Manual de Servicio Hyundai HD120 D6DA PDF

GENERAL
INFORMATION
ENGINE SPECIFICATIONS ...........................................GI- 2
GENERAL ....................................................................... GI- 3
STANDARD BOLTS AND NUTS ...................................GI- 8
ENGINE NUMBER ..........................................................GI- 9
GI-2 GENERAL INFORMATION
ENGINE SPECIFICATIONS
Model D6DA
Type Disel, 4cycle, lnline 6 cylinder,water cooled,direct injection
Aspiration Type Turbo charge Type

Cylinder Bore x Stroke Ø 109 x 118mm
Displacement 6.606
Compression ratio 17.6 : 1
Firing order 1-4-2-6-3-5
Direction of rotation Counter-clockwise viewed from fly wheel
Compression pressure 36-39kgf/cm2(280rpm)
Idle rpm 640±25rpm
Weight Approx. 580kg
Value seat angle Intake 30°
Exhaust 45°
Value face angle Intake 30°

Exhaust 45°
Value Timing Intake Open BTDC 12°
(flywheel travel) Close ABDC 32°
Exhaust Open BBDC 59°
Close ATDC 13°

Value clearance Intake 0.30mm
(cold) Exhaust 0.50mm
Oil pump Gear pump Type
Oil coller Water cooled plate fin type
Injection nozzle Type Multi hole
Valve opening 160/220kgf·cm2
Water pump Type Forced circulation by volute pump
Drive V-belt, Centrifugal type
Thermostat Wax pellet and battom bypass type
Injection timing BTDC 6° ± 1° (when compression stroke No.1 cylinder)
GENERAL GI-3
GENERAL
How to Read Disassembly and Reassembly Drawings
1. The part names and numbers in the drawings correspond to those in the text. The parts are numbered in the order of
disassembly.
2. The inspection items to be performed during disassembly operations are shown in the disassembly drawings.
3. All tightening torque specifications in the reassembly drawings may be considered "dry" unless "wet" is specified.
Definition of Terms
Unless otherwise specified, all dimensional presentation in illustrations representing the following values or limits is in mm
although the unit is not indicated.
1. Nominal Value (Abbr.: NV)

Shows dimension of an individual part, mutual clearance between parts of standard performance. Values however, do
not necessarily conincide with design valuse as they are rounded off to fall within limits necessary for inspection.
2. Repair Limit (Abbr.: RL)
Shows that when specified value is reached, repair is necessary. Repair means adjustment, grinding replacement of
bushings, metals and the like, selection of oversize, selection of shim thickness, etc.
3. Service Limit (Abbr.: SL)
Shows that when specified value is reached, replacement of the parts with new one is necessary.
4. Basic Diameter (Abbr.: BD)
Shows nominal diameter of part to be measured.
5. Tightening Torque (Abbr.: T)
Shows tightening torque of bolts or nuts.
UNIT
The SI unit is used. Metric notation is jointly shown in parentheses.
NOTE, WARNING AND CAUTION

1. Note
A Point of information for the customer.
2. Caution
Information about on activity that could cause damage to the vehicle.
3. Warning
Information about an activity that could cause injury or damage to the driver, occupants or other personnel.
Table of Conversion Rate for Foot-pound Units into SI Units
Unit Sign of unit Sign of Foot-pound unit Conversion rate

Mass quantity of matter kg lbs 1 kg = 2.2046 lbs
g oz 1 g = 0.035274 oz
Dimension m ft. 1 mm = 3.2808 ft.
mm in. 1 mm = 0.03937 in.
Capacity lit. gal. 1 lit. = 0.2642 gal. (U.S.)
0.220 gal. (lmp.)
cc oz 1 cc = 0.033814 oz (U.S.)
0.035195 oz (lmp.)
Force N (Newton) lbf 1 N = 0.2248 lbf
Pressure kPa (kilopascal) lbf/in.² 1 kPa = 0.145 lbf/in.²
1 kPa = 0.2953 in.Hg
Stress N/cm² lbf/in.² 1 N/c m2= 1.45 lbf/in.²
Moment of force Nm lbf.ft 1 Nm = 0.7375 lbf.ft
Output kW (kilowatt) HP 1 kW = 1.34 HP
Temperature °C °F T°C = (1.8 t°C + 32)°F
GENERAL GI-5
General Precautions For Servicing

Before starting the service procedures, check the vehicle for total
distance driven, use conditions, and user's complaints and requests
to know exactly the engine conditions. Record information where
necessary.
To ensure you are doing correct and efficient service jobs, observe
the following precautions:
D68E0001
(1) Before performing the service procedures given in this manual,

know the trouble spots and isolate the possible cause to
determine whether the removal or disassembly procedure is
required.
(2) Select a flat surface for the service job.
D68E0002
(3) Ready and make the most of the special tools required for
servicing. Use the right tools (specified special tools) in the right
place to prevent damages to parts and personal injury.
D68E0003
(4) Carefully check parts for oil leaks before cleaning. After clean-
ing, it may become difficult to spot defective areas.
D68E0004
(5) When servicing the electrical system, be sure to disconnect the

negative cable from the battery.
D68E0005
(6) Cover areas from which parts have been removed to protect
entry of dust and dirt.
D68E0006
(7) Make alignment marks and keep disassembled part neatly

arranged to ensure that they are reassembled into the right
positions.
o Special care must be taken for assemblies involving a
number of parts, similar parts, or parts identical at right-
and left-hand sides to ensure correct reassembly.
o For alignment and punching markings, select a position
that would not mar the appearance and function.
o Clearly distinguish parts to be replaced from those re
used. D68E0007
(8) The oil seals, packings, O-rings, and other rubber parts,
gaskets, and split pins must be replaced with a new one
whenever they are removed. For replacement, use HMC
Genuine parts.
D68E0008
(9) Apply the specified grease to U-packings, oil seals, dust

seals, and bearings before installation.
(10) Special care must be taken in handling sensors and relays

which are suspectible to shocks and heat.
(11) Connector handling precautions

When disconnecting the connectors, never pull the harness.
Hold the connectors. To disconnect locking connectors, push
in the direction indicated by an arrow. D68E0009
(12) From a safety viewpoint, use utmost caution when handling

the engine, transmission and other heavy items.
D68E0010
GENERAL GI-7
(13) When work requires an assistant or two, always make sure of

the safety each other. Never play with switches and levers.
(14) When checking or changing lubricants, wipe off grease and oil
from parts immediately with a waste.
(15) Use care so that hands and fingers are not injured by sharp
edges or corners of the parts.
STANDARD BOLTS AND NUTS

Unless otherwise specified, the parts and equipment of vehicle must be tightened by the following standard bolts nuts.
Tightening torques for these bolts and nuts are shown below.
NOTE:
Threads and seat surfaces must be in dry state.
When there is a difference between the nut and bolt (stud) identification marks, tighten to the torque correspond-
ing to the bolt (stud) identification mark.
Standard bolts and nuts Unit: Nm (kgf m)
Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or O) 8T (Head mark 4 or ⊕)

5 0.8 2.0 to 2.9 (0.2 to 0.3) 3.9 to 5.9 (0.4 to 0.6) 4.9 to 6.9 (0.5 to 0.7)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 6.9 to 10.8 (0.7 to 1.1) 7.8 to 11.8 (0.8 to 1.2)
8 1.25 8.8 to 13.7 (0.9 to 1.4) 16.7 to 25.5 (1.7 to 2.6) 19.6 to 29.4 (2.0 to 3.0)
10 1.25 18.6 to 27.5 (1.9 to 2.8) 34.3 to 53.9 (3.5 to 5.5) 44.1 to 58.8 (4.5 to 6.0)
1.5 17.7 to 26.5 (1.8 to 2.7) 32.4 to 49.0 (3.3 to 5.0) 42.1 to 58.8 (4.3 to 6.0)
12 1.25 33.3 to 49.0 (3.4 to 5.0) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
1.75 30.4 to 46.1 (3.1 to 4.7) 63.7 to 83.4 (6.5 to 8.5) 73.5 to 98.1 (7.5 to 10)
14 1.5 58.8 to 83.4 (6.0 to 8.5) 118 to 157 (12 to 16) 127 to 177 (13 to 18)
2.0 53.9 to 73.5 (5.5 to 7.5) 108 to 137 (11 to 14) 118 to 167 (12 to 17)
16 1.5 93.2 to 127 (9.5 to 13) 177 to 235 (18 to 24) 196 to 265 (20 to 27)
2.0 88.3 to 118 (9.0 to 12) 157 to 216 (16 to 22) 186 to 255 (19 to 26)
Flange bolts and nuts Unit: Nm (kgf m)
Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or O) 8T (Head mark 8 or ⊕)

6 1.0 3.9 to 5.9 (0.4 to 0.6) 7.8 to 11.8 (0.8 to 1.2) 8.8 to 13.7 (0.9 to 1.4)
8 1.25 9.8 to 14.7 (1.0 to 1.5) 18.6 to 27.5 (1.9 to 2.8) 21.6 to 32.4 (2.2 to 3.3)
10 1.25 20.6 to 30.4 (2.1 to 3.1) 38.2 to 58.8 (3.9 to 6.0) 49.0 to 63.7 (5.0 to 6.5)
1.5 18.6 to 28.4 (1.9 to 2.9) 35.3 to 53.0 (3.6 to 5.4) 44.1 to 63.7 (4.5 to 6.5)
12 1.25 37.3 to 53.9 (3.8 to 5.5) 78.5 to 108 (8.0 to 11) 88.3 to 118 (9.0 to 12)
1.75 33.3 to 51.0 (3.4 to 5.2) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
Identification marks of nut Identification marks of stud
D68E0011 D68E0012
ENGINE NUMBER GI-9
ENGINE NUMBER
Example :
D 6 D A Y 1 2 3 4 5 6
1) 2) 3) 4) 5) 6)
1) D: DIESEL ENGINE
G: GASOLINE ENGINE
2) 6: 4 CYCLE 6 CYLINDER
8: 4 CYCLE 8 CYLINDER
3) Engine development order
4) Engine development version
5) Product year
X : 1999 Y : 2000, 1 : 2001, 2 : 2002, 3 : 2003
6) Production sequence number
000001-999999
ENGINE
MECHANICAL
GENERAL ..................................................................... EM- 2
SERVICE STANDARD ................................................. EM- 7
SPECIAL TOOLS ......................................................... EM-17
SERVICE PROCEDURE
Engine Disassembly Check Standard .................. EM-22
Engine Dismounting and Installation ................... EM-24
Engine ..................................................................... EM-26
Crank Shaft Pulley ................................................. EM-34
Flywheel and Flywheel Housing ........................... EM-36
Timming Gear and Camshaft ................................ EM-39
Piston, Crankshaft, Cylinder Block and oil Pan .. EM-45
Liquid Gasket and Oil Application Points ............ EM-57
TROUBLESHOOTING .................................................. EM-59
EM-2 ENGINE MECHANICAL
GENERAL
Iinjection nozzle
Construction and Operation
Cylinder head
Engine Proper
1. Combustion Chamber
The combustion chamber is made up of the cylinder head and O-ring
toroidal piston. The hole type injection nozzle is mounted to the
cylinder head together with the nozzle tube.
The nozzle tube accomplishes the function of holding the Piston

nozzle in position and cooling it. Since the outside of the nozzle
tube is exposed to the water jacket, the top end of the tube is
sealed off with an O-ring and the bottom is staked to prevent
water leakage.
Combustion is accomplished by direct injection of fuel into the

combustion chamber.
A valve recess is machined on the top of the piston for providing

a clearance between the piston and exhaust valve.
KKEM-000
For more effective colling of the combustion chamber, water

directors that direct coolant flow are pressed into the bottom of Water jet
the cylinder head.
KKEM-000
GENERAL EM-3
2. Valve Mechanism
The valve mechanism is an overhead valve type and is con-
structed as shown.
Upper retainer
Rocker
Outer valve spring
Rocker shaft spring Inner valve spring
Rocker shaft
Valve stem seal
Lower retainer
Push rod
Valve stem seal
Exhaust valve
Inlet valve
Camshaft
Tappet
KKEM-902
(a) Both intake and exhaust valves are made of surface treated heat-resistant steel to increase durability.
The valve seat angle of both valves is 45°
A valve stem seal is provided on the stem of valve to control the quantity of lubricant of the valve and valve guide sliding
portions. The inner and outer springs are different in coiled direction.
(b) To prevent abnormal vibration during high speed operation, two unevenly pitched springs are provided as valve
springs.
The inner and outer springs are different in coiled direction.
(c) The rocker is a precision forged carbon steel product.
The rocker end sliding portion is quenched.
The rocker shaft is a hollow round rod with expansion plugs at both ends to seal off the rod. The inside of the shaft
constitutes an engine oil passage.
(d) A steel ball is welded to the bottom end tapper side of the push rod, whereas a spherical concave type end cap is welded
to the top end rocker side. Both ends are carburized and hardened.
(e) The tapper is a cylindrical type and has a spherical surface which makes contact with the camshaft. The tappet can
be removed without removing the camshaft, provided that the cylinder head is removed.
(f) Because of the high cam design, the push rod is shorter, assuring higher rigidity and higher dependability against high
speed rotation.
(g) To facilitate insertion and removal of the camshaft from the rear end of the crankcase, the diameter of the camshaft
bearing is smaller toward the front.
3. Crankcase and Cylinder Liner

(a) The coolant enters the water jacket to flow around each Crank case
cylinder and cool it, and then flows to the cylinder head.
(b) The dry type cylinder liner is adopted and the liner is Cylinder liner
pressfitted to the crankcase in such a way as to facilitate
removal.
KKEM-903
4. Piston and piston ring

(a) Piston
Stamped on the top surface of the piton are a size mark (or
oversize dimension on oversize pisitons) for selection fit
with the cylinder liner, a piston weight mark, part number,
and the "F" with and arrow for the front mark showing the Front Mark
piston installing direction.
Piston pin for connecting piston to connecting rod is of full-
floating type and is prevented form moving out by means of
a snap ring type and is prevented from moving out by KKEM-904
means of a snap ring installed on each end of the pin ends.
On D6AU, a cavity is provided in the piston for colling.
(b) Piston ring

The piston rings are three in total; two compression rings 1st compression ring
and one oil ring. The sliding surface of each piston ring is Taper side wedge
type
hard chrome plated to improve wear resistance. 2st compression ring
The piston ring are shaped as shown in the figure. Taper-faced,in-
ner cut type
Oil ring
Dual type with
coil expander
KKEM-905
GENERAL EM-5
5. Connecting Rod Bearing

Connecting Rod
The connecting rod is an l-section stamp forging. A lead bronze Bushing
bushing is press-fitted into small end. The connecting rod
bearing for the big end is a split type plain bearing. This bearing Oil path
Connecting rod
is soft copper backed kelmet metal, the inside surface of which
is plated with an alloy of lead, tin and copper. The whole bearing Upper bearing Stud bolt
is then plated with tin.
The connecting rod and connecting rod cap are coupled by
knurled connecting rod bolts.
Lower bearing KKEM-906
6. Crankshaft and Main Bearing

(a) Crankshaft Oil hole Pin
The crankshaft is a highly-rigid die forging integral with the Journal
balance weights. The pins, journals, and rear oil seal sliding
surfaces are induction-hardened for improved wear
resistance.
By means of oil passages drilled through the pins and

journals, part of the main bearing lubricating oil is fed to pins Balance weight
for lubrication of the connecting rod bearing KKEM-907
An oil hole in each journal is through to that in pin, feeding

some of the main bearing lubricating to the pin for lubricat-
ing to the pin for lubrication of the connecting rod bearing.
(b) Main bearing

The main bearing is a split type plain bearing and is made
Upper main bearing
of the same material as the connecting rod bearing.
The upper bearing has an oil has an oil groove, but the
lower bearing has no oil groove. Split type thrust plates are Lower main bearing
mounted to the bearing to sypport the thrust of the crankshaft.
Thrust plate
KKEM-908
7. Timing Gear
The timing gears are housed in the timing gear case at the front of the engine. Illustration shows the gear train.
Each gear is a helical gear machined by a shaving machine to high precision and surface-treated for enhanced
durability.
A timing mark is a stamped on each gear.

At resassembly, correct meshing can be achieved by aligning these marks.
On D4A, an oil pipe is installed in the idler shaft that is used for forced lubrication of the injection pump gear.
Air compressor drive gear

Air compressor idler gear
Cam shaft gear
B Idler gear
Fuel injection pump

drive gear
Power steering pump

drive gear
C
Engine oil pump drive gear
A A : Match marks "1"

Crank shaft B : Match marks "2"
C : Match marks "3"
KKEM-292
A bushing is press-fitted into the idlergear which turns on the idle shaft.
The oil hole dirlled through the idler shaft and gear provides an oil passage for lubrication of bushing and gears.
8. Flywheel
Ring gear
The flywheel is made of cast iron. The pilot bearing of the Flywheel
transmission drive pinion is installed at its center. On its
periphery, the ring gear is shrink-fitted that meshes with the
starter pinion.
The ring gear tooth crests are induction-heardened for greater

durability.
Pilot
At the same time, one side of the crests is chamfered to ensure
bearing
that the starter pinion meshes easily when starter is operated. KKEM-909
SERVICE STANDARD EM-7
SERVICE STANDARD Unit : mm
Inspection Item Standard Limit Remedy Inspection Procedure

Cylinder head flatness Less than 0.05 0.1 Grinding or
(0.0019) replace
at direction A
Less than0.03
(0.0012)
at direction B
KKEM-44
Cylinder head height 94.9-95.1 94.7 Replace
KKEM-45
Cylinder head cracks and - - Replace if

Damage necessary
* Using a dye penetrant
KKEM-46
Nozzle protrusion from 2.1-2.7 - Replace Nozzle

cylinder head surface sleeve
Cylinder head
KKEM-47
Valve seating condition Theres should be - Hand lapping

* Using red lead marking good contact around using lapping
compound entire circumference compound
of valve head.
KKEM-48
Valve sink Replace valve or

Intake 0.65-0.95 1.2
valve seat if
necessary
Exhaust 1.15-1.45 1.7

KKEM-49
Unit : mm
Valve seat Intake 29°45′-30° - Regrind or
angle replace valve
Exhaust 44°15′-45°45′
and /or valve
Valve face Intake 29°45′-30°
seat
angle Intake Exhaust
Exhaust 44°45′-45° KKEM-50
Intake valve stem diam- 8.947-8.965 8.90 Replace valve

eter guide and/or
valve
Exhaust valve stem diam- 8.932-8.950 8.80
eter
Intake and exhaust valve 9.020-9.035 9.1

guide diameter
KKEM-51
Side Intake 0.055-0.085 0.18 Replace valve

clearance guide and/or
between
valve stem
valve stem Exhaust 0.070-0.103 0.23
and valve
guide KKEM-52
Valve Inner IN 14.4kgf - Replace

spring at 47.2 if necessary
setting
Ex 14.2kgf
load at 47.4
Outer IN 41.3kgf - Replace

at 50.2
Ex 40.6kgf
at 50.4
KKEM-53
Squareness of valve - 2.00 Replace

spring if necessary
KKEM-54
Unit : mm

Valve spring seat for wear - - Replace,
Visual check
if necessary
KKEM-55
Rocker arm shaft 24.159-24.180 24.14 Replace rocker

diameter arm bushing
and/or shaft
Clearance between 0.030-0.101 0.15
rocker arm shaft and
bushing KKEM-56
Rocker arm and valve - - Resurface of

step cap wear or replace
damage
KKEM-57
Push rod bend - 0.25 Replace
KKEM-58
Adjusting screws and - - Replace

push rods damage
KKEM-59
Valve lifter diameter 31.950-31.975 31.92 Replace valve

lifter
Valve lifter guide 32.000-32.025 32.05

deformation
Clearance between valve 0.025-0.075 0.10

lifter and valve lifter guide
KKEM-60 KKEM-61
Valve lifter Should not be worn - Replace, if Visual check

unevenly necessary
Unit : mm
Flantness of flywheel - 0.04 Replace or grind
KKEM-76
Gear teeth for pitting or - - Replace if Visual check

wear necessary
KKEM-97
Oil clearance between 0.030-0.080 0.20 Replace gear and

idle gear shaft and shaft
bearing
KKEM-98
Idler gear end play 0.070-0.125 0.30 Replace thrust

bearing
KKEM-99
Camshaft bend - 0.05 Replace
KKEM-100
camshaft, Replace
Intake 6.66 6.58
camlift
(A-B)
Exhaust 9.03 8.95

KKEM-101
Unit : mm
Camshaft end play 0.100-0.178 0.30 Replace thrust
plate
KKEM-102
Camshaft 61.45-61.47 61.6 Replace camshaft

No.1
journal diameter
journal No. 61-05-61.07 61.2
No.2
60.65-60.67 60.7
No.3
58.25-58.27 58.4
No.4
Oil clearance between 0.03-0.08 0.15 Replace camshaft

camshaft journal and and/or bearing
bearing KKEM-103
Unit : mm
Timing gear backlash - - Replace gear

Full Crankshaft gear - 0.038-0.13 0.30
air idle gear
brake
Idle gear - ingection 0.03-0.12 0.30
pump gear
Idle gear - 0.027-0.26 0.30

camshaft gear
Camshaft gear - 0.07-0.18 0.30

engine oil pump gear
Camshaft gear - 0.027-0.26 0.40

air compressor
idle gear
Air compressor 0.049-0.147 0.30
gear - Air compres-
sor idle gear
Air compressor 0.046-0.173 0.30
gear- power
steering oil pump
gear (If so fitted) KKEM-104
Clearance between 0.030-0.072 0.30 Replace bearing

injection pump and/or shaft
drive shaft and
bearing
KKEM-105
Injection pump 0.100-0.200 0.30 Replace thrust

drive gear end bearing
play
KKEM-106
Unit : mm
Piston diameter 109 - Replace piston
OUTSIDE
at A:21 and/or liner DIAMETER
Cylinder liner inside 109 109.05

diameter
Clearance between piston 0.093-0.125 -

and cylinder liner
Cylinder liner protrusion 0.01-0.08
KKEM-167
Piston ring Top 3.00 2.90 Replace

breadth
2nd 2.5 2.4
Oil 4.00 3.90
Piston ring Top 3.00 3.20 Replace piston

grooves
2nd 5.0 2.70
breadth
Oil 4.00 4.10
Clearance Top 0.06-0.10 - Replace piston

between piston ring and/or piston
2nd 0.04-0.08 -
ring and piston
ring breadth
Oil 0.02-0.06 -
KKEM-168
Piston ring gap Top 0.30-0.40 1.5 Replace

* Insert the
piston rings 2nd 0.30-0.45 1.20
Where the wear
of the liner is Oil 0.25-0.45 1.20
small
KKEM-169
Unit : mm
Inspection Items Standard Limit Remedy Inspection Procedure
Piston pin diameter 38.987-39.000 36.96 Replace piston,
piston pin and/or
connecting rod
Piston pin hole inside 36.987-37.003 39.05
diameter

piston pin and piston
pin hole
T:Tight
L:Clearance
Connecting rod small 37.015-37.025 37.10 Replace bushing
end bushing inside and/or piston pin
diameter
piston ring and connecting
rod small end bushing KKEM-170
Connecting rod cracks - - Replace ,

or damage if necessary
KKEM-171
Connecting rod - - Clean

oil hole clogged
KKEM-172
Connecting rod 0.1 Replace

squareness Par
200
KKEM-173
Unit : mm
Crankshaft pin diameter 64.94-64.96 64.80 Regrind crank-
shaft and use
undersize bearings
63.80 Replace
crankshaft

connecting rod and
crank pin
KKEM-175
Connecting rod end play 0.20-0.52 1.00 Replace

connecting
rod
KKEM-176
Crankshaft oil hole - - Clean

clogged
KKEM-177
Crankshaft cracks and - - Replace

damage
KKEM-178
Crankshaft bend - 0.09 Replace
KKEM-179
Unit : mm
Crankshaft journal 79.940-79.960 79.8 Regrind crank-
diameter shaft and use
undersize bearings
78.8 Replace
crankshaft

crankshaft journal and
main bearing
KKEM-180
Crankshaft end play 0.050.219 0.50 Replace thrust

bearing
KKEM-181
Cylinder block flatness Less than 0.05 0.10 Regrind and/or

replace
KKEM-182
SPECIAL TOOLS EM-17
SPECIAL TOOLS
NAME PART NO ILLUSTRATON USE
Cylinder liner 09222-62100 Removal of cylinder liner

Puller A
KKST-001
Cylinder liner 09222-8Y000 Removal of cylinder liner

Puller B
KKST-002
Valve tappet remover 09221-8Y000 Removal or lnstallation of valve tappet

and installer
KKST-003
Front oil seal installer 09231-8Y000 Installation of oil seal
KKST-004
Rear oil seal Installer 09231-8Y100 Installation of rear oil seal
KKST-005
Piston guide clamp 09222-88200 Installation of piston
KKST-006
Piston ring tool 09222-83200 Removal and Installation of

piston ring
KKST-007
Flywheel guide bar 09231-8Y200 Remove and Installation of flywheel
KKST-008
Ball bearing puller 09432-8Y000 Removal of ball bearing
KKST-009
Valve stem seal 09222-93000 Installation of valve stem seal

installer
KKST-010
SPECIAL TOOLS EM-19
Valve guide remover 09211-8Y000 Removal of valve guide
KKST-011
Valve spring 09222-8Y100 Removal and installation of

compressor intake valve spring and exhaust
valve spring
KKST-012
Compression gauge 09353-8Y000 For adaptor when checking the nozzle

adaptor pressure
KKST-013
Rear oil seal 09231-8Y300 Removal of rear oil seal sleeve

sleeve remover
KKST-014
Compression gauge 09351-8Y000 Checking nozzle compression
KKST-015
Sliding hammer 09450-75400 Removal and Installation of idler gear

M16 X 1.5
adaptor shaft
KKST-016
Sliding hammer 09450-8Y000 Removal and Installation of idler gear

shaft
(use with sliding hammer adaptor)
KKST-017
Valve stem seal 09222-29000 Remove or valve stem seal

remover
KKST-018
Valve guide installer 09211-8Y100 Installation of valve guide
KKST-020
Front oil seal sleeve 09231-8Y400 Installation of front oil seal sleeve
installer
KKST-021
SPECIAL TOOLS EM-21
Front oil seal sleeve 09231-8Y500 Removal of front oil seal sleeve
remover
KKST-022
Rear oil seal 09231-8Y600 Installation of rear oil seal sleeve

sleeve installer
KKST-023
Nozzle sleeve 09222-8T300 Installation of nozzle tube

installer
KKST-025
Nozzle tube remover 09222-8Y400 Removal of nozzle tube
KKST-026
Target plate 09222-8Y500 For checking of piston cooling jet

position
KKST-027
SERVICE PROCEDURE (Example)

Engine Disassembly Check Standard
Engine overhaul criteria
1. When compression pressure is low.
a. Before the measurement
a) Correctly adjust the valve clearance.
b) Warm up engine. (Until the coolant temperature reaches KKEM-03
around 80°C)
c) Charge the battery fully.
d) Remove the air cleaner.
b. Measurement
a) Remove the nozzle holders completely.
b) Install the gauge adapter in the nozzle holder hole.
c) For the vehicles installed manual engine stop control;
Remove the engine stop cable from the engine stop
lever connected to engine stop position by tape or
string.
d) For the vehicles installed electric engine stop control;
Remove the engine stop motor harness after turning
the engine starter key to “OFF” position.
e) Connect a compression gauge to the gauge adapter.
f) Drive the engine with the starter and read the compres-
sion pressure.
CAUTION
Do not operate the starter for more than 15 seconds at
once.
g) Measure the compression pressure for each cylinder.

If compression pressure is low, be sure to repeat the
measuring.
CAUTION
Make sure no pressure leaks through sealing face.
SERVICE PROCEDURE EM-23
c. For the model installed electric engine stop control:

Check whether the engine starter is at the “OFF” position
and then connect engine stop motor harness.
WARNING
Do not connect electric harness to engine stop motor, when
engine starter key is at “ON” position.
If starter key is at “ON” position, engine stop motor operates
simultaneously then the link of engine stop motor and engine
stop lever of fuel injection pump operate resulting in possible
damages of hand.
Unit : kg/cm2
Compression pressure Difference between
Engine model Engine speed(rpm)
Standard Limit each cylinder
D6DA 36-39 28 Less than 3 280
2. When oil pressure decreases

(Example)
Check the oil pressure warning lamp when the oil and coolant
temperature are heated enough (about 80°C).
a. If the warning lamp is on, check the oil level.
b. Check oil deterioration
If oil quality is poor, replace with suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure
gauge. KKEM-04
d. Measure the oil pressure at coolant temperature of 80°C or
above.
Standard oil pressure : 0.5-5.0 kg/cm2
Service limit : Below 0.5 kg/cm2 (Idle condition)
3. Other factors
a. The blow-by gas increases
b. The engine does not start easily.
c. Engine power decreases
d. Fuel consumption increases
e. Engine makes greater noise
f. Excessive consumption of engine oil
Engine Dismounting and Installation

Dismounting
1. Park the vehicle on level ground and prop the wheels.
2. Remove coolant from radiator and cylinder block, and release
the engine oil from the oil pan.
WARNING
Do not drain coolant or engine oil while engine or radiator is
hot because it may cause burn.
3. Disconnect the oil pressure line of power steering and drain oil.
CAUTION
Please refer power steering maintenance section for the
details.
4. Disconnect the engine stop cable.

a) Turn the engine starter key to “ON” position.
CAUTION Engine
Do not operate engine. stop
position
Bracket stop
b) Check whether engine stop lever of fuel injection pump is cable mounting Engine operating position
at engine operation position, and disconnect the connector KKFL-022
of engine stop motor harness.

c. Turn the engine starter key to “OFF” position.
5. Disconnect electric line, fuel line, air line, speedometer cable,

accelerator control cable and parking brake cable.
CAUTION
• Disconnect battery cable from the (-) terminal
of the battery and remove electric line.
• Cover the hole of pipe, hose and pump so that
no dust inflow.
6. Disconnect all hoses (coolant, heater and air intake) and

disconnect the radiator.
CAUTION
Be careful not to damage the radiator core.
7. Disconnect air intake and exhaust lines.

8. Disconnect clutch housing, transmission control and transmis-
sion from flywheel housing.
CAUTION
Please refer “transmission and transmission control” main-
tenance section for the details.
9. Disconnect cap mounting member from the frame.

10. Connect cable from the engine hanger to the hanger bracket at
the front of the engine and to the hanger brackets at the upper
flywheel housing at the rear of the engine. Loose the cable a bit
and raise the hanger by using the hoist.
11. Remove the engine mounting nuts (both sides of front and
rear).
12. Lift the engine hanger so that the cables are fully tightened, and
then after checking that the cables are securely hooked on the
hanger brackets, lift the engine assembly gently and remove it
from the vehicle.
KKEM-911
Installation
Install engine assembly.
Install engine assembly by reversed order of dismounting.
CAUTION
Check the leaks of oil, fuel, coolant or air.
Connect the engine stop cable.

1. Turn the ignition key at “ON” position.
CAUTION
Do not start the engine yet.
2. Check the connector of engine stop motor harness

3. Connect the engine stop cable adjust the adjusting nut to make
the gap “A” be 1-3mm, which is the distance between crevis
and cable stopper.
4. Turn the ignition key to “OFF” position.
CAUTION
Check engine stop and start after adjustment.
Adjusting nut
KKEM-912
Engine
Cylinder Head
OVERHAUL
T=Tightening torque : kgf·cm
1. Cylinder head cover 5. Cylinder head

2. Oil filler cap 6. Cylinder head gasket
3. Ventilator 7. Cylinder head assist bolt
4. Cylinder head cover gasket 8. Cylinder head bolt
KKEM-09
1. Cylinder head 11. Valve seat 21. Valve stem cap

2. Connect bolt 12. Retainer ring 22. Valve stem key
3. Soft washer 13. Valve lock shaft 23. Valve spring upper seat
4. Nozzle holder 14. Valve gap adjust screw 24. Inner valve spring
5. Nozzle 15. Bushing 25. Outer valve spring
6. Packing ring 16. Rocker arm 26. Valve stem seal
7. Nozzle sleeve 17. Valve lock support 27. Valve spring lower seat
8. O-ring 18. Spacer 28. Valve
9. Valve guide 19. Spring 29. Push rod
10. Plug 20. Plain washer 30. Valve lifter
KKEM-931
Disassembly
Disconnect fuel pipe and nozzle assembly.
Disconnection of cylinder head and rocker arm assembly.

1. Remove the cylinder head additional bolts by loosening the
bolts in the numerical order shown in the figure.
KKEM-19
2. Removal of rocker arm support bolts

Remove the rocker arm assembly by the loosening the bolts in
the numerical order shown in the figure.
KKEM-20
3. Removal of cylinder head bolts

Remove the cylinder head bolts in the numerical order shown
in the figure.
KKEM-20A
Lift the cylinder head from the dowels and place it on the
wooden block.
Moving up and down
1. If the cylinder head is difficult to lift, insert the chisel between the
cylinder head and block to leverage.
CAUTION Cylinder block

Do not damage the machined surface of the head and block
when removing the cylinder head.
KKEM-21
Disassembly of valve spring

1. Remove valve stem key, upper spring seat inner valve spring
and outer valve spring from cylinder head.
Special tool: Valve spring compressor (09222-8Y100)
2. Disassemble intake and exhaust valves.

3. Tag valves to identify the cylinder numbers and to eliminate
valve lapping. KKEM-951
Assembly
Clean the cylinder head completely with the solvent.
CAUTION
Be careful not to damage the cylinder head surface.
KKEM-23
Hand-lap the valve and valve seat if needed.
Apply lapping compound lightly to the valve face. Install the valve
using a special tool, tap and rotate the valve against the seat.
Special tool: Valve-lapping tool
KKEM-24
Grind the valve and valve seat, if needed.
CAUTION
• Grinding of valves and valve seats should only be per-
formed when hand lapping does not result in proper
seating.
• Recheck the valve sink after grinding at all times.
KKEM-25-1 KKEM-25
Angles of valve face and valve seat ;

please refer the service standards.
Intake Exhaust
KKEM-26
Replace the valve seat, if needed.

Hammer
1. Cut the circumference of a valve head at three places with a Brass block
grinder and, install it into the seat as shown and weld the valve
Valve seat
to the seat.
Then push the valve and the seat out with a hammer and a
brass bar. Arc welding
Valve
Grind this part using the
grinder
KKEM-27A
2. Specifications of valve seat surface machining

Unit: mm
Intake Exaust
Cylinder head A 52.000-52.019 45.500-45.516
dimension B 10.1-10.3 10.4-10.6 Intake Exhaust
Valve seat C 52.085-52.100 45.63-45.645
dimension B 7.6-7.8 8.0-8.2 Intake Exhaust KKEM-28
3. Valve seat installation

Heat the cylinder head to about 80°C - 100°C with hot water. On
the other hand, cool the valve seat with dry ice or liquid freon
for approximately 30 minutes. Hold the seat with pincers and
place it into the heated cylinder head.
KKEM-974
Replace the valve guide, if needed. Cylinder head

1. Remove the valve stem seal.
2. Remove the valve guide using a special tool. (Valve guide 23.75mm 22.25mm
remover: 09211-8Y000)
3. Install the valve guide. (Valve guide installer: 09211-8Y100)
84.75mm 86.25mm
CAUTION
Apply engine oil lightly to the outer circumference of valve
guide before installation. KKEM-30
Replace the valve stem seal, if needed.

