Content

General information

• General repair instructions
• Notes on the format of this manual
• Identification
• Lifting instructions
• Conversion table

Maintenance and lubrication

• Maintenance schedule (for general export)
• Maintenance schedule (for Europe)
• Severe conditions maintenance schedule (for general export)
• Severe conditions maintenance schedule (for Europe)
• Recommended fluids and lubricants (for general export)
• Recommended fluids and lubricants (for Europe)
• Oil viscosity chart

Heating and air conditioning

• General description
• Parts location
• Main data and specifications
• Special parts fixing nuts and bolts
• On-vehicle service
• Acondenser
• Condenser fan motor
• Receiver / drier
• Compressor
• Heater unit
• Vent unit (without heater)
• Evaporator (with A/C)
• Duct (without A/C)
• Blower unit assembly
• Defroster nozzle and vent duct
• Rear heater duct
• Control lever assembly
• Control panel illumination bulb
• Troubleshooting
• Special service tool

Frame and bumper

• Front bumper
• Rear step bumper
• Rear bumper and rear guard asm
• Frame dimensions

Sheet metal

• Engine hood assembly
• Engine hood lock
• Front fender panel
• Radiator grille
• Rear body
• Body mounting
• Body dimension

Front alignment

• Front end alignment inspection and adjustment
• Alignment for 4х2 (except high ride suspension)
• Alignment for 4х2 (high ride suspension) and 4х4

Steering power-assisted steering system

• General description
• Power steering system test
• Maintenance
• Fluid level
• Bleeding the power steering system
• Bleeding procedure
• Flushing the power steering system
• Steering wheel free play inspection
• Front end alignment inspection and adjustment
• Special tools
• Power steering unit
• Supplemental restraint system steering wheel and column
• Inflator module
• Steering wheel
• The adjustment method in case a mark is not attached
• Combination switch
• Lock cylinder
• Steering column
• Supplemental restraint system steering wheel and column and associated parts

Front suspension

• Main data and specifications
• Torque specifications
• Front suspension
• Service precaution
• Shock absorber
• Stabilizer bar
• Knuckle
• Upper control arm
• Lower control arm
• Upper ball joint
• Lower ball joint
• Bump rubber

Rear suspension

• Main data and specifications
• Torque specifications
• Rear suspension
• Leaf spring and shock absorber
• Leaf spring assembly
• Troubleshooting

Wheels and tires

• Main data and specifications
• Torque specifications
• Wheels and tires
• Troubleshooting

Propeller shaft

• Main data and specifications
• Torque specifications
• Rear propeller shaft
• Rear propeller shaft assembly
• Front propeller shaft

Rear axle

• Main data and specifications
• Torque specifications
• Recommended liquid gasket
• Recommended thread locking agents
• Rear axle assembly
• Servicing
• Rear axle
• Differential assembly
• Differential cage assembly
• Limited slip differential (LSD)

Front wheel drive

• Main data and specifications
• Special parts fixing nuts and bolts
• Recommended liquid gasket
• Recommended thread locking agents
• Servicing
• General description
• Front drive axle assembly
• Front axle drive shaft
• Front hub and disc (4х2 except high ride suspension model)
• Front hub and disc (4х4, 4х2 high ride suspension, 4х4 rigid hub, 4х4 shift on the fly model)
• Front hub and disc (4х4 manual locking hub model)
• Troubleshooting

Driveline / axle

• Service precaution
• Shift on the fly system
• Shift on the fly electrical equipment
• Shift on the fly system and association parts

Brake control system

• Service precaution
• General description
• General diagnosis
• Diagnostic trouble codes
• Diagnosis by "ABC" warning lamp illumination pattern
• Basic diagnostic flow chart
• Basic inspection procedure
• Wheel speed sensor inspection procedure
• Symptom diagnosis

