2001 SERVICE MANUAL
Diode.........................................................................................................SEE 1999-2001 SERVICE MANUAL
Connector.................................................................................................SEE 1999-2001 SERVICE MANUAL
Reading the Circuit Diagram......................................................................SEE 1999-2001 SERVICE MANUAL
Connector Symbol .......................................................................................SEE 1999-2001 SERVICE MANUAL
Joint Connector ...........................................................................................SEE 1999-2001 SERVICE MANUAL
Main Data and Specifications .........................................................................SEE 1999-2001 SERVICE MANUAL
Bulb Specifications .....................................................................................SEE 1999-2001 SERVICE MANUAL
Fuse and Fusible Link Location .................................................................SEE 1999-2001 SERVICE MANUAL
Fuse Block Circuit .......................................................................................SEE 1999-2001 SERVICE MANUAL
Reference Table of Fuse ............................................................................SEE 1999-2001 SERVICE MANUAL
Relay Location .............................................................................................SEE 1999-2001 SERVICE MANUAL
Relay List ......................................................................................................SEE 1999-2001 SERVICE MANUAL
Diode Location .............................................................................................SEE 1999-2001 SERVICE MANUAL
Reference Table of Grounding Point .........................................................SEE 1999-2001 SERVICE MANUAL
Grounding Point Location...........................................................................SEE 1999-2001 SERVICE MANUAL
Cable Harness Routing ..............................................................................SEE 1999-2001 SERVICE MANUAL
System Repair ..................................................................................................SEE 1999-2001 SERVICE MANUAL
Start and Charging.......................................................................................SEE 1999-2001 SERVICE MANUAL
Engine Control Module................................................................................SEE 1999-2001 SERVICE MANUAL
Engine Stop System ....................................................................................SEE 1999-2001 SERVICE MANUAL
Headlight, D.R.L and Cornering Light........................................................SEE 1999-2001 SERVICE MANUAL
Clearance Light, Taillight, License Plate Light, ID Light and Illumination Light.......SEE 1999-2001 SERVICE MANUAL
Turn Signal Light, Hazard Warning Light and Stoplight ..........................SEE 1999-2001 SERVICE MANUAL
Horn and Backup Light ...............................................................................SEE 1999-2001 SERVICE MANUAL
Dome Light and Body Interior Light ...............................................................................................................8- 4
Transmission Control Module (TCM) .........................................................SEE 1999-2001 SERVICE MANUAL
Windshield Wiper and Washer ...................................................................SEE 1999-2001 SERVICE MANUAL
Audio and Cigarette Lighter........................................................................SEE 1999-2001 SERVICE MANUAL
8-2 CAB AND CHASSIS ELECTRICAL

Meter and Warning/Indicator Light.............................................................SEE 1999-2001 SERVICE MANUAL

Heater, Air Conditioning, Condensor Fan and Ceramic Heater ..............SEE 1999-2001 SERVICE MANUAL
Service Terminal ..........................................................................................SEE 1999-2001 SERVICE MANUAL
ABS (Anti-lock Brake System)....................................................................SEE 1999-2001 SERVICE MANUAL
Power Window .............................................................................................SEE 1999-2001 SERVICE MANUAL
Power Door Lock .............................................................................................................................................8-12
Wiring Diagram ............................................................................................SEE 1999-2001 SERVICE MANUAL
 CAB AND CHASSIS ELECTRICAL 8-3

MEMO
8-4 CAB AND CHASSIS ELECTRICAL

DOME LIGHT AND BODY INTERIOR

LIGHT
GENERAL DESCRIPTION
The circuit consists of the dome light, dome light The dome light can be lit using the switch
switch, door switch and body interior switch. mounted on the instrument panel regardless of the
The dome light lights up when the left side door is position of the ignition switch.
opened with the switch set at the door mode. It can
be lit by operating ON or OFF of the dome light
switch.

LIGHTING CIRCUIT

BATTERY (+)

BODY INTERIOR SW
DOOR BODY DOOR DOME LIGHT
OFF INTERIOR LIGHT OFF
ON ON

TO BODY
INTERIOR
LIGHT

DOME DOOR SW
LIGHT SW (DRIVER SIDE)
:Lighting circuit by door SW

:Lighting circuit by dome light SW

:Lighting circuit by body interior SW

NOTE:Arrow marks " " indicate the direction of current

Figure 1. Lighting Circuit

 L-2 DOME LIGHT <CREW CAB>
RELAY BOX ASM(No.1)

L-4 BODY INTERIOR LIGHT

N-7 DOOR SW(RH) L-3 REAR DOOR SW(RH)
PARTS LOCATION

L-1 DIODE
L-3 DIODE(CREW CAB)

FUSE BOX ASM

F-6 N-2 DOOR SW(LH)
H-20

H-3

L-32
REAR DOOR SW(LH)
P-2
STARTER SW
B-67
KEY CYLINDER SW P-4

Figure 2. Parts Location

B-68
BATTERY

P-3

P-1

RELAY BOX ASM

B-272 JOINT CONNECTOR
FL-1, FUSIBLE LINK
J-20 ID LIGHT RELAY
H-6, H-7

H-10 B-7 B-86 DOME LIGHT SW

H-12 B-158 BODY INTERIOR SW

CAB AND CHASSIS ELECTRICAL 8-5

D08L200005
8-6 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM

FL-1 80A
2L MAIN

5W
0.85R
2 C
H-6
0.85R 0.85R 0.5R
P-1 P-3 D
P-2 P-4 F-6 10A
DOME LIGHT 6
H-10

0.5R
P-5
FRAME
1
L-2 2
H-20

DOME LIGHT

0.5R
1

BODY INTERIOR LIGHT

L-4
OFF DOOR

ON

L-2 L-2
3 2 OFF DOOR

ON
0.5Y

0.5GR/B

0.5GR/B L-4 L-4

B
3 2
1

0.5Y

0.5GR/B
L-1
DIODE

4
1
H-10
L-1 L-3
2 0.5GR/B

L-3

0.5GR/B

0.5GR/B

0.5GR/B
2
0.5GR

A 0.5GR H-20
1
0.5GR

3
REAR DOOR SWITCH (RH)

REAR DOOR SWITCH (LH)