1. Remove the valve stem seal.
(valve stem seal remover: 09222-8Y000)
2. Install the valve stem seal. KKEM-972
Install the lower spring seat and valve first. Then apply engine
oil to the lip of the stem seal and push the guide with a special
tool.
Special tool: valve stem seal installer(09222-93000)
CAUTION
• Check for any cracks or damages of rubber, after valve
stem seal installation.
• If the tip that touches the lower spring seat is worn or
KKEM-772/KKEM-971
deformed, do not use the special tool.
Replace the nozzle sleeve, if needed.

1. Remove the nozzle sleeve.
Nozzle sleeve
(Nozzle tube remover: 09222-8Y400)
Special tool
Cylinder head
KKEM-952
2. Install nozzle sleeve.

Install O-ring to the cylinder head. Apply the adhesive (super
three bond No. 1210 or equivalents) at the lower part of new
copper nozzle sleeve and insert sleeve into the cylinder head.
CAUTION
Damaged O-ring cause oil leaks, overheating or crack of head.
KKEM-34
3. Stick the nozzle sleeve into the cylinder head tight using a
Special tool
Nozzle sleeve
special tool. Insert the seat press (special tool) into nozzle
sleeve. Push the ball slowly through the hole with the special
tool so that the end of nozzle sleeve be fastened tight to the
cylinder head. Cylinder head
Special tool
Special tool: (nozzle sleeve installer: 09222-8Y300)
KKEM-35
Assemble the cylinder head.
CAUTION
• Apply the engine oil to the contact points of all parts.
• Check the valves whether they are installed to the right
cylinders.
• Since the valve spring has various pitches, install them as
the painted parts facing downward.
KKEM-36
Pressing the upper spring seat, install the valve stem key tight to the
valve spring seat.
Special tool: Compressor (valve spring compressor: 09222 –

8Y100)
CAUTION
• When pressing with valve spring press, be careful not to
damage the stem seal by the touch with upper seat.
• Push the valve stem gently by the hammer for the precise
installation of valve stem key. KKEM-951
Rocker arm assembly No 1 support
Apply the engine oil to the rocker arm shaft and bushing.
CAUTION
Check whether the rocker arm shaft is installed as the “UP”
mark facing upward. Disassemble may cause the melting of
valve stem.
Timing gear shaft
KKEM-38
CAUTION No 1 support
Check whether the oil hole of rocker arm assembly number 1
support coincides with the shaft oil hole. Incorrect installation
may cause the burning of whole valve assembly.
Oil hole KKEM-39
Installation of cylinder head and rocker arm assembly

1. Apply the engine oil to the valve lifter face and valve lifter guide,
and then install the valve lifter guide.
2. Install the cylinder head gasket.
CAUTION
When using the new cylinder head gasket, clean the surface
of the cylinder head, cylinder block and head gasket free of all
KKEM-40
dirt, water and grease.
3. Install the cylinder head over the dowels on the cylinder block.
4. Apply the engine oil to the both ends of push rods and install in
the right order.
5. Install rocker arm assembly to the cylinder head and check
whether push rod contacts adjusting screws.
CAUTION
Unfasten the lock nut loose and raise the adjusting screw fully
to the maximum. KKEM-41
6. Fasten the cylinder head bolts and additional bolts (marked *)

in three steps by the order shown in the figure.
CAUTION
Flywheel side
Pan side
Apply engine oil at the thread of bolts and at the lower part of
bolt head.
1-26 blots (at the cylinder head bolts)
27-32 bolts (additional bolts)
KKEM-42
7. Fasten the rocker arm support bolts in three steps in the

numerical order shown in the figure. Fasten the bolts by the
specified torques at the final step.
Rear
Front
KKEM-43
Crank Shaft Pulley
COMPONENTS
For Truck 5
8
7
6
4
2
T=6500kgf-cm 1
For Bus
1. Nut
2. Spacer
3. Bolt
4. Crank shaft pulley
5. Crank shaft damper
6. O-ring
7. Sleeve
8. O-ring
KKEM-941
Disassembly Disassembly Special tool

Remove the crankshaft pulley.
CAUTION
• Use the plug, if needed.
• Do not remove the crankshaft pulley, if it is not necessary.
(Front) KKEM-66
Assembly
Replace the crankshaft front oil seal sleeve, if needed.
1. Remove the oil seal sleeve by using the special tool (Front oil Special tool
seal remover: 09231-8Y500, sliding hammer: 09450 -8Y000).
2. Install the new sleeve (Special tool: front oil seal sleeve
installer: 09231-8Y400) Install the new O-ring to the sleeve,
apply the enough oil to the center part of the pulley. Use the
crankshaft sleeve press to insert the crankshaft sleeve. Then KKEM-751
take care not to damage or wear out the O-ring.

Flywheel and Flywheel Housing
COMPONENTS
7
10
5 T=1900kgf.cm
3
1 8
9 T=Tightening torque : kgf·cm
1. Helicert 6. Ring gear

2. O-ring 7. Flywheel
3. Flywheel housing 8. Stay
4. Dust cover 9. Plug
5. Crank shaft rear oil seal 10. Ball bearing
KKEM-761
1. Replace the bal bearing if necessary.

SST : Ball bearing puller (09432-8Y000)
KKEM-761
KKEM-761
Assembly
Replace the oil seal, if needed.
1. Remove the oil seal.
2. Lightly apply the engine oil to the outer circumference of oil
seal, and install the oil seal to the flywheel housing. (Special
tool: 09231-8Y100). Check whether the oil seal is securely
installed to the flywheel housing.
KKEM-70
CAUTION
Apply the oil seal lubrication grease (Lithium based) to the oil
seal rib.
Replace the O-ring, if needed.

1. Install the O-ring. O-ring
CAUTION
Apply the adhesive to the flywheel housing so that the O-ring
is not detached. Install the flywheel housing.
KKEM-71
2. Assemble the rear oil seal sleeve.
Special tool: Rear oil seal sleeve installer (09231-8Y600)
KKEM-973
Replace the flywheel ring gear, if needed.

1. Remove the ring gear.
a. Heat the ring gear around 200°C.
b. Tap the ring gear evenly around the circumference to
remove the ring gear with the metal rod.
CAUTION
Do not overheat the ring gear.
KKEM-72
2. Install the ring gear.

a. Heat the ring gear evenly about 200°C.
b. Insert the ring gear using the metal rod so that the cham-
fered gear faces the block of the flywheel.
CAUTION
Do not overheat the ring gear.
KKEM-73
Install the flywheel.

1. Make sure that there is no dust or coarse parts at the holes of Flywheel
crankshaft and flywheel and each contact points. Insert the
guide bar to the crankshaft.
Special tool: Flywheel guide bar (09231-8Y200)

Guide bar
CAUTION
Insert one of the bars to the collar knock and insert the other
bar to the other side of collar knock.
2. Insert the flywheel into the guide bar gently as flywheel touches
the collar knock, and push it fully to be securely installed.
3. Apply the engine oil to the surface of flywheel bolt bearing and
threads of flywheel bolts. Fasten the flywheel bolts tentatively
Guide bar
by hands.
4. Remove the bars, and fasten the remaining two flywheel bolts
tentatively as described in no 3.
5. When fastening the bolts, fasten them gradually and slowly with KKEM-981
the specified torques. And then loosen them a little bit and
fasten them again by the specified order and torques. Fastening order “O” mark
Crankshaft collar
WARNING
Be careful not to drop the flywheel, since it is heavy.
CAUTION
• Align the “O” marks of flywheel and crankshaft collar
knock to be coincided.
• When fastening bolts, apply the engine oil the bolts threads
KKEM-75
and flywheel face.
Fastening torques: 1900kgf-cm

Timming Gear and Camshaft
DESCRIPTION
7 6
4
B 3
2
C
5
OVERHAUL 13 A
16 1
T=320 15
18
7 12
6
17
8 13
16 12
15
14
4 2 T=250
T=2800
13
11
5
T=1600
10
9
3
1 T=2100
13
1. Crank shaft gear 9. Injection pump gear thrust plate 18. Camshaft
2. Idler gear 10. Collar
3. Fuel injection pump drive gear 11. Injection pump drive shaft A. Match marks "1"
4. Camshaft gear 12. Key B. Match marks "2"
5. Engine oil pump drive gear 13. Thrust plate C. Match marks "3"
6. Air compressor idler gear 14. Bushing
7. Air compressor drive gear 15. Pin
8. Power steering pump drive gear 16. Idler gear shaft
(If so fitted) 17. Camshaft thrust plate
KKEM-291
OVERHAUL
Tacho sensor
1. Seal sub assembly 6. O-ring

2. Crank shaft front oil seal 7. Bearing holder case
3. Timing gear case cover 8. Bearing
4. Timing gear case 9. Oil seal
5. Gasket
KKEM-78
SERVICE PROCEDURES EM-41
Disassembly
Disassemble crankshaft pulley.
Caution: Use the puller, if needed.
Remove idler gear shaft.

Remove idler gear shaft using special tool.
Special tool: Sliding hammer (09450-75400)

KKEM-311
Sliding hammer adapter (09450-75400)
Removal of camshaft
Remove thrust plate set blots, and remove camshaft and gear.
CAUTION
Rotate the camshaft slowly so that the bearing should not be
damaged.
KKEM-85
Remove camshaft gear and injection pump drive gear,

if needed.
Place the shaft assembly on the wooden plate and fix it with vise.
Remove the nut, and remove the gear by using gear puller.
KKEM-86
Assembly
Replace drive shaft oil seal sleeve of fuel injection pump, if needed.
Sleeve
1. Remove sleeve by using special tools.
a. Place the puller (1) and (2) on sleeves.
b. Hook the puller between shaft and sleeve.
c. Insert the puller (3).
Drive shaft
d. Fasten the center bolt (4) after inserting puller, and remove
sleeve.
Special tool: Puller
Sleeve
KKEM-87
2. Insert shaft sleeve along with the new O-ring by using special
tool.
a. Install O-ring (5) inside of the press (6).
b. Insert oil seal sleeve into press with new O-ring and insert
it into drive sleeve.
c. Tap the part (A) lightly with hammer to connect the edge of
the press with shaft edge (B) and then oil sleeve is positioned. Sleeve
CAUTION O-ring
• Install O-ring on sleeve and apply the oil on the shaft.

• When installing shaft sleeve, be careful no to damage the
O-ring.
• Do not reuse the sleeve once it is removed. Drive shaft
O-ring
Special tool: Press
O-ring KKEM-88
Distance from the shaft edge to sleeve end (c): 85.2 – 85.8 mm
KKEM-89
Replace oil seal of timing gear cover, if needed.

1. Remove oil seal using screwdriver.
2. Install the new oil seal.
Special tool: Front oil seal installer (09231- 8Y000)

Special tool
KKEM-331
Install drive gear of fuel injection pump to the shaft.

1. Install collar thrust bearing and key to the shaft.
2. Install the preheated gear (1) about 100°C to the shaft.
CAUTION
Check whether gear (1) is securely installed to collar (2) and
shaft (3).
KKEM-91
Install camshaft gear to shaft.

Install camshaft gear along with thrust plate.
CAUTION
• When installing gear to camshaft,
• Heat the gear with the hot water (approximately 100°C) and
install gear to camshaft by using the press.
• When fastening the bolts, apply the engine oil to the bolts
thread and nut surfaces. KKEM-92
Install camshaft.
Lubricate the camshaft and install the camshaft assembly to
cylinder block.
CAUTION
When installing camshaft, rotate the camshaft slowly so that
the bearing is not damaged.
KKEM-93
Install idler gear shaft.

Install idler gear shaft with thrust plate using plastic hammer.
CAUTION
Make sure that oil hole faces downward. If it doesn’t, idler gear
shaft and bushing will be damaged. Oil hole
Crank shaft
KKEM-94
Installation of Idler Gear

When installing idler gear, coincide the assembly marks of crank-
shaft, camshaft gear, fuel injection pump drive gear and idler gear.
CAUTION
• If installed wrong, it may cause improper injection timing
and finally engine damage or engine performance deterio-
ration will be resulted.
KKEM-95
• When fastening bolts, apply the engine oil to the bolts
threads and surface.
Measurement of gear backlash

Measure the backlash of each gear using dial indicator.
Replace gear, when needed. (Refer the maintenance standard)
Timing gear cover installation

Install oil pump and oil strainer. KKEM-96
Install crankshaft pulley.

Piston, Crankshaft, Cylinder Block and Oil Pan
OVERHAUL
T=800~1200
1. Cylinder liner 9. Cylinder block 18.Connecting rod bearing cap

2. Plug 10. Camshaft bearing 19. Key
3. Pin 11. Piston ring 20. Crank shaft
4. Seal plate 12. Piston 21. O-ring
5. O-ring 13. Piston pin 22. Sleeve
6. Plug 14. Retainer ring 23. Collar
7. Oil jet pipe for piston cooling 15. Connecting rod 24. Crankshaft main bearing
8. Connector bolt 16. Bushing 25. Crankshaft thrust bearing
(Oil check valve) 17. Connecting rod bearing 26. Crankshaft bearing cap
KKEM-107
OVERHAUL
3
1 2
2
6
7
5
T=400~500
1. Push rod cover

2. Gasket
3. Water gallery cover
4. Injection pump bracket
5. Oil pan
6. Soft washer
7. Plug
8. Sound insulator
KKEM-391
Disassembly
Disassemble piston along with connecting rod.
1. Remove the carbon dirt of the cylinder liners by scrubbing the
liner edges to the circumference direction by scrapper or sand
paper (No. 150).
KKEM-124
2. Pull out the piston and connecting rod assembly out of upper
“O” mark
cylinder.
CAUTION
• Disassemble connecting rod, as connecting rod do not
touch the cooling jet.
• Arrange the piston and connecting rod caps orderly.
KKEM-421
Remove the connecting rod.

Remove the retainer rings that installed at both ends of pistons by
using retainer ring pliers.
CAUTION
Preheat the piston for about 5 minutes by soaking in the hot
water of 80 - 90°C, before disassembling pins.
KKEM-126
Remove piston rings.
Special tool: Piston ring tool (09222 – 83200)
CAUTION
• Since piston rings are made of special forgery and brittle,
handle them with special care.
• Distinguish the rings by the equivalent cylinders and
separate them each other.
KKEM-422
Remove cylinder liners.

Draw assembly mark at the cylinder block and liner flange, before
disassembling cylinder liners.
Assembly
CAUTION mark
• Do not draw assembly mark with punch.
• After disassembling cylinder liners, write down numbers
at the circumference or arrange them orderly.
KKEM-128
Special tool : Cylinder liner puller A(09222-62100)

Cylinder liner puller B(09222-8Y100)
KKEM-431
Assembly
Check piston cooling jet position.
CAUTION
• Do not disassemble cooling jet except disassembly in-
spection or when it is necessary.
• When cooling jet is disassembled, replace the cooling jet
check valve of cylinders.
KKEM-130
Cooling jet position checks are as follows.

1. Remove connector bolts of piston cooling jet, and install the
special tools.
2. Use the oil pump; whose pressure is approximately 2kgf/cm2
Piston cooling jet
and oil speed is 2.5 L/min.
Connector bolts
3. Prepare the new engine oil.
Inspection oil hose
4. Connect the oil line. Connect the outlet of oil pump to special
tool (connector bolts). KKEM-131
5. Install special tool on the cylinder block.
Special tool: Target plate (09222 – 8Y500) Positioning pin
Target plate
Cylinder block
KKEM-132
6. Perform an injection test by operating the oil pump to maintain

the oil pressure as approximately 2kgf/cm2 and by pumping the
new oil from jet. It is normal, if the spray of the injection is
centered at around φ 10mm of the plate.
WARNING
Engine oil is extremely flammable.
Spray test should be performed at the places where ventila-
Spray
tion is excellent.
Target
φ 10mm
Abnormal Normal
KKEM-133
7. If the spray of the cooling jet is scattered around the target plate,
readjust the nozzle.
KKEM-134
8. Spray form Spray forms

When checking the piston cooling jet position, make sure that Spray
spray is like number 4 in the figure not like the other 1,2 and 3.
CAUTION Cooling jet
If the end of jet is damaged, spray is poor, so replace it with the

new one. Whenever replacing the cooling jet, check the piston
Normal
cooling jet position of the new one always. Abnormal
KKEM-135
9. After checking piston cooling jet position, install the cooling jet
on the cylinder block by using the right bolts (with soft washer).
Fastening torque: 270 ~ 320kgf-cm
10. After installing piston, check the interference of cooling jet and
piston when the piston is at the bottom dead center position.
KKEM-136
Insert the cylinder liners into the cylinder block. Liner identification mark
1. When installing the new cylinder liner, check the mark of (Cylinder No.1, cylinder No.2,…..
cylinder No.6 from the front.)
cylinder block with mark of liner.
CAUTION
When installing the cylinder liner and block, be careful to
choose the right ones.
In case of using the new cylinder liner, check the X,Y and Z
mark of cylinder liner flange with the same marks of upper Vehicle moving direction
cylinder block.
Position of mark X,Y,Z.
KKEM-461
2. When reusing the liner, install the liner at the right position by
coinciding the assembly marks that was drawn before the
disassembly.
Assembly mark
KKEM-138
3. Lightly apply the engine oil around the outer circumference of

liner, and install the liner by pressing the whole flange. If it is
hard to install by hand, use the cylinder liner guide.
CAUTION
• Use the new one, if the liner has been dropped.
• Handle with care so that the liner is not damaged.
KKEM-139
Replace the camshaft seal plate, if needed.

1. Remove the seal plate.
2. Install the seal plate. Cylinder block
Install O-ring to end plate and install this assembly to the O-ring
cylinder block.
CAUTION
End plate
• Take care not to damage the cylinder block and end plate
in installing. Besides, apply the liquid gasket around the KKEM-141
O-ring (three bond 1215).

Disassembly Sleeve
• Don’t reuse the O-ring after removal.
Special tool
Replace the crankshaft rear oil seal sleeve, if needed.
1. Remove the crankshaft sleeve using special tool.
(Rear oil seal sleeve remover: 09231 – 8Y300) Assembly
CAUTION Special tool

Do not disassemble the crankshaft, if necessary. O-ring
KKEM-142
2. Install the new sleeve.

(Special tool – rear oil seal sleeve installer: 09231 – 8Y600)
Install the new O-ring to the sleeve and apply enough oil to
crankshaft.
Use the crankshaft sleeve press in installing crankshaft sleeve.
Take care not to damage the O-ring.
Special tool: Press

Dimension: 4.3 – 4.7 mm KKEM-143
Grind the crankshaft pin or journal and use the undersize bearing, Unit: mm
if necessary.
Outer diameter
Undersize
CAUTION Pin Journal
• When crankshaft pin or journal is worn out, 4 different
0.25US 64.69-64.71 79.69-79.71
types of under size bearing can be used.
0.50US 64.44-64.46 79.44-79.46
0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
• Bearing set consists of upper and lower bearing. So it 0.75US 64.19-64.21 79.19-79.21
should be replaced by the set. 1.00US 63.94-63.96 78.94-78.96
Filler dimension (R)

Crank pin: 3.75 – 4.25 mm
Journal: 3.00 – 3.50 mm
Good Defect
KKEM-144
Install the crankshaft.

1. Install the crankshaft bearing to the cylinder block and bearing
cap.
CAUTION
• Install the bearing with oil hole to the block side, and
bearing without the oil hole to the bearing cap side.
• Apply the clean engine oil to the bearing surface.
2. Install the crankshaft to the cylinder block.

3. Insert the crankshaft thrust bearing to the cylinder block groove.
4. Insert the thrust bearing at the side of number 4 bearing.
CAUTION
Apply the engine oil to each thrust bearing surface.
KKEM-145
5. Install the crankshaft-bearing cap.

Install the bearing caps by the numerical order from the timing
gear side by placing the arrow mark of the bearing cap face the
timing gear side.
KKEM-146
6. Fasten the cap bolts by the following order.
Unit: kgf-cm
#1, #2, #3, #5, #6, #7 #4
+2° +2°
700 + 57° 0 700 + 52° 0
Timing gear side
CAUTION
• Apply the engine oil to the lower part of bolt thread and
head.
• Check whether the crankshaft rotates smoothly.
• Check the clearance of crankshaft end. KKEM-147
Replace the piston pin bushing, if needed.

1. Remove the bushing using hydraulic press.
CAUTION
Operate the press slowly and gently.
2. Assemble the piston bushing.

C0.5-C1.0 mm
Grind the one side of bushing hole at the connecting rod
homogenously wide 0.5 – 1.0 mm.
CAUTION
• Unbalance champering cause the wrong grinding of
pressed bushing, and finally results in the melting during
Connection rod
installation.
• Remove the dust from the inside of the hole. KKEM-491
3. Check the bushing position after installation.

a. Check the oil hole of bushing and oil passage of connecting
rod whether they are arranged as the rod of 6 mm in
diameter can be inserted.
CAUTION
Misalignment of oil holes may cause insufficient lubrication
and melting.
KKEM-155
b. The new piston pin inserted to the piston pin bushing must
be rotated easily without shaking.
Assemble the piston and connecting rod. “O” mark

Let the O-mark of upper piston be opposite direction of connection
rod assembly mark.
CAUTION
• Use the new retainer ring.
• Heat the piston for about 5 minutes by soaking it into the
Alignment mark
water of 80 –90°C.
KKEM-412
Install the piston ring.

Bottom side
1. When installing the piston rings, install by the order of oil ring, of the ring
No. 2 ring and top ring, and identification mark of ring end
should face upward.
CAUTION
Identification
Apply the engine oil to piston ring. mark
Special tool: piston ring tool (09222 – 83200)

KKEM-513
2. Connect the end of coil expander, and install the coil inside the Ring number Shape
piston ring by letting the gap of piston ring should be at the 180°
distant from the joint part of the coil. Top
Number 2
Oil
KKEM-512
3. Align the piston ring, as the gap positions of rings are equal.
Connection
KKEM-159
Engine front
Oil jet
“O” mark
KKEM-511
Install the connecting rod and piston to cylinder liners.

“O” mark
1. Apply the engine oil to piston, cylinder liner and connecting rod
bearing surface.
2. Fix the piston ring using the special tool and insert the piston F R
and connecting rod assembly using wooden rod.
CAUTION
• Check whether the O-mark of upper piston is at the engine
Tappet chamber
front (crank pulley) side. KKEM-521
• Align the oil holes when installing bearing on connecting

rod and cap.
• When assembling connecting rod assembly to piston,
take care not to damage the piston cooling jet by the
connecting rod. If piston-cooling jet is hit, then adjust or
replace it.
Special tool: Piston guide clamp (09222 – 88200)
KKEM-522
Install the connecting rod cap. “O” mark

1. Apply the engine oil to the bearing surface.
2. Coincide the assembly mark of connecting rod and cap.
Ailgnment
KKEM-421
Fasten the cap bolts.

1. Measure the total length of bolt. If the length is more than 8.5
mm, replace it with the new bolt.
Fastening torque (1650 ~ 1850 kgf.cm)
Dimension (A): 83.5 mm
2. Fasten the bolts by the following order.

a. Fasten the nut by the force of 700kfg-cm
b. Fasten the nut again around 1/4 rotation(90°)
c. Fasten the nut again around 1/8 rotation(45°)
CAUTION
• Apply the engine oil at the lower part of bolt threads and
nuts.
• Fasten the nut again, even if the nut is fully fastened.
Liquid Gasket and Oil Application Points

General gaskets and liquid gaskets are used in engine. Apply the liquid gasket considering the following facts.
1. Application points and width of liquid gasket.
Liquid gaskets in use.
Three bond TB1207D or general electric NO. 2992 – 10: 04132 – 1207 (a), (b), (c) silver color
Three bond TB1207B: 04132 – 1217 (c), (d) black color
Unit: mm
Part name Application points Application width
(a) Timing gear cover Where contacts the cylinder block 1.5-2.5
Liquid gasket
Liquid gasket
KKEM-571
(b) Flywheel housing Flange face where contacts cylinder block 1.5-2.5
Liquid gasket
Bolt holes of cylinder block

KKEM-573
(c) Intake manifold Flange face where contacts cylinder head 1.5-2.5
Liquid gasket
KKEM-572
Unit: mm
Parts name Application points Application width

(d) Intake air pipe Flange face where contacts intake air-fold 1.5-2.5
Liquid gasket
KKEM-581
(e) Coolant pipe (for the Flange face where contacts coolant pump 1.5-2.5
model, which adopts
air compressor)
Liquid gasket
KKEM-582
2. Application of liquid gasket and assembly order of components

1) Remove the old liquid gaskets completely among junction parts, and also remove the oil, water and dirt by the cloth.
2) Apply the proper amount of liquid gasket only. Let the beginning and end of the gasket be overlapped.
3) When assembling the liquid gasket applied parts, align the parts orderly. If not, apply the gasket again.
4) Assemble the parts within 20 minutes after applying the liquid gasket. If 20 minutes have passed, remove the
applied gasket and apply the new gasket again. (Adhesion is weak due to the hardening)
5) Wait for more than 15 minutes to engine start after assembly.
3. Components disassembly
When disassembling each component, try to lift various parts in turn instead of lifting only one side of the flange.
CAUTION
Oil pan flange are deformed sometimes in removing oil pan.
Therefore, insert several plates along the circumference and remove the oil pan using screwdrivers.
TROUBLESHOOTING EM-59
THOUBLESHOOTING
Symptom Possible cause Remedy/Prevention
Engine Coolant
overheating • Insufficient coolant • Add coolant.
• Defective thermostat • Replace the thermostat.
• Overflow of coolant due to leakage of • Repair.
exhaust into cooling system
• Coolant leakage from cylinder head gasket • Repair gasket.
• Defective coolant pump • Repair or replace.
Radiator
• Clogged with rust and scale • Clean radiator.
• Clogged with iron oxide due to leakage • Clean coolant passage and
of exhaust into cooling system correct exhaust leakage.
• Clogged radiator core due to mud • Clean radiator.
or other debris
• Defective radiator cap pressure valve • Replace radiator cap
Abnormal combustion
• Incorrect injection timing • Adjust injection timing
• Reduced injection pressure • Adjust injection pressure.
• Poor fuel • Use good quality fuel.
• Poor nozzle spray • Adjust or replace nozzle.
• Unsatisfactory automatic timer true angle • Repair or replace timer.
Other problems
• Defective or deteriorated engine oil • Change engine oil.
• Unsatisfactory operation of oil pump • Replace or repair.
• Insufficient oil • Add oil.
Excessive oil Pistons, cylinder liners, and piston rings
consumption • Wear of piston ring and cylinder liner • Replace piston rings and cylinder liner.
• Worn, sticking or broken piston rings • Replace piston rings and cylinder liner.
• Insufficient tension on piston rings • Replace piston rings and cylinder liner.
• Unsuitable oil (viscosity too low) • Change oil as required.
• Incorrectly fitted piston rings (upside down) • Replace piston rings.
• Gaps of piston rings in line with each other • Reassemble piston rings.
Valve and valve guides
• Worn valve steam • Replace valve and valve guide.
• Worn valve guide • Replace valve guide.
• Incorrectly fitted valve stem seal • Replace stem seal.
• Excessive lubricant on rocker arm • Check clearance between rocker arm and shaft.

Excessive oil Excess oil feed
consumption • Defective oil level gauge • Replace oil level gauge.
• Oil level too high • Drain excess oil.
Other problems
• Over cooled engine (low temperature wear) • Warm up engine before moving vehicle.
Check cooling system.
• Oil leakage from miscellaneous parts • Repair.
Piston Operation
stick • Abrupt stoppage of engine after running • Operate engine properly.
at highspeed
• Hill climbing using unsuitable gear • Select suitable gear.
Oil
• Insufficient oil • Add oil.
• Dirty oil • Change oil.
• Poor quality oil • Replace with proper engine oil.
• High oil temperature • Repair.
• Low oil pressure • Repair.
• Defective oil pump • Repair oil pump.
• Reduced performance due to worn oil pump • Replace oil pump.
• Suction strainer sucking air • Add oil and/or repair strainer.
Abnormal combustion • See Symptom : "Engine overheating"
Coolant • See Symptom : "Engine overheating"
Lack of power Intake
• Clogged air cleaner • Clean element or replace element.
Overheating • See Symptom " Engine overheating"
Fuel and nozzle
• Poor nozzle spray • Adjust or replace injection nozzle.
• Clogged nozzle with carbon • Clean nozzle.
• Wear or seizure of nozzle • Replace nozzle.
• Air in fuel system • Repair and bleed air from fuel system.
• Clogged fuel filter • Replace element.
• Use of poor fuel • Use good quality fuel.
Abnormal combustion • See Symptom : "Engine overheating."
Piston, cylinder liners, and piston rings • See Symptom : "Engine overheating."
Other problems
• Breakage of turbine or blower • Replace turbine, blower or/and turbocharger
(If so equipped turbocharger)
TROUBLESHOOTING EM-61

Difficult Electrical system
starting • Discharged battery • Charge battery.
engine • Defective wiring in starter circuit. • Repair wiring of starter.
• Loose or open-circuit battery cable • Tighten battery terminal connections or
replace battery cable.
• Break of glow plug or intake air heater • Replace.
(If so equipped)
Air cleaner
• Clogged element • Clean or replace the element.
Fuel system
• No fuel in tank • Supply fuel or bleed of fuel system.
• Clogged fuel line. • Clean fuel line.
• Air sucked into fuel system through • Tighten fuel line connections.
fuel line connections.
• Clogged fuel filter • Replace element.
• Loose connection in high-pressure line • Tighten sleeve nut of high pressure line.
• Water in fuel • Drain and clean fuel system
Difficulty start- Nozzles
ing engine • Seized nozzle • Replace nozzle.
• Broken or fatigued nozzle spring • Replace spring.
Oil system
• Oil viscosity to high • Use proper viscosity oil, or install an oil
immersion heater and warm up oil.
Other problems
• Seized piston • Replace piston, piston rings, and liner.
• Seized bearing • Replace bearing and/or crankshaft.
• Reduced compression pressure • Overhaul engine.
• Ring gear damaged or worn • Replace the ring gear and/or starter pinion.
• Improperly adjusted or broken • Adjust or replace the accelerator cable.
accelerator cable
Rough idling Injection pump • Refer to "FUEL INJECTION PUMP".
Nozzles
• Uneven injection pressure • Adjust.
• Poor nozzle spray • Adjust or replace nozzle.
• Carbon deposit on nozzle tip • Remove carbon.
• Seized needle valve • Replace nozzle.

Rough idling Engine body
• Improper valve clearance • Adjust valve clearance.
• Improper contact of valve seat • Replace or repair valve and valve seat.
• Idling speed too low • Warm up engine.
• Compression pressure of cylinders • Overhaul engine.
markedly different from one another
Leakage of Cylinder head gasket
exhaust gas • Fatigued gasket (aging) • Replace gasket.
• Damage • Replace gasket.
• Improper installation • Replace gasket.
Cylinder head bolts
• Loose bolts • Tighten bolt.
• Elongated bolts • Replace bolt.
• Improper tightening torque or • Tighten properly.
tightening sequence
Cylinder block
• Cracking • Replace cylinder block.
• Surface distortion • Repair or replace.
• Fretting of cylinder liner insertion portion • Replace cylinder liner or cylinder block.
(insufficient projection of cylinder liner)
Cylinder head
• Cracking • Replace cylinder head.
• Surface distortion • Repair or replace.
Cylinder liners
• Cracking • Replace cylinder liner.
• Corrosion • Replace cylinder liner.
• Insufficient protrusion of cylinder liner • Replace cylinder liner.
Other problems
• Incorrect injection timing • Adjust injection timing.
LUBRICATION
SYSTEM
GENERAL ...................................................................... LU- 2
SPECIFICATIONS .........................................................LU- 3
SERVICE STANDARD .................................................. LU- 4
SERVICE PROCEDURES
Oil Pump and Oil Strainers ..................................... LU- 7
Oil Filter and Oil Cooler .......................................... LU- 9
TROUBLESHOOTING ...................................................LU-11
LU-2 LUBRICATION SYSTEM
GENERAL
Engine lubrication is accomplished by forced lubrication system using gear pump. The engine oil in the oil pan in drawn
up through the oil strainer by the oil pump and force-fed to the filer and oil cooler to lubricate all parts.
Rocker arm shaft
Turbo charger
A
Air compressor Oil cooler
Inj.pump
A
Camshaft Piston
Check valve Main oil hole

B Turbo down prevent valve
Shafty valve Pressure gauge
Crankshaft Journal
A B
Oil pump
Shafty valve A
Regulator valve
A
Safety valve
Full flow oil filter Oil Fan

Suction strainer
Bypass oil filter
A : to oil pan
B : to crankshaft
KKLU-591
SPECIFICATIONS LU-3
SPECIFICATIONS
Items Specification Remarks
Lubricating type Forced circulation with oil pump

Oil pump Gear pump
Relief valve Plunger valve
Oil filter One-piece, element filter
Oil cooler Shell and plate type
Regulator valve Plunger valve
SERVICE STANDARD
Unit : mm (in)

Cleaerance between gear 0.075-0.135 0.17 -
and case
KKLU-194
Gear end play 0.050-0.095 0.15 -
KKLU-195
Gear backlash 0.073-0.207 0.40 -
KKLU-196
Clearance between 0.040-0.083 - -

driven gear and shaft
KKLU-197
SERVICE STANDARD LU-5
Unit : mm (in)

Clearance between drive 0.040-0.085 - -
shaft and oil pump cover
KKLU-198
Oil cooler air tightness - - Replace,

air pressure : if necessary
6kg/cm2 (85.3 lb/sq.in)
KKLU-202
Tightening torque
Unit : kg·m
D6DA
Items Remarks
Size Torque
Oil pump cover bolt M8 x 1.25 1.8~2.7
Oil cooler nut M8 x 1.0 1.0~1.5
Oil filter cartridge M38 x 1.5 4.0~5.0
Oil cooler bypass valve M22 x 1.5 3.0~4.0
Oil jet check valve M12 x 1.5 2.7~3.2
Main relief valve cylinder (Cylinder block side) M28 x 1.5 8.0~12.0
Regulator valve M22 x 1.5 3.0~4.0
Oil cooler plug M20 x 1.5 2~3
SERVICE PROCEDURES LU-7
SERVICE PROCEDURES
Oil Pump and Oil Strainers
COMPONENTS
T = Tightening torque : kgf.cm
1. Oil pump 5. Rotor

2. Oil strainer 6. Collar
3. O-ring 7. Oil pump body assembly
4. Oil pump cover
KKLU-189
Installation
O-ring
Oil strainer installation
Oil strainer
1. Fasten bolts 1,2 and 3 tentatively.
2. Center cylinder block with the bolt hole of the bracket.
3. Fasten the bolt 3 tentatively.
4. Fasten the bolts 1,2 and 3 with the specific torques.
CAUTION KKLU-190
Make sure whether the O-ring is installed securely.

