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For that reason, you will not find it difficult to repair or to maintain some of the innovative features loaded on the vehicle when you have the manual. Using this repair manual is the true way to keep your vehicle working properly. After your payment, you will have instant access to your download. We will always try to get the full satisfaction of our customers.

Even after you have purchased this manual, we will pay full attention to any issues, regardless of the nature of the situation. So please make sure your email address is correct. Any questions please contact: admin servicemanualperfect. Always wear gloves when holding or moving the cylinder head assembly or cylinder block: never use bare hands. For safe operation 1 Correctly wear protection tools cap, safety glasses, gloves, safety shoes, etc.

Preparation for disassembly 1 Prepare general tools, SST, measuring tools, greases, and non-reusable parts. Keeping out foreign matter If foreign matter such as dust, sand or metal pieces enter the engine, it could cause a malfunction. Prevention of part damage If there is damage to rotating parts or the connection surface of parts, it could cause oil leaks or seizures. Disassemble by striking the parts gently with a plastic hammer. Use aluminum plates between the parts and the vise.

Washing the parts 1 Wash the parts thoroughly before reassembly, dry with compressed air, and coat with the specified oil.

Removal and reassembly of fuel system parts 1 Work area for removing and reassembling fuel system parts a Perform the work in an area with good ventilation where there is no machinery that cause sparks, such as welders, grinders, drills, electric motors or stoves.

Reassembly position and direction 1 Reassemble the parts in the position and direction they were in before disassembly. Reassemble at the median of the ranges for tightening torques and adjustment values. Tightening by extension tool attached torque wrench 1 For the case a torque wrench is used after extending the total length by combining with SST or another tool, the L1 L2 actual tightening torque becomes excessive when the reading on the torque wrench is at the specified torque.

To use a SST or extension tool, calculate the reading of torque wrench using the following formula. Handling the hose clamps 1 Before removing the hose, check the insertion depth of the hose and the clamp positions to make sure that reassembly is performed correctly. Adjustment and checking work Adjust to the service standard values by using gauges and testers.

Disposal of waste fluid, etc. When draining waste fluid from the vehicle, receive it in a container. If oil, fuel, coolant, oil filters, batteries or other harmful substances are directly discharged or scrapped without permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids etc. Further, always recover or wipe up any waste fluid that is spilt. Protection of function parts Before connecting the battery terminal after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection.

Failure to connect the controller connectors or incomplete connection may damage the elements inside the controllers. Always disconnect the battery plug before performing electric part inspections or maintenance. The resistance value is out of the specified range when measured at a high ambient temperature immediately after using a truck, therefore measure the resistance after the engine is cooled sufficiently. Handling the connectors 1 To disconnect a connector with lock, push the connector 2 Release the lock to the fitted side to ease the tab of the lock and then release the lock.

Connector inspection 1 With the connector connected, hold the connector Looseness of swaged area housing and check for insertion and locking conditions. Fitting condition 2 With the connector disconnected, pull the wire harness lightly. Check for terminal disconnection, condition of Core breakage swaged area and core breakage Caution: Terminal Always use a gold plated male terminal to test a gold plated deformation female terminal.

Pull lightly 3 Visually check the connector for a presence of rust, metal chip or water, and bend of the terminal. Check for corrosion, intrusion of foreign matter and terminal deformation 4 Check the terminal contact pressure by inserting a male terminal prepared for inspection into the female terminal to check the fitting and sliding conditions. Repairing the connector terminal 1 If the contact area is contaminated, clean it using an air gun or cloth.

Never polish the contact area with a sandpaper. Doing so causes the plating on the surface to come off. At this time, use a gold plated female terminal when the male terminal to be connected on the part is plated with gold.

Likewise, use a tin plated female terminal silver when the male terminal to be connected on the part is plated with tin.

This can prevent oxidation and wear of the contact. Connector grease 1 The connectors in the areas prone to be exposed to water are filled with grease to prevent corrosion of terminals. Wipe grease off these parts promptly if attached. Handling the wire harness 1 Before removing the harness, check the route and clamp positions to make sure that reassembly is performed correctly. If it is broken, replace it with new one or repair it securely using vinyl tape or the like.

Be very careful when handling electric parts. Use a circuit tester that suits the measurement object and objective.

Analog type: This type is convenient for observing movement during operation and the operating condition. The measured values are used as a reference or as a guideline. Digital type: A fairly accurate reading is possible. However, it may be difficult to observe variation or movement. See the instruction manual when using a circuit tester. The information below describes the precautions required when there are polarity differences between analog and digital circuit testers. The resistance values of the same semiconductor Forward 4 Germanium measured with two types of circuit testers having different current diode power supply voltages are different.

In this case, it is necessary to conduct a thorough analysis on a defect and replicate the condition and environment where the defect occurred. Performing troubleshooting without checking the defect phenomena may cause oversight of important points in repair work or result in a deadlock. Likewise, a defect that resulted from the vibration during truck operation cannot be identified while the truck is stopped.

The replication methods of defect phenomena described here are effective in that external factors exert an influence on a truck while it is stopped. Note: In replicating defect phenomena, the area or location of defect needs to be found as well as checking the defect phenomena. To do this, find the circuit that may include a defect according to the defect phenomena and connect a tester to it before testing.

After that, try the defect replication method and check the circuit for abnormality and also defect phenomena. To narrow the causes of defect phenomena, refer to the list of defect phenomena of each system. Vibration method: For defects that may be caused by vibration Vibrate lightly 1 Parts and sensors Cause vibration on the suspected part by tapping it lightly by hand to see if the defect occurs.

Note: Note that applying a strong impact on relays may cause the point to open. Note: Shake lightly Pay special attention to the root of the connector, fulcrum of vibration and penetrated area of the body.

Shake lightly 2. Watering method: For defects that may occur in rainy or high temperature conditions 1 Pour water on a truck to see if the defect occurs. Spray water onto the front surface of radiator to change the temperature and humidity indirectly.

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