H-20
5
0.5GR/B

0.5GR/B

H-10 1 1
L-31 L-32
A B
0.5GR

3 4
0.85LG/R
RELAY; TAIL(5) H-3 H-12
DOME LIGHT SWITCH

1 4
B-86 B-86
1.25GR/R
0.5GR/B

B-86 B-86
DOOR SWITCH (LH)

0.5LG/B 3 2 1 1
DOOR SWITCH (RH)

ILLUMINATION
CONTROLLER(3) N-7 N-2
0.5B

3B 2 7 3B
HEADLIGHT BRACKET (LH) B-7 E

B-272 JOINT CONNECTOR 3B

FRAME-LH (CENTER) J-9 F

52836A

D08L200003
Figure 3(a). Circuit Diagram
 CAB AND CHASSIS ELECTRICAL 8-7

CIRCUIT DIAGRAM

0.85LG/R
RELAY, TAIL(5)
3
H-70
0.85R
C

0.85LG/R
0.5R
D

2
H-70

0.85R

0.5LG/R
BODY INTERIOR LIGHT SWITCH
1
B-158 0.85R

1 2
J-20 J-20

ID LIGHT
RELAY:
B-158 B-158
J-20 J-20
3 2
5 4
0.5R/Y

0.85R/G
5
H-69

11
0.85R/Y

0.85R/G
0.85R

H-69

0.85R/G
0.5B

0.5B
0.85R/G
0.85R/Y

0.85R/Y

2
0.85R

3B

3B

H-10
0.5R/G

1 2 3 4 1 2 3 4
LIGHT
CAB

SOURCE
POWER

MARKER

EARTH

LIGHT
CAB

SOURCE
POWER

MARKER

EARTH

ID LIGHT

J-143 J-144

MANUFACTURER'S MANUFACTURER'S
CONNECTION(FRT) CONNECTION(RR)

3B
F

52836A

D08L200004
Figure 3(b). Circuit Diagram
8-8 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

1 2

1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9

2 3 4
4 3 2 1
5 1 2 3 4

Figure 4. Connector List

 CAB AND CHASSIS ELECTRICAL 8-9

DOME LIGHT BULB

BODY INTERIOR LIGHT BULB
Remove or Disconnect (Figure 5)

Preparation:Disconnect the battery ground

cable.

1. Lens Terminal
SW No. 2 4 1 3
Hold the lens and pull it downward. position
2. Bulb ON
OFF

Figure 6. Dome Light Switch

Connector
Remove or Disconnect (Figure 7)

Preparation: Disconnect the battery ground

cable.
Screw

Lenz 1. Meter cluster

Refer to the METER AND
WARNING/INDICATOR LIGHT in this section.
2. Dome light switch
805L100001 Release the lock pushing the switch from the
Figure 5. Dome Light Bulb
back side of the meter cluster.
Install or Connect
1. Meter Cluster
To install, follow the removal steps in the reverse 2. Dome Light Switch
order.

DOME LIGHT SWITCH

Inspect (Figure 6)

Check the continuity between the dome light

switch connector terminals.
Repair or replace the switch when the result of
inspection is found abnormal.

Figure 7. Dome Light Switch Removal

8-10 CAB AND CHASSIS ELECTRICAL

Install or Connect Remove or Disconnect (Figure 9)

To install, follow the removal steps in the reverse Preparation:Disconnect the battery ground
order noting the following point. cable.
Push the switch with your fingers until it locks
securely. 1. Door switch
Remove the screw.
DOOR SWITCH Disconnect the connector of the switch.
REAR DOOR SWITCH
Inspect (Figure 8)

Check to see if there is any continuity between

the terminals and the body while operating the door
switch.
Repair or replace the switch, when the result of
inspection is found abnormal.

Figure 9. Door Switch Removal

Install or Connect

To install, follow the removal steps in the reverse

order.

Connector
No. N-2 N-7
Te L-31 L-32
rm
ina
SW lN
o. 1 Body
operation

Push

Release

Figure 8. Door Switch

 CAB AND CHASSIS ELECTRICAL 8-11

BODY INTERIOR LIGHT SWITCH

Inspect (Figure 10)

Check the continuity when the switch is in "ON"

position.

Terminal
SW No. 1 2 3
position
OFF
ON

Figure 10. Body Interior Light Switch Check

Remove or Disconnect (Figure 11)

Preparation: Disconnect the battery ground

cable.

1. Body interior light switch

To release the lock, push the switch from
back side of switch panel.
Disconnect the connector.

1. Body Interior Light Switch

Figure 11. Body Interior Light Switch Removal

Install or Connect

To install, follow the removal steps in the reverse

order.
8-12 CAB AND CHASSIS ELECTRICAL

POWER DOOR LOCK

GENERAL DESCRIPTION
The circuit consists of the door lock switch,
actuator for the front passenger door, rear doors
and the door lock controller.
The door lock controller is always provided with
battery voltage. The key or the inside lock knob on
the drivers door can activate the lock mechanism
of all the doors.
When the drivers door lock switch is turned on,
current flows for about one second to the door lock
actuator of each door connected in parallel with the
controller to activates the actuator to lock and
unlock the doors.

OPERATION OF DOOR LOCK CONTROLLER

When locking When locking

the door. the door.