Apply the oil when inserting O-ring.
Assembly
Disassemble and inspect the safety valve of oil pump, if needed.
1. Remove safety valve from the cylinder block.
KKLU-191
2. Disassemble safety valve after removing retainer ring.
KKLU-192
3. Install the valve, spring, seat and retainer ring orderly.

4. Install the safety valve to the cylinder block.
Tightening torque: 800-1200
KKLU-193
SERVICE PROCEDURES LU-9
Oil Filter and Oil Cooler
OVERHAUL
1. Oil cooler 8. Oil filter element 15. Oil cooler element

2. Oil cooler case gasket 9. Center Bolt 16. Gasket
3. Water gallery color 10. Oil cooler safety valve 17. Plug
4. Reamer bolt 11. Oil filter safety valve 18. Oil pipe
5. Coolant pipe 12. Pressure regulator valve 19. Turbocharger oil one-way valve
6. O-ring 13. Spring
7. Oil filter assembly 14. Oil cooler case
KKLU-631
Disassembly
Remove the oil filter element
Using special tool, loosen the nuts of oil filter and oil cooler.
Special tool: Wrench
Assembly
Oil filter element installation.
1. Apply some oil to the new filter gasket.
2. Fasten the new filter by hand until the gasket touches the cover.
Then, using special tool, fasten it again by 1/4 – 1 rotation.
Special tool: Wrench
Install the oil cooler assembly.

1. Fasten the 2 reamer bolts.
2. When the gap between oil pipe and oil filter (A) becomes 0.5
mm or less, fasten another bolts.
KKLU-201
TROUBLESHOOTING LU-11
TROUBLESHOOTING
Symptom Probable cause Remedy Remarks
Does not Low oil level
increase • Oil leakage in the cooling system Repair and add oil
oil pressure • Oil leakage
Poor oil viscosity
• Oil aging Replace
• Fuel added in oil
Faulty oil pressure switch Replace
Clogged oil filter element Replace element
Clogged oil strainer, Loosen oil line connector, Repair or replace
pipe crack faulty of relief valve and by pass valve
Abrasion or damage in oil pump Replace
Excessive oil Oil leakage in engine Repair or replace Refer Engine Body
consumption Oil leakage in crankshaft oil seal Repair or replace
Oil leakage in cooling system Repair or replace
• Defect of water jacket in oil cooler
Abnormal compression Check compression Refer Engine Body
INTAKE AND
EXHAUST
GENERAL .............................................................. IE - 2
SPECIFICATIONS ................................................. IE - 5
SERVICE STANDARD .......................................... IE - 6
SPACIAL TOOLS .................................................. IE - 7
SERVICE PROCEDURES
Air Intake and Exhaust System ...................... IE - 8
Air Cleaner and Duct ....................................... IE-11
Muffler .............................................................. IE-15
Turbo Charger ................................................. IE-17
TROUBLE SHOOTING .......................................... IE-21

IE-2 INTAKE AND EXHAUST
GENERAL
Air Intake System
<5ton>
Duct assembly
Inter cooler
Air cleaner
<8ton>
Duct assembly
Air cleaner
Inter cooler
KKIE-006/KKIE-007
GENERAL IE-3
Aero town
Duct assembly
Inter cooler
Air cleaner
assembly
Turbo charger
KKIE-005
Paper element type

The paper filter is plastic coated and heat treated for better water
and oil resistance.
The incoming air is whirled by the guide vanes or blades at a high
speed and the larger particles of dusts are centrifugally separated
by the "cyclone effect". The smaller particles of dusts are elimi-
To engine Atmosphere
nated by the filter paper element, and the air filtered clean is sucked
by the engine. KKIE-021
The double-element type of paper element air filter is optionally

available. The inner element of this type should not be removed
unless the filter replaced. The air cleaner for buses has a resonant
chamber at its top to reduce noise.
Aero town
Muffler assembly
Pipe assembly
Muffler inlet
Pipe assembly
Muffler outlet
KKIE-000
SPECIFICATIONS IE-5
SPECIFICATIONS
Engine model D6DA Remarks
Air cleaner type Dry air cleaner type
Element type Paper type
Super charger Turbo charger Water cooled
SERVICE STANDARDS
Unit : mm
ITEM STANDARD LIMIT REMEDY REMARK
Flatness of intake Less than 0.1 0.50 Grind or replace :
manifold Grind limit :
0.05mm each flange
Abrasion or damage of - - Grind or replace
exhaust manifold
KKIE-248
Air leakage in inter cooler Doesn't have any air - Replace intercooler
leakage in 2.0kg/mm²
air pressure
Clogged intercooler pin - - Clean
KKIE-771
SPECIAL TOOLS IE-7
SPECIAL TOOL
NAME PARTS ILLUSTRATION USE
Exhaust manifold 09285-8Y000 Using exhaust manifold
compression ring ring compression
clamp
KKST-024
SERVICE PROCEDURE
Air Intake and Exhaust System
a detailed drawing [plan]

7 7
8 8
5
4
7 6
1 2 3
14
13
12
10
2EA 9
4EA
11
15
1. Exhaust manifold gasket 7. Exhaust manifold seal ring 13. Intake elbow 1
2. Spacer 8. Expand ring 14. Intake elbow 2
3. Exhaust manifold front 9. Intake pipe joint 15. Intake elbow pipe
4. Exhaust manifold middle 10. Air heater gasket (wire mash)
5. Exhaust manifold rear 11. Air heater
6. Intake manifold 12. Air heater gasket
SERVICE PROCEDURE IE-9
Installation
Intake Pipe Installation
Install the intake manifold.
Exhaust Manifold Assembly (Assembly Type)
1. As shown in the seal ring installation to the exhaust manifold,
install them by keeping the same distance between seal rings
Liquid gasket
to prevent the leak of gas and oil.
KKIE-802
Special tool: Exhaust manifold compression ring clamp (09285
– 8Y000)
Liquid gasket
KKIE-803
• Assemble expander ring and seal ring to the ring groove.

Exhaust manifold
(The expander ring to inside and the seal ring to outside)
Seal ring
Upward
Expander ring
Downward
KKIE-811
KKIE-812
Exhaust manifold Installation

1. Install the gasket at the right place of exhaust manifold.
“HEAD” mark
CAUTION
Put the gasket as the “HEAD” mark faces the opposite direc-
tion of exhaust manifold.
2. Install the spacer at the right place as shown in the figure.

KKIE-245
Corresponding cylinder number.
Spacers (2)
Manifold
Assembling method Stud
Combination I
Gasket
Nuts (2)
I Except 7 and 9
Exhaust manifold
II 7, 9
Exhaust manifold
Stud
3. Fasten the flange nut by hands. II
Gasket
Nuts (1)
CAUTION Spacers (1) KKIE-813
When fastening flange nut, assemble the spacer carefully not

to touch the machined parts of the flange (A).
4. Fasten the flange nuts orderly and gradually (3 steps) and 16 15 12 11 8 7 9 10 13 14 17 18

fasten the nuts with the specified torque at the final stage.
Tightening torque: 300-350 kgf-cm
5. Fasten lock nuts.

5 3 1 2 4 6
KKIE-814
Air Cleaner and Duct
<5ton>
Braket upper
2
Braket lower
1
7
4
8
5
6
9
Braket air Cleaner mounting

Disassembly
1. Clamp-Boot
2. Duct assembly
3. Rubber-Boot
4. Clamp
5. Duct assembly air Cleaner lower
6. Clamp
7. Duct hose turbo charger
8. Hose-air cleaner duct
9. Air cleaner assembly
*Reassembly is the reverse of disassembly procedure.

KKIE-001
<8.5ton>
2
Bracket upper
1
4
11 Bracket lower
7
6
9
8 5
10
12
Holder assy-air cleaner
Stay-air cleaner
Disassembly
1. Clamp-boot 8. Clamp hose
2. Duct assembly upper 9. Hose-air cleaner to engine
3. Rubber-boot 10. Resonator-rear
4. Resonator front 11. Band air cleaner
5. Clamp hose 12. Air cleaner assembly
6. Duct assembly lower
7. Clamp hose
*Reassembly is the reverse of disassembly procedure. KKIE-011

<Aero Town>
4
3
Disassembly Procedure
1. Hose-duct to free cleaner
2. Free cleaner assembly
3. Duct air outlet
4. Hose-air cleaner to engine
5. Air cleaner assembly
6. Holder-air cleaner
*Assembly is the reverse of disassembly.

KKIE-004
Air Cleaner
6
Deterioration damage
5
Deterioration, 4
Gasket damage 3
2
1. Wing nut
1 2. Cover
3. Sealing
4. Wing nut
5. Element
6. Air cleaner body
KKIE-022
1. When there is dry dust on the element

If there is dry dust on the element, clean the dust by blowing 100
PSI {7 kgf/cm²} or lower compressed air against the element.
Blow the compressed air from inside the element up and down
along the frills of the filter paper and clean the whole element
evenly.
NOTE:
1. Do not strike the element or strike it against other
object to remove dust.
KKIE-023
2. Do not blow compressed air from outside the element.
2. When there is moist dust on the element
If the element is contaminated with moist soot, replace it
regardless of the specified replacement frequency.
3. Inspection of element
After the element has been cleaned, put an electric lamp inside
the element to check for damage and pin holes. If there are thin
portions in the filter paper, replace the element. If the packing
on the top surface of the element is broken, replace the
packing.
4. Cleaning of air cleaner body
Clean the inside of the air cleaner body and discharge the
deposited dust.
KKIE-024
Muffler
<5ton>
2.1~2.6 kgf.m
1
2.1~2.6 kgf.m
5 6
6
5 4 4
2 4~4.5 kgf.m
1
8
4~4.5 kgf.m
7
2.1~2.6 kgf.m
1. Gasket exhaust pipe 6. Pipe assembly - exhaust front "A"

2. Muffler assembly 7. Pipe assembly - exhaust front
3. Strap muffler 8. Pipe assembly - tail
4. Bracket-muffler support
5. Cushion rubber
KKIE-010
<8.5ton>
4.5~6.0 kg.m
Torque 4.5~6.0 kg.m
4
3
2
6
1
5
1. Pipe assembly
2. Bracket pipe
3. Cushion rubber
4. Bracket muffler
5. Muffler assembly
6. Pipe assembly
<Aero town> 5
6
1
3
7
8
1. Gasket
4
2. Exhaust brake
3. Pipe assembly muffler inlet
4. Clamp
5. Muffler assembly
6. Cushion rubber
7. Bracket
8. Pipe assembly muffler outlet
KKIE-003/KKIE-001
Turbo Charger
Intake air outlet
Bearing Turbine housing
Piston ring
Oil inlet
Bearing housing
Intake air inlet

Exhaust gas outlet
Compressor wheal
Shaft and turbine wheel
Oil outlet
Compressor cover
Exhaust gas inlet
Waste gate
KKIE-025
The turbocharger uses the energy of the exhaust gases to feed Exhaust gas
more air under pressure into the engine.
The exhaust gases are accelerated in the turbine housing and Compressed air
directed onto the turbine wheel to turn it. Compressor

Turbine
This spins the compressor wheel, which results in the intake air Cylinder
being forced into the engine cylinders.
Exhaust
The turbocharger can be divided into two basic sections: the Air inlet from air gas
turbine wheel that is driven by the exhaust gases and the compres- cleaner
<Principle of turbo charger> KKIE-026
sor wheel which forces intake air into cylinders.
The shaft connecting the turbine wheel with the compressor wheel
is supported in floating type bearings, which absorb vibrations
during high speed operation that are caused by slight imbalance of
the shaft.
The shaft axial load is borne by the thrust bearing.
The bearing housing has its inside cooled and lubricated by engine
oil to prevent seizure and other troubles of the sliding parts.
Turbo Charger Disassembly
4
3
12
5
19
11
10
8 17
6
7
22
15
9
13
14
16 21
20
18
1. Turbo charger 10. Bracket-joint pipe 19. Pipe-water in

2. Gasket-joint pipe 11. Turbo gasket-charger 20. Pipe-water out
3. Joint pipe 12. Pipe-oil inlet 21. Bracket-pipe
4. Insulator turbo charger 13. pipe-oil out No.1 22. Holder-pipe
5. Clamp hose 14. Hose-oil pipe
6. Air inlet hose 15. Clamp
7. Clamp-hose 16. Pipe-oil out No.2
8. Hose-turbo charger 17. Gasket-upper
9. Pipe-inter cooler in 18. Gasket-lower
KKIE-815
Management Instructions
Attentions in driving
1. Check the engine oil level, and check whether the oil pressure
increases normally after engine start.
2. Avoid from sudden start or acceleration immediately after
engine start and drive the vehicle after enough idling.
3. If abnormal conditions like strange noise, vibration, output
decrease or excessive smoke, pull over the car and check the
car.
4. Stop the engine after enough idling instead of stopping the
engine immediately after pull over. (Sudden engine stop may
damage the turbo charger)
CAUTION
If the car is driven without air-cleaner filter, dust and dirt
may cause a detrimental damage to engine and turbo-
charger. Check and replace the oil periodically since oil
deficiency, oil deterioration and pollution are critical causes
of engine and turbocharger defect. If the car is started or
accelerated suddenly after start, or engine is stopped
immediately after pull over, oil supply to the turbocharger
is discontinued to cause the bearing melting inside the
turbocharger, which rotates with high speed (90,000 – 100,
000 rpm). Therefore, perform enough idling.
Treatment instruction
1. Use the genuine parts when replacing air cleaner and engine
oil filter.
2. Clean and change the air cleaner filter periodically.
3. As for the engine oil, use the standard oil recommended by our
company, which is better or equivalent to API C, D class.
4. Check engine oil leaks or any abnormal noise from turbo-
charger frequently.
5. Check the exhaust pipe periodically to prevent gas leak.
Intercooler
From turbocharger
The intercooler is the air -to-air heat exchange system using a
corrugated-fin heat exchanger installed in front of the radiator.
The intake air compressed by the turbocharger to have high
temperature is cooled through heat exchange with the
atmosphere. The resultant highdensity air is sent into the To inlet manifold
engine cylinders.
This improves the combustion efficiency and as a result, the
fuel economy and power output, while reducing harmful ex-
haust gases to a minimum. KKIE-009
TROUBLE SHOOTING IE-21
TROUBLE SHOOTING
Sympton Probalbe cause Remedy
Low output Insufficient intake air
o Loaded air cleaner element Clean
o Air suction (with dust and other foreign matter) Repair
from intake system
o Defective turbocharger
o Intake shutter kept closed Check
Low exhaust efficiency
o Deformed front pipe, muffler and/or tail pipe Replace
(large exhaust resistance)
o Exhaust brake valve kept closed Adjust
Whitish and much ex- Incorrect injection timing Adjust
haust gas Low compression pressure Check
Low quality fuel Replace
Defective turbocharger
o Oil leaks due to worn piston ring, and/or insert Replace
o Damaged oil seal due to clogged oil return pipe Replace
Dark and much exhaust Loaded air cleaner element Clean
gas Trouble in engine proper Check
Nonuniform fuel injection amount to cylinders Adjust
Incorrect injection timing Adjust
Abnormal noise and/or Poor connection of intake and exhaust systems Correct
vibration from intake Deformed front pipe, mufler or tail pipe(large exhaust resistance) Replace
and exhaust system
Turbo charger makes Rotor rubbing on adjacent parts beacause of worn bearings :
abnormal noises and o Failure of oil supply-clogged or damaged oil screen and oil line. Check oil line, condition
vibration o Unadequate oil filtering or solid matter in oil line. of oil and oil filter
o Contaminated oil
Unbalaced rotor Disassemble and repair.
o Foreign material in air inlet system or exhaust manifold and Also check air inlet
striking wheel system.
o Bent shaft
Sympton Probalbe cause Remedy

Engine output Excessive exhaust gas leaks Check specifically exhaust
decreases. manifold at turbocharger inlet
and cylinder head.
Restricted or deformed muffler Repair or replace.

Air leaks from compressor outlet side Repair or replace.
Restricted air cleaner Clean or replace element.
Dirt accumulation in compressor cover and wheel Clean.
Carbon build-up behind turbine wheel Clean.
Oil leaks in exhaust Clogged or crashed oil drain system Replace.
or air inlet manifolds Excessive piston ring or ring groove wear Repair or replace.
(white exhaust Restricted air cleaner Clean or replace element.
smoke) Damaged piston rings under operation with worn bearings Replace.
COOLING
SYSTEM
GENERAL ......................................................................CL- 2
SPECIFICATION ............................................................ CL- 3
SERVICE STANDARD .................................................. CL- 4
SERVICE PROCEDURES
Cooling Pump ..........................................................CL- 6
Thermostat ............................................................... CL- 9
Radiator.................................................................... CL-10
Cooling Fan .............................................................CL-11
TROUBLESHOOTING ...................................................CL-12
CL-2 COOLING SYSTEM
GENERAL
The engine is cooled by forced circulation of coolant by the water pump.
COOLING SYSTEM DIAGRAM
1. Radiator cap 6. Cylinder head 11. Air compressor (If so fitted)

2. Radiator 7. Thermostat 12. Turbo charger
3. Coolant pump 8. Bypass hose 13. Coolant temperature gauge
4. Cylinder block 9. Thermostat cover 14. Reservoir tank
5. Oil cooler 10. Car heater (If so fitted) 15. Drain flug
KKCL-721
SPECIFICATION CL-3
SPECIFICATION
Item Specification Remark
Engine model D6DA

Cooling method Water cooled
Water pump Centrifugal type
Thermostat Type Wax pillet type
Valve opening temperature 82°C
Fan operating oil Silicon oil
CL-4 COOLING SYSTEM
SERVICE STANDARD
Unit : kgf-cm2
Maintenance items Nominal valve Limit Remedy Inspection procedure

Coolant leak - - Radiator
replacement
Pin clog - - Cleaning
KKCL-236
Opening pressure 0.5 0.4-0.6 - Replacement

of radiator cap
valve
0.9 0.75-1.05
KKCL-237
Deformation and damage - - Replacement

of cooling fan and clutch if necessary
KKCL-239
CAUTION
Check the opening pressure of coolant filter cap valve written on the cap.
If the cap pressure is not correctly controlled, due to the abnormal high pressure of coolant system, hoses may
be disconnected and burnt and engine may be damaged.
SERVICE STANDARD CL-5
Tightening torque
Unit : kg·m
D6DA
Item Remark
Size Torque
Cooling fan nut and bolt M8 x 1.25 2.2
Cooling fan coupling nut and bolt M10 x 1.5 4.4
Water pump pulley and nut M10 x 1.5 4.8
CL-6 COOLING SYSTEM
SERVICE PROCEDURE
Cooling Pump
COMPONENTS
1. Fan coupling
2. Pulley center
3. Shaft assembly
4. Seal
5. Case
6. Gasket
7. Vane
8. Cover
OVERHAUL
KKCL-731
SERVICE PROCEDURE CL-7
Disassembly
Vane and shaft removal
Using the press, push the shaft end.
KKCL-222
Pulley center removal

Using the press, push the shaft end which touches pulley center.
KKCL-223
Seal removal from case

Tap the seal with the brass bar.
CAUTION
After removing seal from case, replace it with the new one.
(Do not reuse)
KKCL-224
Assembly
Shaft assembly installation
Insert shaft assembly into the case.
CAUTION
Let the bearing side coincides with shaft fringe.
KKCL-225
Pulley center installation

Insert the pulley center into the shaft.
A: 18mm
KKCL-226
CL-8 COOLING SYSTEM
Seal Installation
1. Apply some liquid seal around the cooling seal and case
2. Install the seal.
CAUTION
Replace the seal with the new one.
KKCL-227
Vane assembly
Insert the vane into the shaft.
CAUTION
Push the vane until the vane face touches the shaft end.
KKCL-228
Installation “R” mark
Cooling pump assembly installation

Reamer bolt installation position
KKCL-229
Installation of cooling pump suction pipe

Refer “liquid gasket application position” section of Engine mainte- Liquid gasket
nance.
KKEM-582
Thermostat
Assembly chart
1
1. Thermostat cover
2
2. Gasket
3
3. Thermostat
4 4. Thermostat case
KKCL-761
Inspection and Maintenance T1: temperature to start open valve

T2: temperature to keep the valve open
Thermostat function check
10 mm
1. Check the valve opening temperature (T1) and valve lift by
soaking into the hot water. Lift
CAUTION
Check the valve opening temperature (T1) written on the 0°C Temperature
10°C
thermostat seat. T1°C T2°C KKCL-232
Thermostat valve opening temperature
Temperature to start open valve(T1) Service standard

71 69-70 (125-195
L1: When the
82 80-84 145-215 ) temperature is cool
L2: When the
Thermostat valve lift temperature is T2°C
I: valve lift
L1
Temperature to start Measured Valve lift(l) L2
KKCL-233
open valve(T1) temperature(T2)

Gasket
71 85 (185 F) 100 or more
82 95 (203 F) Seat
2. Soak the heated thermostat into the normal temperature water.

Thermostat
It is normal, if it closes completely within 5 minutes. If not, it is
defective to be replaced.
Assembly KKCL-234
1. Remove water and dust from the thermostat case.

2. If the gasket is corroded, damaged or deformed, then replace
it with the new one.
3. Before installing hoses, apply the liquid gasket on the thermo-
stat case.
4. To prevent radiator clogging, do not use too much liquid gasket.
CL-10 COOLING SYSTEM
Radiator
Radiator consists of the upper tank, radiator core, lower tank and
Upper tank
other components. It functions to cool down the heated coolant
through circulating inside the engine. Coolant passes through the Radiator core
radiator core, which consists of many tubes and pins and goes back
to the water pump by way of upper tank and lower tank. The
external air cool coolant as it passes the radiator core. Lower tank
KKCL-236
Disassembly
Remove the radiator.
WARNING
To prevent the risk of burn, do not drain the coolant when the
engine and radiator are hot.
CAUTION
When disassembling or reassembling radiator, take care not
to damage the radiator core.
Cooling Fan
COMPONENTS
2
T=250
T = torque : kgf-cm
1. Fan clutch
2. Cooling fan
T=480 3. Fan coupling
KKCL-781
1. Impact the fan clutch and fan

Take care not to damage the fan and fan clutch while mainte-
nance and inspection. If damaged, it may hurt the cooling
capacity. Besides, since the fan is made of plastic, it may be
damaged or deformed when excessive force is applied.
2. Replace the fan

Fan does not have to be replaced, if it is free from defect. When
replacing the fan, use the same type fan. If the fan is replaced
with the bigger or smaller one in terms of capacity, it may cause
over-cooling or overheating respectively. Then cooling capac-
ity and durability deteriorate in the end.
3. Other factors
Check whether the temperature sensor (bimetal) contains dust
or mud. If it is the case, it may cause inconstant cooling,
overheating or overcooling. Remove the mud or dust from the
bimetal surface using brush or equivalents. Do not apply the
excessive force. Do not paint the fan or fan clutch.
CL-12 COOLING SYSTEM
TROUBLESHOOTING
Symptom Probable cause Remedy Remarks
Over heat Defection V-belt
• Defective tension Adjust
• Belt cut Replace
Clogged cooling pipe Clean
Faulty thermostat Replace
Faulty water pump
• Loosen water pump shaft with flange Replace
• Loosen water pump shaft with impeller
• Defect impeller
• Poor clearance impeller and case
Clogged radiator fin Clean
Faulty auto cooling fan coupling
• Faulty bi-metal Replace
• Faulty auto cooling fan coupling body
• Clogged bi-metal Clean
Faulty cooling fan Replace
Low coolant Add
Over cool Faulty thermostat Replace
Coolant is Faulty radiator hose
very fast • Loosen hose connection Retighten
deminish • Crack or damage cooling hose Replace
Faulty radiator
• Loosen radiator core from body Replace
• Loosen pressure cap
Faulty water pump
• Faulty seal Replace
• Faulty oil seal
• Defective pump gasket
Faulty oil cooler Replace Refer Lubrication
system
Defective thermostat gasket Replace
Faulty heater hose
• Loosen hose connection Retighten
• Crack or damage hose Replace
Faulty cylinder head gasket Replace Refer Engine
AIR
COMPRESSOR
GENERAL ............................................................. AC - 2
SPECIFICATIONS ................................................ AC - 3
SERVICE STANDARD ......................................... AC - 3
SERVICE PROCEDURE....................................... AC - 6
TROUBLE SHOOTING ......................................... AC-11

AC-2 AIR COMPRESSOR
GENERAL
Description
A 13
6 12
3
2 14 4
5 7
8
11 9
15
11
16
10
17
1. Valve seat 7. Piston 13. Air intake pipe

2. Suction valve 8. Cylinder block 15. Bolt
3. Delivery valve 9. Connecting rod 16. Air compressor
4. Piston ring 10. Crank shaft 17. Bearing
5. Piston pin 11. Bearing hold A. To tank
6. Cylinder head 12. Soft washer B. Air suction
KKAC-031
SPECIFICATIONS AC-3
SPECIFICATIONS
ITEM SPECIFICATION REMARKS
Air compressor Type Water cooled

Cylinder bore X stroke 85 X 50
Cylinder capacity 285cc
SERVICE STANDARDS Unit : mm

ITEM STANDARD LIMIT REMEDY REMARKS
Outer diameter of piston 18.0 Replace bushing
or piston pin
Clearance between piston 0.016-0.044 0.08
pin and connecting rod
KKAC-103
Inner diameter connecting rod 37.0 -
Thickness of connecting rod 1.51 -

bearing KKAC-111
Outer diameter of crank pin 34.0 -
KKAC-112
D
Clearance between connect- 0.017-0.083 0.1 Replace
ing rod and crank pin
KKAC-113
AC-4 AIR COMPRESSOR
Unit : mm
Piston outer diameter 84.940-84.960 -
(skirt part)
Inner diameter of cylinder 90.00-90.022

Outer diameter
liner of piston
Clearance between piston 0.0400-0.0820 0.18 Replace

and liner
KKAC-115
Clearance piston pin hole and 0.012T-0.16L 0.08 Replace

piston pin
T=tightening
L=Loosening
KKAC-116
Outer diameter of piston pin
KKAC-121
Thickness of Compression 2.0 1.92 -
piston ring ring

Oil ring 4.0 -
Gap of piston Compression 2.0 2.07 Replace

KKAC-122
ring ring
Oil ring 4.0 -
Clearance be- Compression 0.005-0.040 0.08 -
tween ring and ring
ring groove Oil ring -
KKAC-123
SERVICE STANDARD AC-5
Unit : mm
Piston ring cap Compression 0.15-0.30 1.0
ring
Oil ring 0.2-0.70 1.0
KKAC-124
Outer diameter of crank shaft 40.002-40.013 39.98 Replace

journal
KKAC-125
Inner diameter of Cylinder 89.975-90.010 90.030 Replace

brearing holder block
Bearing
holder
KKAC-126
AC-6 AIR COMPRESSOR
SERVICE PROCEDURE
Disassembly and Assembly
T=300~350
1
Do not disassembly the
cylinder head center bolt.
6
9 7
2 8
T=300
3
T=230~260
4
5 10 11
T=250~300
20 21 22
13
19
18
17
14 15
T=1,100~1.300
1. Cylinder head bolt 9. Piston 17. Ball bearing

2. Cylinder head assembly 10. connecting rod assembly 18. Woodruff key
3. Suction valve 11. connecting rod bearing 19. Crank shaft
4. Cylinder packing (Upper) 12. Cylinder liner 20. Ball bearing
5. Cylinder packing (Lower) 13. O-ring 21. O-ring
6. Piston set 14. Rod nut 22. Bearing hold
7. Retainer ring 15. Drive gear
8. Piston pin 16. Cylinder block
KKAC-061
SERVICE PROCEDURE AC-7
Disassembly
Remove the drive gear.
1. Remove the lock nut from the compressor drive gear.
CAUTION
Drive gear may be damaged, if lock nut is not fully loosened.
KKAC-071
2. Pull the gear form the shaft, and remove the woodruff key.
KKAC-072
Remove the connecting rod and piston.

1. Rotate the crankshaft to the top dead center position.
2. Fully open the nut staking by the chisel, and loosen the nut.
3. Remove the connecting rod and piston.
Remove the piston ring.
Special tool: Piston ring tool (09222-83200) KKAC-073
CAUTION
• Since the piston rings are so brittle, which are made by
special forgery, handle with special care.
• When reusing the piston rings, align the parts orderly to
prevent the mis-assembly first of all.
Remove the connecting rod.

1. Using the retainer ring pliers, remove the retainer ring installed
KKAC-074
at both ends of the spring.
2. Put the metal pad to the pin, and tap it with the special tool and
hammer.
CAUTION
Before disassembling pin, heat the piston for about 5 minutes
with the hot water of 80-90°C (176°F ~ 194°F).
KKAC-075
AC-8 AIR COMPRESSOR
Remove the ball bearing.

Using the special tool, remove the ball bearing from the end of
crankshaft.
Disassembly
KKAC-081
CAUTION
Before assembly, make sure to apply the engine oil to every
frictional part and replace the O-ring and gaskets with the new
ones.
Install the connecting rod and measure end play.

1. Install connecting rod.
CAUTION
Check whether the assembly marks coincide.
2. Apply the enough engine oil to the connecting rod bolts and
Assembly mark
threads, and fasten the bolts.
KKAC-082
3. Measure the endplay of connecting rod. If the clearance

exceeds the service limit, replace the connecting rod.
End play
Assembly standards: 0.2 – 0.4 mm
Service limit: 0.50 mm
KKAC-083
SERVICE PROCEDURE AC-9
4. Fasten nut with the lock washer.
KKAC-091
If the clearance exceeds the limit, replace the crankshaft

bearing or cylinder block.
Assembly standard: 0.30 mm – 0.84 mm
Limit: 1.0 mm
KKAC-092
Assemble piston
CAUTION
Apply the engine oil to the slippery places of the parts, and
Ring face
then assemble them.
1. Assemble the piston ring. When assembling piston ring to
piston, check whether the skirt is at the bottom and use special
tool. Assemble the piston ring as the ring face identification Identification mark
mark faces upward. KKAC-093
Special tool: Piston ring tool (09222- 83200)
Top ring
No. 2 ring, Oil ring
No.3 ring
KKAC-093
Assemble the piston and connecting rod.

When inserting piston pin into piston, install the retainer one ring to
the end of piston and then apply the oil to the piston pin. Fix the
piston and connecting rod and insert the new retainer ring to the
other end.
CAUTION
Heat the piston for about 5 minutes with the hot water of
approximately 80-90°C (176-194°F). KKAC-094
AC-10 AIR COMPRESSOR
Assemble cylinder liner and cylinder head.

No.3 ring
1. Rotate the crankshaft to the top dead center position. Top ring
2. Align the pistons with the same distance between rings.

3. Assemble the cylinder liner and cylinder head. Piston pin
CAUTION
When assembling O-ring to cylinder liner and cylinder head, No.2 ring Oil ring
be careful not to be twisted.
Assemble the cylinder head assembly.