Anti-lock brake system

• Service precaution
• Torque specifications
• Electronic hydraulic control unit
• Front wheel speed sensor
• Rear wheel speed sensor
• Front speed sensor rotor
• Rear speed sensor rotor
• G-sensor

Brakes

• General description
• Main data and specifications
• Torque specifications
• Servicing
• Front brake assembly
• Rear drum brake assembly
• Brake control
• Master cylinder
• Vacuum booster

Parking brake system

• Service precaution
• Parking brake lever
• Front parking brake cable
• Parking brake lever
• Parking brake rear cable
• Main data and specifications

Troubleshooting

• Hard starting
• Unstable idling
• Insufficient power
• Excessive fuel consumption
• Excessive oil consumption
• Overheating
• White exhaust smoke
• Dark exhaust smoke
• Oil pressure does not rise
• Abnormal engine noise
• Rotating part wear of turbocharger
• Oil leakage from turbochrger
• Insufficient acceleration and/or lack of power due to turbocharger
• Battery charging and noise problem
• Starter motor problem

Engine mechanical

• Main data and specifications
• Torque specifications
• Recommended liquid gasket
• Loctite application procedure
• Servicing
• General description
• Removal and installation
• Engine repair kit
• Engine overhaul
• Lubrication system Inter cooler
• Special tools

Engine cooling

• Main data and specifications
• Diagnosis
• Draining and refilling cooling system
• Water pump
• Thermostat
• Radiator
• Fan clutch with cooling fan

Fuel system

• Main data and specifications
• General description
• Fuel tank
• Fuel pump
• Fuel tube / quick - connector fittings
• Filler neck
• Fuel filler cap
• Injection pump
• Injection nozzle
• Special tools

Engine electrical

• Main data and specifications
• General description
• Torque specifications
• Generator
• Starter motor
• Pre-heating system

Engine driveability and emissions

• Abbreviation charts
• General description for ecm and sensors
• Strategy based diagnostics chart
• General service information
• On-board diagnostic (OBD)
• Tech 2 operating flow cart (start up)
• Check engine lamp (MIL) “on” steady
• Ecm connector pin assignment and output signal
• General description for egr (exhaust gas re-circulation)
• General description for injection pump
• Strategy based diagnostics chart
• Miscellaneous test
• Snapshot display with TIS2000
• Service programming system (SPS)
• How to use breaker box
• No check engine lamp (MIL)
• Diagnostic trouble code
• Symptom diagnosis

Exhaust system

• Main data and specifications
• General description
• Removal and installation
• Inspection and repair
• General description
• Egr system diagram
• Inspection
• EGR cooler
• Turbocharger
• Inspection and repair
• Special tools
• Ihi service network

Accelerator control

• Removal and installation

Engine mechanical

• Service precaution
• General description
• Engine diagnosis
• Cylinder head cover
• Common chamber
• Exhaust manifold
• Crankshaft pulley
• Timing belt
• Camshaft
• Cylinder head
• Valve stem oil controller, valve spring and valve guide
• Piston, piston ring and connecting rod
• Crankshaft and main bearings
• Rear oil seal
• Engine assembly
• Cylinder head
• Valve spring, oil controller, valve, valve guide
• Camshaft
• Crankshaft
• Piston and connecting rod
• Cylinder block
• Main data and specification

Engine fuel

• Service precaution
• General description
• Fuel metering
• Fuel filter
• Fuel pump
• Fuel tube / quick - connector fittings
• Fuel pump relay
• Fuel tank
• Filler neck
• Fuel gauge unit
• Fuel filler cap
• Main data and specifications

Engine electrical

• Service precaution
• Battery
• Main data and specifications

Ignition system

• Service precaution
• General description
• Diagnosis
• Ignition coil
• Spark plug
• Crankshaft position sensor
• Main data and specifications

Starting and charging system

• Service precaution
• Starting system
• General description
• Diagnosis
• Starter
• Charging system
• General on-vehicle inspection
• Generator
• Main data and specifications