Battery(+) Battery(+)

Relay;Door lock Relay;Door lock

To actuator
To actuator
(Actuator
(Actuator
operates to
operate
unlock
to lock side)
position)

Door lock sw. Door lock sw.

(Lock position) (Unlock position)

NOTE: Arrow marks indicate the direction of current

825LX003

Figure 12. Operation of Door Lock Controller

 <REAR DOOR(CREW CAB)(RH)>

D-10 REAR DOOR LOCK ACTUATOR(RH)

FUSE BOX ASM D-9 REAR DOOR LOCK ACTUATOR(LH)

F-7
PARTS LOCATION

H-18(CREW CAB)

<REAR DOOR(CRREW CAB)(LH)>

H-19(CREW CAB)
H-2

P-2

D-8 FRONT DOOR B-306

LOCK ACTUATOR H-11 B-12 P-4
(RH) H-12

Figure 13. Parts Location

H-3
P-3
P-1
F-27 BATTERY

H-6

B-1
B-272 JOINT CONNECTOR
H-61 H-18(CREW CAB)
B-7 RELAY BOX ASM

FL-1 FUSIBLE LINK

D-4 FRONT DOOR LOCK SWITCH(LH)

CAB AND CHASSIS ELECTRICAL 8-13

D08L200006
8-14 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM
FL-1 80A F-27 15A
MAIN POWER DOOR LOCK
2
H-6
8W 5W 5W 3W
2L

0.85R
P-1 P-3
P-2 P-4

RELAY: 6
DOOR LOCK B-12

P-5

FRAME 0.85BR/R
B-12 A
2

B-12
0.85BR/Y B
3

B-12 B-12 B-12

7 5 1
0.3G/B

0.85BR/R

0.85BR/Y

0.85BR/R

0.85BR/Y
0.3G/B
0.3R/G

4 3 1 4 3
H-11 H-61 H-61 H-2 H-2
0.3G/B

0.85BR/R

0.85BR/Y

0.85BR/R

0.85BR/Y
0.3G/B

5 6
UNLOCK

6 2 1 2 1
0.85B

B-306 B-306
D-4 D-4 D-4 D-8 D-8
LOCK

UNLOCK

UNLOCKL

UNLOCK
LOCK

LOCK

LOCK

DOOR LOCK SW B-306

3

D-4 DOOR LOCK SWITCH & DOOR LOCK

4 ACTUATOR-LH ACTUATOR-RH
0.5B

0.3B
2B

3
H-11
2B

1
3B 3B 2 B-272 52836A
HEADLIGHT BRACKET (LH) B-7
JOINT 00/12/22 0
CONNECTOR
180 240
D08L200001

Figure 14(a). Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-15

CIRCUIT DIAGRAM

B
0.5BR/R

0.5BR/R
0.5BR/Y

0.5BR/Y
6 14 1 4
H-12 H-12 H-3 H-3
0.5BR/R

0.5BR/Y

0.5BR/R

2 1 2 0.5BR/Y
1
H-18 H-18 H-19 H-19
0.85BR/R

0.85BR/Y

0.85BR/R

0.85BR/Y

1 2 1 2
D-9 D-9 D-10 D-10
UNLOCK
UNLOCK

LOCK
LOCK

REAR DOOR LOCK REAR DOOR LOCK

ACTUATOR-LH ACTUATOR-RH
(CREW CAB) (CREW CAB)

52836A
00/12/22 00/1
180 240
AIMI
Workshop Manu
D 0 8 L 2 0 0 0
D08L200002

Figure 14(b). Circuit Diagram

8-16 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

B-12 B-272 D-4 H-18 H-19 D-8 D-9 D-10

1 2 3 4 5
1 2 3 1 2 3 3 2 1
6 7 8 9 10 1 2 2 1
4 5 6 7 8 4 5 6
6 5 4

H-2 H-11 H-3 H-6

1 2 H-6 2 1

1 2 3 3 2 1 1 2 3 3 2 1
1 2 H-7 2 1
4 5 6 7 8 8 7 6 5 4 4 5 6 6 5 4

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

H-12

6 5 4 3 2 1
1 2 3 4 5 6
7 8 9 10 11 12 13 14 1413 12 11 10 9 8 7

P-4 P-3 P-5 P-1 P-2

B-306 H-61

1 2
3 4 5 6
1 2 3 4 4 3 2 1

Figure 15. Connector List

 CAB AND CHASSIS ELECTRICAL 8-17

DIAGNOSIS

QUICK CHART FOR CHECK POINT

Door Door lock actuator
Check point Door
Fuse lock sw
lock Front
F-27 (15A) (Driver (Passen- Rear Rear Cable
Trouble mode controller (RH) (LH) harness
side) ger side)

1. All the doors do not lock and

unlock (1) (2) (3)

2. All the doors do not get

locked (or unlocked) (1) (2)

3. Driver side door does not get

locked (or unlocked) (1) (2)
4. Front passenger side door

does not get locked (or
(1) (2)
unlocked)
5. Rear door-RH side does not
get locked (or unlocked) (1) (2)

6. Rear door-LH side does not

get locked (or unlocked) (1) (2)

NOTE: Figure in parenthesis ( ) indicates the order of inspection.

8-18 CAB AND CHASSIS ELECTRICAL

1. ALL THE DOORS DO NOT LOCK AND UNLOCK

IS FUSE F-27 (15A) NORMAL?

YES NO

IS THE DOOR LOCK SWITCH NORMAL? REPLACE THE FUSE

YES NO

IS B-7 GROUNDED SECURELY? REPLACE THE DOOR LOCK SWITCH

YES NO

DISCONNECT THE CONTROLLER CONNECTOR GROUND IT SECURELY

IS THE BATTERY VOLTAGE APPLIED AT THE 6 B-12
AND GROUND?