1. Assemble the suction valve of cylinder head assembly.
2. Assemble the cylinder packing.
CAUTION
Packing thickness (upper part, lower part).
Packing must be replaced after used once.
3. Assemble the valve seat pin smoothly to the upper part of

cylinder by aligning the center.
KKAC-101
CAUTION
Do not apply the excessive force in assembling pin to the
holes.
Take care so that dust and dirt are not included.
Do not disassemble the cylinder head assembly (center bolt).
4. Connect the cylinder head bolt.
CAUTION
Abide by the fastening torque (300 – 350kg-cm ).
KKAC-102
Abide by the fastening torque of center bolt (250 – 300 kg-cm).
(Do not disassemble the center bolt nor apply any torque).
TROUBLE SHOOTING AC-11
TROUBLE SHOOTING
Sympton Probably cause Remedy
Malfunction of Unloader valve
unloader valve o Stickly Clean or replace
o Deflection or wear Repair or replace unloader
valve assembly
Air pipe and joints
o Air leakage Replace or tighten pipe joints
Pressure regulator
o Function Adjust and/or repair pressure
regulator.
Noisy operation Piston
o Wear of piston pin boss or piston pin Replace it
o Seized, damaged or worn connecting rod small end Replace it
o Worn piston or liner Replace it
o Damaged or seized piston Replace it
o Inclusion of foreign matter on top surface of the piston Replace piston
o Carbon deposit Clean piston
Valve
o Inlet valve is lowered excessively Repair or replace
o Loosened discharge valve holder Tighten it
Bearing
o Damaged or worn ball bearing and/or connecting Replace bearing
rod metal
Charging efficiency Valve
dropped o Abnormal wear, damage, or poor contact Replace valve assembly
Piston, liner, and piston rings
o Worn piston and liner Replace
o Seized piston Replace piston, piston rings
and liner
o Worn or broken piston ring Replace it
Air pipe and joints
o Leakage of high pressure air Replace or tighten pipe joint
o Clogged air pipe Replace
Air cleaner
o Clogged element Clean or replace element
AC-12 AIR COMPRESSOR
Sympton Probably cause Remedy

Excessive carbon Piston rings Replace piston rings and/or
or oil in the com- o Worn, sticking or broken piston rings cylinder liner
pressor cylinder
head or discharge o Insufficient piston ring tension Replace piston rings and/or
line cylinder liner
o Unsatisfactory piston rings Replace piston rings and/or
cylinder liner
Cylinder liner, piston, and rings
o Wear of liner, piston, or rings Replace
FRONT
SUSPENSION
GENERAL ............................................................................... FS - 2
SPECIFICATIONS ................................................................... FS - 2
SERVICE STANDARDS ......................................................... FS - 2
SPECIAL TOOLS .................................................................... FS - 3
SERVICE PROCEDURE ......................................................... FS - 4
TROUBLESHOOTING ............................................................ FS-10
FS-2 FRONT SUSPENSION
GENERAL
The suspension consists of semi-elliptical piled leaf springs and
Shock absorber
shock absorbers. The suspension supports the weight of the body
and absorbs the vibration and shock from the road surface, thereby
preventing their direct transmission to the body for effective protection
of he body, passengers and cargo. The suspension also supresses
irregular vibrations of the wheels to assure stable operation.
Construction and operation Front axle
Leaf spring 54AR0545
Depending on the road surface condition and load weight, the leaf
springs deflect to provide buffering function. Any change in the span
caused by the load is coped with by movement of the spring shackle
at the rear end.
Shock absorber adequately damps axle vibration.
In addition, stabilizers are provided to reduce the rolling which
occurs when the vehicle markes a turn.
SPECIFICATIONS
Vehicle model
Item HD120
Leaf spring
L x Width x t - No. of leaves 1300 x 70 x 11 - 7
Shock absorber
Model SA301 SA401
Max. O.D. 54 63.5
Cylinder I.D. 30 35
Stroke 210 210
Damping force when extended 1960N (200kgf)
SERVICE STANDARDS
Service Standards Table Unit:mm
Nominal Value
Maintenance item Limit Remedy
(Basic dimeter in [ ])
Leaf spring Spring bracket to shackle pin
0 to 0.05 0.3 Replace shackle pin
suspension clearance (Front side)
Spring bushing to shackle pin
0.075 to 0.15 0.3 Replace bushing
clearance
Spring bracket to shackle pin
0 to 0.05 0.3 Replace shackle pin
clearance (Rear side)
Shackle bushing to shackle pin
0.025 to 0.15 0.3 Replace bushing
clearance (Rear side)
Shackle link to shackle pin Replace shackle link or
0.025 to 0.15 0.3 shackle pin
clearance
Spring bushing to shackle pin
0.075 to0.15 0.3 Replace bushing
clearance (Front side)
SPECIAL TOOLS FS-3
TIGHTENING TORQUE TABLE

Unit: mm
Tightening torque
Location tightened Screw size O.D,x pitch (mm)
kg·m
U-bolt mounting bolt M16 x 1.50 20.8 to 28.2
Shackle pin lock blt M12 x 1.25 3.5 to 5.5
Mounting nut
Shock absorber lower M24 x 1.50 36 to 44
bracket pin nut
SPECIAL TOOLS
Tool
(Number and name) Illustration Use
Puller set Removal of gear and bearing

09431-83100
ASST0030
Drift Removal of oil seal and bearing

09517-83300
ASST0020
SERVICE PROCEDURE
REMOVAL
Removal of front suspension
NOTE
o Remove the brake hose from a side first.
Install to brake side first and use care not to
twist the brake hose.
o Plug removed brake hose to prevent entry of
dust and dirt.
o After installation, bleed brake system.
Brake hose section Tire section

Oil pipe 59±3 kg·m
1.3~1.7 kg·m
shackle link
section
19~26 kg·m Knuckle arm section
Brake hose 10.4~17.3 kg·m
2.1~3.2 kg·m
Shackle pin
section
U-bolt section
20.8~28.2 kg·m
(3.5~5.5) kg·m
Shock absorber section
54AR0612
SERVICE PROCEDURE FS-5
Removal Procedure
(1) Removal of shackle pin lock bolt
Remove the nut from the spring bracket and, using the Bar
remove the lock bolt.
Shackle pin
Bar lock bolt
54AR0060
(2) Removal of shackle pin

Remove the grease nipple from the shackle pin and, using the
special tool, puller set, remove the shackle pin. Be sure to
remove the nut first for the back side.
Puller set
09431-83100
54AR0142
Disassembly, Inspection and Correction

Disassembly of front suspension
BD ... Basic Diameter

NV ... Nominal Value
L ... Limit
Spring bracket bushing to

shackle pin clearance
Spring bracket to
shackle pin clearance NV L
BD in [ ]
NV L
BD in [ ] 7 [28]0.02~0.14 0.3
[28]0~0.04 0.3
2
Shackle link to shackle pin

4 clearance
Break, wear NV L
6 BD in [ ]
1
Deformation [28]0.02~0.24 0.3
7
2
3
2
7
Shackle pin to spring
bushing clearance
3
NV L
BD in [ ]
[28]0~0.12 0.3
Rubber bushing wear,

deformation, crack
Shackle pin to spring
bushing clearance
NV L
BD in [ ]
If functional deterioration
or fluid leak is evident,
[28]0~0.12 0.3
replace as assembly
Disassembly sequence
1. Lock bolt 5. Clip
2. Shackle pin
6. Front leaf spring
3. Side washer
7. Bushing
4. Shackle link
For parts with an encircled number, refer to Disassembly and Reassembly

Procedure that follows.
NOTE
To reassemble, reverse the order of disassembly.
54AR0074
(1) Alignment marking
Center bolt
Make an alignment mark on the leaf spring.
Alignment mark
54AR0405
(2) Disassembly of leaf spring

Compress the leaves with a press and remove the center bolt
and clip bolts.
54AR0406
(3) Removal of clips

Using a drill press, countersink the rivet where it is staked and
remove the clip.
54AR0407
(4) Removal of bushings Leaf spring or

Using the special tool, Drift, remove bushing from the wound-up shackle link
ends of the leaf spring and shackle link.
Metal bushing
Drift
09517-83300
54A0333A
Reassembly Procedure
(1) Installation of bushings
Drift
Using the special tool, Drift press-fit the bushing into the wound- 09517-83300
up ends of the leaf spring and into the shackle link. Leaf spring or
shackle link
Metal bushing
54A0333B
(2) Application of grease

Clean leaf surfaces and apply chassis grease between leaves.
54AR0408
(3) Installation of clips

Using a riveting machine, fit clips into position. Riveting machine
Leaf spring
54AR0409
(4) Reassembly of leaf springs

(a) Line up the alignment marks on all leaves and assemble
the leaves together by temporarily tightening the center Center bolt
bolt.
Alignment mark
54AR0405
(b) With the leaves compressed with a press, tighten center

Stake bolt heat at
bolt and clip bolts. three places with a
punch after
torquing
54AR0550
Installation
Shock absorber
Installed dimensions:34.5 B
A
D C
B
A
C Leaf spring Shim
20.8~28.2 kgf.m
Pin
(wet)
Spring bracket Washer
Side washer bushing
Spring Spring bushing
Shackle
bushing
link
Shackle pin Shackle pin
Section A-A Section C-C Section B-B 54AR0532
Installation Procedure
(1) Combination of right and left leaf springs
Height code
When the leaf spring assembly is replaced, select an assembly
so that the combination of the height codes on right and left
springs conforms to any one of the combinations shown below.
NOTE
Install the spring according to the classification symbols
54AR0410
of the camber as follows.
(The camber classification symbols are marked on the
upper side of the spring as +,O or - ).
Combination of leaves
Item
1 2 3 4 5 6 7
Leaf spring
assembly, LH + + O O - O -
Leaf spring
assembly, RH
+ O + O O - -
(2) Locating the shackle pin

Using the Bar, align the lock bolt holes in spring bracket and
shackle link with shackle pin lock bolt groove.
(3) After installation, feed chassis grease into each grease nipple.
Bar
54AR0472
TROUBLESHOOTING
NOTE
Inspection the front and rear suspensions at the same time.
Symptom Probable cause Remedy

Spongy feel Defective shock absorber Replace
Cyclic bounce Tire unevenly worn Replace
Wheels and tires out of balance Correct balance
Bumps directly Tire inflation pressure too high Adjust
received Cracked or broken leaf spring Replace
Vehicle tends to Broken leaf spring Replace
develop noise Worn spring metal bushing Replace
when not loaded Worn shock absorber rubber bushing Replace
Shock absorber left loose Retighten
Vehicle tends to Damaged spring bracket Replace
develop noise U-bolt left loose Retighten
when loaded
REAR
SUSPENSION
GENERAL ............................................................................... RS - 2
SPECIFICATIONS ................................................................... RS - 2
SERVICE STANDARDS ......................................................... RS - 2
SPECIAL TOOLS .................................................................... RS - 3
SERVICE PROCEDURE ......................................................... RS - 4
TROUBLESHOOTING ............................................................ RS-10
RS-2 REAR SUSPENSION
GENERAL Rear axle
The leaf springs mounted between the frame and rear axle, not only
support the weight of vehicle body, but also absorb any vibration and
shock from the road surface, thereby preventing their direct Leaf spring
transmission to the body for effective protection of the body,

passengers, and cargo. They also help suppress irregular vibrations
of the wheels to ensure road stability.
55AR0001
SPECIFICATIONS
Vehicle model
HD120
Item
Leaf spring Main 1300 x 70 x 11 - 10
L x Width x t - No. of leaves Helper 1020 x 70 x 11 - 6
SERVICE STANDARDS
SERVICE STANDARDS TABLE
Unit:mm
Nominal Value
(Basic dimeter in [ ])
Spring bracket bushing to
[32] 0 to 0.05 0.3 Replace spring bracket or shackle pin
Spring bushing to
[32] 0.025 to 0.15 0.5 Replace bushing or shackle pin
shakcle pin clearance
Shackle link to
[32] 0 to 0.05 0.3 Replace shackle link or shackle pin
Shackle link bushing to
[32] 0.025 to 0.15 0.5 Replace bushing or shackle pin
Screw size O.D, Tightening torque

Location tightened
x pitch (mm) kg·m
U-bolt M20 x 2 45 to 47
Shock absorber i bolt tighten nut M22 x 1.5 26 to 35
Shackle pin lock bolt M10 x 1.25 3.5 to 5.5
Rubber bumper tighten nut M12 x 1.25 3.4 to 5.0
SPECIAL TOOLS RS-3
SPECIAL TOOLS
Tool

09431-83100
ASST0030

09517-83300
ASST0020
SERVICE PROCEDURE
REMOVAl
Removal of front suspension
Brake hose section
Oil pipe
19~25 Nm
(1.9~2.6kgf·m)
U-bolt section
350~475N.m
(35.9~48.5 kgf·m) (wet) Brake hose
21~31 Nm
(2.1~3.2kgf·m)
Propeller shaft section

67~100Nm
34~54Nm
(6.8~10.2 kgf·m)
(3.5~5.5 kgf·m)
NOTE
o Remove the brake hose from frame side first and reinstall it
from the rear axle housing first, use care not to twist the
brake hose.
o Plug removed brake hose to prevent entry of dust and dirt.
o After installation, bleed brake system.
55AR0140
SERVICE PROCEDURE RS-5
Removal Procedure
Shackle pin
(1) Removal of shackle pin lock bolt lock bolt
Remove the nut from the spring bracket, one at front and two in
the rear, and remove the lock bolt using the Bar. Bar
Nut
54AR0481
(2) Removal of shackle pin

Remove the grease nipple from the shackle pin and, using the
special tool, puller set, remove the shackle pin. Puller set
09431-83100
55AR0055
Disassembly, Inspection and Correction

NV ... Norminal Value
L ... Limit Shackle link bushing to
Spring bracket to
shackle pin clearance NV L
BD in [ ]
NV L
BD in [ ] [28]0.02~0.14 0.3
[28]0~0.04 0.3
1
Spring bracket to
shackle pin clearance 8
NV L 7
2
BD in [ ]
[28]0~0.04 0.3
4
8
6
5
Shackle link to shackle pin
3 clearance
2 NV L
Shackle pin to spring BD in [ ]
bushing clearance 8
[28]0~0.04 0.3
NV L
BD in [ ] Spring bushing to
[28]0~0.12 0.3 shackle pin clearance
NV L
BD in [ ]
[28]0~0.12 0.3
1. Lock bolt 5. Clip
2. Shackle pin 6. Rear main leaf spring
3. Side washer 7. Rear helper leaf spring
4. Shackle link 8. Spring bushing
For parts with an encircled number, refer to

Disassembly and Reassembly Procedure that follows.
NOTE
To reassemble, reverse the order of disassembly. 55AR0133
(1) Alignment marking
Make an alignment mark on the leaf spring.
Alignment mark
55AR0553
(2) Disassembly of leaf spring

Compress the leaves with a press and remove the center bolt
and clip bolts.
55AR0554
(3) Removal of clips

Using a drill press, countersink the rivet where it is staked and
removed the clip.
54AR0347
(4) Removal of bushings Leaf spring or

Using the special tool, Drift, remove bushing from the wound-up shackle link
ends of the leaf spring and shackle link.
Metal bushing
Drift
09517-83300
54A0333A
(1) Installation of bushings
Drift
Using the special tool, Drift press-fit the bushing into the wound- 09517-83300
Leaf spring or
up ends of the leaf spring and into the shackle link. shackle link
Metal bushing
54A0333B
(2) Application of grease

Clean leaf surfaces and apply chassis grease between leaves.
55AR0304
(3) Installation of clips Riveting machine

Using a riveting machine, fit clips into position.
Leaf spring
55AR0168
(4) Reassembly of leaf springs

(a) Line up the alignment marks on all leaves and assemble the Center bolt
leaves together by temporarily tightening the center bolt.
Alignment mark
55AR0555
(b) With the leaves compressed with a press, tighten center

bolt and clip bolts.
Stake bolt heat at
three places with a
punch after
torquing
55AR0556
Installation
A B
A 34~53Nm
34~53Nm Leaf spring Bolt B (3.5~5.5) kg·m
(3.5~5.5)kg·m
Side washer 350~475Nm
Sprin buhing (35.9~48.5kgf·m)
Shackle link bushing
Side washer
Pack grease
Shackle pin
Side washer
Pack grease Shackle link
Section A-A Spring bushing Shackle pin
Section B-B
55AR0002
Installation Procedure
(1) Combination of right and left leaf springs Height code
When the leaf spring assembly is replaced, select an assembly
so that the height codes on the right leaf spring is identical to that
on the left spring.
(2) Locating the shackle pin
Using the Bar, align the lock bolt hole in spring bracket and
shackle link with the lock bolt groove in shackle pin. 55AR0557
(3) After installation, feed chassis grease into each grease nipple.
NOTE
Install the spring according to the classification symbols
of the camber as follows.
(The camber classification symbols are marked on the
Bar
upper side of the spring as +,O or - ).
Combination of leaves 54AR0481

Item
1 2 3 4 5 6 7
Leaf spring
assembly, LH + + O O - O -
Leaf spring
assembly, RH
+ O + O O - -
TROUBLESHOOTING
NOTE
Inspection the front and rear suspensions at the same time.

Cyclic bounce Tire unevenly worn Replace
Wheels and tires out of balance Correct balance
Bumps directly Tire inflation pressure too high Adjust
received Cracked or broken leaf spring Replace
Vehicle tends to Broken leaf spring Replace
develop noise Worn spring metal bushing Replace
when not loaded
Vehicle tends to Damaged spring bracket Replace
develop noise U-bolt left loose Retighten
when loaded
STEERING
GENERAL ............................................................................... ST - 2
SPECIFICATIONS ................................................................... ST - 5
SERVICE STANDARDS ........................................................ ST - 6
SPECIAL TOOLS .................................................................... ST - 9
SERVICE PROCEDURE ......................................................... ST-10
TROUBLESHOOTING ............................................................ ST-29
ST-2 STEERING
GENERAL
The steering system allows the driver to freely change the traveling
direction of the vehicle. The steering force of the steering wheel is
transmitted through the steering shaft, power steering booster,
pitman arm and drag link to the knuckle arm to steer the vehicle.
The system has an integral type power steering booster installed in
the gear box to reduce the steering effort.
The power steering system hydraulic pressure circuits are as
shown below.
Oil tank → Oil pump → Power steering booster
Piping
Integral power steering booster
The integral power steering booster to reduce the steering effort
consists of the power cylinder section (output section) serving also
as the steering gear and the control valve section (control section).
Columm shaft
Oil reservoir tank
Oil pump
Steering gear arm
Power steering
booster
Drag link
Tie rod
Knuckle arm
56AR0177
GENERAL ST-3
(1) When traveling straight ahead

Operation of integral power steering booster
(when traveling straight ahead)
When there is no steering torque from the steering wheel, no
relative displacement occurs between the stub shaft and
worm shaft, so that the rotor remains in the neutral position
of the worm shaft. Therefore, the hydraulic fluid delivered
from the oil pump directly passes through the worm shaft
groove to return to the oil tank. In other words, no operating
pressure difference is produced between the cylinder
chambers A and B and as a result, the piston remains in the
neutral position and does not move.
To cylinder
Rotor chamber B
chamber A
To oil tank
From oil pump
Cylinder
chamber A To cylinder
Stub shaft Chamber A To oil tank
To cylinder
Piston From oil Rotor

chamber B
pump
To cylinder From toil pump
Worm shaft To cylinder
chamber A
Torsion bar chamber B
Worm shaft
To cylinder
Cylinder To oil tank

chamber B
56AR0149 56AR0150
ST-4 STEERING
(2) Right turn

Operation of integral power steering booster
(when right turn is made)
When the steering wheel is turned clockwise, the load from
the tires acts on the worm shaft to twist the torsion bar. As a
result, the rotor turns clockwise with respect to the worm
shaft, decreasing the axial direction groove clearance. This
limits flow of the hydraulic oil to the oil tank and now the
hydraulic oil from the oil pump enters the cylinder chamber A
to cause the piston to move to the cylinder chamber B.
The hydraulic oil in the cylinder chamber moves, the torsion
bar that has been twisted returns to the neutral position. The
force that has caused twisting of the torsion bar during
steering is transmitted to the steering wheel as a steering
reaction force which gives the driver a sense of steering
response.
A left turn is also made on the same operating principles as
the right turn but in opposite direction.
From cylinder
Rotor chamber B
From oil pump

Cylinder To cylinder To cylinder
Stub shaft chamber A chamber A chamber A
From oil pump To oil tank

Piston
Rotor From cylinder
To cylinder chamber B chamber A
To oil tank From toil pump

Worm shaft To cylinder
Torsion bar chamber A
Worm shaft
Cylinder
chamber B
56AR0152
SPECIFICATIONS ST-5
(3) Manual steering Worm shaft

Even if the hydralic pressure ceases to act on the power
Tube
steering booster due to a stalled engine, defective oil pump,
oil leaks or other causes, the mechanical power is directly
transmitted from the stub shaft to the worm shaft by the Ball nut
stopper mechanism provided between the stub shaft and
Sector shaft
worm, allowing manual steering.
Steering gear assembly (recirculating ball type) 56AR1149
In this steering gear assembly, many balls are interposed
between the worm shaft screw and the ball nut to transmit
the turning effort of the worm shaft through the ball nut to the
sector shaft.
The ball nut is fitted with a pair of tubes. Each end of the tube
is tongue-shaped and is connected to the end of ball pas-
sage to recirculate the balls.
Sliding friction is replaced by rolling friction by interposing the
balls between the worm shaft and the ball nut, allowing the
driver to operate the steering gear with a light steering effort.
SPECIFICATIONS
Vehicle model
HD120
Item
Steering wheel
Type 2-spoke type
Steering shaft Universal joint type(Telescopic-Tilt type)
Power steering booster
Type Intergral type
Cylinder inner diameter ∅90
Piston operating area 63.6cm²
Regulsated pressure 105kg/cm²
Oil capacity 1
Power steering oil pump
Type Vane type
Delivery rate 15cc/rev.
Fluid flow rate 12 /min.
Relief set pressure 105 kg/cm²
Allowable rpm range 500~6000 rpm
Power steering oil tank
Type Oil pump separating type
Capacity 1.4
ST-6 STEERING
SERVICE STANDARDS
Unit:mm
Nominal Value
(Basic diameterine)
Steering Steering wheel play 20-40 Adjust
wheel and Steering Play in axial direction 0.2 or less Correct or replace
shaft upper shaft (vertical) assembly
Play of joint in turning direction 1.5' or less Replace assembly
(play of needle bearing and spider)
Play of yoke spline tube and 30' or less Replace asembly
steering lower shaft (spline shaft)
in turning direction
Steering Sleeve lever shaft and 0.015 to 0.111 0.4 [38] Replace
linkage bushing to clearance (Brg type)
Conecting link pin and bushing 0.045 to 0.175 [42] 0.4 Replace
to clearance
Steering gear Sector Pitman arm side 38 37.9 Replace
sector shaft O.D. Side cover side
Ball nut rack spline and sector shaft 0.2 to 0.5
to clearance
Worn shaft After sector 4 to 8 Lower cover
starting shaft installation Bending adjusting
torque kg·cm Before sector 4 to 7 Adjust of
shaft installation Adjustment screw
Intergral Play of ball nut assembly in axial 0.04 Replace
power steering direction
booster Body to ball nut clearance 0.11 [90] 0.16 Replace
Rotor to worm shaft clearance 0.01 to 0.03 [35.5] 0.03 more Replace
than
Sector Pitman arm side 57.975 57.875 Replace
shaft O.D. Side cover side 47.975 47.875 Replace
Backlash between ball nut rack 0.1 to 0.35 Adjust
and sector shaft gear
Power Ridge wear on pressure plate and 0.01 No sticking wear
steering side plate surfaces in friction with rotor and streaks
and vane Replace
SPECIFICATIONS ST-7
Unit:mm
Nominal Value
(Basic diameterine)
Power Flow control valve to rear body 0.03 No sticking wear
steering clearance and streaks
Replace as flow control
valve assembly or rear
body assembly
Pump relief set pressure Mpa (kg/cm²) 105 Replace as flow control
at 1,800 rpm valve assembly or rear
body assembly
ST-8 STEERING
Tightening Torque Table
Screw size O.D.

Location tightened Tightening torque (kg.m)
x pitch (mm)
Steering Steering wheel nut M20 x 1.5 5.5
shaft Worm shaft and yoke mounting bolt M10 x 1.25 5 to 5.5
Lock plate bolt M5 x 0.8 0.4 to 6.0
Grease nipple M6 x 0.75 0.3 to 0.5
Link and Steering shaft M12 x 1.25 3.7
bracket Lock lever bolt M18 x 1.25 1
Steering lever M12 x 1.25 2
Linkage Ball stud castle nut M20 x 1.5 20.7 to 34.5
Intergral Pitman arm nut M36 x 1.5 40 to 45
power steering Ball tube screw M6 x 1.0 0.45 to 0.55
booster Taper plug PT 1/8 0.9 to 1.3
Retainer M32 x 1.5 Tighten fully, turn back by 180°,
tighten again to 39 (4), then turn
back by 20° and stake.
Adjusting screw lock nut M14 x 1.5 12 to 13
Side cover bolt M12 x 1.25 5.5 to 6.5
Adjustingplug M80 x 1.5 23 to 25
Valve housing bolt M16 x 1.5 12 to 13
Lock ring M80 x 1.5 Tighten lock ring with 12kg·m, and
secure 2 points not to be removed.
Plug M48 x 1.5 30 to 40
Power Cartridge assembly screw - 0.6 to 0.9
steering Rear body bolt 5 to 6
oil pump Flow control valve plug 5 to 6
Hose connector bolt 1.8 to 2.5
Oil pump gear tighten nut 9
Power Plate screw M6 x 1.0 0.4 to 0.5
steering
oil tank
SPECIAL TOOLS ST-9
SPECIAL TOOLS
Tool

09431-83100
ASST0030

09517-83300
ASST0020
ST-10 STEERING
SERVICE PROCEDURE
REMOVED AND INSTALLATION
5.5kg·m
5~6kg·m
4~6kg·m
5~6kg·m
10.4~17.3kg·m
8kg·m
22.1~33.1kg·m
56AR1281
SERVICE PROCEDURE ST-11
STEERING SHAFt
Removal
(1) Remove the negative terminal of the battery.
(2) Remove the column cover.
(3) Remove the cable band and remove all starter switch
connectors. Connector
(4) Remove the multifunction switch connector. Multifunction

switch
(5) Insert the key and turn to the ON position.
Connector
Remove the engine stop cable from the starter switch.
Column cover
Stater switch
Cable band
56AR0013
(6) Remove the steering wheel using the special tool, puller set.
(7) Remove the multifunction switch.
Puller set
56AR0131
(8) Fix the steering using lock lever and put matching marks to
the spline shaft and spline tube.
(9) Remove the dust cover from the column end and remove the
support attaching bolts. Lock lever
(10) Remove the link and bracket to steering shaft bolts.
Upper and lower
shaft assembly
Link and bracket
to steering
shaft bolt
Support
Dust cover
Spline Spline shaft

tube
Matching marks
56AR1282
ST-12 STEERING
(11) Remove the steering upper shaft assembly and spline shaft
Screw Extractor
assembly together with the starter switch.
(12) Hold the column end in a vise and drill a 5.5 to 6.0 mm
Threading end of
diameter, 10 to 15 mm deep hole in the end of the twist-off twist-off head
head bolt from which the head has been removed.
(13) Turn the special tool, Screw Extractor, counterclockwise to
thread it into the hole until the bolt is removed.
(14) Remove the starter switch from the steering column. 56AR0015
Installation
(1) Install a new twist off head bolt and tighten it to 13 to 15 Nm
(1.3 to 1.5 kgfm) to twist off the bolt head.
(2) After installation, make sure that the steering lock functions Twist-off Starter switch
head bolt
properly.
(3) If no abnormality is found, reverse the removal procedure to
make installation.
56AR1156
(4) Install the steering wheel as shown in the illustration. Horn pad Contact plate assembly
Steering wheel
Lower cover
Cancel pin 56AR0154
Disassembly, inspection and correction
1 Steering shaft play

in axial direction
NV 0.2 or less
Joint play in turning

direction
2
NV 15' or less
5
6
Spline play in axial
Joint play in turning 7 direction
direction NV 30' or less
NV 15' or less
8
1. Steering upper shaft assembly
2. Spline shaft assembly
3. Lock plate
4. Bearing
5. Dust cover
6. Dust seal
7. Rubber cover
8. Spline tube assembly
56AR1283
ST-14 STEERING
Reassembly
Apply multi-purpose type

grease [NLGI No.2 (Li soap)]
or chassis grease [NLGI No.1 4.9~6.4 kg·m
(Ba-Al soap)]
Section A-A
8 3 4~7 kg·m
7 5 A
2
6
0.3~0.5 kg.m A 1 5.5 kg·m
4
0.4~0.65 kg·m
Face yokes in same

direction
Assembly sequence
8→7→6→5→2
1→4→3 ↑
56AR1284
Link and Bracket Section
Section Z-Z SectionX-X
Lever and roller set

Lever and clutch set
Color
2 kg·m
0.1~0.5 Clearance
Shim attaching point
(When two or more shims are
1 kg·m
required, install the same
amount of shims on both sides.) Lock lever
A
(66.7)
0.4 kg·m Section Y-Y
Lever
(3.7 kgfm)
(25°)
Stopper
position
Color
Operation angle
Adjust poistion 46°~36°
Bracket
56AR0338
ST-16 STEERING
DRAG LINK
Apply grease
(Molybdenum disulfide grease)
Dust cover
Pack with grease
(Molybdenum disulfide
Clip graease)
56AR0003
Ball stud
Apply grease on lip
Dust cover grease)
Fill with grease
Clip grease)
NOTE
Do not remove parts other than dust cover and clip.
56AR1229
TIE ROD
Apply grease
(Molybdenum disulfide grease)
Fill with grease
(Molybdenum disulfide Dust cover
grease) 8 kg·m
Clip
56AR0004
Ball stud Apply grease on lip

grease)
Dust cover
Fill with grease

Clip grease)
NOTE
Do not remove parts other than dust cover and clip.
56AR1229
ADJUSTMENT AFTER INSTALLATION Play 20 to 40

Steering wheel play
Place the vehicle in straight ahead position and start the engine.
Lightly turn the steering wheel clockwise and counter-clockwise
and check that the outside circumference play does not exceed the
nominal value range.
NOTE
If the steering wheel play is out of the range, adjust installation 56AR0195
of parts and backlash.
Adjustment of steering angle

Set the front wheels on the turning radius gauges and adjust the
steering angle to the specified value by knuckle stopper bolt.
Front axle
Tie rod arm
Knuckle stopper bolt
56AR0204
ST-18 STEERING
Integral power steering booster

Ball nut assembly

axial play
L 0.04 12
Body (cylinder) to balll 11

nut (piston) clearance 24 14
BD 0.11 16
NV 0.11 15 Turning condition
L 0.16 13 17
25 Sector gear 19
26 backlash 18
NV 0.10~0.35
22
31 L 0.6 or less 21
5 23
30
Turning condition 28
29
20
BD ... Basic Diameter 1
NV ... Nominal Value Deterioration
27
L ... Limit damage
Rotor (outside) to
3
4 worm shaft clearance
Sector shaft O.D. 6 2 NV 0.01 to 0.03
7 9 L More than 0.03
Item Nominal diameter Limit Turning condition
8
Packing section 47.975 47.875 10
Bearing section 47.975 47.875
1. Taper plug 13. Piston (Ball nut) 25. Seal ring
2. Pitman arm 14. Adjusting plug 26. Plug
3. Lock nut 15. Ball bearing 27. Oil seal
4. Side cover 16. Y-paking 28. Y-packing
5. Sector shaft 17. Side rail 29. Backup ring
6. Retainer 18. Steel ball 30. Needle bearing
7. Adjusting screw 19. Bearing cage 31. Body
8. Y-packing 20. Worm shaft
9. Backup ring 21. Rotor For parts with an encircled number,
10. Needle bearing 22. Seal ring refer to Disassembly Procedure that
11. Dust covcer 23. Stub shaft assembly follows.
12. Valve housing 24. Seal ring

56AR0185
NOTE
1. Align the stamped mark on the sector shaft end with the
body center mark to place the sector shaft in the neutral
position.
2. Loosen the lock nut of the adjusting screw beforehand.
3. Do not disassembly the ball nut assembly, adjusting screw,
needle nut bearing, etc. except when necessary.
(1) Removal of pitman arm

Remove the pitman arm from the steering gear using the
special tool, puller set.
Puller set
09431-83100 56AR0186
(2) Removal of side cover and sector shaft

Drive out the sector shaft and side cover as a unit from the
body, lightly striking with a plastic hammer.
Plastic hammer
56AR0187
(3) Separation of sector shaft from side cover

Screw in the adjusting screw to remove the side cover from
the sector shaft.
Screw in adjusting screw.

(Do not remvoe adjusting
screw unless necessary)
56AR0049
(4) Removal of ring nut

Remove the lock ring, using the wrench.
Wrench
56AR0188
(5) Removal of adjusting plug

Remove the adjusting plug, using the Wrench.
Wrench
After
loosening,
back off 180°
56AR0188
ST-20 STEERING
(6) Removal of ball nut assembly

Remove the ball nut assembly as a unit from the body. When
removing, make sure that the assembly is slowly removed to
prevent the piston from turning to cause damage to the inside
surface of the body.
NOTE
1. Thoroughly clean the disassembled metallic parts
56AR0189
in a cleaning oil. Handle carefully the piston section
to prevent damage.
2. To remove the adjusting screw, loosen the staken
retainer and remove the screw.
Reassembly and Adjustment
0.9~1.3 kg.m 10~11kg·m

1 13
24 21 14 25 22 23 15 23~25kg·m
12
17
11
Pack with grease

26
27 Apply liquid gasket
25~28kg·m 20 19 1816
32
0.45~0.55kg·m
Pack with grease 4
31 5~5.5kg·m
12~13kg·m
Apply liquid gasket

25~30kg·m
2
5
7 10 9 8 6
28 29 30 Retainer-fully tighten,
back off 180°, retorque to
39 Nm (4 kgfm), back off
Pack with grease 20° and then stake.
Assembly sequence
25 23 16←17 28←31←30←29←1
↓ ↓ ↓
21→20→19→18→13→23→22→15→12→11 ↓
→32→3→2
14→27→26
5→7→6
4→8→9→10
For parts with encircled number, refer to Reassembly Procedcure that follows.
NOTE
1. Replace the packings, O-rings, seal rings, etc. wih new ones.
2. As a sealant, use the THREEBOND No.1102,
and as a grease, use the Limax No.2 or equivalents.
56AR0190
ST-22 STEERING
(1) Tightening of retainer

Fully tighten and then back off 180°.
Bar
Retorque to 39 Nm (4kgfm).
Back off 20° and make sure that the adjusting screw turns
smoothly.
56AR0163
(2) Staking of retainer end portion (2 places)

To press-fit the Y-packing to the adjusting plug, use the Bar.
Bar
56AR0164
(3) Installation of Y-packing and backup ring

Insert the Y-packing and backup ring and then insert the special
Drift
tool, Drift, to correct the bend of the backup ring. 09517-83300
NOTE
When the body section is installed, use the special tool,
Drift for correction.
56AR0165
(4) Assembly of thrust bearing

Insert the side race, bearing cage and steel balls.
56AR0166
(5) Installation of O-ring and seal ring. Install ball nut assembly
(6) Installation of ball nut assembly carefully not to cause
damage to body inside
surface
56AR0198
(7) Tightening of adjusting plug
Wrench
23~25 kg·m
56AR0188
(8) Tightening of ring nut.
Wrench
56AR0188
(9) Installation of sector shaft.

