Content

Introduction

• How to use this manual
• Identification information
• General repair instructions
• Abbreviations used in this manual

Engine mechanical

• Description
• Troubleshooting
• Diesel engine diagnosis
• Diesel electrical system diagnosis
• Engine tune-up
• Compression check
• Timing belt
• Timing gears
• Cylinder head
• Cylinder block

Turbocharger system

• Description
• Precautions
• Troubleshooting
• Turbocharger electrical system diagnosis
• Turbocharger

Fuel system

• Description
• Replacement of fuel filter
• Fuel heater system
• Injection nozzles (1PZ and 1HZ)
• Injection nozzles (1HD-T)
• Injection pump
• Power control system (PCS) (HDB30(W/ M/T) only)

Cooling system

• Description
• Troubleshooting
• Check and replacement of engine coolant
• Thermostat
• Radiator

Lubrication system

• Description
• Troubleshooting
• Oil pressure check
• Replacement of engine oil and oil filter
• OIl pump
• Oil cooler and relief valves
• OIl nozzles and check valves

Starting system

• Pre-heating system
• Super glow type
• Fixed delay type (HZJ80 AND HDJ80)
• Fixed delay type (PZJ, HZJ75, HZB and HDB)
• Troubleshooting
• Starting system circuit
• Starter
• Starter relay (PZJ, HZJ and HDJ)
• Starter relay (HZB and HDB)
• Voltage converter timer (HZJ80 and HDJ80) (W/24 V starter)
• Voltage converter relay (HZJ80 AND HDJ80) (W/24 V starter)
• 24 V hold warning relay (HZJ80 and H DJ80) (W/ 24 V starter

Charging system

• Precautions
• Troubleshooting
• Charging system circuit
• On-vehicle inspection
• Alternator

Service specifications

• Engine mechanical
• Turbocharger system
• Fuel system
• Cooling system
• Lubrication system
• Starting system
• Charging system

Standard bolt torque specifications

SST and SSM

• SST (special service tools)
• SSM (special service materials)