YES NO

IS THE DOOR LOCK CONTROLLER NORMAL? REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT
BETWEEN FUSE F-27 (15A) AND 6 B-12

YES NO

REPLACE THE DOOR LOCK CONTROLLER

REPAIR A POOR CONNECTION AT THE CONNECTORS
OR AN OPEN CIRCUIT BETWEEN 1 D-4 AND B-7
 CAB AND CHASSIS ELECTRICAL 8-19

2. ALL THE DOORS DO NOT GET LOCKED (OR UNLOCKED)

IS DOOR LOCK SWITCH NORMAL?

YES NO

DISCONNECT THE DOOR LOCK CONTROLLER REPAIR OR REPLACE THE DOOR LOCK
CONNECTOR SWITCH
IS THERE CONTINUITY BETWEEN 5 B-12 AND
4 B-12 OF HARNESS SIDE CONNECTORS

YES NO

REPLACE THE DOOR LOCK CONTROLLER REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT IN
THE CIRCUIT

3. DRIVER SIDE DOOR DOES NOT GET LOCKED (OR UNLOCKED)

REPLACE THE DOOR LOCK SWITCH

4. FRT PASSENGER SIDE DOOR DOES NOT GET LOCKED (OR UNLOCKED)
5. RR DOOR-RH SIDE DOES NOT GET LOCKED (OR UNLOCKED)
6. RR DOOR-LH SIDE DOES NOT GET LOCKED (OR UNLOCKED)

REPLACE THE DOOR LOCK ACTUATOR

8-20 CAB AND CHASSIS ELECTRICAL

DOOR LOCK RELAY

The door lock controller sends out to each door
lock actuator the lock/unlock signals received from
door lock switch from the driver seat side.

DOOR LOCK

8-97250192-0
051500-3680
12V
DENSO
MADE IN JAPAN

Figure 16. Door Lock Relay

Circuit Inspection (Figure 17)

Check the voltage and the continuity between the

controller harness side connector terminals.

1 2 3
B-12
4 5 6 7 8

Harness side

Termi- Item Connect-

Wire
nal Connected to to be ing Checking conditions Standard
color
No. checked terminal
Door lock SW Driver seat side Unlock Continuity
7 R/G (Unlock) 7-Ground door
Lock No continuity
Door lock SW Driver seat side Unlock No continuity
5 G/B (Lock) 5-Ground door
Conti- Lock Continuity
nuity
1 B Ground (Resis- 1-Ground Continuity
tance) Continuity
Actuator
3 BR/Y 3-2 (There is some
(Unlock) resistance)
Continuity
Actuator
2 BR/R 2-3 (There is some
(Lock) resistance)

6 R Fuse F-27 (15A) Voltage 6-Ground Battery voltage

Figure 17. Door Lock Relay Circuit Check

 CAB AND CHASSIS ELECTRICAL 8-21

Inspect (Figure 18) DOOR LOCK SWITCH

Remove the connector of the door lock controller,
and check the continuity and the voltage between
the controller side connector terminals.
(Connect the + terminal of the battery to 6
B-12 and the terminal to 1 B-12 )
(DRIVER SEAT SIDE)
The door lock switch on the drivers door is
connected with the door lock cylinder and the inside
lock knob with a rod. The switch sends lock/unlock
signals to the door lock controller.

1 B-12 2 B-12 .........Continuity

1 B-12 3 B-12 .........Continuity Door lock ASM

(Then, ground 5 B-12 )

2 B-12 .........Voltage for approx. 1 second Door lock SW

(Disconnect the ground of 5 B-12 , and ground 7

B-12 .)
3 B-12 .........Voltage for approx. 1 second

Replace the controller if the result of the inspection

is found abnormal.
Figure 20. Door Lock Switch
B-12

Inspection (Figure 21)

3 2 1 Check to see if there is any continuity between

8 7 6 5 4 the connector terminals of the door lock switch.
Replace the switch if the result of the inspection
is found abnormal.
Controller side

Figure 18. Door Lock Relay Check

1 2 3
D-4 Switch side
4 5 6
Inspect (Figure 19)

After confirming that there is continuity between Terminal

the harness side connector terminals 3 B-12 and 2 No. 1 2
Operation
B-12 of the door lock controller, apply battery
voltage to each of the terminals to conduct the Lock +
operation test.
If the door lock will not operate, check the door Unlock +
lock actuator for functionality.

Figure 21. Circuit Check

B-12

1 2 3 Harness
4 5 6 7 8 side Remove or Disconnect

Connecting terminal Refer to Section 10 CAB for DOOR LOCK

Operation ASSEMBLY (front and rear).
3 (BR/Y) 2 (BR/R)
+ Unlock Install or Connect
+ Lock
Refer to Section 10 CAB for DOOR LOCK
Figure 19. Circuit Check ASSEMBLY (front and rear).
8-22 CAB AND CHASSIS ELECTRICAL

DOOR LOCK ACTUATOR Inspection (Figure 23)

Receiving forward or reverse current from the
door lock controller, the door lock actuator locks or
unlocks the door with the rod connected to the door
lock mechanism.
Door lock ASM
Apply the battery voltage to the connector
terminals of the door lock actuator to check the
operation.
When the door lock actuator is checked on the
vehicle and there is no continuity, and when the
door lock actuator itself is checked and no trouble
is found, check the circuit between the door lock
actuator and the door lock controller for any failure.

Actuator

Figure 22. Door Lock Actuator

D-8 D-9 D-10

Door lock ASM

2 1

Actuator side Actuator side

Door FRT RR-LH RR-RH

Passenger
Actuator Connector
No. D-8 D-9 D-10
Terminal
Operation No. 1 2 1 2 1 2
1 2
Lock + + +
Unlock + + +

Figure 23. Door Lock Actuator Check

Remove or Disconnect

Refer to Section 10 CAB for DOOR LOCK

ASSEMBLY (Front and rear).