Put the rack (ball nut) and gear (sector shaft) in mesh in the
neutral position.
56AR0191
(10) Tightening of lock nut

NOTE
Apply sealant to
Apply grease to the Y-packing and backup ring at installa- threaded portion.
tion. (12~13 kg·m)
56AR0192
(11) Adjustment of sector gear backlash

Dial gauge
Place the gears in the neutral meshing position and measure
Backlash
the backlash at the pitman arm end (L=250 mm). If NV 0.10~0.35
necessary, adjust by the adjusting screw.
NOTE
1. After adjustment, move the pitman arm again to make
sure that the piston (ball nut) moves smoothly over the NV ... Nominal Value
entire operating angle range (pitman arm). 56AR0193
2. The starting torque of the sector gear is less than 145

Ncm (15 kg·m) when the pump delivery rate is 12 lit./
min, (Adjust by the adjusting plug.)
ST-24 STEERING
POWER STEERING OIL PUMP

Disasembly, inspection and correctin
L ...Limit
Flow control valve to

front body clearance 2
L 0.03
3
4
Rotor and vane sliding Set
portion ridged wear
L 0.01
8
7
9
6
5
1. Hose connector
Deterioration
2. Plug
damage 11 10
3. Flow control valve assembly
4. Flow control spring 13 Turning condition
5. Bolt 12
14
6. Rear body 15
Turning condition
7. Cartridge assembly
8. Pressure plate
9. Straight pin
10. Retaining ring (snap ring)
11. Drive shaft For parts with an encircled number, refer to
12. Retaining rind (snap ring) Disassembly Procedure that follows.
13. Ball bearing
14. Retaining ring (snap ring) NOTE
15. Oil seal 1. Do not disassemble the flow control vlve but
16. Front reuse unless defective.
2. Do not remve the oil seal except for replacement.
If remved, repalce with a new one.
56AR1204
Disassembly procedure
Removal of cartridge assembly Remove with the
(1) Before disassembly, put matching marks on the periphery. staight pin is its
place.
(2) Remove the cartridge assembly, pressure plate and straight pin
and put matching marks on the periphery of the cartridge assembly.
NOTE
The rotor, vane and cam ring have been precision ma-
chined as a unit. Take care not to damage them. If replace- 56AR5629
ment is necessary, replace as a cartridge assembly.
Reassembly
(1) On occasion of periodic maintenance, replace the oil seals.
O-rings and other rubber parts, using a repair kit.
(2) Install parts, aligning the alignment marks put at disassembly
and noting the rotor direction and vane turning direction.
Check to see that the rotor and vane slide smoothly without
excessive play
2 5~6 kg·m
4
5~6 kg·m
1~1.4 kg.m
3 1
16
9 15 14
6 3~4 kg·m
11
5~6 kg.m 12 10
5 13
7 8
Assembly sequence
16→15→14→10→9→8→7→6→5→2→1
11→13→12 ↑ 3→4 ↑
56AR1206
Pressing of oil seal

Front body
Drift
09517-83300
Oil seal 56AR5630
Installation of cartridge
Cartridge
assembly
Side plate
Front body
56AR1207
ST-26 STEERING
NOTE Pressure change by shims

1. When installing the parts. Check correct matching of pin Approx. 605 kPa (6.2 kg/cm²)
holes.
per 0.5 mm thick shim
Approx. 245 kPa (2.5 kg/cm²)
per 0.2 mm thick shim
Adjustment Standard value of valve assembly relief

Adjustment of Relief Set Pressure of Flow Control Valve Assembly. pressure
When the valve assembly was disassembled, be sure to adjust the 9.3~11.3 Mpa (95~115 kg/cm²)
relief pressure by the following procedures after reassembly. (pump speed 1,800 rpm)
Adjust by adding or removing shims. Addition of shims will lower the
pressure.
POWER STEERING OIL TANK

8
Disassembly
1
5
1. Cap
2. Oil strainer
6
3. Reservoir cover
4. Reservoir gakset
7 5. Spring
6. Filter element
7. Reservoir body
8. Bolt
56AR0174
Reassembly
1 8
3
4
2
5
Assembly sequence
8→7→6→5→4→3→2→1 Return port Delivery port
56AR0139
Adjustment after Installation

Bleeding
(1) Fill the oil tank with hydraulic fluid to the brim of the filler cap.
(2) With the front wheels reised on jacks and the engine running
at idle, turn the steering wheel clockwise and counterclock-
wise and add the fluid if the level is low.
(3) After the tank fluid level established, increase the engine
speed and repeatedly turn the steering wheel until no more
air bubbles come out in the tank.
(4) After bleeding, check each section for leaks and check that
the oil tank is filled up to the level mark.
Peformance Verification tests

Relief set pressure
To make sure that the power steering booster and oil pump are 10.3 Mpa (105 kg·m)
working well, perform tests on the floolwing.
(1) If the fluid pressure when the steering wheel is released with
the engine running at idle is (5 kg.cm²) or more, check the
power steering booster, oil pump and oil circuit for cloging.
(2) If the relief pressure readings are beyond the values given
56AR0194
below, the relief valve is in faulity operation. If the reading is
below the assembly standard value, the relief valve or spring
is defective.
ST-28 STEERING
Test item Test procedure Assembly standard

Checking smooth Raise front wheels and turns steering wheel fully clockwise Steering wheel to
operation and counterclockwise several times. operate smoothly
on entire stroke.
Measuring 1) Mount combination of an oil pressure gauge capable of 5 kg/cm² or less
hydraulic measuring more than (135 kg/cm²) and a stop valve between
pressure the pump delivery port and booster inlet and bleed the system.
2) With the engine running at idle, turn the steering wheel clockwise
and counterclockwise to raise the fluid temperature to 50~60°C.
3) With the engine running at idle, fully open the stop valve.
4) Release the steering wheel and measure the fluid pressure.
Measuring 1) Slowly increase the engine speed to 1000 to 1200 rpm, close the Relief set pressure
relief stop valve and measure the maximum fluid pressure. 105 kg/cm²
pressure 2) Do not keep the stop valve fully closed for more than 15 seconds.
TROUBLESHOOTING ST-29
TROUBLESHOOTING
Symptom Probable cause Remdy
Hard steering Steering ger mechanism defective
o Angular contact bearing damaged Replace
o Worm and ball nut worn Replace
o Insufficient oil quanity Add oil
o Improper oil viscosity Replace oil
o Incorrect rear cover hsim adjustment Adjust rear cover shim
o Incorrect rack starting torque adjustment Adjust worm and
ball nut starting torque
Powser steering booster gear mechanism defective
o Thrust bearing damaged Replace screw and
housing assembly
o Ball of ball scre worn Replace screw and
housing assembly
o Low fluid level in oil tank Add fluid
o Air not compeletely bled Bleed air
o Improper fluid viscosity Replace fluid
o Trouble in power steering booster system Repair or repalce
o Incorrect pipe connections Correct
o Defective oil pump Repair or replace
o Flow control valve in faulty operation Correct
o Oil pump malfunctioning Correct or replace
Steering linkage defective
o Universal joint abnormally worn, damaged or Replace steering shaft
poorly lubricated assembly or apply grease
o Deformed link Replace link
Front axle defective
o King pin poorly lubricated Apply grese
o Poor front wheel alignments (toe-in, camber, caster) Correct wheel alignments
o Front wheel tires underinflated Adjust
o Thrust bearings damaged Replace
Other troubles
o Cargo one-sided toward the front of the bed Distribute cargo evenly
throughout the bed
Unstable steering Steering gear mechanism defective
bacause of excessive o Worn rack and gear unit of worm and ball nut Replace
free play of steering o Sector shaft worn Replace sector shaft
wheel o Worm and ball nut worn Replace
o Loosen steering gear mounting bolts Tighten to the
specified torue
ST-30 STEERING

Unstable steering Power steering booster gear mechanism defective Replace screw and
bacause of excessive o Worn rack and rear in ball screw unit housing sector shaft
free play of steering o Worn bearing in sector shaft Replace bearing
wheel o Worn ball in ball screw Replace screw and
housing assembly
o Loose power steering booster mounting bolts Tighten to the
specified torque
o Air trapped and air not completely bled Add fluid, retighten all
parts, and bleed air
Steering linkage defective
o Looseness in universal joint Pack with grease if the
problem still persists,
replace steering shaft
assembly
o Looseness in drag link ball stud Replace knuckle arm, pitman
arm or drag link
o Looseness in tie rod end ball stud Replace tie rod end
Front axle defective
o Worn wheel hub bearing Replace
o Worn king pin or bushing Replace king pin or
bushing
Other troubles
o Uneven brake application Readjust or replace lining
o Cargo one-sided toward the front of the bed Distribute cargo evenly
throughout the bed
Vehicle pulls to Front axle steering system defective
one side o Improper wheel alignment Correct
o Deformed front axle Replace
o Worn or damaged wheel hub bearing Replace
o Worn or damaged king pin Replace king pin
or bushing
o Steering wheel is off-center Correct
o Steering gear defective Repair or replace
o Power steering booster defective Correct or replace
Other troubles
o Cargo one-sided Distribute cargo evenly
o Sagging or broken leaf spring Replace
o Uneven brake application Correct
o Right and left tires unevenly inflated Adjust

Vehicle pulls to o Right and left tires greatly different in the degree of wear Replace tires
one side o Right and left tires different in outer diameter Replace with equal
diameter tires
o Right and left wheel bases greatly different Correct wheel base
o Bent rear axle housing Replace axle housing
Steering wheel jerks Front axle assembly defective
o Excessive clearance between king pin and bushing Replace king pin or
bushing
o Worn or deteriorated wheel hub bearing Replace
o Improper wheel alignment (particularly camber and caster) Correct wheel alingment
o Looseness in knuckle arm or tie rod ball stud Replace knuckle arm or
tie rod end
o Excessively uneven tire pressure Adjsut tire pressure
o Knuckle arm, tie rod arm, backing plate and knuckle, etc. Tighten to specified
improperly tightened torque
o U-bolt, nut, etc. of front spring loose Tighten to specified
torue
o Lateral and radial runouts of front tires, and incorrect static Correct wheel balance
and dynamic balance
Steering gear steering system defective
o Improper play in worm and ball nut and sector shaft Adjust
o Angular contact bearing worn Replace
o Loosen drag link ball stud Replace knuckle arm,
pitman arm or drag link
o Sector shaft worn Replace sector shaft
o Worm and ball nut worn Replace
Power steering booster steering system defective
o Improper play in ball screw unit and sector shaft Adjust
o Worn thrust bearing Replace
o Defective power steering booster Correct or replace
o Looseness in ball stud of drag link Replace knuckle arm,
pitman arm or drag link
o Worn sector shaft and bearing Replace sector shaft
and bearing
o Worn ball and groove in ball screw Replace screw and
housing assembly
ST-32 STEERING

Steering wheel jerks Other troubles
o Excessive runout of propeller shaft Correct or replace
o Reduction pinion and gear damaged and in poor Replace pinion and gear or
tooth contact corect tooth contact
o Excessive tire runout Correct or replace
Power steering booster system defective
Hard steering in both Low pressure due to fluid leaks Retighten leaky parts
clockwise and counter- or replace seal ring,
clockwise directions O-ring, etc.
Valve malfunctioning Check and correct valve
or repalce screw and
housing assembly
Piston damaged or foreign substance trapped Check for foreign substance in
hydralic fluid, and check
and correct inside surface
of body and sliding surface
of piston, or replace screw
and housing assembly
Hard steering particularly Rack mesh torque out of adjustment Adjust stub shaft
in middle rotating torque
Great difference in steer- Clogged hydraulic circuit Check and correct hydraulic
ing effort between clock- circuit or repalce screw
wise and counter- and housing assembly
clockwise rotations
Hard steering particularly Air trapped due to low fluid level Bleed air and then add fluid
during idling
Hard steering particularly Valve malfunctioning Check and correct valve
at beginning or replace screw and
hosuing assembly
Hard steering due to Defective oil pump Correct or replace oil
problems not in power pump
steering booster Clogged hydraulic piping Correct or replace
piping
Insufficient grease in steering linkage joints Pack joints with grease
Insufficient front tire inflation pressure Adjust to the specified
air pressure
Incorrect front wheel alignments Measure wheel alignments if
incorrect, adjust to the
specified values

Hard steering due to King pin thrust bearing damaged Correct or replace
problems not in power King pin short of grease Apply grease to king pin
steering booster Cargo one-sided toward front Distribute cargo evenly
Steering wheel Power steering booster defective
oscillations o Valve and roll edge damaged or control seal ring or Replace screw and
O-ring damaged housing assembly
o Improper fluid in power steering system Replace with the specified
hydraulic fluid
Problems not in power steering booster
o Uneven tire pressure Adjust to specified
pressure
o Incorrect front wheel alignment Measure wheel alignment
If incorrect, adjust to
specified values
o Front wheels out of balance Replace with wheel
balancer or replace
tires or wheels
o Worn drag link or tie rod end ball joint Replace drag link
assembly or tie rod end
o Worn king pin and king pin bushing Disassembly and replace
If defective
Poor returnability Incorrect steering gear rack starting torque adjustment Adjust main shaft
of steering wheel starting torque
Power steering booster defective
o Rack torque out of adjustment Adjust stub shaft torque
o Clogged hydraulic circuit Check and correct circuit
or replace screw and
housing assembly
o Clogged hydraulic piping Correct or replace
piping
Front wheel alignment off Measure wheel alignment
If incorrect, adjust to
specified values
Vehicle wanders due to Steering gear defective
excessive free play of o Sector shaft gear worn Adjust steering wheel free
steering wheel play with adjusting screw
or replace cross shaft
o Damaged or worn worm and ball nut serrating Replace worm and ball nut
ST-34 STEERING

Vehicle wanders due to Problems in power steering booster
excessive free play of o Worm sector shaft gear Adjust with adjusting
steering wheel screw or replace
sector shaft
o Damaged or worn stub shaft serrations Replace screw and
housing assembly
Other problems
o Worn front wheel bearings Replace
o Mounted or joined parts loose Retighten to specified
torque or replace
detective parts
Insufficient steering Incorrect pitman arm mounting angle Mount at correct
angle or clockwise and position
counterclockwise steering Knuckle stopper bolt out of adjustment Using tuning radius gauge,
angles differ adjust clockwise and counter-
clockwise steering angles with
knuckle stopper bolts
Fluid leaks Fluid leaks from steering gear Retighten leaky parts to
specified torque, or replace oil
seal and apply liquid packing
Fluid leaks from power steering booster Retighten leaky parts to
specified toque or replace
O-ring, seals, etc.
Fluid leaks from oil pump
o Defective oil pump housing Disassemble, check and
replace if defective
o Defective gasket, oil seal Disassemble, check and
replace if defective
o Loose bolts Retighten to specified
torque
Fluid leaks from oil tank
o Fluid leaks from oil tank due to overfilling Adjust to specified level
o Fluid leaks from oil tank due to trapped air Bleed air and adjust
to specified level
o Improperly welded pipes Braze or replace
Loose hydraulic piping and connections Retighten to specified
torque or replace

Abnormal hydraulic Maximum generated hydraulic pressure insufficient due to Disassemble, check, correct,
pressure in oil pump defective oil pump or replace defective parts
Excessively high generated pressure at engine idling due to Correct o replace
crushed or clogged hydraulic line hose or pipe
Strange sound, vibration or noise from oil pump
* The oil pump poduces some howling sound which is not an indication of any functional problem
(particularly when turning the steering wheel while the vehicle in standstill)
Grinding noise Air in oil pump Check fluid level and hose
clip, bleed air, or replace
oil pump
Seizure of parts in oil pump Replace oil pump
Squeaking noise Seizure of parts in oil pump Replace oil pump
Low whirring noise Loose pump bracket and mounting bolts and nuts Retighten to specified
torque
Defective pump Replace oil pump
BRAKE
SYSTEM
GENERAL ............................................................................. BRa - 2
SPECIFICATIONS ................................................................. BRa - 5
SERVICE STANDARDS ........................................................ BRa - 6
SERVICE PROCEDURE ....................................................... BRa - 9
TROUBLESHOOTING .......................................................... BRa-56
BRa-2 BRAKE SYSTEM
GENERAL
SERVICE BRAKE
Fluid Air cleaner

reservoir
tank Brake
master
cylinder Brake booster (hydromaster)
Brake Vacuum pump

pedal
Safety cylinder Vacuum tank
To atmosphere
Brake shoe
Brake
Air line drum
Brake drum Wheel cylinder
Fluid line
Return spring
Wheel cylinder
Return spring Brake shoe
Front wheel brake Rear wheel brake
VB58001
The service brakes are vacuum servo hydraulic brake consisting of

devices such as brake master cylinder, brake booster (hydromaster)
and wheel cylinders and are used to decelerate or stop the traveling
vehicle.
When the pedal is depressed, the depression force is converted into
a hydraulic pressure, which is then amplified by the brake booster
(hydromaster) and acts on the wheel cylinders. The wheel cylinders
press the brake shoes against the brake drums to produce a
frictional force
Vacuum Pump
1) The vacuum pump which is installed on the back of the alternator
Rotor
has its rotor coupled with the alternator shaft so that it rotates
with the alternator. Within its cylindrical housing, as the rotor
rotates, its three movable vanes are made to move toward the
housing inside surface by centrifugal force, thereby producing
pumping action. The resultant vacuum pressure keeps the
Housing
VB58003
inside of the vacuum tank at vacuum.
GENERAL BRa-3
2) The rotor and housing cylinder are eccentrically arranged and

air from the vacuum tank is taken through the inlet port into the
Suction Housing
pump and gradually compressed before it is discharged from
the outlet port. Engine oil enters the pump through the oil port Vane
and keeps the housing oil tight and lubricates and cools the Rotor
housing inside. The oil is then discharged from the outlet port
with compressed air and returns to the oil pan.
Compression
Discharge
VB58005
3) A check valve is provided at the inlet port to prevent air and

Check valve
engine oil from flowing back from the vacuum pump to the
vacuum tank when the engine is stopped.
VB58007
BRAKE BOOSTER (Hydromaster) Disphragm Vacuum valve

Relay valve piston Atmosphere valve
1) When brake booster is not operated
Since no fluid pressure acts on the relay valve piston, the Relay valve section
vacuum valve is in opened position and the atmosphere valve
in closed position.
Since the diaphragm air hole is clear, both chambers A and B B Ball check valve
A Hydraulic piston
of the power cylinder are evacuated and the power piston Power piston
Push rod
Return spring VB58009
pressed toward the chamber B by the return spring.
With the hydraulic piston also pulled an the ball check valve
opened, the brake fluid passes through the center hole of the
hydraulic piston and flows into the hydraulic cylinder.
When the brake booster is not in operation, therefore, the
hydraulic piston serves only as a fluid path.
BRa-4 BRAKE SYSTEM
2) When brake booster is operated

Atmospheric air pressure
When the pedal is depressed, the fluid pressure from the master from air cleaner
cylinder acts on the relay valve piston and hydraulic piston. Relay valve section
The diaphragm, pushed by the fluid pressure acting on the back
To wheel
surface of the relay valve piston, closes the vacuum valve. As cylinde
(wheel brake)
soon as the vacuum valve is closed, the atmosphere valve is
From master cylinder
opened, so the atmospheric air from the air cleaner enters the
To vacuum tank
power cylinder. VB58011
At the time, a pressure difference is produced between the

chambers A and B. The force produced by the pressure
difference overcomes the return spring and the power piston
moves the push rod to push the hydraulic piston.
When the hydraulic piston operates, the ball check valve is
closed and the brake fluid passage between the master cylinder
and the hydraulic cylinder is closed, preventing backflow of the
high pressure fluid generated in the hydraulic cylinder to the
master cylinder and instead transmitting the hydraulic pressure
to the wheel cylinder. The hydraulic pressure developing in the
hydraulic cylinder is the sum of the thrust transmitted from the
power piston to the hydraulic piston and the pressure acting
directly on the hydraulic piston from the brake master cylinder.
SPECIFICATIONS BRa-5
SPECIFICATIONS Unit:mm
Vehicle model
HD120
Item
Brake type Hydro-vacuum servo hydraulic brake acting on all wheels, internal
expansion type
Front 2-leading type
Rear Dual 2-leading type
Vacuum pump
Type Vane type
Delivery rate 120 cc
Brake booster (hydromaster)
Power cylinder
I.D. x stroke 241.3 x 163
Hydraulic cylinder
I.D. x stroke 19.05 x 159
Relay valve piston
O.D. 25.4
Safety cylinder
I.D. x stroke 30 x 32
Vacuum tank
Capacity 30lit.
Wheel brake
Brake drum I.D. (limit) 320 (322)
Brake lining width x thickness (limit)
Front 120 x 11.6 (5.0)
Rear 150 x 11.6 (5.0)
Brake shoe clearance 0.2 ~ 0.3
Wheel cylinder I.D.
Front 36.51°
Rear 38.1
BRa-6 BRAKE SYSTEM
SERVICE STANDARDS
Service brakes
Nominal
Maintenance item Limit Remedy and remarks
(Basic diameter in [ ])
Brake Free travel of brake pedal 3.5 to 9.2 Adjust by push
pedal rod of brake
master cylinder
Pedal shaft to bushing clearance [20] 0.06 to 0.24 0.4 Replace bushing
Return spring Load/installed length 45 N (4.6 kgf)/124.2 38 N (3.9 kgf)/124.2 Replace
Brake Cylinder to piston clearance [38.1] 0.05 to 0.14 0.2 Replace piston
master
cylinder Return spring Free lenngth 125 100 Replace
Brake Valve seat Load N (kgf)/ 54 to 64 49 (5.0)/30.2 Replace
booster spring installed length (5.5 to 6.5)/30.2
(hydro-
master) Piston return 160 to 195 140 (14.5)/181
spring (16.2 to 19.8)/181
Valve fitting to relay valve piston [25.4] 0.04 to 0.11 0.13 Replace piston
clearance
Hydraulic piston to cylinder clearance [19.5]0.05 to 0.13 0.15 Replace piston
Valve body guide wear depth - 0.5 Replace
Bend of push rod 0.13 or less 0.3 Replace
Fluid Apply 11.8 MPa 1.47MPa (15kgf/cm²) Check and replace
tightness (120 kgf/cm²) or less related parts
fluid pressure to
hydraulic cylinder
and measure amount
fluid pressure
falls in 15 seconds
Air tightness Set vacuum pressure 3.3kPa (25mmHg)
when not in brake booster to or less
operating 67 kPa (500 mmHg),
close cock, and
measure amount
vacuum pressure
falls in 15 seconds
Operation Set vacuum pressure 125 to 225 kPa 105 to 245 kPa
starting in brake booster to (1.3 to 2.3 kgf/cm²) (1.1 to 2.5 kgf/cm²)
pressure 67 kPa (500mmHg).
Slowly apply
presure from
master cylinder and
read pressure
indicated by master
cylinder pressure
gauge when pointer
of vacuum gauge
deflects
SERVICE STANDARDS BRa-7
Nominal
Brake Operation Set vacuum pressure 1.57 kPa (16 kgf/cm²)/ 1.57 kPa (16 kgf/cm²)/
booster at full load in brake booster to 10.1 to 11.1 kPa 9.81 to 11.4 kPa
(hydro- 67 kPa (500mmHg). (103 to 113kgf/cm²) (100 to 116 kgf/cm²)
master) Slowly depress pedal
of master cylinder
and read pressure
indicated by
hydraulic cylinder
pressure gauge for
master cylinder
pressure gauge
Air tightness Block vacuum supply 3.3 kpa (25mmHg)
at full load at full load and or less
read amount vacuum
pressure falls in
15 seconds thereafter
Residual Set master cylinder 78 to 125 kPa 59 to 155 kPa Check and replace
pressure pressure to 490 kPa (0.8 to 1.3 kgf/cm²) (0.6 to 1.6 kgf/cm²) related parts
(5 kgf/cm²), loosen
air bleeder screw at
end of hydraulic
cylinder to release
master cylinder
pressure, and read
pressure indicated by
wheel cylinder
pressure gauge
Safety Return spring Load/installed length 18 to 2 N 15 N (1.5 kgf)/48 Replace

cylinder (1.81 to 2.21 kgf)/48
Cylinder to piston clearance [30] 0.06 to 0.12 0.17 Replace piston

Brake Inside Vehicle with 320 drum 320 322 Replace
drum diameter Mark * shows
*321
standard inside
diamter when
oversize lining
is used
Cylindricity 0.05 0.2 Correct

Brake Front Load/installed length 325 N (33 kgf)/192 If gaps between Free length Re-
shoe coils or between 180.5 place
380 N (39 kgf)/228.4
return coil and cover Free length
spring are evident 215.2
Rear Load/installed length 390 N (40 kgf)/217 If gaps between Replace
coils or between
380 N (39 kgf)/228.4
coil and cover
420 N (43 kgf)/266.5 are evident
Brake Brake lining thickness 12.0 5 Replace linings
shoe Side shoulder
means werar limit
BRa-8 BRAKE SYSTEM
Nominal
Wheel Piston to body Front [34.93] 0.03 to 0.09 0.2 Replace
cylinder clearance
Rear [36.51] 0.03 to 0.09
Piston to body Load/installed 15 N (1.5 kgf)/14.2 12 N (1.2 kgf)/14.2 Free length Re-
clearance length
47.5 place
Brake shoe clearance 0.2 1.0 Adjust

Service brakes
Screw size Tightening torque

Location tightened O.D. x pitch(mm) Nm (kgfm)
Brake pedal Brake pedal shaft bolt and nut M12 x 1.25 48 (4.9)
Brake pedal to master cylinder attaching bolt M12 x 1.25 72 (7.3)
and nut 60 (6.1)
Brake master cylinder bolt M12 x 1.25 48 (4.9)
Brake master cylinder push rod adjusting nut M12 x 1.25 25 to 34 (2.5 to 3.5
Brake master cylinder nipple M12 x 1.5 44 to 64 (4.5 to 6.5)
Brake booster Valve fitting M36 x 1.5 3.9 to 9.8 (0.4 to 1)
(hydromaster)
Hook bolt and nut M10 x 1.25 1 to 2 (0.1 to 0.2)
Valve body screw M4 x 10.7 145 to 245 (15 to 25)
Cylinder cap M33 x 1.5 59 to 98 (6 to 10)
Cylinder lock nut M33 x 1.5 39 to 54 (4 to 5.5)
Power piston nut M14 x 1.5 15 to 39 (1.5 to 4)
Elbow assembly PT 1/2 15 to 39 (1.5 to 4)
Hose connector PT 1/2 0.3 to 0.8 (0.03 to 0.08)
Poppet valve assembly nut M3.5 x 0.6 6.9 to 8.8 (0.7 to 0.9)
Air bleeder screw M10 x 1.25 235 to 265 (24 to 27)
Safety cylinder Cylinder cap - 78 to 98 (8 to 10)
Check bolt and nut M20 x 1.5 35 to 53 (3.6 to 5.4)
Wheel brake Wheel Front M10 x 1.5 63 to 94 (6.4 to 9.6)
cylinder bolt M12 x 1.75 63 to 94 (6.4 to 9.6)
Rear M12 x 1.75 63 to 94 (6.4 to 9.6)
Pipe assembly tightening M10 x 1.0 12 to 16 (1.2 to 1.6)
Pipe connec- Front M8 x 1.25 7.8 to 12 (0.8 to 1.2)
tor bolt
Pipe clamp bolt Vehicle with 320 drum M6 x 1.0 3.9 to 5.9 (0.4 to 0.6)
Bleeder screw M10 x 1.0 7.8 to 12 (0.8 to 1.2)
SERVICE PROCEDURE BRa-9
Screw size
O.D. x pitch Tightening torque
Location tightened
(mm) Nm (kgfm)
Wheel brake Wheel cylinder Stop perspring screw M6 x 1.0 5.9 to 9.8 (0.6 to 1)
Brake pipe tightening 4.76 M10 x 1.0 12 to 16 (1.2 to 1.6)

6.35 M12 x 1.0 19 to 25 (1.9 to 2.6)
SERVICE PROCEDURE
BRAKE SYSTEM DIAGRAM
AIR LINE
8 OIL LINE
12
1 2 6 5
10
16 7
3 4
17
14
13
11
11
11
15
1. Air compressor 7. Drain valve 13. Magnetic valve

2. Air drier 8. Air gauge 14. Exhaust brake valve
3. Fuzzy tank 9. Dual brake valve 15. Oil reservoir
4. Protection valve 10. Parking brake valve 16. Low air pressure switch
5. Air reservoir 11. Air master 17. Remote chamber
6. Safety valve 12. Quick release valve
5TBR-005
BRa-10 BRAKE SYSTEM
VACUUM PUMP
Disassembly, inspection and reassembly
Alternator
1. Vacuum housing
2. Rotor
3. Vane
4. Plate
Reverse the disassembly procedure to assemble.
Wear, NOTE
3 When reassembling, check the parts for metal
damage 1
4 2 dust and other foreign matter.
Spindle wear
VB58015
Testing 10 lit. vacuum tank
a) Set up as illustrated and turning the alternator pulley, measure Engine oil
performance of the vacuum pump. If the measured value is less

than the nominal value, disassemble and check for vane damage,
housing, rotor and plate contact surface damage. Replace if any Vacuum
Alternator
defect is found. pump
Ultimate vacuum
VB58017
Vacuum 91 kPa (680 mmHg) or more
Nominal value
Speed 3000 rpm
Evacuation characteristic after 20 seconds (with 10 lit. tank

load)
At Vacuum 73 kPa (550 mmHg) or more
low
speed Speed 1500 rpm
Nominal value
At Vacuum 80 kPa (600 mmHg) or more
low
speed Speed 3000 rpm
BRAKE FLUID TANK

Fro brake For clutch
Inspection of reed switch function
1) Draining of brake fluid
a) Remove the radiator grille from the front of the cab and
remove the brake fluid pipes for brake and clutch.
NOTE
Brake fluid will mar the paint. Wipe out quickly if spilled. VB58019
b) With one end of the removed pipes placed in a container,

depress the brake pedal repeatedly until the fluid level in the
brake fluid tank falls to "L" level line.
VB58021
2) Inspection
Brake fluid tank
Check that the warning lamp in the meter cluster lights up when
the brake fluid level falls to the "L" level. If not, replace the brake
fluid tank assembly.
NOTE
Check with the engine running.
L level
VB58023
BRAKE PEDAL
Removal
Stop lamp switch
1) Depress the brake pedal and clutch pedal repeatedly to drain Brake pedal
bracket, LH
brake fluid from the brake fluid tank.
2) Remove the meter hood, meter cluster, instrument corner,
panel an instrument control panel side cover.
Brake hose
Brake pipe
Brake pedal
VB58025
BRa-12 BRAKE SYSTEM

L ... Limit
10
11
Clearance between pedal

shaft and bushing
BD 20
8
NV 0.06 to 0.24
L 0.4 7 9
5
4
1
Deterioration of spring
Load/installed length
NV 45N (4.6 kgf)/124.2 3
L 38N (3.9 kgf)/124.2
1. Return spring
2. Bolt
3. Brake master cylinder
4. Brake pedal
5. Brake pedal
6. Pedal pad
7. Bushing
8. Pedal shaft
9. Brake pedal bracket, RH
10. Stop lamp switch
11. Meter cluster bracket
VB58027
Reassembly and adjustment
72 Nm
Apply grease.
(7.3 kgfm)
11 2
48 Nm
(4.9 kgfm)
8 7 4
10
Section A-A
1
48 Nm
(4.9 kgfm)
A *232mm
5 60 Nm
(6.1 kgfm)
Z
3 6 9
m m
200
oke
Str
*273mm
Assembly sequence
11→10→9→8→4→3→2→1
5→6→7 ↑
VB58029
1) Rotate the stop lamp switch to adjust the brake pedal pad center
position (point Z) to the dimension marked *, and then secure it
with the lock nut.
590 N (60 kgf)
At this point, check to ensure that the stop lamp switch is in the
OFF state.
2) Check to ensure that when the brake pedal is depressed all the
way, the full stroke is 200mm. 65 mm or more
3) Rotate the brake master cylinder push rod to adjust the free Floor board
VB58031
travel of the brake pedal pad center position (point Z) to 3 to

9mm, and tighten the lock nut to the specified torque.
4) After adjustments, remove the air from inside the brake system
and clutch system (refer to Group 41 clutch). After bleeding,
depress the brake pedal several times to check for air leaks from
the brake pipe and brake hose connections.
5) Clearance between brake pedal and floor board
Start the engine and depress the brake pedal by 590N (60kgf)
to check that the clearance between the brake pedal and floor
board is 65mm or more.
BRa-14 BRAKE SYSTEM
BRAKE MASTER CYLINDER

Disassembly and Inspection

NV ... Nominal Value Deterioration of spring
L ... Limit Free length
NV 125
L 100 5
6
Wear, damage,
deformation 4
3
Damage 2
1
Disassembly sequence 7
1. Push rod complete
2. Boot
3. C-ring Clearance between piston and cylinde
4. Piston complete BD 38.1
5. Nipple NV 0.05 to 0.14
6. Gasket L 0.2
7. Cylinder
VB58033
Reassembly
Repair kit: 25 to 34 Nm
Brake master cylinder kit. (2.5 to 3.5 kgfm)
6 5
7
3
1
4 2
Apply grease
(rubber grease)
Assembly sequence NOTE

Apply an ample amount of assemblng oil (NA-166M or equivalent) to cylinder
7→ 6→ 5→ 4→ 3→ 2→ 1
bore and the entire periphery of secondary cup of piston complete.
VB58035
Removal and installation

NOTE
When the oil pipe is removed, use care to make sure that brake
fluid is not split on the frame or bracket.