Engine driveability and emissions

• Abbreviation charts
• Component locator
• Ecm circuit diagram
• Ground point chart
• General description for fuel metering
• General description for electronic
• Ignition system ignition coils and control
• General service information
• Typical scan data and definitions
• Service programming system
• ECM diagnostic trouble codes (DTC)

Engine exhaust

• Service precaution
• General description
• Three way catalytic converter and center
• Exhaust pipe
• Exhaust silencer and rear exhaust pipe
• Main data and specifications

Engine lubrication

• Service precaution
• General description
• Oil pump
• Oil pan and crankcase
• Oil pump oil seal
• Main data and specification

Engine speed control system

• Service precaution
• Accelerator pedal control cable

Induction

• Service precaution
• Air cleaner element

Engine diagnosis

Transfer case

• Service precaution
• General description
• Transfer rear oil seal
• Transfer case assembly
• Transfer control unit
• Transfer disassembly
• Main data and specifications

Transfer control system

• Service precaution
• General description
• System components
• Functions of switch and indicator lamp
• Parts location
• Circuit diagram
• Connector list
• Diagnosis
• Memory erasing procedure
• Diagnosis from symptom

Transmission control system (AW30–40LE)

• Service precaution
• General description
• Diagnosis
• Tcm diagnostic trouble
• On-vehicle service

Clutch

• Main data and specifications
• General description
• Torque specification
• Servicing
• Clutch
• Clutch control
• Master cylinder
• Slave cylinder
• Hydraulic damper cylinder
• Troubleshooting
• Special service tool

Construction and function

• Description
• Control mechanism
• Gear train (transmission mechanism) operation and Hydraulic circuit

Diagnosis

Manual transmission

• Main data and specifications
• General description
• Torque specification
• Repair kit
• Removal and installation
• Disassembly
• Inspection and repair
• Reassembly
• Special service tool

Electrical-body and chassis

• General information
• Notes for working on electrical items
• Symbols and abbreviations
• Parts for electrical circuit
• Reading the circuit diagram
• Main data and specifications
• Relay and fuse
• Grounding point
• Main cable harness routing
• System repair
• Connector list

Cruise control system

• Service precaution
• General description
• Brake switch
• Clutch switch
• Starter switch
• Cruise control main switch
• Cruise control switch
• Cruise control unit
• Cruise actuator
• Mode switch
• Diagnosis

Accessories

• Parts location
• Circuit diagram
• Connector list
• Radio
• Front speaker
• Tweeter
• Rear speaker (extend cab)
• Rear speaker (crew cab)
• Clock
• Antenna

Supplemental restraint system (SRS)

• Service precaution
• Definitions
• Diagnosis
• SRS connector body face views
• Repairs and inspections required after an accident
• On-vehicle service
• Air bag assembly handling / shipping / scrapping
• Air bag assembly shipping procedure for live (undeployed) air bag Assemblies
• SRS connectors
• SRS control unit
• Driver air bag assembly
• Steering wheel
• SRS coil assembly
• Steering column
• Passenger air bag assembly
• Pretensioner seat belt (if so quipped)
• Main data and specifications
• Special tools

Restraint control system

• Service precaution
• System schematic

Cab

• Windshield
• Rear window assembly
• Front door assembly
• Rear door assembly (crew cab)
• Instrument panel
• Floor console
• Console box (without floor console)
• Headlining
• Interior trim panels
• Fuel filler lid opener lever/cable
• Quarter glass (extend cab)
• Font seat
• Rear seat (crew cab)
• Jump seat (extend cab)
• Front seat belt
• Rear seat belt (crew cab)
• Rear seat belt (extend cab)
• Front wheel extension
• Rear wheel extension
• Tail gate assembly

Immobilizer system

• Service precaution
• General description
• Circuit diagram
• Parts location

Antitheft system

• Service precaution
• General description
• Diagrams and schematics
• Diagnosis