Install or Connect

Refer to Section 10 CAB for DOOR LOCK

ASSEMBLY (Front and rear).
 METRIC AND FASTENER INFORMATION 9-1

SECTION 9

METRIC AND FASTENER INFORMATION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Metric Fasteners .................................................................................................... See 1999-2001 Service Manual
Replacement Fasteners..................................................................................... See 1999-2001 Service Manual
Fastener Strength Identification........................................................................... See 1999-2001 Service Manual
Prevailing Torque Fasteners................................................................................. See 1999-2001 Service Manual
Recommendations for Reuse ........................................................................... See 1999-2001 Service Manual
Six-Lobed Socket Head Fasteners ....................................................................... See 1999-2001 Service Manual
Decimal and Metric Equivalents ........................................................................... See 1999-2001 Service Manual
Conversion Table................................................................................................... See 1999-2001 Service Manual
9-2 METRIC AND FASTENER INFORMATION

MEMO
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 STEEL CAB 10-1

SECTION 10

STEEL CAB

CONTENTS
SUBJECT PAGE

Steel Tilt Cab ......................................................................................................... See 1999-2001 Service Manual

Steel Crew Cab ................................................................................................................................................... 10E
10-2 STEEL CAB

MEMO
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 STEEL CREW CAB 10E-1

SECTION 10E

STEEL CREW CAB

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Cab Description.............................................................................................................................................. 10E- 2
Design and Construction ...................................................................................................................... 10E- 2
Windows ................................................................................................................................................. 10E- 2
Diagnosis of Steel Crew Cab ........................................................................................................................ 10E- 3
On-Vehicle Service ..........................................................................................SEE 1999-2001 SERVICE MANUAL
Cab Interior...................................................................................................SEE 1999-2001 SERVICE MANUAL
Drivers Seat ............................................................................................SEE 1999-2001 SERVICE MANUAL
Passenger Seat .......................................................................................SEE 1999-2001 SERVICE MANUAL
Rear Seat .................................................................................................................................................10E- 5
Front Seat Belts:Side Seat Belt Tongue .............................................................................................. 10E- 6
Front Center and Driver Side Seat Belt Buckle.....................................SEE 1999-2001 SERVICE MANUAL
Front Center Seat Belt Tongue and Passenger Side Seat Belt Buckle ....SEE 1999-2001 SERVICE MANUAL
Rear Seat Belt: Side Seat Belt Tongue .................................................................................................10E- 8
Rear Door-side Seat Belt Buckle and Rear Center Seat Belt/Buckle .................................................10E- 9
Instrument Panel .....................................................................................SEE 1999-2001 SERVICE MANUAL
Instrument Panel Reinforcement ...........................................................SEE 1999-2001 SERVICE MANUAL
Headlining ...............................................................................................................................................10D-11
Cab Floor Cover ......................................................................................................................................10E-13
Doors.............................................................................................................SEE 1999-2001 SERVICE MANUAL
Description ..............................................................................................SEE 1999-2001 SERVICE MANUAL
Front Door ...............................................................................................SEE 1999-2001 SERVICE MANUAL
Front Lock Mechanism............................................................................SEE 1999-2001 SERVICE MANUAL
Front Lock Cylinder and Outside Door Release Handle .....................SEE 1999-2001 SERVICE MANUAL
Front Trim Panel .....................................................................................SEE 1999-2001 SERVICE MANUAL
Front Window and Window Regulator Assembly ................................SEE 1999-2001 SERVICE MANUAL
Rear Door.................................................................................................................................................10E-14
Rear Door Lock Mechanism...................................................................................................................10E-15
Rear Door Outside Door Release Handle .............................................................................................10E-16
Rear Door Trim Panel .............................................................................................................................10E-17
Rear Window and Window Regulator Assembly .................................................................................10E-19
Rear Step Assembly ...................................................................................................................................10E-21
Cab Replacement.........................................................................................SEE 1999-2001 SERVICE MANUAL
Specifications..................................................................................................................................................10D-22
Fastener Torques....................................................................................................................................10D-22
10E-2 STEEL CREW CAB

CAB DESCRIPTION
DESIGN AND CONSTRUCTION WINDOWS

The Steel Crew Cab Model (figure 1)is all steel Door windows are covered in this section under
welded construction. The cab fully surrounds the "Doors". All other windows are covered in CAB
engine. The cab rests on three mount brackets MAINTENANCE (SEC.2B) under "Stationary
which are bolted to the frame rail on both sides of Glass".
the truck.
The combination brake fluid/clutch fluid reservoir
is located inside the cab, on the left side of the
dash.