NOTE
VB58037
1. Before disassembly, remove dirt and dust from the surface
and use care not to allow foreign matter, dust, dirt or water
to enter.
2. Put alignment marks before disassembly.
3. Never immerse rubber parts in cleaning solvent.
1) For inspection and correction, disassemble the brake booster
into the relay valve piston section, the hydraulic cylinder section,
the power cylinder section and the end plate section.
2) Wipe or wash to clean to disassembled parts as described
below.
a) Rubber parts or parts containing rubber parts
Wipe with cloth wetted by brake fluid or alcohol.
b) Metallic parts
Clean with cleaning fluid (trichlene or metal cleanser), dry
with compressed air and completely remove cleaning fluid.
BRa-16 BRAKE SYSTEM
Clearance between valve fitting Rust on piston outside surface

and relay vlave piston and valve fitting inside surface
BD 25.4
NV 0.04 to 0.11
L 0.13 18 19
7 17 1516
Load/installed length 6
NV 54 to 64 8 13
(5.5 to 6.5 kgf)/30.2 14
L 49 N (5.0 kgf)/30.2 12
4 911
2 3
1
5
10 44
Corrosion of guide 45
Rust, damage section inside surface
Clearance between hydraulic Guide section 40
piston and cylinder wear depth 39 41
BD 19.05 L 0.5 37 38
3136
NV 0.05 to 0.13 42 32
L 0.15 28 29
20 34 55
43 54 53
22 53
2423
27 26 25 48
21 49
50
51
Bend of push rod
NV 0.13 or less 47
L 0.3
52 33
47 46
30
Repair kit:
hydromaster kit
35 Load/installed length
For parts with an encircled NV 160 to 195N
number, refer to Disassembly (16.2 to 19.8 kgf)/181
Procedure that follows. L 140 N (14.5 kgf)/181
1. Retaining ring 15. Valve fitting 29. Gasket 43. Hose connector
2. Pipe and cover assembly 16. O-ring 30. Straight pin 44. Plug
3. Gasket 17. Retaining ring 31. Hydraulic piston assembly 45. O-ring
4. Spring 18. Relay valve piston 32. Cup packing 46. Push rod nut
5. Valve body 19. Cup packing 33. Hook bolt 47. Washer
6. Valve seat spring 20. Cylinder 34. End plate assembly 48. Piston plate
7. Diaphragm assembly 21. Cap 35. Return spring 49. Rubber packing
8. Gasket 22. Gasket 36. Retaining ring 50. Gasket
9. Nut 23. Retaining ring 37. Washer 51. Piston plate
10. Gasket 24. Washer 38. Retainer 52. Push rod assembly
11. Poppet 25. Spring 39. Cup packing 53. Clamp
12. Air valve 26. Outlet valve assembly 40. Washer 54. Hose
13. Vacuum valve assembly 27. Plug 41. Oil seal 55. Cylinder shell assembly
14. Elbow assembly 28. Lock nut 42. Gasket
VB58039
NOTE
1. Before disassembly, remove dirt thoroughly from the out-
side of the hydromaster.
2. Before disassembly, put matching marks on mating
sections.
3. Wipe or wash clean the disassembled parts as described
below.
a) Rubber parts and components with rubber parts.
Wipe the parts using clutch wetted with brake fluid or
alcohol.
b) Metal parts
Wash in cleaning agent (trichlene or metachlene) and
remove cleaning agent completely using the com-
pressed air and dry.
4. Check rubber parts visually for damage, wear, swelling,
etc. and replace them if any defect is found.
1) Fixing of brake booster
Hold the special tool, Work Bench, in a vice and install four hook
Hook bolt
bolts of the brake booster, aligning with the guide position of the Hydromaster
work bench. Guide
Work Bench
VB58041
2) Remove and installation of relay valve section retaining ring
Pliers
Retaining
ring
VB58043
3) Removal and installation of relay valve section valve fitting
Box
VB58045
BRa-18 BRAKE SYSTEM
4) Removal of hydraulic cylinder (2) Loosen after loosening

lock nut.
Loosen the lock nut and then loosen the cylinder by holding it
with the special tool, Spanner, on flats.
Spanners
Lock nut (1) First loosen
VB58047
5) Removal of retaining ring from outlet valve
Pliers
VB58049
6) Removal of hydraulic piston

Needle
a) When compressed air is not used
With the return spring compressed using the special tool,
Hook Clamp. Remove the straight pin from the hydraulic
piston using a needle or the like.
Hook clamp
Return spring
VB58051
b) When compressed air is used

With compressed air supplied through the cylinder shell
pipe to push to the hydraulic piston, remove the straight pin Apply compressed
air
from the hydraulic piston using a needle or the like.
Hydraulic
piston
Needle
VB58053
7) Remove of push rod nut from power piston

Socket
With the special tool, Ring Assembly, held in a vice, install the 910-23531
Power piston
power piston, aligning its push rod nut with the flat portion of the assembly
Ring Assembly
ring assembly. Then align the push rod nut with the flat portion
910-11031
of the special tool. Socket, and remove the push rod nut.
VB58055
BRa-20 BRAKE SYSTEM
Reassembly
Apply THREEBOND
5 11 (1324 or equivalent) to
19
threaded portion, tighten
18 9 nut to 0.3 to 0.8 Nm
(0.03 to 0.08 kgfm), and
44 to 64 Nm
then crush thread.
(4.5 to 6.5 kgfm)
15 to 39 Nm
15
6.9 to 8.8 Nm 10 (1.5 to 4 kgfm)
Apply rubber grease (0.7 to 0.9 kgfm) (Apply sealant to
44 12 threaded portion)
53 35 8
16 7 13 14
54 17 6
49 1 to 2 Nm
55 1 (0.1 to 0.2 kgfm)
2
51
6.9 to 8.8 Nm
48 (0.7 to 0.9 kgfm)
47 24 27
52 4 23 1
29 3
21
145 to 245 Nm
39 to 54 Nm 50 (15 to 25 kgfm)
(4 to 5.5 kgfm) 46 26
20 25
(After tihtening, 30 42
stake two places 22 Face convex portion
with puch) 28 toward hydraulic cylinder
31
Apply airmaster paste to 43 59 to 98 Nm
cylinder shell inside 33 45 15 to 39 Nm (6 to 10 kgfm)
surface and rubber packing. (1.5 to 4 kgfm)
3.9 to 9.8 Nm (Apply sealant to
34 (0.4 to 1 kgfm) threaded portion)
32
39
41
40
38
37 Apply brake fluid.
36
Assembly sequence
5 → 13 → 12 → 11 → 10 → 9
18 → 19 → 15 → 17 → 16
21 → 27 → 26 → 25 → 24 → 23 → 22 → 20 → 28 → 29
31 → 32
34 → 44 → 41 → 40 → 39 → 37 → 36 → 42 → 43 → 45
52 → 47 → 51 → 50 → 49 → 48 → 47 → 46
55 → 33 35 → 30 → 7 → 8 → 6 → 14 → 54 → 53 → 3 → 4 → 2 → 1
For parts with an encircled number,

refer to Reassembly Procedure that follows.
VB58057
Reassembly Procedure Power

piston
1) Installation of power piston section push rod nut Socket
assembly
With the special tool, Ring Assembly, held in a vice, install the
Ring Assembly
power piston, aligning its push rod nut with the flat portion of the
ring assembly.
Install the washer, piston plate, rubber packing, piston plate and
washer over the push rod and tighten the push rod nut to
VB58059
specified torque using the special tool, Socket.
2) Installation of outlet valve retaining ring
Cap
Outlet valve
spring
Washer
Retaining ring
Inset Tool
VB58061
3) Insertion of cup packing into hydraulic piston Cap packing
Cup insert
Hydraulic
piston
VB58063
4) Installation of end plate oil seal

NOTE
When installing, face the oil seal lip toward the hydraulic
cylinder.
Press-fit Bar
VB58065
BRa-22 BRAKE SYSTEM
5) Installation of poppet valve to relay valve section Nut

Poppet Gasket
Air valve
Valve
body
Vacuum valve
assembly
Apply adhesive
(THREEBOND 1324 or
equivalent) to
threads
Torque Driver
0.3 to 0.8 Nm
(0.03 to 0.08 kgfm)
Tighten nut to the
specified torque
using the special
tool, Torque Driver
Crash the threads
with pliers or
similar tool.
NOTE
Be sure to use a new poppet valve assembly
VB58067
6) Installation of hydraulic piston

a) When compressed air is not used Straight pin
Hydraulic piston
With the return spring compressed by the special tool, Hook
Clamp, and the hydraulic piston and push rod holes aligned, Hook Clamp
insert the straight pin.
Return spring
VB58069
b) When compressed air is used

With the push rod pushed up by compressed air supplied Push rod
through the cylinder shell pipe, align the hydraulic piston
Supply compressed
and push rod holes and insert the straight pin.
air
Hydraulic
piston
Stright pin
VB58071
7) Installation of hydraulic cylinder

Tighten the lock nut, making sure that the cap plug and the end 30°
plate plug are 30° out of alignment. Plug
Cylinder
Nut
Spanner
Plug
VB58073
8) Installation of valve fitting
Box
910-21981
VB58077
9) Installation of valve body

Screw Valve body
Gasket
Spring
Diaphragm assembly
Guide Pin
VB58079
BRa-24 BRAKE SYSTEM
Inspection after installation

1) Performance check
Simple Test as installed on Vehicle
This is a check method without use of instruments. If there is any
doubt to the test results, check performance of individual units
using a tester.
a) Overall check
VB58081
With the brake booster negative pressure set at 0, depress
the brake pedal as you would in ordinary braking and start
the engine and run idle. If the brake pedal moves down
slightly after about two or three seconds, the brake booster
is performing well.
b) Oil tightness check
With the engine running at idle, depress the brake pedal
fully, if the pedal is pushed back, the hydraulic piston cup
and ball check valve are not oil tight.
c) Air tightness check of poppet valve (atmospheric air valve)
With the engine running at idle, put a thread near the poppet
valve atmosphere side pipe without depressing the brake
pedal.
If the thread is drawn in, the poppet valve atmospheric air
valve is leakly.
Then depress the brake pedal. If the thread is rapidly drawn
in at the moment, the relay valve piston and poppet valve
are performing well.
d) Poppet valve (vacuum valve) and rubber packing check
With the engine running at idle, depress the brake pedal. If
you feel suction at your finger applied to the end of atmo-
spheric air valve side pipe of the poppet valve, the poppet
valve vacuum valve or the power cylinder rubber packing is
not air tight.
2) Performance check
Performance check of brake booster proper
Check the body performance in details using the Stationary Tester (Jidosha Kiki Part No.911-0020).
After all preparations for the test have been completed, bleed the fluid pressure system and test the following items.
If the results of tests show values out of the assembly standard or limit, check and replace related parts.
Pressure gauge (PG2)
Wheel cylnder
Pressure gauge (PG1)

Cock Control valve
To vacuum pump
From master cylinder

Vacuum gauge (VG1)
VB58075
Test item Test condition Assembly standard Limit

Fluid Apply fluid pressure of 11.8 MPa (120 kgf/cm²) (PG2) 1470 kPa (15 kgf/cm²) -
tightness to hydraulic cylinder and measure the amount of pressure or less
drop in 15 seconds.
(In this test no vacuum state is created in brake booster.)
Air tightness Set vacuum pressure in brke booster to 67 kPa 3.3 kPa (25 mmHg) -
when not in (500 mmHg), close cock, and measure amount of vacuum or less
operation pressure falls in 15 seconds.
Vacuum gauge (VG1)
Operation Set vacuum pressure in brake booster to 67 kPa 125 to 225 kPa 105 to 245 kPa
start (500 mmHg). Gradually apply pressure from master cylinder (1.3 to 2.3 kgf/cm²) (1.1 to 2.5 kgf.cm²)
pressure and read pressure indicated by mastr cylinder side
pressure gauge (PG1) when pointer of vacuum gauge
(VG1) swings.
Operation at Set vacuum pressure in brake booster to 67 kPa (500 mmHg). 1570 kPa (16 kgf/cm²) 1570 kPa (16 kgf/cm²)
full load Slowly depress pedal of master cylinder and read 10.1 to 11.1 MPa 9.81 to 11.4 MPa
pressure indicated by hydraulic cylinder side pressure (103 to 113 kgf/cm²) (100 to 116 kgf/cm²)
gauge (PG2) for master cylinder side pressure gauge (PG1).
Air tightness During operation at full load, cut off vacuum supply and 3.3 kPa (25 mmHg) -
at full load read amount of vacuum pressure falls in 15 seconds or less
thereafter. Vacuum gauge (VG1)
Residual Set pressure of master cylinder to 490 kPa (5 kgf/cm²) (PG1), 78 to 125 kPa 59 to 155 kPa
pressure loosen air bleeder screw at end of hydraulic cylinder, (0.8 to 1.3 kgf.cm²) (0.6 to 1.6 kgf/cm²)
release master cylinder side pressure, and read pressure
indicated by wheel cylinder side pressure gauge (PG2).
BRa-26 BRAKE SYSTEM
SAFETY CYLINDER
NV 18 to 22 N
(1.81 to 2.21 kgf)/48
L 15 N (1.5 kgf)/48 Disassembly sequence
1. Cylinder cap
1 Cylinder to piston clearance 2. Cylinder packing
BD 30 3. Spring
2 NV 0.06 to 0.12 4. Piston
L 0.17
5. Check bolt nut
3
6. O-ring
Rust, damage 7. Packing
5 4
6 8. Check bolt
7 9. Boot
8 14 10. Snap ring
11. Stopper
12. Bleeder
12 13. O-ring
14. Cylinder
13 11
BD ... Basic Diameter 10 Repair kit: o Corroded metal stopper
NV ... Nominal Value 9 Safety clinder kit o Rust, damage on inner surfaces
L ... Limit
VB58083
Reassembly
12
9
10 11 7
A
8 5
6
B
4
3
14
13 Section A-B
2
235 to 265 Nm
(24 to 27 kgfm)

14 11→10→9→8→7→4→3→2→1 Before reinstallation, apply brake fluid to cylinder bore and
12→ 13 5→ 6 piston external surfaces.
VB58085
WHEEL BRAKE Brake pipe

13 to 17 Nm
Bracket
Front wheel brake Brake hose
1.3 to 1.7
kgfm)
1) Brake hose Clip
To remove the brake hose, first disconnect the bracket side end 21 to 31 Nm
(2.1 to 3.2
(frame side) and then disconnect the wheel brake side end. To kgfm)
Packing
install, reverse this procedure.
NOTE VB58087
Install the brake hose taking care not to twist it.

2) Removal and installation
3) Disassembly, inspection and correction
NOTE
1. Wash the disassembled metallic parts in a cleaning
solvent or gas oil. Wash the rubber parts in an alcohol
solution (do not immerse for more than 30 seconds)
and blow dry with compressed air.
2. Never immerse the rubber parts in a cleaning solvent or
gas oil.
3. If the brake lining required replacement, replace as a
brake lining kit.
Deterioration of spring 1. Pipe assembly
3 Load/installed length 2. Pipe assembly
1 NV 325 N (33 kgf)/192 3. Hose and pipe joint assembly
L Springhaving gaps 4. Return spring
10
between coils and between 5. Split pin
coil and cover 6. Nut
8 7. Washer A
8. Brake shoe assembly
4 9. Wheel cylinder
10. Backing plate assembly
2
For parts with an encircled number,
Cracks, burn, damage 9 refer to Disassembly Procedure that
Thickness of lining 5 follows.
NV 12
L 15 8 NOTE
7 1. For repair limit of the brake drum,
6 see 3) Correction of drum,
Score or uneven wear of inside surface Disassembly Procedure.
I.D. Cylindricity Brake drum 2. The shoe squareness adjust bolt
NV 320 NV 0.05 of the backing plate maintains
L 322 L 0.2
shoe squareness.
Do not loosen this bolt.
VB58089
BRa-28 BRAKE SYSTEM
1) Removal of return spring
Using a screwdriver, remove the return spring.
2) Replacement of brake lining
a) Service points of removal Large screwdriver
When drilling out the brake lining rivets, use care not to
enlarge or damage the brake shoe hole by the drill.
VB58091
b) Service points of installation

o Rivet starting from the center portion and working toward
the ends. Make sure that no gap is produced between the
shoe and lining.
o Stake the rivets to 17 to 19 kN (1700 to 1900 kgf).
o Select the lining according to the operating conditions of the
vehicle. Use linings of the same size and paint color on right
and left wheels of the same axle. VB58093
o After relining, check contact with the drum inside and

correct poor contact if any. Correct the lining as incorpo-
rated into the wheel and brake assembly.
3) Correction of drum
If the drum has a cylindricity of 0.2 mm or poorer or is scratched,
correct to the repair limit. After machining, use an oversize
lining.
Drum diameter Repair limit Service limit

320 321 322
4) Reassembly
a) Vehicle with 320 drum brake
3.9 to 5.9 Nm
(0.4 to 0.6 kgfm) 7.8 to 12 Nm
Drum turning direction After bleeding,
when traveling ahead torque to 2 (0.8 to 1.2 kgfm)
3 63 to 94 Nm
7.8 to 12 Nm
1 (6.4 to 9.6 kgfm)
(0.8 to 1.2 kgfm)
9 12 to 16 Nm
(1.2 to 1.6 kgfm)
35 to 53 Nm
Apply grease 4 (3.6 to 5.4 kgfm)
(HIREX No.2 or 8
equivalent) 10
Holder pin
6
5 7
Apply grease Brake shoe assembly
(HIREX No. 2
or equivalent) Backing plate assembly
This part cannot be
adjusted in order to
maintain the right
angle of the shoe
Holder pin section

10→9→3→2→1→8→7→6→5→ 4 Keep the lining surface free of oil and grease.
Installation of Brake Shoe Assembly

Reassembly Procedure that follows. Fit the nut over the holder pin and tighten until the washer A
is forced lightly against the stepped portion of the holder pin.
Then back off the nut (0 to 60°) to the split hole of the first fit
of the holder pin and lock with a split pin. Then, install the
return spring.
VB58095
Reassembly procedure
1) Wheel cylinder installation position
The wheel cylinder body has an identification mark to indicate
the installation position. Install according to the mark
Identification mark Installation position
RF Right front wheel
RR Right rear wheel
Identification mark
LF Left front wheel VB58097
LR Left rear wheel

BRa-30 BRAKE SYSTEM
2) Installation of return spring

Using a screwdriver, fit the return spring.
Small Phillips screwdriver
VB58099
3) Adjustment of holder pin Brake shoe

This adjustment is not required under normal circumstances. assembly
When the holder pin has been replaced and when the brake
drags despite the adjustment of correct brake shoe clearance
performed immediately after the lining has been replaced, the
following adjustment is necessary as brake shoe squareness is 319±0.5mm
probably incorrect.
a) Accessing from the back of backing plate, turn the wheel VB58101
cylinder adjust so that the O.D. of brake shoe assembly
measures about 319±0.5 mm.
Also, centrally align the brake shoe assembly.
b) Referring to Front Axle, install the wheel hub and brake drum.
NOTE
If the wheel hub and brake drum is hard to install all the
way into position because of the brake shoe assembly
excessively tilted, turn the holder pin to correct the tilt.
c) Bleed the brake system of air.
Brake drum Backing plate

d) Through the check hole, insert a 0.2-mm feeler gauge into
the space between the drum and lining. Then, turn the wheel Feeler gauge
cylinder adjuster in the direction indicated by the stamped
arrow to expand the brake shoe assembly so that the feeler
gauge cannot be removed easily. Holder pin
e) Loosen the nut on the holder pin. Turn the holder pin Brake shoe
clockwise or counterclockwise so that the feeler gauge can assembly Nut
easily be removed and inserted. 24 to 35 Nm
(2.4 to 3.6 kgfm) VB58103
f) Repeat steps d) and e) until the feeler gauge becomes hard
to remove.
g) Lightly depress the brake pedal two to three times to center
the brake shoe assembly.
h) Repeat steps d) and e) again.
i) Remove the feeler gauge when it contacts the lining to the
full width. Then, reinsert it and adjust the holder pin so that
you feel the gauge binding in the depths. Now, tighten the
nut to specification.
NOTE
In step h), when the feeler gauge becomes hard to
remove or insert indicates that the gauge contacts the
lining to the full width.
Front wheel cylinder

1) Disassembly and inspection
1
8
2 7
6
3 9
1. Adjuster stopper
Clearance between piston and body 2. Adjsuter
BD 34.93 3. Adjuster screw
NV 0.03 to 0.09 4. Boot
L 2
5. Piston
6. Piston cup
7. Bleeder screw
BD ... Basid Diameter Repair kit: 8. Body
NV ... Nominal Value Wheel cylinder kit 9. Backup ring
L ... Limit
VB58105
2) Reassembly
A 0.6 ~ 1.0 kg.m

1
8
2
5 4
A
9 6
Section A-A
Apply rubber grease
(NIGLUBE RX-2 or
equivalent).
Assembly sequence
9→8→6→5→4→3→2→1
VB58107
BRa-32 BRAKE SYSTEM
Rear wheel brake 13 to 17 Nm

Brake pipe (1.3 to 1.7 kgfm)
1) Brake hose
Bracket
To remove the brake hose, first disconnect the bracket side end
(frame side) and then disconnect the rear axle housing side end. Clip
To install, reverse this procedure.

Brake hose
Packing
NOTE
21 to 31 Nm
Install the brake hose taking care not to twist it. (2.1 to 3.2 kgfm) VB58109
2) Removal and installation

3) Disassembly, inspection and correction
NOTE
1. Wash the disassembled metallic parts in a cleaning
solvent or gas oil. Wash the rubber parts in an alcohol
solution (do not immerse for more than 30 seconds)
and blow dry with compressed air.
2. Never immerse the rubber parts in a cleaning solvent or
gas oil.
3. If the brake lining required replacement replace as a
brake lining kit.
1
9
NV 390 N (40 kgf)/217
8 7
L Springhaving gaps
6 between coils and between Disassembly sequence
coil and cover 1. Pipe assembly
2. Return spring
2 3. Split pin
4. Nut
8 7 5. Washer A
6. Brake shoe assembly
Cracks, burn, damage 7. Wheel cylinder
Thickness of lining 6 5 4 3 8. Wheel cylinder cover
NV 12
9. Backing plate assembly
L 5
Brake drum
Score or uneven wear

of inside surface For parts with an encircled number, refer to Disassembly
I.D. Cylindricity Procedure that folows.
NV 320 NV 0.05
L 322 L 0.2 NOTE
1. For the repair limit of the brake drum, see 3)
Correction of drum, Disassembly Procedure.
2. The shoe squareness adjust bolt of the backing
NV ... Nominal Value plate maintains shoe squareness.
L ... Limit Do not loosen this bolt
VB58111
1) Removal of return spring
Using a screwdriver, remove the return spring.
2) Replacement of brake lining
a) Service points of removal Large screwdriver
When drilling out the brake lining rivets, use care not to
enlarge or damage the brake shoe hole by the drill. VB58113
b) Service points of installation

o Rivet starting from the center portion and working toward
the ends. Make sure that no gap is produced between the
shoe and lining.
o Stake the rivets to 17 to 19 kN (1700 to 1900 kgf).
o Select the lining according to the operating conditions of
the vehicle. Use linings of the same size and paint color
on right and left wheels of the same axle. VB58115
o After relining, check contact with the drum inside and

correct poor contact if any. Correct the lining as incorpo-
rated into the wheel and brake assembly.
NOTE
On FL series, never use the lining other than the standard
lining. (LP1023)
3) Correction of drum
If the drum has a cylindricity of 0.2 mm or poorer or is scratched,
correct to the repair limit. After machining, use an oversize
lining.
Drum diameter Repair limit Service limit
320 321 322
BRa-34 BRAKE SYSTEM
4) Reassembly
a) Vehicle with 320 drum brake
Caution plate Direction of drum rotation

during forward motion 3.9 to 5.9 Nm
Bleeder screw (0.4 to 0.6 kgfm)
(final tightening
6
after air extraction) 1
7.8 to 12 Nm
63 to 94 Nm
7 (0.8 to 1.2 kgfm)
(6.4 to 9.6 kgfm)
8
2 Apply grease
(HIREX No.2 or
12 to 16 Nm
equivalent)
9 (1.2 to 1.6 kgfm)
Caution plate
Holder pin
4
3 5
Brake shoe assembly
Apply grease
(HIREX No.2 or Backing plate assembly
equivalent)
This part cannot be
adjusted (to maintain shoe angle)
Holder pin section
Assembly sequence
9→8→8→1→6→5→4→3→ 4

Reassembly Procedure that follows.
NOTE
Keep the lining surface free of oil and grease.
Installation of Brake Shoe Assembly

Fit the nut over the holder pin and tighten until the washer A is forced
lightly against the stepped portion of the holder pin. Then back off
the nut (0 to 60°) to the split hole of the first fit of the holder pin and
lock with a split pin. Then, install the return spring.
VB58117
Reassembly procedure Return spring

Brake shoe
1) Installation of return spring (drum dia. 320) assembly
Catch the shorter hook of the return spring onto the brake shoe
Caution plate
assembly as shown on the caution plate attached to the brake
shoe assembly. Catch the other hook with a small Phillips
screwdriver and insert the tip of the screwdriver into the return
spring mounting hole in the brake shoe assembly. Then, pry the Small Phillips
screwdriver VB58119
hook into the hole.
2) Adjustment of holder pin <Vehicles with 320 drum brake only>
Brake shoe
This adjustment is not required under normal circumstances. assembly
When the holder pin has been replaced and when the brake
drags despite the adjustment of correct brake shoe clearance
performed immediately after the lining has been replaced, the
following adjustment is necessary as brake shoe squareness is 319±0.5mm
probably incorrect.
a) Accessing from the backing plate, turn the wheel cylinder VB58121
adjuster so that the O.D. of brake shoe assembly measures

about 319±0.5 mm. Also, centrally align the brake shoe
assembly.
b) Install the wheel hub and brake drum.
NOTE
If the wheel hub and brake drum is hard to install all the way
into position because of the brake shoe assembly exces-
sively tilted, turn the holder pin to correct the tilt.
BRa-36 BRAKE SYSTEM
Rear wheel cylinder

1) Disassembly and inspection
7
6
4
2
3
1
8 Disassembly sequence
1. Adjuster stopper
4 2. Adjsuter
9 3. Adjuster screw
4. Boot
5. Piston
11 10 6. Piston cup
L ... Limit
7. Piston cup
Clearance between piston and body
8. Piston
BD 36.51
NV 0.03 to 0.09 9. Bleeder screw
Repair kit: L 0.2 10. Body
Wheel cylinder kit 11. Backup ring
58AR38-1
2) Reassembly
0.6~1.0kg·m
1 10
5
3
6
Apply rubber grease 8
(RG-4 or equivalent) Section A-A(Rear)
to internal surface of
cylinder and periphery
of piston
Assembly sequence
11→10→8→6→5→4→3→2→1
58AR38-2
Inspection and Adjustment after Installation

Shoe clearance adjustment Shoe Gap
Adjuster
Adjuster
Before adjustment, referring to Item (2). Wheel cylinder
1) Jack up the axle and check to ensure that the hub is free from
looseness.
2) Remove the adjusting hole plug from the backing plate. Using
Shoe Gap Adjuster, turn the adjuster of the wheel cylinder in the
VB58123
direction of an arrow stamped on the backing plate, until the tire
drags a little when turned by hand.
NOTE
1. The arrow in stamped on the area near the adjusting
hole plug of the backing plate.
2. Make adjustment at two places on each wheel.
3) After depressing the brake pedal several times, make sure that
the tire drags a little when turned by hand. If the tire turns lightly
repeat the above procedures beginning with step 2).
4) Bake off the adjuster of the wheel cylinder 8 to 9 notches in the
direction opposite to that of the arrow.
NOTE
Make adjustment at two places on each wheel.
5) Turn the tire by hand and make sure that the tire does not drag.
Filler gauge
If the tire drag, repeat the procedure begining with steps (2). Brake drum
6) Remove the check hole plug from the backing plate. Insert a
filler gauge between the brake drum and the lining. Make sure
that the clearance when slight resistance is left while withdraw-
ing the gauge is 0.2 mm.
NOTE
Make the check at two places on each wheel. Lining
VB58125
BRa-38 BRAKE SYSTEM
Replacement of brake fluid and bleeding of brake system
Brake fluid reservoir tank
Vinyl
Brake pedal Brake master cylinder

Brake booster (hydromaster)
container
Vacuum tank
Safety cylinder container
VB58127
NOTE
Before replacing the brake fluid or bleeding the brake
system, stop the engine and depress the brake pedal
several times to reduce the negative pressure in the
vacuum tank until warning lamp lights.
1) Replacement of brake fluid

a) Mount the special tool, vinyl Pipe to the bleeder screw
of the wheel cylinder.
b) Loosen the air bleeder and depress the brake pedal
several times until brake fluid ceases to run out.
c) Mount a vinyl pipe to the air bleeder of the brake
booster.
d) Loosen the air bleeder and depress the brake pedal
repeatedly several times until there is no more brake
fluid in the reservoir tank and brake fluid ceases to run
out from the air bleeder.
e) Bleed the clutch system by the same procedures.
f) While pouring in fresh brake fluid (fluid in fully-en-
closed container free from water, dust, etc.) into the
reservoir tank, depress the pedal repeatedly until the
fluid in the brake system is replaced with the fresh
fluid.
NOTE
1. Use brake fluid that conforms to SAE J1703f or
FMVSS No. 116 DOT3. Never mix different kinds of
brake fluid as such a mixture can cause brake drag.
2. If the fluid in the brake system is replaced with fresh
fluid, the fluid that runs out will change in color.
Keep close watch on the fluid that runs out. Air bleeder valve
At the time, thread the air bleeder valve of the safety cylinder VB58129
back until the valve is lightly blocked by the stopper.

g) Tighten all the air bleeders, fill the reservoir tank with the
specified quantity of brake fluid, and bleed the brake and
clutch.
2) Bleeding of brake system
a) Make sure that the brake fluid in the fluid reservoir tank is at
H level.
NOTE
The brake fluid level will fall curing bleeding operation.
Perform bleeding operation while pouring fresh brake
fluid (which is kept in the fully-enclosed container and
is free of dust, water, etc.) into the fluid reservoir tank.
b) Tighten the front and rear check bolts of safety cylinder to
block up the fluid passages from the brake booster.
c) Install one end of transparent vinyl pipe to the air bleeder of
hydraulic cylinder of brake booster and place the other end Rear safety cylinder
of the vinyl pipe in the container filled with brake fluid.
d) Depress the brake pedal all the way several times. Then,
Front safety
with the pedal kept depressed, loosen the air bleeder to
cylinder
bleed air together with brake fluid.
Immediately after bleeding, close the air bleeder and re-
Check bolt Air bleeder valve
lease the pedal. VB58131
e) Repeat this operation until there is no more air bubble in

brake fluid flowing out from the air bleeder.
f) Bleed air from the air bleeder of relay valve of brake booster
in the same manner as described in d) and e).
g) Return the front check bolt of safety cylinder to the original
position and back off the front air bleeder valve until it comes
in contact with the stopper.
h) Bleed air from the air bleeder of front wheel cylinder in the
same manner as described in d) and e).
BRa-40 BRAKE SYSTEM
i) Depress the brake pedal all the way repeatedly (Depress

the pedal 5 to 6 times continuously until the pedal cause a
reaction. Then, depress the pedal three times repeatedly).
Repeat the air bleeding of master cylinder until there is no
more air bubble produced in fluid reservoir tank. (It takes 4
to 8 seconds between releasing of pedal and formation of air
bubble at the surface of fluid in the fluid reservoir tank.)
j) Return the rear check bolt of safety cylinder to the original
position and back off the rear air bleeder valve until it comes
in contact with the stopper.
k) Bleed air from the air bleeder of rear wheel cylinder in the
same manner as described in d) and e).
l) Make sure that wheel brake shoe clearance has been
adjusted to 0.2mm. Then, depress the brake pedal with a
force of about 590N (60 kgf) and make sure that a clearance
of 65mm or more is provided between the pedal and
toeboard.
m) If a pedal-to-toeboard clearance is not within the nominal
value, bleed air again from the following parts in the order of
mention until the clearance is within the nominal value.
1) Brake booster relay valve
2) Front wheel cylinder
3) Brake booster hydraulic cylinder
4) Rear wheel cylinder
n) After completion of air bleeding, tighten the front and rear air
bleeder valves until they come in contact with the respective
stoppers.
o) Check the fluid level in the fluid reservoir tank and add brake
fluid until the fluid reach the H level.
p) Start the engine and increase negative pressure until warn-
ing lamp goes out. Then, depress the brake pedal and
check each part for fluid leaks.
Tightening of brake pipes
Pipe diameter Thread diameter

Mouthpiece shape Pitch (mm) Tightening torque
(mm) (mm)
4.76 10 1.0 12 to 16 Nm
(1.2 to 1.6 kgfm)
6.35 12 1.0 19 to 25 Nm
(1.9 to 2.6 kgfm)
FULL AIR BRAKE (WEDGE BRAKE)

General
ATBR-700
Specification
Item Front Rear
Specification 360 X 160 Å
Brake type Leading & Trailing Å

Effective radius 180 mm Å
Lining usable thickness 10 mm Å
Lining area 1106 cm² Å
Brake chamber Type 12

Spring chamber Type 12 / 16
BRa-42 BRAKE SYSTEM
Schematic diagram
1 2 8 6 17
13 20
4 7 10
5 12
3
FR RR
18
16
15
14
19
11
1. Air compressor 8. Air gauge 15. Brake chamber spring

2. Air drier 9. Dual brake valve 16. Magnetic valve
3. Air tank 10. Parking brake valve 17. Low air pressure switch
4. 4-circuit protection valve 11. R-12 relay valve 18. Exhaust brake valve
5. Air reservoir 12. R-14 relay valve 19. Quick release valve
6. Safety valve 13. Double check valve 20. Quick release one way valve
7. Drain valve 14. Brake chamber
ATBR001A
Description of operation
3
3
4
8
8
7 7
6
1
10 3
11
1. Brake spider
2. Expander unit
3. Shoe
4. Return spring
5. Dust cover
6. Actuating cylinder
7. Thrust piece
8. Hold-down spring 5
9. Trailing shoe
10. Brake chamber
11. Spring chamber
ATBRA002/ATBRA004
BRa-44 BRAKE SYSTEM
Brake actuation
Activation of the brake, see illustration, is by the actuation cylinder
which pushes the wedge (9) down between the two cage guided 13 14
10
rollers (11) and the pistons (12), thereby displacing them sideways
and so pushing the brake shoes (3) against the brake drum. The
brake drum drags the brake shoes by the forward driving direction
in the turning direction, see illustration. Thereby the front brake shoe
or leading shoe and the rear brake shoe or trailing shoe are
supported by the thrust pieces (7) in the abutment. Both brake shoes
9
air sliding shoes, i. e. they glide on the abutment thrust pieces (7).
The brake force ration for the leading and trailing shoes is
11
approximately 3:1. The brake performance in the forward and the 17
reverse directions is virtually the same.
12 16
When the braking operation is ended the wedge (9) is pushed back
to its initial position by the spring (10). At the same time the shoe
return springs (4) pull the brake shoes (3) back from the brake drum
ATBRA003
and the piston (12) into the housing (2) are pushed back into the idle
position.
Automatic adjuster
16 14
Each piston (12) in the expander unit is provided with an automatic
adjustment mechanism, which individually and continually and
adjusts, thereby ensuring adequate clearance between the brake 16
drum and lining.

Upon actuating, see above, the wedge (9) is pushed between the
rollers (11) against the preloaded spring (10) and the rollers (11) roll
17 18
on the wedge incline and the piston (12). Thereby each piston (12) ATBRA005
with the adjuster ring (13) and the adjuster nut (14) are pushed
outwards, thus beginning the braking operation.
Through the sideways displacement of the pistons (12), the spring 19

13
loaded pin (16) comes against the flank of the spiral groove (17) in 14
the adjuster ring (13), see above, causing the adjuster ring (13) to
turn by a degree corresponding to the travel of the piston (12).
18
By termination of the braking operation, the wedge (9) is pushed 9
back to its initial position by spring (10). The shoe return springs (4)
via the brake shoes (3) push the adjuster nut (14), adjuster ring (13), 11
and piston (12) back into their initial position. 12 ATBRA007
An increase in clearance resulting from lining wear in accordance

with above increases the stroke of the wedge (12) and the piston
(12) is pushed further outwards. Automatic adjustment occurs as
soon as the rotation of the adjuster ring (13) is greater as the pitch
of the serration's (18)-saw tooth from-between the adjuster ring (13)
and the adjuster nut (14). Thereby the engagement of the serration's
18, loaded by curved wire spring (19), jump on tooth.
Upon releasing the brake, see right illustration, the adjuster screw
(15), adjuster nut (14), adjuster ring (13) and piston (12) are pushed
back by the shoe return springs (4). 13 14
The pin (16) is then pushed against the flank of the spiral groove (17)
causing the adjuster nut (14) and the adjuster ring (13) to turn by a 31
degree corresponding to the tooth pitch.
Through the thread in the adjuster nut (14), the adjuster screw (15)
moves outwards thereby compensating the lining wear.
The adjuster screw (15) is fixed by leaf spring (31) and the brake
shoe (3).
The optimized tooth pitch of the serration's (18) provide adjustment
in very small-almost infinitesimal-uniform steps of 0.03 mm
12 15
ATBRA009
BRa-46 BRAKE SYSTEM
Installation
Expander unit
25
24
10
21
2
2
13 14 15
9 31
22
18 13 11 23 20
14 29 15
31 33
11
10
24
32
16 26 30 33
27 28 17 12 19
2. Housing 21 Roll below

9. Wedge 22. Spring retainer
10. Pressure spring 23. O-ring
11. Roller 24. Spring retainer
12. Piston 25. Snap ring
13. Adjuster ring 26. Pressure spring (long)
14. Adjuster nut 27. Pressure spring (short)
15. Adjuster screw 28. Spigoted screw
16. Pin 29. Washer
17. Spiral groove 30. Protective cap
18. Serration 31. Leaf spring
19. Curved wire spring 32. Concave seat
20. Roller cage 33. Toothed wheel
ATBR-703/ATBR-703A
1. Dissambly is the reverse of installation.

5
2. Fasten cover 5 to brake spider 1with M8 bolts.
Tightening torque 22±2Nm.
1
ATBRA011
3. Set hold-down springs 8 and so that they are against the brake
spider 1, and fasten with screw with hexagonal recessed hole
M10 and washer. 8
NOTE
? The opening of the hold-down spring must face brake
shoe.
ATBRA013
4. Install thrust pieces 7 in brake spider 1.
NOTE
? Lubricate thrust pieces before installation.
The plane surface of the thrust pieces and the brake
spider must be non-lubricated
? The thrust piece with the angled shoe abutment (arrow)
must be fitted to the leading shoe side.
The slope of the abutment must point towards the
centre of the brake. 7
? The thrust piece with the straight shoe abutment must 1
be fitted to the trailing shoe.
ATBRA015
BRa-48 BRAKE SYSTEM
5. Moisten seat "Z" before installation, point 4.