604L200001

Figure 1 Steel Crew Cab


DIAGNOSIS OF STEEL CREW CAB
TROUBLE POSSIBLE CAUSE
Seat will not move 1. Obstructed adjustment mechanism.
2. Frozen or obstructed guide rails.
3. Broken adjustment lever.
Seat moves only on 1. Obstructed guide rail.
One Side 2. Obstructed adjustment mechanism.
Seat is Hard to 1. Tension spring is broken or
Move disconnected.
2. Rusty or obstructed guide rails.
Seat will not Stay in 1. Missing or disconnected adjustment
Desired Position springs.
2. Broken adjustment lever.
Door will not Latch 1. Door is out of alignment.
or Latches with 2. Striker is out of alignment.
Difficulty 3. Cam of the locking mechanism is in
the closed position.
4. Locking mechanism is not attached
securely to the door.
5. Cam of the locking mechanism is
bent or broken.
Door will not Lock 1. Disconnected lock rod between the
outside handle and locking
mechanism.
2. Arm of the lock cylinder has not
properly engaged the lug of the
locking mechanism.
3. Lug of the locking mechanism is
broken.
4. Frozen lock cylinder.
Door will not Open 1. Door out of alignment.
but It is Unlocked 2. Striker bolt out of alignment.
(Door Handles do 3. Frozen locking mechanism.
not Work Freely)
STEEL CREW CAB 10E-3
CORRECTION
1. Remove the obstruction.
2. Replace obstruction and/or remove
the seat and the adjustment
mechanism . Clean the guide rails
and lubricate.
3. Replace the adjustment machanism.
1. Remove the obstruction.
2. Remove the obstruction.
1. Remove or connect the spring.
2. Remove the obstruction and/or
lubricate.
1. Remove or connect the spring(s).
2. Replace the adjustment machanism.
1. Align the door.
2. Align the striker.
3. Unlock the door, pull the outside
handle, and manually rotate the
cam.
4. Tighten the attaching screws of the
locking mechanism.
5. Straighten the cam or replace the
locking mechanism.
1. Connect rod. Use a new clip.
2. Remove the lock cylinder and install
as directed later in this section.
3. Replace the locking mechanism.
4. Lubricate the lock cylinder or
replace.
1. Align the door.
2. Adjust the striker bolt.
3. Remove the locking mechanism and
lubricate or replace it.
10E-4 STEEL CREW CAB

DIAGNOSIS OF STEEL CREW CAB (CONT.)

TROUBLE POSSIBLE CAUSE CORRECTION

Door will not Open, Disconnected rod from the door release If disconnected from the release
It is Unlocked, but mechanism to the locking mechanism. mechanism, remove the mechanism
Release and connect the rod to it. If
Handle/Lever Works disconnected from the locking
Freely mechanism, connect the rod.

Door is Hard to 1. Frozen hinge-dirty or incorrect 1. Clean the hinge and lubricate.
Open lubricant.
2. Door is out of alignment. 2. Align the door.

Door Window is 1. Rusty or dirty regulator. 1. Remove the regulator, clean and
Difficult to Move lubricate.
2. Obstructed run channel. 2. Remove obstruction.

Door Window will 1. Obstructed or frozen regulator. 1. Remove the regulator, clean and
not Close or lubricate.
Regulator Handle 2. Obstructed regulator guide channel. 2. Remove obstruction.
will not Work 3. Obstructed run channel. 3. Remove obstruction.
4. Misaligned run channel. 4. Reposition run channel bracket
and/or division channel.

Door Window will 1. Stripped window regulator handle. 1. Replace handle.

not Move but 2. Stripped window regulator shaft. 2. Replace regulator.
Regulator Handle 3. Regulator roller is not in the guide 3. Remove regulator and install as
Moves Freely channel. outlined in this section.
4. The teeth of the regulator gear are 4. Replace regulator.
broken.
 STEEL CREW CAB 10E-5

REAR SEAT

Clip

1. Rear seat cushion

2. Rear seat frame

755L200001
Figure 2. Rear Seat Removal or Installation

Remove or Disconnect (Figure 2)

1. Rear seat cushion (1)

Pull the seat cushion at the three clip positions
from the seat frame.
2. Rear seat frame (2)
Remove the 6 bolts.

Install or Connect (Figure 2)

To install, follow removal steps in the reverse order,
noting the following point.

1. Tighten the rear seat frame mounting bolts to the

specified torque.

Tighten

Rear seat frame bolts to 13 Nm (9 lbft).

10E-6 STEEL CREW CAB

FRONT SEAT BELTS:SIDE SEAT BELT TONGUE

Bracket

Seat belt
tongue side
assembly

5
1

1. Seat belt lower ancher bolt

2. Retractor cover
3. Through bolt anchor cover
4. Seat belt upper anchor bolt
5. Retractor mounting bolt
Seat belt lower anchor bolt mounting hole

760L200001
Figure 3. Side Seat Belt Removal or Installation
 STEEL CREW CAB 10E-7

Remove or Disconnect (Figure 3)

1. Seat belt lower ancher bolt (1)

2. Retractor cover (2)
Remove the 2 mounting screws.
3. Through bolt anchor cover (3)
4. Seat belt upper anchor bolt (4)
5. Retractor mounting bolt (5)
Remove the bolt and pull out the upper bracket
of the retractor from the panel.

Install or Connect (Figure 3)

To install, follow the removal steps in the reverse

order, noting the following points:
1. Apply the sealant around the seat belt lower
anchor bolt mounting hole.(Figure.4)

Figure 4. Sealant Application

2. Install the lower anchor in the specified direction

and tighten it to the specified torque.(Figure 5)

Tighten

Anchor bolt to 45 Nm (33 lbft)

NOTICE: Install the seat belt lower anchor so
that it may not run on the anchor detent bead

Figure 5. Anchor Direction

10E-8 STEEL CREW CAB

REAR SEAT BELTS: SIDE SEAT BELT TONGUE

2
Clip
4

Bracket

Seat belt
tongue side
assembly

1
5

1. Seat belt lower ancher bolt

2. Rear piller lower trim cover
3. Through bolt anchor cover
4. Seat belt upper anchor bolt
5. Retractor mounting bolt
Seat belt lower anchor bolt mounting hole

760L200008
Figure 6. Side Seat Belt Removal or Installation

Remove or Disconnect (Figure 6) Install or Connect (Figure 6)