Set expander unit 2 in the brake spider 1, and fasten with M12
Z
bolts.
NOTE 1
? The opening of the leaf spring 31 must face to the

centre of the brake.
ATBR-720
? Head expander dimension "S" see below illustration.
6. Smear the break shoe contact areas of the brake spider with (158mm)
grease. 31
31
1
ATBR-721
7. Place the brake shoes 3 on the brake spider 1, and slide them Forward Rotation
under the hold-down springs 8.
3 3
NOTE :
? Before assembly smear the brake shoe contact areas
and the shoe webs in the area of the hold-down springs
with grease.
1
ATBR-722
8. Fit shoe return springs 4 ensuring they are positioned correctly.

1
Cross nut Cross nut

ATBR-723
9. Fit the plugs (arrow) in the cover 5 openings.

Rubber plug
Dust cover
Rubber plug
Rubber plug
ATBR-724
Maintenance and servicing

General remarks
Brakes and brake drums must be maintained in good working
conditions to ensure safe and proper vehicle operation.
It is very important that vehicle manufacturer preventive maintenance
schedules be followed and that wear parts be replaced when
needed. The replacement of wear parts is described in the following
sections concretely.
• The replacement of wear parts should be axle-wise, i.e. in
both brakes.
• Only use original spare parts from the vehicle manufacturer.
• Repair and service functions to be carried out only by
vehicle manufacturer authorized repair facilities employ-
ing trained and qualified personal.
Only common shop tools are necessary for the servicing and repair.
Bedding procedure
A new brake lining must be bedded in carefully in order that opimal
brake effectiveness is attained. During the bedding period when the
lining is not fully match with the drum, it is important to avoid heavy
and continous use of the brakes, particularty from high speeds,
otherwise local overheating the lining and the drum will a consequent
detraction in brake performance.
Other brake parts

All rubber parts are be renewed not later than every 2year. This also
applies to the shoe return and hold-down springs (4,8). Should the
springs become damaged, e.g. over extended, corroded, over
heated etc. beforehand, an earlier replacement is necessary.
Brake lining replacement

The brake lining must be renewed when its remaining thickness has
reached 4,5 mm or the wear indicator step in the lining, or when they
have become burned, glazed of contaminated with oil.
The visual control should be carried out in defined intervals according
to duty levels, the leading shoe lining has the higher wear rate.
• Only brake lining material which is approved by the vehicle
manufacturer may be used.
• When replacement is necessary then all linings in the
ATBR-710
brakes or the axle must be used.
BRa-50 BRAKE SYSTEM
Should the drum wear be greater than the lining to drum clearance
thus preventing renewal of the drum, de-adjustment of the brake
shoes will be necessary. This is carried out by engaging a screwdriver,
in the toothed wheel 33 via the opening (arrow) in cover 5 and
turning the toothed wheel 33 in the clockwise direction until sufficient
clearance is attained.
Upon renewal of the drum the resetting of the adjuster screw 15 can
be done by hand.
Remove the upper and lower return spring 4 with a suitable tool
(Screwdriver) and withdraw the shoes from the hold-down spring 8. 33
De-rivet the lining by removing the peened end of the rivet with a drill 15
tacking care not to enlarge the rivet holes in the shoe. Clean shoe Screwdriver
and ensure it is not damaged or deformed. Fit new linings holohedral
ATBRA017
to the shoes.
Before assembly of the brake the new lining should be turned or
ground to a diameter of 359,5-1,5 mm by a drum diameter of
360mm, to ensure a correct lining/drum fit and facilitate the bedding
process. By overturning observe the expander unit distance "S" of
158 mm. The thickness of the standard size lining is dimensioned
accordingly. If machine equipment is not available, the thinner
service lining should be used.
Actuating cylinder replacement

Release lock nut and remove cylinder. Screw lock nut onto new
cylinder by at least 27mm, smear cylinder thread with TEROSON-
ATMOSIT. Screw the cylinder in to the thread of the expander unit
until abutment and then return so far to obtain the requisite position
of the air connection.
A
The lowest drainage hole must be open and point as near as
possible vertical to the ground. 9
It is very important that the lowest hole remains open and the 2
other holes are sealed with a plug.
Tighten lock nut with a tightening torque 300±20Nm.
During the assembly of the operation cylinder it has to be generally
noted, that the free end of the wedge, which reaches out of the
wedgd assembly housing is aligned according to the housing center
A - see illustration and not sloping. If it is sloping it is possible, that
the wedge is not in it's correct position, i.e. the rollers 11are not in
contact with the pistons 12. 12 11 12
To avoid mistakes during the reassembly of the operation cylinder, ATBR725
it is necessary to follow the work sequences and notes below.
1. Align the wedge 9 with the axle A of the wedge assembly

housing.
2. Push the wedge 9 in this position in the direction of the arrow into
the housing 2. The rollers 11 must point in the direction of the
pistons 12.
3. It has to be noted, that the rollers with their cage are not allowed
to rest on the guide at the side of the housing.
4. Place the rollers carefully between the pistons. The roller cage
shall not abut at the edge of the piston.
NOTE
? It is possible to check the original position of the
wedge. With a sight pressure of the hand rotate the
outer end of the wedge. Does it more into the housing,
the correct position was not reached.
Continuing the assembly of the brake system, i.e. fixing of the

operation cylinder at the brake, it must be sure, that the wedge
keeps in its original position.
Maintenance and assembly of the expander unit

The adjuster is in principle maintenance free. The expander unit
should be inspected for damage and waer after not more than 2
years in service. Should damage occur beforehand, or the expander
unit or adjuster mechanism fail, then these pats should be replaced
completely.
In any case the rubber parts must be renewed every 2 years.
Damaged rubber parts must be replaced directly.
BRa-52 BRAKE SYSTEM
Exhaust Brkae
OFF
Vacuum Tank Vacuum chamber
ON
3-way magnet valve
Exhaust brake
indicator lamp Exhaust brake valve
Cold start indicator lamp Engine
Fuse
Battery
Exhaust brake switch
Cold start switch
VB58133
The exhaust brake system, functioning as an auxiliary brake for the

On exhaust
foot brake, consists of the butterfly valve type exhaust brake unit stroke
Exhaust brake
and the intake silencer that minimizes intake noise occurring when valve
the exhaust brake is activated.
Exhaust manifold
When the exhaust brake switch is turned ON, the 3-way magnet
valve actuates causing air pressure in the air tank to be delivered to
the control cylinder of the exhaust brake unit. This closes the
exhaust brake valve, thus activating the exhaust brake. At the same 58BA02-2
time, the air pressure is delivered to the control cylinder of the intake
silencer, which closes the intake silencer valve. Depression of
either clutch pedal or accelerator pedal, or shifting into natural turns
OFF the electric circuit temporarily, deactivating the exhaust brake
system.
The pressure inside the exhaust pipe building up when the exhaust
pipe is closed is applied to the piston as a counteracting force during
the exhaust stroke, which offers the braking force.
EXHAUST BRAKE
Exhaust brake valve
9
6
2 Disassembly sequence
1. Pin
11 2. Protector
5 3. Washer
4. Clevis pin
5. Power chamber
6. Bushing
7 12
14 8 7. Bearing
8. Clevis
9. Lock nut
13 3
1 10. Retainer
10 2-1 11. Valve assembly
12. Bracket
13. Cover
14. Gasket
15. Lever
VB58135
Inspection Vacuum gauge

Airtightness check Vacuum
1) Apply vacuum of -500mmHg or more to power chamber and
check wheather the vacuum gauge indicates nominal vlue after
15 seconds
Nominal value -475mmHg or more Power chamber
VB58137
Assembly procedure
Adjustment of fully
1) Adjustment of fully opened butterfly valve. opened butterfly valve
Turn the adjusting bolt until the adjusting bolt head reaches the
same height as of lever and tighten the bolt with lock nut.
Lever
Adjusting bolt
VB58139
BRa-54 BRAKE SYSTEM
2) Adjustment of clevis length Vacuum
Depress the power chamber to the adjusting bolt (of fully

Lock nut
opened position) contacts with lever then adjust the clevis
Clevis
position as shown is illustration beside and tighten with lock nut.
Lock nut
Adjusting bolt
Adjusting bolt VB58141
3) Adjustment of closed butterfly valve Vacuum

Body
While applying -650mmHg of vacuum pressure, turn the adjust-
ing bolt and make sure that the clearance between butterfly Clearance
valve and body is to 0.4~0.6 mm then tight the lock nut.
Butterfly
Lock nut
Adjusting bolt
VB58143
Reassembly
6
11
4
8
2
7
37.5°
1,3
37.5°
10 2-1
Reassembly sequence
10→ 11→3→2
2→ 1
4→ 6→9→ 8 → 7
VB58145
BRa-56 BRAKE SYSTEM
TROUBLESHOOTING
Poor braking Loosen of brake fluid Check for brake fluid
action leaks, correct and add
brake fluid
Air in system Bleed the system
Leaks in brake fluid line Correct the leaks and
add brake fluid
Leaky brake master cylinder and wheel cylinder Correct or replace the
assembly
Excessive brake shoe clearance Adjust shoe clearance.
If brake lining wears
exceeding the limit,
replace the lining.
Worn brake lining Replace brake lining
Defective master cylinder, wheel cylinder, and hydromaster Check the parts and
replace as necessary
Water or grease between the brake drum and brake lining Clean, or replace brake
lining
Burnt brake lining Replace brake lining
Poorly lubricated brake booster power cylinder or air Replace defective parts
leaking due to damaged rubber packing and lubricate power
cylinder
Excessive Excessive brake shoe clearance Adjust shoe clearance.
pedal travel If brake lining wears
exceeding the limit,
replace the lining.
Loss of brake fluid Check for brake fluid
leaks, correct and add
brake fluid
Leaks in brake fluid line Correct the leaks and
add brake fluid
Leaky brake booster Check the parts and
Defective brake master cylinder piston cup Replace piston complete
Air in system Bleed the system
Excessive brake pedal play Check and replace parts
as necessary
Vehicle pulls to Improper brake shoe clearance or brake lining contact Adjust shoe clearance.
one side when Replace linings.
braking
Grease on linings or drum internal surfaces Remove contaminants or
replace linings
Brake drum runout or left loose Correct runout.
Tighten drum to
specification.
TROUBLESHOOTING BRa-57

Vehicle pulls to Tires not uniformly inflated Inflate correctly
one side when Use same linings
Mismatched lining materials
braking
Brake shoe return spring lost tension or broken Replace return spring
Chassis spring U-bolt left loose Tighten U-bolt nut to
specification
Distorted backing plate Replace backing plate
Defective wheel cylinder Disassemble wheel
cylinder, check body,
piston, and cup, and
replace parts as necessary
All brakes drag Small brake shoe clearance Adjust shoe clearance on
four wheels
No play in brake pedal; poor brake pedal return action Adjust play in brake pedal.
Lubricate collar and bushing
internal surfaces for
smooth brake pedal action.
Weak or broken brake pedal and brake master Check and replace as
cylinder return springs necessary
Plugged brake master cylinder return port Disassemble and clean
Brake master cylinder piston cup deformed Replace piston complete
Defective brake booster relay valve Replace binding relay
valve piston
Defective brake booster power piston Lubricate rubber packing
as necessary
One brake drags Small brake shoe clearance Adjust shoe clearance
Weak or broken brake shoe return spring Replace
Restricted oil pipe Clean or replace
Brake shoe assembly installed improperly Correct
Defective wheel cylinder Check piston and piston cup
and replace as necessary
Brakes squeak Brake drum dragging Check and correct by referring
to above
Brake linings are worn causing the drum to come
Replace linings
Into contact with rivet heads
Hardened lining surfaces Replace linings
Rough or worn brake drum internal surfaces Corect surfaces or replace
Brake drum becoming loose Tighten to specification
Brake shoe not in tight contact with lining Replace linings
Brake shoe assembly installed improperly Poor braking action or
sticking brake pedal
BRa-58 BRAKE SYSTEM

Poor braking action or Complete vacuum in not created Check connections and
sticking brake pedal pipings and replace as necessary.
Or check vacuum pump.
Vacuum is not held properly Check connections and

pipings and replace as
necessary. Or, check the
vacuum tank check valve,
brake booster poppet valves
(vacuum valve, air valve),
power piston packing, and
diaphragm and replace as
necessary
Defective brake booster relay valve Check the brake booster

fluid line and clean and
Poor braking action Brake booster not airtight Check poppet valve (air
valve), power piston
packing, and diaphragm
for airtightness and
Pedal springs back Brake fluid on the wheel cylinder side flows back Replace hydraulic piston
to the master cylinder side at the hydraulic assembly or cup packing
cylinder of brake booster
Starting the engine Defective brake booster relay valve Check for relay valve
produces braking piston's return motion
and valve seals and
Exhaust Exhaust Abnormal air pressure Check for air compressor

brake brake performance and piping and
ineffective correct as required
Check and repair clutch switch,
microswitch, and
exhaust brake harness
Faulty electrical circuit Replace

Air piping crushed Replace
3-way magnet valve inoperative Clean
Exhaust brake valve inoperative Replace
Exhaust brake valve shaft sticking Disassemble control cylinder
and replace defective parts
Control cylinder inoperative Replace

Exhaust brake 3-way magnet valve inoperative Clean
cannot be Exhaust brake valve inoperative Replace
released
Exhaust brake valve shaft sticking Check and repair clutch
switch, microswitch, and
exhaust brake harness
Faulty electrical circuit Replace
(1) Wheel brakes

Poor Air leaks when Loosen connectors Tighten connectors
braking brake pedal is Leaky primary and secondary valves of dual brake Disassemble dual
brake valve to remove
action depressed valve
foreign matter or
replace inlet valve
Damaged dual brake valve O-ring Disassemble dual brake
valve and replace O-ring
Air leaks when Loosen connectors Tighten connectors

brake pedal is Leaky primary and secondary valves of dual brake Disassemble dual
brake valve to remove
released valve
foreign matter or
replace inlet valve
Low air Air leak Check air line and
pressure correct air leaks
Air pressure governor improperly adjusted Adjust air pressure
governor
Air compressor malfunctioning Overhaul air compressor

No air leaks Brake booster power cylinder poorly lubricated or Apply grease to cylinder
rubber parking damaged shell inner surface
and rubber packing.
Replace damaged
rubber parking
Poor sealing by the brake booster hydraulic piston Replace the valve seal
valve seal
Damage or wrong cup packing in brake booster Replace and reinstall
correctly the cup
hydraulic piston. Or foreign matter deposited on
packings
packing.
Excessive brake shoe clearance Adjust shoe clearance.
Replace brake lining if
it has worn to limit.
Oil or grease on brake lining Wash deposits off the surface

or replace
brake lining
Hardended lining surface Machine brake lining
surface or replace
lining
Brake fluid leak from fluid circuit or loss of brake fluid Correct the leaks and
bleed the system. Or
add brake fluid up to
"H" level.
Air in fluid line Bleed the line
Worn wheel cylinder cup resulting in brake fluid leak Replace cup
BRa-60 BRAKE SYSTEM

Brake The brake Improper return motion of the primary or Disassemble, check,
and clean dual brake
drum shoes are not secondary valve of the dual brake valve, or
valve and correct
over- moving away exhaust port being plugged with foreign matter problem or replace
heats from the brake Brake booster exhaust port plugged with foreign mater Disassemble, check,
and clean brake booster
drum when the
and correct problem
brake pedal is or replace
released (brake Bent brake booster push rod Replace push rod
dragging) Brake booster power cylinder rubber packing poorly Apply grease to rubber
lubricated packing
Small brake shoe clearance Adjust shoe clearance
Weak or broken brake shoe return spring Replace return spring
Poor return motion of wheel cylinder piston and cup Replace piston and cup
Brake fluid not returning due to blocked brake pipe and Remove and flush with
joint brake fluid, or replace
Brakes are noisy Brake lining worn to allow rivet head to be exposed Replace brake lining
when pedal is depressed Hardened brake lining Replace brake lining
Unevenly worn brake drum inner surface Machine or replace
drum
Brake shoe not in tight contact with brake lining Replace brake lining
Brake drum left loose Retighten
Vehicle pulls to one side Improper brake shoe clearance or brake lining in poor Adjust shoe clearance.
contact Correct poor contact or
when brake pedal is
reline brake lining
depressed
Oil or grease on brake lining and brake drum inner surface Completely remove deposits
or reline brake lining
Brake drum runout, or left loose Correct runout.
Retighten
Uneven right and left inflation pressures Adjust to specified

inflation pressure
Different brake lining materials used Reline brake lining

or pad of the same material
Weak or broken brake shoe return spring Replace return spring

Chassis spring U-bolt left loose Retighten
Deformed backing plate Replace backing plate
Wheel cylinder piston malfunctioning Disassemble when cylinder,
check body, piston, and
cup, and replace any defective
part
Abrupt braking action Small brake shoe clearance Adjust shoe clearance
of wheel brakes Large brake shoe clearance Adjust shoe clearance
( 1 ) indicator lamp Air in brake system Bleed system
lights up Brake fluid leak from fluid circuit Correct leaks
(2) Air dryer

Air Air tank drain Desiccant becoming ineffective Replace desiccant,
dryer cock drains oil filter, and filter
Exhaust port Heater fails to operate and air dryer is frozen Replace heater if
defective. Replace
does not drain
thermostat if defective
Air dryer Valve inoperative due to foreign matter trapped Disassemble and check
valve and replace valve
interior is
complete as necessary
frozen
An open-circuited heater aggravating heat Check heater for continuity
with a multimeter and replace
insulating effect heater if there is an
open circuit
Heater inoperative due to defective thermostat Use following procedure
to check thermostat
and replace if
found defective
o Leave thermostat
under environment
0°C or below and check for
continuity
using a multimeter.
o heat thermostat to
make sure that it
turns OFF at
temperature between
0°C and 20°C.
Snow being packed on air dryer, lowering temperature Remove snow and ice
with care not to
to an abnormal low
damage air dryer
and heater wires
Heater inoperative due to heater and thermostat Connect heater and
thermostat wires
wires left disconnected
properly
Air leaks from Valve fails to seat properly due to foreign matter Disassemble and check
valve and replace valve
exhaust port
complete. Or replace
valve body if its sliding
surface is damaged.
Engine oil is Oil working up in air compressor Replace piston rings

an cylinder liner
discharged
from exhaust
port
ANTI-LOCK
BRAKE
SYSTEM
GENERAL ............................................................................. BRb - 2
SERVICE PROCEDURE ....................................................... BRb - 8
TROUBLESHOOTING .......................................................... BRb-12
BRb-2 A.B.S
GENERAL
A.B.S
1. A.B.S Function
When vehicle is braked while driving, or braked suddenly, or
road is slippery due to rain or snow, skid happens easily, When
skid happens, braking force is reduced and stopping distance
is lengthened. Or it may cause an accident because the ve-
hicle slips to the wrong direction and handle steering is
worsened. So ABS is a safety seeking system that prevents
wheel stuck or slips to maintain the vehicle direction stability
and ensures the steering control and achieves optimum stop-
ping distance.
2. Structure of A.B.S
• 4S/3M (4 Wheel speed sensors, 3 Modulator valves) : AOH
BRAKE
• 4S/4M (4 Wheel speed sensors, 4 Modulator valves) : FULL
AIR BRAKE
Air Line
4S/4M structure
Wire
Wheel speed sensor
Modulator valve
E.C.U
Relay
valve
Wheel speed sensor
Quick relay
valve Modulator valve
Wheel
speed sensor
5TBRC101
4S/4M is a basic structure diagram in this book.

GENERAL BRb-3
3. A.B.S Warning lamp

ABS warning lamp operates as follows.
Ignition Normal A.B.S warning System is in normal

Switch operation light turns off operation
after flashing
ON.
instantly.
After A.B.S warning Lamp turns off if the
repairs of light remains vehicle drives faster
onwhen ignition than 7 km/h and sys
A.B.S
switch in the tem is in normal
system
ON position operation.
Defective. A.B.S warning Warning light

light remains remains on when
onwhen ignition the vehicle drives
switch in the faster than 7 km/h.
ON position ABS system is
SPBR-005
defective.
If the ECU senses a fault when driving a vehicle, ABS warning

light turns on.
4. ABS modulator valve * Easy detection by sound
ABS modulator valve controls air pressure of corresponding We can check ABS operation by the air breathing
brake. 2 modulator valves of rear axle wheel are installed at sound coming from ABS modulator valves.
the right side frame of rearward,and 2 A.B.S modulator valves 1. Brake pedal is depressed
2. Turn on the Ignition switch
are installed at front axle frame. And relay valve is used to de- 3. Wait for ABS warning light turns on
liver air pressure to the A.B.S modulator valve. 4. Listen to the valve cycle one by one at
the diagonal direction.
5TBRC-102
BRb-4 A.B.S
5. ABS sensor Front axle Bushing

ABS system consists of pulse wheel installed at the wheel hub, Knuckle
and sensor at the opposite direction of the pulse wheel. Sen- Hub Pulse Sensor clip
wheel
sor feedback the information on the wheel speed to the ECU
continuously. The shape of shafts sets sensor position.
• Steering shaft sensor is installed at the steering knuckle. Sensor
• Drive shaft sensor is installed at the shaft-housing block.
SPBR-007
Rear axle
Sensor
Pulse wheel
Hub Bushing
Sensor clip
Block
Axle
housing
SPBR-008
6. Structure of E.C.U system

ECU corresponds to the brain of ABS system. This system
receives the information from sensors and remits the signals
to ABS modulator valve.
Installed inside the cap

SPBR-002
ECU version is displayed on the part number identification tag. Manufacturing

4S/4M (F/AIR) : 446 004 411 0 information
4S/3M(AOH) : 446 004 413 0 •

W A B C O •
ABS
4S/4M 24V
•
Parts
ABS composition ECU version Number
and shape
SPBR-003
WHEEL SPEED SENSOR a

Pulse wheels (a) are installed at the wheel hubs facing the ends of b
sensors (b). Sensor is fixed with sensor clip (c).
c SPBR-010
GENERAL BRb-5
A.B.S modulator valve OUT

ABS modulator valve controls the air pressure of the correspond-
ing brake in ABS operation.
Port 2 IN
Generally speaking, modulator valve is placed on the cross mem-
ber or frame side rail near brake chamber.
Port 1
SPBR-011
ASR operation principle

1. This system reduces the slips of driving wheel when driving on
a slippery road, and improves the towing capability. If one driv-
ing wheel starts slip, ASR applies air pressure to brake the
wheel and then engine torque is delivered to the better towing
wheel.
ASR Valve SPBR-015
2. Since ASR operates by itself, driver doesn’t have to select on/

off mode. When driving wheel slips in acceleration, ASR indi-
cation light turns on and it stops when slip stops.
When normal When wheel

driving (ASR ASR operates slip stops (ASR
indication in excessive wheel indication light is
light is slip (ASR indication OFF)
OFF) light is ON)
SPBR-014
3. When ASR is installed, ASR is displayed on the meter set as

“ASR”.
ASR OPERATION Right drive Slip

Left drive wheel
Specified
Speed
1. Differential Brake Control wheel slip rate

If the slip rate of one drive wheel exceeds specified slip rate,
Vehicle speed
ECU controls ASR valve and ABS modulator valve to brake the
Brake chamber of right
slipping wheel. If the slip rate lies within the specification, brake drive wheel
Pressure
is released.
Time
Differential brake control SPBR-020
Air line BRb-6
8 Oil line
12
1 2 6
AUX FR RR
5 DIAGRAM
(8) (10) (12)
10
4 17
3 7 18
AIR HORN PARKING CABLE
SPRAY NOZZLE
Air over hydraulic brake
15
14 T/M
PARKING
BRAKE
21 9 21
19 11
20
11
11 19
13
16
21 21
1. Air compressor 6. Safety valve 11. Air master 16. Oil reservoir
2. Air drier 7. Drain valve 12. Quick release valve 17. Low air pressure switch
3. Fuzzy tank 8. Air gauge 13. Double check valve 18. Remote chamber
4. Protection valve(PR-4) 9. Dual brake valve 14. Magnetic valve 19. ABS modulator valve
5. Air reservoir 10. Parking brake valve 15. Exhaust brake valve 20. ASR solenoid valve
21. Wheel speed sensor
SPBR-010
A.B.S
8 6
1 2 17
GENERAL
13
AUX(24) Full air brake
10 20
CLUTCH 7
4 5 12
3
FR RR
(15) (15)
PTO & A/HORN
7
18 16
5
23 14 23
21
21
13
22
19 11
9 21
21
23 23
1. Air compressor 7. Drain valve 13. Double check valve 19. Quick release valve
2. Air drier 8. Air gauge 14. Brake chamber 20. Quick valve
3. Fuzzy tank 9. Dual brake valve 15. Spray brake chamber 21. ABS modulator valve
4. Protection valve(PR-4) 10. Parking brake valve 16. Magnetic valve 22. ASR solenoid valve
5. Air reservoir 11. R-12 relay valve 17. Low air pressure switch 23. Wheel speed sensor
6. Safety valve 12.Check valve 18. Exhaust brake valve
SPBR-010
BRb-7
BRb-8 A.B.S
SERVICE PROCEDURE Sensor installed

at the knuckle
Sensor
WHEEL SPEED SENSOR Sensor

clip tap
1. Removal of wheel speed sensor-Front Axle
• Block both the rear tires and apply the parking brake firmly. Bushing
• Lift up the tire and put a safety support beneath the axle if
needed.
• Remove the wire clamp, which holds the sensor cable.
• Remove the sensor cable from chassis wires. Sensor clip SPBR-031
• Remove the sensor from sensor holder and rotate to re-

move if needed. Do not pull the cable
2. Installation of wheel speed sensor – Front axle
• Connect the sensor cable to chassis wires.
• Install the wire clamp to fix the sensor cable.
• Apply the lubricant recommended by WABCO on the sen-
sor spring clip and sensors.
• Install the clip onto the sensor spring. Check the spring clip
tap to face inside of the vehicle.
• Push to insert sensor spring clip to bushing of the steering
knuckle until the clip stops.
[Caution]
• Push by hands without using the tools.
3. Push the sensor fully inside the sensor spring clip until it touches
pulse wheel.
4. Remove the block and supports.
Removal of the wheel speed sensor – Rear axle

1. Block the tires so that the vehicle won’t move
2. Lift up the rear tire and put a safety support beneath the axle
3. Release the parking brake, and rotate the slack adjuster to
lengthen the lining clearance.
4. Remove wheel and tire assembly from the shaft.
5. Remove the brake drum and hub.
6. Remove sensor from the mounting block of the axle housing.
Rotate it to remove if needed. Do not pull the cable.
7. Remove the sensor spring clip from mounting block.
8. Remove sensor cable clamp.
9. Remove the sensor cable from chassis wire.
SERVICE PROCEDURE BRb-9
Installation of wheel speed sensor - Rear Axle

1. Apply the lubricant recommended by WABCO on the sensor
spring clip and sensor.
2. Install sensor spring clip. Check whether spring tap clip faces
inside vehicle.
3. Push to insert sensor spring clip to sensor holder until the clip
stops.
4. Push the sensor fully inside the sensor spring clip until it touches
pulse wheel.
Spring clip
Sensor
holder
Sensor Spring
clip tap
SPBR-032
5. Be careful with the sensor cable not to interfere with brake shoe.
6. Note that cable shouldn’t be tightened too much nor cut off,
and enough space should be assured for the moving of sus-
pension system.
7. Connect sensor cable to chassis wire.
8. Install sensor cable clamp.
9. Install wheel hub and brake drum assembly.
CAUTION
• Be careful not to shock to the wheel speed sensor.
10. Adjust the sensor using flange hole of axle if needed with the
rod of ø5. When the adjustment is not enough, readjust it after
removing drum assembly.
BRb-10 A.B.S
A.B.S MODULATOR VALVE

Removal of A.B.S modulator valve
1. Set the ignition switch at “OFF” position and apply the parking
brake firmly
2. Block both front and rear tires so that the vehicle do not move.
3. Lift up the tires and put a safety support beneath the axle if
needed.
4. Remove the wire connector from ABS valve
5. Remove the air-line from ABS valve port 1 (inlet) and port 2
Port 2 Port 1
(outlet).
6. Remove 2 mounting screws and nuts.
7. Remove ABS valve.
Installation of ABS modulator valve SPBR-033
1. Install ABS valve with 2 mounting screws and nuts. Tighten the
screw with the specified torque.
2. Connect the brake chamber line to ABS port 2. Connect the air
supply to ABS valve port 1.
3. Connect the wire connector to ABS valve and tighten it with
bare hands.
4. Remove the block and safety support.
5. Check the installation state.
Installation check
1. Apply the brake and listen to the air outlet sound from ABS
modulator valve.
2. Check the electrical cable connection, when something is wrong
with ABS modulator valve cycle after key switch on.
3. Check whether ABS warning light works properly while driving
the vehicle.
ASR VALVE
Working principle of ASR valve
1. Turn the key switch “off’:” and apply the parking brake.
2. Block the front and rear tires so that the vehicle won’t move
anyway.
3. Lift up the vehicle and safety support beneath the shaft, if
needed.
4. Reduce the air pressure by releasing air from the air pressure
tank.
5. Remove the key switch from ASR valve.
SERVICE PROCEDURE BRb-11
6. Remove the air-line from the port 1 (inlet) and port 2 (outlet) of
ASR valve. Port 1
(Air inlet)
7. Remove 2 mounting screws and nuts. Remove ASR valve. Air line
Port 2 (outlet)
Valve adjuster
(Do not open)
SPBR-034
Installation of ASR valve

1. Install ASR valve with 2 mounting screws and nuts and tighten
the screws with the specified torques.
2. Connect the air inlet line and air outlet line to port 1 and port 2
respectively.
3. Connect the wire connector to ASR valve and tighten with the
bare hand.
4. Remove the block and safety support.
5. Check the installation state.
Installation check( Check for diagnostic device)

1. Start the engine.
2. Fill the air tank fully and park the car.
3. Press the brake pedal.
4. Operate and check the ASR valve.
5. Listen to the exhaust sound of ASR valve.
6. Release the brake pedal.
7. Remove the diagnostic device.
8. Check whether ABS warning lamp turns off while driving.
BRb-12 A.B.S
FAULT DIAGNOSIS AND TROBLESHOOTING

1. Diagnosis
• Blink code diagnostic Blink code
Connect the connector under the instrument panel to the switch
blink code switch. Diagnose any fault by operating the switch

button as specified.
6-pin
• Scan tool diagnostic connector
Diagnose as the operation manual by connecting connec- SPBR-023
tor under the instrument panel to the connector of the diag-

nostic tool.
• When no tool is available.
Connect the 2 wires to the connector as shown in the figure.
Then you can diagnose by the blink code. General wire
No.4,
No.9
16-pin connector
SPBR-024
* KET TYPE
1 2 3 4 5 6 7 8 : RESERVED
Vehicle CAN(L) LINK(-),B ABS CAN - L L-LINE K/ENTRY
SAE J SAE J CHECK (Low ISO-9141 CODE
Speed
1939 1708/1587 speed) SAVING
9 10 11 12 13 14 15 16
CAN(H) LINK(+),A CAN-H K-LINE BATT
GND SAE J SAE J (Low ISO-9141 (12V,24V)
1939 1708/1587 speed)
5TBE-101
2. Operation of blink code

Press the blink code switch for a second and release it for the
diagnosis.
One of the Following state can be the case in blink code
diagnostic.
Symptom Cause Troubleshooting

ABS warning lamp doesn’t turn on Bulb is not tightened enough or blown. Is the bulb blown?
when the engine starts. Is the bulb blown? Is the bulb disconnected?
Improper battery voltage (it must be Check ECU electrical wire of bat-
within 22 and 32v) tery connector.
Measure the voltage.
Blink code diagnostic failure Improper switch operation time Press the switch as specified.
(ABS warning lamp is on after the op- Diagnosis = press it for a second
eration of blink code diagnostic) Fault deletion = press it for 3 seconds.
Wire connection is wrong. Check the wire connection
Warning lamp doesn’t blink for 8 times Fault still remains. Find out and repair the fault.
quickly after pressing the blink code
switch for a minimum 3 seconds.
TROUBLESHOOTING BRb-13
3. Diagnostic procedures
Description Procedure Warning lamp blinking Troubleshooting

Diagnosis • Stage 1 1. Normal if warning lamp turns on and Normal
Turn the ignition key turns off after a while. (no troubleshooting is needed)
on 2. When warning lamp does not turn on, Check wire or bulb.
wire has fault or fuse is blown.
3. If the warning lamp is on continuously, a. Proceed to stage 2
one of the following is the case, b. Proceed to stage 2.
a. Fault c. It’s normal if the warning lamp turns
b. Wheel speed sensor fault before off after driving the vehicle with 7
engine off. km/h (no troubleshooting is
c. Vehicle is not driven after ECU needed)
troubleshooting. d. Connect the connector
d. ECU connector is disconnected.
• Stage 2 Warning lamp blinks with 2-digit blink Judge whether it is actual fault or
Ground the terminal code. memorized fault.
No 4 of diagnosis In case of actual fault.
connector for 0.5 or - Repeat the one blink code cycle.
3.0 seconds or con- In case of memorized fault
nect it to the terminal - Blinking stops after showing the
No 9. memorized faults. (Displayed only
once)
• Stage 3 First unit blinking = blinking 1 to 8 times Find out the faulty position reading the
Check the blink code After 1.5 seconds fault codes.
by counting the 2nd unit blinking = blinking 1 to 6 times
blinking Repeat the first unit blinking after 4 sec-
onds
• Stage 4 In case of actual fault Shoot the trouble and Repeat stage
Turn the ignition key In case of memorized fault 1, 2 and 3 until it shows the normal
off and shoot the fault. code (1-1)
Record the trouble for later use.
(The last fault is displayed first code)
Fault • Stage 5 System code is displayed after warning
deletion Turn the ignition key on lamp blinking for 8 times. All faults are deleted.
and ground the terminal
No 4 of diagnosis con- In case it won’t blink 8 times. Actual fault remains.
nectorfor 3.0 or 6.3sec- (System code is displayed) (Repeat the stage 1 through stage 5)
onds or connect it to the
terminal No 9.
BRb-14 A.B.S
ABS warning lamp mode and blink mode

1. Warning lamp operation
1) When system is normal
IGNITION
ON
SWITCH OFF
WARNING ON
OFF
LAMP
3 seconds max. 5TBR-110
2) When system is abnormal (now)
IGNITION
SWITCH ON
OFF
WARNING ON
LAMP OFF
5TBR-111
3) When sensor is abnormal in previous ignition on (normal now)
IGNITION
IGNITION ON
SWITCH
SWITCH OFF
WARNING ON
LAMP OFF
Vehicle 7 KPH
speed 0 KPH
2. Fault diagnosis and fault code deletion using warning lamp

Turning on the self-diagnostic
1) Diagnosis mode
switch is the same as connecting
a. Self-diagnostic mode start the terminal No 4 and terminal No
Turn on the self-diagnostic switch on for 0.5 to 3.0 seconds 9 of the KET type diagnosis
- If it is faulty now, it displays only 1 fault that happened lately. connector.
Self
diagnostic ON On for 0.5 to 3.0 sec.
switch OFF
10 digit 1 digit 10 digit 1 digit 10 digit 1 digit
WARNING ON for the fault for the fault for the fault for the fault for the fault for the fault
code1 code1 code1 code1 code1 code1
OFF
LAMP 1.5 sec. 1.5 sec. 4 sec. 1.5 sec. 4 sec. 1.5 sec.
5TBR-113
- If it is not faulty now, it displays the latest 4 fault codes in sequence from the latest one and the other fault
codes more than 4 are displayed regardless of time sequence.
Self
diagnostic ON On for 0.5 to 3.0 sec.
switch OFF
10 digit 1 digit 10 digit 1 digit 10 digit 1 digit
WARNING ON for the fault for the fault for the fault for the fault for the fault for the fault
code1 code1 code1 code1 code1 code1
OFF
LAMP 1.5 sec. 1.5 sec. 4 sec. 1.5 sec. 4 sec. 1.5 sec.
5TBR-114
- Self-diagnostic mode terminates once ignition switch is turned off or vehicle speed is detected.
b. Blink stops if the ECU terminal of warning lamp is grounded for 6.3 to 15.0 seconds during blink code output.
Self On for 0.5 to 3.0 sec. On for 6.3 to 15 sec.

diagnostic ON
switch OFF
10 digits 1 digits 10 digits 1 digits
WARNING ON for the fault for the fault for the fault for the fault
code1 code1 code2 code2
LAMP OFF
1.5 sec. 1.5 sec. 4 sec. 1.5 sec.
5TBR-115
c. If self-diagnostic switch is on more than 15 seconds in ignition on state, it judges as lamp fails and stores the
mode into EEPROM.
2) System mode (fault code deletion)
a. System mode start
Turn on the self-diagnostic switch for 3.0 to 6.3 seconds in ignition switch on state, and then system mode
starts.
- When system is faulty now: system code is displayed continuously without fault code deletion.
Self On for 3 to 6 sec.

diagnostic ON
switch OFF
ON SYSTEM CODE SYSTEM CODE SYSTEM CODE SYSTEM CODE

WARNING
OFF
LAMP 1.5 sec. 4 sec. 4 sec. 4 sec.
5TBR-116
- When system is not faulty now: fault code is deleted and system code is displayed after lamp blinking 8
times in a short intervals.
Self On for 3 to 6 sec.