1. Seat belt lower ancher bolt (1) To install, follow the removal steps in the reverse
2. Rear piller lower trim cover (2) order, noting the following points:
Remove the two clips and pull the cover 1. Apply the sealant around the seat belt lower
upwards. anchor bolt mounting hole.(Figure.7)
3. Through bolt anchor cover (3)
4. Seat belt upper anchor bolt (4)
5. Retractor mounting bolt (5)
Remove the bolt and pull out the upper bracket
of the retractor from the panel.
 STEEL CREW CAB 10E-9

Tighten

Anchor bolt to 45 Nm (33 lbft)

NOTICE: Install the seat belt lower anchor so
that it may not run on the anchor detent bead

Figure 7. Sealant Application

2. Install the lower anchor in the specified direction

and tighten it to the specified torque.(Figure 8)

Figure 8. Anchor Direction

REAR DOOR-side SEAT BELT BUCKLE AND REAR CENTER SEAT BELT/BUCKLE

3 Rear seat belt

reinforcement

4 Rear floor panel

3

1. Rear seat cushion

2. Lower anchor bolt
3. Door-side seat belt buckle
2 4. Center seat belt tongue
5. Center seat belt buckle

760L200009
Figure 9. Rear Door-side Seat Belt Buckle and Rear Center Seat Belt/Buckle Removal and Installation

Remove or Disconnect (Figure 9)

1. Rear seat cushion (1) 3. Door-side seat belt buckle (3)

Refer to Rear seat in this section. 4. Center seat belt tongue (4)
2. Lower anchor bolt (2) 5. Center seat belt buckle (5)
10E-10 STEEL CREW CAB

Install or Connect (Figure 9)

To install, follow the removal steps in the reverse

order, noting the following points:
1. Apply the sealant around the door-side seat belt
buckle lower anchor bolt mounting hole.(Figure
10)

Figure 10. Sealant Application

2. Install the anchor in the specified direction and

tighten it to the specified torque.(Figure 11)

Tighten

Anchor bolt to 45 Nm (33 lbft)

3 Install the anchor bracket to match the detent
bead. (Figure 11)

Rear seat belt reinforcement

Anchor bracket Detent bead

760L200003
Figure 11. Anchor Bracket Installation
 STEEL CREW CAB 10E-11

HEADLINING

Dome light Roof ventilator Adhesive tape

5 5
2
1. Roof ventilator grille
2. Front retainer
4 3. Interior light
4. Roof reinforcement
5. Headlining
1 3 6. Insulator

666L200001
Figure 12. Headlining Removal or Installation.

Remove or Disconnect (Figure 12)

Front side
Preparation:Disconnect the battery ground cable.
1. Roof ventilator grille (1) (Figure 13)
Remove one mounting screw and pull the four
mounting clips.

Roof panel 1

Roof ventilator
grille

Clip

668L100001

Figure 13. Roof Ventilator Grille Removal

10E-12 STEEL CREW CAB

2. Front retainer (2)

Remove the 5 clips.
3. Interior light (3) (Figure 14)
After removing the lens, remove the 2 screws.
Disconnect the connector.

Connector

Screw

Lens

805L200002

Figure 14. Interior Light

4. Roof reinforcement (4)

Remove the 4 screws.
5. Headlining (5)
6. Insulator (6)

Install or Connect (Figure 12)

To install, follow the removal steps in the reverse

order.
 STEEL CREW CAB 10E-13

CAB FLOOR COVER

2
4

5 1

8
1. Drivers seat
2. Passenger seat with engine cover
3. Automatic transmission (A/T)
control lever cover
4. Center console
5. Parking brake lever with cable
6. Automatic transmission (A/T)
6 with shift cable
7. Driver and center seat belt buckle
8. Cab floor cover

676L200001
Figure 15. Cab Floor Cover Removal and Installation.

Remove or Disconnect (Figure 15) Install or Connect (Figure 15)

1. Drivers seat (1) To Install, follow the removal steps in the reverse
Refer to Drivers seat in this section. order, noting the following point:
2. Passenger seat with engine cover (2) 1. Before installing the cab floor cover, apply the
3. Automatic transmission (A/T) control lever sealant to the contact surface of the cab floor
cover (3) cover.
Refer to AUTOMATIC TRANSMISSION (SEC.
7A3).
4. Center console (4)
5. Parking brake lever with cable (5)
6. Automatic transmission (A/T) with shift cable.
(6)
Refer to AUTOMATIC TRANSMISSION (SEC.
7A3).
7. Driver and center seat belt buckle (7)
8. Cab floor cover (8)
10E-14 STEEL CREW CAB

REAR DOOR

Hinge

1. Mounting bolt
2. Rear door assembly

650L200001
Figure 16. Rear Door Assembly Removal or Installation

Remove or Disconnect (Figure 16)

1. Mounting bolt (1)

Remove the 3 mounting bolts for each hinge.
2. Rear door assembly (2)

Install or Connect (Figure 16)

To Install, follow the removal steps in the reverse
order, noting the following point:
1. Tighten the mounting bolt to the specified
torque.

Tighten

Mounting bolts to 25 Nm (18 lbft).

 STEEL CREW CAB 10E-15

REAR DOOR LOCK MECHANISM

1. Rear door trim panel

2. Water-proof sheat 3
3. Glass run rear channel
4. Lock mechanism

2
1

Figure 17. Lock mechanism
Remove or Disconnect (Figure 17)
1. Rear door trim panel (1)
Refer to Rear door trim panel in this section.
2. Water-proof sheet (2) (Figure 18)
Peel off the water-proof sheet carefully with a
cutter or knife. Take care not to damage it when
peeling it off.
651L200001
3. Glass run rear channel (3)
Remove the 2 mounting screws and pull the rear
channel out.
4. Lock mechanism (4)
Remove the 3 mounting screws and disconnect
the locking links.
Install or Connect (Figure 17)
To Install, follow the removal steps in the reverse
order, noting the following points:
1. Tighten the mounting screw to the specified
torque.

Tighten

Mounting screws to 6 Nm (52 lbin)

2. After installation, check the operation.

635LX005
Figure 18. Water-proof Sheet Removal
10E-16 STEEL CREW CAB

REAR DOOR OUTSIDE DOOR RELEASE HANDLE

1. Rear door trim panel

2. Water-proof sheat
3. Outside door release handle
3

2
1

652L200001
Figure 19. Outside Door Release Handle Removal or Installation

Remove or Disconnect (Figure 19) Install or Connect (Figure 19)

1. Rear door trim panel (1)
Refer to Rear door trim panel in this section.
2. Water-proof sheet (2) (Figure 18)
Refer to Rear door lock mechanism in this
section.
3. Outside door release handle (3) (Figure 20)
Disconnect the link and remove the 2 mounting
bolts.
To Install, follow the removal steps in the reverse
order, noting the following point:
1. Tighten the mounting bolt to the specified torque.
Tighten
Mounting bolts to 13 Nm (113 lbin) ~18 Nm
(13 lb ft)

View A

Outside door release handle

652L200002
Figure 20. Outside Door Release Handle Removal
 STEEL CREW CAB 10E-17

REAR DOOR TRIM PANEL

1. Inside lever garnish

2. Regulator handle
3. Arm rest
4. Rear door trim panel

655L100001
Figure 21. Trim Panel Removal or Installation

Remove or Disconnect (Figure 21)

1. Inside lever garnish (1)

Remove the mounting screw and pull the bezel
out toward you while pulling and holding the
inside lever.
2. Regulator handle (2)
Remove the clip on the rear side of the regulator
handle using a wire.
3. Arm rest (3)
4. Rear door trim panel (4) (Figure 22)
Remove the clip at 11 positions.

Clip position

655L200001

Figure 22. Trim Panel Clip Position

10E-18 STEEL CREW CAB

Install or Connect (Figure 21)

To Install, follow the removal steps in the reverse

order, noting the following points:
1. Adjust the trim panel clip to the mounting hole on
the door panel side and install the trim pad.
(Figure 23)

Clip mounting hole

655L200002
Figure 23. Rear Door Panel Clip Position

2. Carefully install the arm rest and tighten the

mounting screws. (Figure 24)

Rear door trim panel

Arm rest

655L200003

Figure 24. Arm Rest Installation

 STEEL CREW CAB 10E-19

REAR WINDOW AND WINDOW REGULATOR ASSEMBLY

1. Rear door trim panel

2. Water-proof sheet
3. Door bottom bracket
4. Rear door glass plug
5. Rear window glass
6. Window regulator
7. Glass run
8. Glass run rear channel

8
7

2
4

6
1
3

651L200002
Figure 25. Rear Window and Window Regulator Removal or Installation

Remove or Disconnect (Figure 25)

1. Rear door trim panel (1)

Refer to Rear door trim panel in this section.
2. Water-proof sheet (2)
Refer to Rear door lock mechanism in this
section.
3. Door bottom bracket (3)
Remove the 4 mounting screws.
4. Rear door glass plug (4)
5. Rear window glass (5)
Operate the requlator to adjust the glass height
and expose the access hole. Remove the 2
bolts mounting the bottom channel and the
requlator. Remove the glass from the bottom
access hole.
6. Window requlator (6)
Remove the 5 mounting screws, and remove it
through the access hole. (Figure 26) Window regulator
mounting screws
651L200003

Figure 26. Window Screw Position

10E-20 STEEL CREW CAB

7. Glass run (7) 1. Align the notch a of the glass run lip with the
Pull the glass run out from the channel. door outer waist line A . Align the glass run slit b
8. Glass run rear channel (8) with the door B and fit the glass run between A
Remove the 2 mounting screws. and B . Next, align the notch c of the glass run
lip with the door outer waist line C and fit the
Install or Connect (Figure 25) glass run between B and C . Fit the glass run in
To Install, follow the removal steps in the reverse the channel within the door. (Figure 27)
order, noting the following points: Fit the glass run with the lip toward the outside
of the vehicle.

NOTICE: When reusing the glass run, apply

the sealant to the range shown in the figure.
(Figure 27)

Sealant application range

B b
Glass run

c
D A a a
a a E
a

b b c c c c
b b

Sealant
Inside Outside Outside Inside
Glass rum

Glass rum
c
a
Lip

C
A Glass rum

View D View E Section a-a Section b-b, c-c

655L200004
Figure 27. Glass Run Installation
2. Tighten the mounting screw to the specified 3. Check the water-proof sheet for breakage.
torque.

Tighten

Mounting bolts to 7 Nm (61 lbin)

 STEEL CREW CAB 10E-21

REAR STEP ASSEMBLY

1. Rear step stay

2. Rear step assembly

620L200001
Figure 28. Rear Step ASM Removal or Installation

Remove or Disconnect (Figure 28)

1. Rear step stay (1)

Remove the 2 bolts from each side.
2. Rear step assembly (2)
Remove the 4 bolts.

Install or Connect (Figure 28)

To Install, follow the removal steps in the reverse

order.
10E-22 STEEL CREW CAB

SPECIFICATIONS
FASTENER TORQUES
Nm (lbft)

Figure 29. Fastener Torques

 STEEL CREW CAB 10E-23

Nm (lbft)

Rear Door - side and Rear Center Seat Belt / Buckle mounting Bolts

45(33)

Bracket

Seat belt
tongue side
assembly
45(33)
45(33)

Rear Door Hinge mounting bolts Rear Door Lock Mechanism mounting screws

6(52)
25(18)
Nm(lbin)

Rear Window Regulator mounting screws

Hinge

7(61)
Nm(lbin)

760L200010
Figure 30. Fastener Torques