ON
diagnostic
OFF
switch
ON
WARNING OFF
LAMP 1.5 sec. 4 sec. 4 sec. 4 sec.
8XFAST : CLEAR ALL 5TBR-117
System code
- No 1: 6S/6M (6X2ATC), No 2 : 4S/4M, No 3 : 4S/3M (MAR/VAR FRONT), No 4 : 6S/4M, No 5 : 6S/6M
(6X4ATC), No 6 : 4S/3M (VAR REAR), No 7 : 4S/2M(VAR BOTH)
b. Function test (retarder reconfiguration)
After system code output for 3 times
- If the self-diagnostic switch is turned on 3 times with the interval of 0.5 and 3.0 seconds, retarder or
exhaust relay is reset. In other words, retarder configuration is executed.
Self
ON 0.5 sec. 3sec. 0.5 sec. 3sec . 0.5 sec.
diagnostic
OFF
switch SYSTEM CODE
ON
WARNING OFF
LAMP 4XFAST : RETARDER
RECONFIGURATION 5TBR-118
blink code timing
On for Off for

0.5 sec. 0.5 sec. NORMAL
On for 0.1 sec.
FAST
Off for 0.2 sec. 5TBR-119

BRb-16 A.B.S
3. Specification of fault codes
1st digit (Fault type) 2nd digit (Fault location)
1=No faulty 1=No faulty
2=ABS Modulator 1=FRT STEER AXLE RH
3=Too much air gap (Clearance between sensor and pulse wheel) 2=FRT STEER AXLE LH
4=Short or disconnection of sensor harness 3=REAR DRIVE AXLE RH
5=Sensor signal poor 4=REAR DRIVE AXLE LH
6=Pulse ring defect
7=System faulty 1=Data communication poor

2=ASR valve faulty
3=Exhaust brake relay faulty
4=ABS warning lamp faulty

5=Poor set up ASR
6=Poor ASR engine control valve
8=ECU 1=Too low voltage

2=Too high voltage
3=Internal faulty
4=System faulty
4=Ground faulty
Fault Remedy
Fault location Faulty Description System reaction Remarks
Code type
WSS FRT LH Air gap 32 ABS : 1
Tire size 52 Doesn’t active at specific 2
Short at power supply 42 wheel 3
Short at ground 42 4
Circuit cut 42 ATC : 5
Circuit short 42 Doesn’t active 6
Pulse ring 62 7
Slip 32 8
Circuit problem 52 9
Speed signal poor 32 10
Abnormal speed(Chattering) 52 11
Abnormal frequency 52 12
WSS FRT RH Air gap 31 ABS : 1
Pulse ring 61 7
Slip 31 8
WSS REAR LH Air gap 34 ABS : 1
Pulse ring 64 7
Slip 34 8
WSS REAR RH Air gap 36 ABS : 1
Pulse ring 66 7
Slip 36 8
BRb-18 A.B.S
Fault Remedy
Code type
WSS 3RD LH Air gap 35 ABS : 1
Pulse ring 65 7
Slip 35 8
WSS 3RD RH Air gap 33 ABS : 1
Pulse ring 63 7
Slip 33 8
MODULATOR Inlet,outlet valve circuit cut 22 ABS : 13
FRT LH Circuit cut 22 Doesn’t active at specific 15
Short at ground 22 wheel 16
Short at power supply 22 Does’nt active at FRT RH, 14
REAR LH(3RD LH),ATC
FRT RH Circuit cut 21 Doesn’t active at specific 15
REAR LH(3RD LH),ATC
REAR LH Circuit cut 24 Doesn’t active at specific 15
REAR LH(3RD LH),ATC
REAR RH Circuit cut 23 Doesn’t active at specific 15
REAR LH(3RD LH),ATC
3RD LH Circuit cut 26 Doesn’t active at specific 15
REAR LH(3RD LH),ATC
Fault Remedy
Code type
3RD LH Circuit cut 25 Doesn’t active at specific 15
REAR LH(3RD LH),ATC
Retardar Short at power supply 73 Doesn’t active at DBR 17
(DBR circuit) Circuit cut 73 59
Power DIAGONAL1 GND is disconnected from power 85 ABS : 20
Low voltage (DIAGONAL1 POWER) 81 Does’nt active at FRT RH, 21
DIAGONAL1 POWER CUT 85 REAR LH,3RD LH 22
Abnormal valve relay DIAGONAL1 Power 83 Doesn’t active at ATC 23
DIAGONAL1 GND is disconnected 85 ABS: Active,Warning lamp: ON 24
DIAGONAL2 GND is disconnected from power 85 ABS : 25
Low voltage (DIAGONAL2 POWER) 81 Does’nt active at FRT RH, 26
DIAGONAL2 POWER CUT 85 REAR LH,3RD LH 27
Abnormal valve relay DIAGONAL2 Power 83 Doesn’t active at ATC 23
DIAGONAL2 GND is disconnected 85 ABS: Active,Warning lamp: ON 29
DIAGONAL 1,2 Over voltage 82 Doesn’t active at ATC,ABS 49
Diff Brake Valve Short at power supply 72 ABS : 17
Does’nt active at FRT RH,
Circuit cut 72 REAR LH,3RD LH 18
Short at ground 72 Doesn’t active at DIFF.LOCK 19
Diff Lock Short at power supply 76 ABS : 17
Does’nt active at FRT RH,
Circuit cut 76 REAR LH,3RD LH 18
Short at ground 76 Doesn’t active at ATC 19
PROP Valve Short at power supply 76 Doesn’t active at DIFF.LOCK 17
Circuit cut 76 18
Warning lamp Abnormal warning lamp 74 Always light on 40
CAN Abnormal 71 ATC : Active 41
Cut 71 Doesn’t active at ATC 42
Too much time 71 44
Internal error 83 45
C O N F I G U R A - Abnormal ATC 75 Doesn’t active at ATC,ABS 50
TION Abnormal ABS 84 51
EEPROM Abnormal wheel parameter 84 Doesn’t active at ATC,ABS 52
Abnormal check sum 84 53
ECU Internal error 83 Doesn’t active at ATC,ABS 54
Short at load 84 55
Over slip/ dienamo test 71 56
Modulater valve operating time 21 57
Internal error 83 58
SID : Subsystem IDentifier

FMI : Fault mode IDentifier
WSS : Wheel Speed Sensor
BRb-20 A.B.S
Code Fault cause / repair

1 Vehicle speed amplitude is too low. Check axle bearing, pulse ring teeth and push the sensor fully once again.
2 Tire size or the number of pulse ring teeth is different from other wheels.
3 Check wire ring. DC power is detected at sensor wire.
4 Check sensor wiring. Replace the sensor if needed. Ground short is detected. Normal value is approximately 1.6 k
5 Check sensor wiring. Replace the sensor if needed. Circuit short is detected.
6 Check sensor wiring. Replace the sensor if needed. Short between 2 sensor wires (IG/IGM) is detected.
7 Check any damage of pulse ring with the tester. Replace it if it gets faulty repeatedly. If air gap code is detected
along with this code, adjust the air gap. Air gap is displayed periodically with its rotations.
8 Adjust the air gap. This code is displayed when the slip is detected more than 16 seconds. (In case of dynamo test)
9 Check the inconsistency with other sensors. IG or IGM of other sensors is detected. Repair the circuit.
10 Check the air gap. Check any poor connection between wire and connector. Measure the amplitude of sensor
signals and compare it with the specified value. Fault code due to wrong signals of the temporary wheel speed
sensor.
11 Check any poor connection between wire and connector. Check any damage on pulse ring. Measure the ampli-
tude of sensor signals and compare it with the specified value. No countermeasure is available if it is due to
brake squeeze or chattering.
12 Check any poor connection between wire and connector. Replace ECU, if the fault repeats.
13 Check the modulator wire. Common mode of inlet (EV) or outlet (AV) is disconnected temporarily or permanently.
In case of normal, the value of AV to common and EV to common is approximately 5.5 , and the value from AV
to EV is about 1.1
14 Check the modulator wire. Inlet (EV) or outlet (AV) circuit is short form the power.
15 Check the modulator wire. Inlet (EV) or outlet (AV) circuit is blown. It’s identical with code. 13.
16 Check the modulator wire. Inlet (EV) or outlet (AV) circuit is disconnected from GND.
17 Check wire. Output is disconnected from power.
18 Check wire. Output is disconnected.
19 Check wire. Output is disconnected from GND.
20 Check front LH, rear RH, 3rd RH modulator wire. Common mode of modulator is disconnected from the power.
21 Check power wire and fuse. Voltage is too low.
22 Check terminal 12 (GND) of 18P connector. It’s not connected to GND.
23 If this fault repeats, replace ECU. Inner relay of ECU is wrong.
24 Check front LH, rear RH, 3rd RH modulator wire. Common mode of modulator is disconnected from GND
25 Check front RH, rear LH, 3rd LH modulator wires. Common mode of modulator is disconnected from the power
26 Check power wire and fuse. Voltage is too low.
27 Check terminal 11 (GND) of 19P connector. It’s not connected to GND.
29 Check front RH, rear LH, 3rd LH modulator wires. Common mode of modulator is disconnected from GND.
40 Check wire and IND bulb. Have you ever pressed ABS check switch more than 16 seconds? Output mode
cannot detect the load. Adjust wheel speed sensor signal or check tire size.
41 Adjust wheel speed sensor signal or check tire size.
Code Fault cause / repair

42 Check wire. More than one SAE J1939 data link wire is not connected.
43 Check wire. More than one SAE J1939 data link wire is disconnected.
44 Check other ECU, which uses SAE J1939. That ECU transmits wrong signals.
45 If this fault repeats, replace ECU.
49 Check alternator and battery. It shows too high voltage more than 5 seconds.
50 Check the parameter setting. Diff valve is detected under the condition of no Engine Control Unit (CAN, PWM,
PROP)
51 Wrong ECU
52 Check the parameter setting. If this fault repeats, replace ECU.
53 Check the parameter setting. Didn’t you remove the connector while diagnosing with diagnostic equipment?
Reset the parameter.
54 Replace ECU if this fault repeats.
55 Modulator is not connected. This fault is not memorized. It is normal if this code shows up in the EOL test where
CAB is only assembled.
56 Check air gap. One axle rotated faster than the other axle. It is normal if it shows up in the speed test of R/T.
57 Modulator keeps operating more than 3 minutes. It comes back to normal after some delay.
58 Replace ECU if this fault repeats.
59 Check wire. No load on the DBR output mode. Load was detected before. Reset the parameter setting if there
is no actual load.
PARKING
BRAKE
GENERAL .............................................................................. BRc - 2
SPECIFICATIONS ..................................................................BRc - 3
SERVICE STANDARDS ........................................................ BRc - 3
SERVICE PROCEDURE ........................................................ BRc - 4
TROUBLESHOOTING ........................................................... BRc - 9
BRc-2 PARKING BRAKE
GENERAL
When the parking brake lever inside the cab is pulled up, the
shoes of the parking brake located behind the transmission
press against the drum to the bring the vehicle to a stop.
Parking brake
Parking brake
lever
Parking brake cable
58AA0001
Parking Brake Lever

The parking brake lever incorporates a lock mechanism which
holds the lever in the raised position.
Pressing the knob at the end of the lever disengages the pawl of
the lock plate from the tooth of the bracket, the lever becomes
unlocked, and can return to its original position.
58AA0385
Parking Brake Camshaft lever Camshaft lever

return spring Camshaft
When the parking brake lever is pulled up, the control wire pulls
on the camshaft lever and the camshaft rotates. This expands Anchor pin Shoe
brace return
the shoe and lining assembly.
spring
The expanded shoes press against the drum, and the friction Shoe and
lining
applied to the drum surface controls the rotation of the propeller assembly Brake drum
shaft that is connected to the brake drum.
If the parking brake lever is released, the return spring pulls the Adjusting wheel spring
Adjusting screw
58AA0287
camshaft lever back to its original position.
The shoe and lining assembly separates from the brake drum
surface by the force of the shoe return springs, and the brake
drum and propeller shaft are freed.
SPECIFICATIONS BRc-3
SPECIFICATIONS
Transmission model
KH10, M6S6
Description
Parking brake type Internal expansion type acting on propeller shaft

Brake drum I. D. 203.2 mm
Brake lining width x thickness 50 x 40 mm
Control Mechanical control with wire
Air control type
SERVICE STANDARDS
Service Standards Table
Nominal value
Parking brake lever stroke (number of detents) 7 to 10 - Adjust
Brake drum 205 Repair if the
service limit has
+0.3 not yet been reached;
∅203.2 0
replace if the limit
has been exceeded
Static rotational imbalance 0.88 Ncm (90 gfcm) - Replace
or less
Brake lining thickness 4.0 1.4 Replace
Shoe clearance 0.1 to 0.25 - Adjust
Shoe return Load/installed length M5S 145 N (15 kgf)/57.5 115 N (12 kgf) Replace
spring /57.5
Adjusting wheel Load/installed length 78 N (8 kgf)/59 63 N (6.4 kgf) Replace

return spring /59
Tightening Torque Table

Location tightened
O.D. x pitch (mm) Nm (kgfm)
Camshaft lever fastening nut M8 x 1.25 6.9 to 13 (0.7 to 1.3)
Transmission main shaft and transfer driver shaft rear lock nuts M27 x 1.5 245 to 345 (25 to 35)
BRc-4 PARKING BRAKE
SERVICE PROCEDURE
Parking Brake
(1) Before removing the parking brake, apply chocks to the front
wheels.
245 to 345 Nm
(2) For removal of the propeller shaft, refer to Propeller shaft (25 to 35 kgfm)
section. 58AA0310
(3) When removing the companion flange, use care not to cause
damage to the oil seal.
(4) Remove the parking brake control.
(5) Removal and installation of the transmission main shaft rear
lock nut.
Disassembly and inspection
Deterioration Load/Installed length

NV 145 N (15 kgf)/57.5
L 115 N (12 kgf)/57.5
9 Contamination, burn, hardening by
aging cracks, damage
Deterioration 7
Lining thickness
NV 4.0
Wear L 1.4
10 2
8 5
6 Drum diameter
12
NV Ø 203.2 -0.3
0
L 205
Uneven wear, cracks, score
11 (Use a lathe for correction)
4
Deterioration Load/Installed length
NV 78 N (8 kgf)/59
L 63 N (6.4 kgf)/59 NV .... Nominal Value
L ..... Limit
1. Parking brake drum 7. Cam shaft lever return spring
2. Shoe return spring 8. Cam shaft
3. Adjusting wheel return spring 9. Cam shaft lever
4. Adjusting screw and nut assembly 10. Spring spacer
5. Shoe and lining assembly 11. Support plate
6. Anchor pin brace 12. Dust cover
58AA0122
SERVICE PROCEDURE BRc-5
Reassembly
9 Section B-B
6.9 to 13 Nm
8 10 (0.7 To 1.3 kgfm)
1 Anchor pin
5°:FK series 2
15°:FL series Apply grease
7 (brake grease AKB100
Apply grease or equivalent)
Apply grease
(Brake grease AKB100 (brake grease
or equivalent) AKB 100 or
5 6 equivalent)
11
12
Section A-A
Assembly sequence
Apply grease
12 → 11 → 10 → 9 → 8 → 7 → 5 → 4 → 3 → 2 → 1 Apply grease A
(brake grease AKB 100 4 3 (brake grease AKB 100
or equivalent)
NOTE or equivalent)
Keep the brake lining surface free of grease. 58AA0293
Parking Brake Control

Parking brake Parking brake

lever
Ball bushing Cam shaft lever
Lock nut Parking brake cable
Parking brake cable
58AA0004
BRc-6 PARKING BRAKE
Parking brake lever

Disassembly
4
Deterioration 3
Reassembly 10
5
Removal procedure 9
1. Pilot switch
8
2. Pin
11
3. Snap ring 6
4. Pin
1
5. Lock latch
6. Knob
7. Return spring 7
8. Grip
9. Release rod
10. Parking brake lever
11. Parking brake bracket 58AA0127
7
6 4
5
3 11
9
Apply adhesive when screwing in Before staking
Stroke Without With
spacer spacer
Nominal Less than 0.6~0.96
10 value 0.6
8 1 After staking
After staking Spacer
Without With 2 Lever Spacer

spacer spacer B 2
Nominal
0.06 to 0.6 0 to 0.36 Striker plate
value
Before staking
58AA0007
SERVICE PROCEDURE BRc-7
Air Parking Brake

\The air parking brake uses compressed air generated by air compressor to operate parking brake.
When the parking brake is released, the compressed air is sent to remote air chamber through dash control valve and quick
release valve to overcome the spring tension inside the remote air chamber causing the parking cable to be loosened.
When the parking brake is applied, the dash control valve makes the compressed air to be extracted through quick release
valve, thereby the parking brake cable is pressed by spring tension of remote chamber to tighten the propeller shaft.
Parking brake
2 Dash control valve
3 Quick release valve
4 Cable
Air line
Remote air chamber
1 Air tank
58AA0164
Air parking brake adjustment

1) Fill the air tank with compressed air (6 kgf/cm² or more) and push the CAB control valve to actuate the remote air chamber.
2) Connect the clevis of parking brake to remote chamber.
3) Hard-tight the parking brake assembly ball so that the play of lever is to 1~2 mm.
4) Adjust the remote air chamber stroke to be 30~33 mm with ball while pulling the CAB control valve and tighten the nut.
5) Adjust the brake lining clearance to be nominal value (0.1~0.25 mm) if occurs slipping in parking brake.
Inspection of parking brake.
If the stroke of remote chamber push rod is 25 mm or more, adjust the lining clearance so that the stroke of chamber is
30~33 mm.
Push rod
58AA0165
BRc-8 PARKING BRAKE
Adjustment
Lock latch
Lever stroke
NV 7 to 10 notches
Striker
plate
To adjust brake shoe clearance, raise vehicle on

jacks and bring adjusting hole to the lower most
position by turning the drum.
Brake shoe clearance

NV 0.1 to 0.25 mm
NV ... Nominal Value 58AA0133
Place the camshaft lever in its released position.

Turn the adjusting screw by using a screwdriver through the Re-
duce
shoe clearance adjusting hole in the drum until the shoes firmly
contact the drum, and then back off the screw 8 notches. The Expand
shoe clearance then should be the nominal value of 0.1 to 0.25
mm.
Back out
8 notches
58AA0114
Adjust the parking brake lever stroke by turning the cam shaft
Lock nut Ball stud Control wire
lever lock nut so that the number of the clicks produced when the
lever is pulled up all the way from its released position with a
force of 295 N (30 kgf) corresponds to the nominal value (7 to 10
notches).
After making the adjustment, operate the parking brake lever two
or three times to make sure that the stroke is correctly adjusted,
the parking brake operates normally and the brake drum does 58AA0115
not drag.
TROUBLESHOOTING BRc-9
TROUBLESHOOTING
Parking brake Problems withe parking brake control mechanism
does not work o No shoe clearance and no play in lever stroke Adjust shoe clearance and
when the parking brake lever is pulled up with control wire
a force of 295 N (30 kgf).
o Poor engagement between parking brake lever Correct bracket
assembly lock plate pawl and bracket tooth installation for proper
engagement or replace
part which is defective
o Elongated or broken parking brake control wire Replace control wire
Problems with shoe and drum assembly
o Excessive shoe clearance and resultant increase Adjust brake shoe clearance
of parking brake lever stroke
o Deformed or distorted drum Correct by grinding
drum inner surface
or replace drum
o Unevenly worn shoe lining due to uneven Replace shoe and
contact with drum lining assembly
o Oil or grease on drum inner surface or shoe lining Clean drum inner surface
and replace shoe
and lining assembly
Inadequate rlease Problems with parking brake control mechanism
of parking brake o Weakened or broken return spring of parking Replace return spring
brake lever assembly
o Incorrect parking brake lever stroke Adjust stroke
o Parking brake control wire does not move smoothly Adjust or replace
o Elongated control wire inner cable control wire
o Excessive sliding resistance due to broken
control wire inner cable
Problems with shoe and drum assembly
o Weakened or brake shoe return spring or camshaft Replace shoe return
lever return spring spring and/or camshaft
lever return spring
o Tool small brake shoe clearance Adjust brake shoe clearance
TRANSMISSION
(M6S6)
GENERAL ............................................................................. TMa - 2
SPECIFICATIONS ................................................................. TMa - 3
SERVICE STANDARDS ........................................................ TMa - 4
SPECIAL TOOLS .................................................................. TMa - 7
SERVICE PROCEDURE ....................................................... TMa - 8
TROUBLESHOOTING .......................................................... TMa-42
TMa-2 TRANSMISSION (M6S6)
GENERAL
TRANSMISSION PROPER
The transmission changes the torque produced by the engine to a
torque the vehicle requires. The torque, or drive power, is increased
or decreased by shifting several groups of gears.
Since the engine always turns in one direction, the transmission
also performs the function of changing the direction of rotation so
the vehicle can be backed.
3rd 2nd
5th 4th 1st -Rev.
Shift fork
Synchromesh
Drive pinion
1st
2nd
3rd
5th
4th
Rev.
Costant mesh gear
NOTE:
This illustration shows a 5-speed transmission. 22AA0375
SPECIFICATONS TMa-3
SYNCHRONIZER ASSEMBLY
<Pin type> Synchronizer
Synchronizer ring stem
Synchronizer cone
Sleeve
2nd gear
Sunchronizer hub
Shifting pin Shifting spring

Shifting ball
22AA0376
The transmission gears are kept in constant mesh with the drive <Key type>
Synchronizer
pinion by the constant-mesh gears, main shaft gears, and counter sleeve Synchronizer ring
shaft gears. Shifting key Synchronizer cone
5th gear 4th gear
The rotating motion imparted by the drive pinion to the constantmesh
gears is transmitted to all main shaft gears which turn freely. When
the gearshift lever, the synchromesh function causes the synchronizer
sleeve to mesh with a gear to change the speed of rotation from the Shifting key Synchronizer hub
spring
pinion and transmit it to the rear axle. 22AA0312
The constant-mesh slide design is employed between the 1st and
reverse gear.
SPECIFICATONS
TRANSMISSION PROPER
Type K360
GEAR RATIO 1st 6.453
2nd 3.604
3rd 1.813
4th 1.000
5th 0.803
6th -
Rev. 6.453
Oil capacity (with P.T.O) 5.5
Transmission control Floor shift, remote control type
SERVICE STANDARDS
SERVICE STANDARDS TABLE Unit: mm
Nominal value
Backlash 1st gear 0.08 to 0.20 0.5 Replace

2nd gear 0.08 to 0.20 Check for damaged
3rd gear 0.09 to 0.21 tooth surface
4th gear 0.09 to 0.21
5th gear (drive pinion and 0.04 to 0.17
constant-mesh gear)
Reverse gear Counter shaft 0.08 to 0.20
Main shaft 0.09 to 0.21
-
End play 1st gear (main shaft) 0.15 to 0.35 0.5 Replace gear or washer
2nd gear (main shaft)
3rd gear (main shaft)
4th gear (main shaft) 0.25 to 0.40
Reverse gear (main shaft) 0.15 to 0.35
Reverse gear (reverse gear shaft) 0.2 to 0.9 1.2
Play in diametric direction after assembly of - 0.12 Replace defective parts
reverse gear needle bearing
Main Play in diametric direction after - 0.12 Replace defective parts
shaft assembly of pilot bearing
Syn- Synchronizer ring keyway to shifting 4.75 to 4.95 5.8 Replace
chro- key clearance
mesh Synchronizer hub keyway to shifting 0.05 to 0.20 0.5
key key clearance
type Fit between synchronizer hub and T0.0069 to L0.088 0.2
main shaft in turning direction
Play between synchronizer hub and 0.052 to 0.148 0.3
synchronizer sleeve in turning
direction
Synchronizer ring to main shaft 4th 1.45 to 1.85 0.2
gear assembly gear cone clearance
Syn- 2nd and 3rd synchronizer assembly 0 1.5 Replace
chro- synchronizer ring to main shaft 3rd
mesh 2nd gear assembly synchronizer 0.052 to 0.148 0.3
key cone clearance
type Fit between 2nd and 3rd synchronizer T0.005 to L0.107 0.2
hub and main shaft in turning
direction
SERVICE STANDARDS TMa-5
Nominal value
Maintenance item (Basic diameter in [ ]) Limit Remedy and remarks
Main 2nd gear bearing sleeve O.D. -0.10 Replace

-0.030
shaft [68]
-0.043
3rd gear bearing sleeve
4th gear bearing sleeve -0.030
[55]
-0.043
1st gear - 0.12 Replace defective

Clearance in diametric
parts. If two needle
direction after assembly 2nd gear roller bearings are
3rd gear used for a gear, use
of main shaft needle bearings of the same
roller bearing 4th gear package color for
Reverse gear replacement
Play between synchronizer sleeve and main 0.052 to 0.148 0.3 Replace
shaft in turning direction
Lower Shift fork to synchronizer 1st and Rev. 0.3 to 0.5 1.0 Replace
gear sleeve clearance 2nd and 3rd
shift 4th and 5th
Tilt of shift fork claw 1st and Rev. 0.1 or less 0.2 Replace
2nd and 3rd
4th and 5th
Alignment or bend of 1st and Rev. 0.03 or less 0.06 Corret or replace
shift rail 4th and 5th
2nd and 3rd 0.02 or less 0.04
Upper 1st and Rev. return spring Load/installed 85 N (8.7kgf)/ 7.3 N (7.4 kgf)/ Replace
gear
shifter length 27.6 27.6
Speedo- Speedometer gear bushing to speedometer [12] 0.02 to 0.07 0.15 Replace
meter
gear clearance
gear
Backlahs between speedometer gear and 0.13 to 0.29 0.36 Replace
speedometer worm
Trans- Ball stud to housing clearance 0.10 to 0.40 1.0 Replace ball stud or
mission housing, whichever
control
is worn
Housing bushing to pipe A clearance 0.07 to 0.17 0.6 Replace bushing
Front cross shaft to bushing clearance 0.07 to 0.17 0.6 Replace bushing
Rear cross shaft to bushing 0.02 to 0.25 0.6 Replace bushing
Spring Load/installed 52 N (5.3 kgf)/ 42 N (4.3 kgf)/ Replace
length 45.4 45.4

Location tightened
O.D. x pitch (mm) Nm (kgfm)
Transmission Clutch housing bolt M16 x 2.0 190 (19.2)
proper Gearshift upper mounting bolt M8 x 1.25 23 (2.3)

Gearshift lower mounting bolt M8 x 1.25 23 (2.3)
Gearshift fork set bolt M10 x 1.25 29 (3.0)
Drain plug and level plug M20 x 1.5 54 to 83 (5.5 to 8.5)
Main shaft front lock nut M36 x 1.5 245 (25)
Main shaft rear lock nut M27 x 1.5 245 to 345 (25 to 35)
Reverse shaft lock piece bolt M10 x 1.5 40 (4.1)
-
Rear cover and extension housing bolt M10 x 1.5 40 (4.1)
Backup lamp switch M18 x 1.5 49 (5.0)
Speedometer gear bushing M27 x 1.5 145 (15)
Mounting bolt of transmission (clutch housing) M10 x 1.5 40 (4.1)
onto engine (flywheel housing)
Counter shaft rear lock nut M36 x 1.5 345 (35)
Rear bearing retainer mounting M10 x 1.5 40 (4.1)
Jaw set bolt M14 x 1.5 135 (13.6)
Lock pin mounting nut M8 x 1.25 17 (1.7)
Support plate and shoe assembly or M10 x 1.5 40 (4.1)
dust cover mounting bolt
Transmission Front mechanism housing bolt M12 x 1.25 48 (4.9)
control Select lever bolt M12 x 1.25 37 to 54 (3.8 to 5.5)
Gearshift lever bolt M12 x 1.25 36 (3.7)
Select rod and shift rod ball joint nut M8 x 1.25 8.8 to 14 (0.9 to 1.4)
Tighten ball joints M8 x 1.25 19 to 27 (1.9 to 2.8)
M10 x 1.25 38 to 59 (3.9 to 6.0)
SPECIAL TOOLS TMa-7
SPECIAL TOOLS
Unit: mm
Tool name Part No. Shape Use
Puller set 09431-83100 Removal of drive pinion and
reverse shaft
ASST0030
SERVICE PROCEDURE
REMOVAL AND INSTALLATION OF TRANSMISSION
Key points for removal
1) Detach the control rod and associated parts around the
transmission.
2) Remove the power cylinder with hoses and pipes left attached.
3) Remove the propeller shaft.
Interlock switch
Hub and release bearing Backup lamp switch
Cable bracket
Clutch housing
Return spring
Clutch booster
Dust plug
22AA0004
4) Remove the drain plug and inspection plug to remove trans-

mission oil. On vehicles with full-power PTO, remove
transmission oil also from the PTO case.
Inspection Drain
plug plug
22AA1335
5) When draining the transmission oil, check the oil for quantity,
quality, and metal chips and particles.
The drain plug is magnet and metal particles adhering to it
should be removed after the inspection.
22AA0381
SERVICE PROCEDURE TMa-9
6) Support the transmission proper with a jack.

Then, loosen the clutch housing attaching bolts to separate the
transmission from the engine. There are grooves at three loca-
tions in the clutch housing provided for easy removal of the
transmission. To remove, insert a screwdriver into the grooves.
22AA0380
7) Move the transmission rearward until the drive pinion splines

come out of position. Never jerk the transmission.
22AA0379
Key points for installation Apply grease

[molybdenum disulfide base
1) Check the drive pinion splines for rust. If rust gathers, use a grease (NLGI No.2) Li soap]
wire brush to clean of rust. Then, apply grease by hand to the
surfaces of the drive pinion over which the clutch slides.
2) Check the clutch release lever for proper height.
3) Using a jack or crane, carefully insert the transmission assem-
bly into the pilot bearing of the engine flywheel, with care not to
damage the spline shaft. 22AA0668
Then, secure the clutch housing by tightening mounting bolts

on its periphery. [32 Nm (3.3 kgfm)]
4) After ensuring that the drain plug has been torqued to
specification, pour in transmission oil through the inspection port.
5) Install the control rod and associated parts around the
transmission.
6) Install the power cylinder Drain plug
Inspection plug
54 to 83 Nm
7) Install the propeller shaft. 54 to 83 Nm
(5.5 to 8.5 kgfm)
(5.5 to 8.5 kgfm)
22AA1336
Inspection and adjustment after installation

1) Adjust the transmission control.
2) Check the clutch pedal.
3) Adjust the parking brake.
TRANSMISSION ASSEMBLY
Disassembly
Companion
Upper gear shifter
flange
Clutch housing Lower gear shifter Parking brake drum

(vehicles with C5 clutch)
Reverse gear Parking brake
cover assembly
Extension housing
Clutch housing
(vehicles with C6, C7 clutch)
22AA1337
Disassembly Procedure (Vehicles with center parking brake)
Using the Socket Wrench, remove the main shaft rear lock nut.
Socket Wrench
22AA0310
Reassembly
Upper gear shifter Apply sealant

mounting bolt (8 places) (THREEBOND 1104J
23 Nm (2.3 kgfm) or equivalent
Apply sealant
to mating surfaces
(THREEBOND 1215J
or equivalent
to mating surfaces
Lower gear shifter

Apply sealant
mounting bolt (11 places)
(THREEBOND 1215 or
23 Nm (2.3 kgfm)
equivalent
to mating surfaces
Main shaft rear

lock nut
245 to 345 Nm
(25 to 35 kgfm)
Rear cover mounting

bolt (9 places)
40 Nm (4.1 kgfm)
Inspection plug and drain plug

Inspection plug
54 to 83 Nm
(5.5 to 8.5 kgfm)
Drain plug
54 to 83 Nm
(5.5 to 8.5 kgfm)
NOTE
Apply sealant (THREEBOND 1105D or equivalent) to threads in
inspection and drain plugs. 22AA1338
Cluch housing
1) To mount the clutch housing to the transmission case, using
the Vinly Tape.
Vinyl Tape
Drive pinion
22AA0666
2) Tighten the clutch housing mounting bolts in diagonal order

and uniformly, and finally tighten to specified torque.
190 Nm
(19.2 kgfm)
-
22AA0667
Transmission
Inspection before disassembly
Before attempting to disassemble the transmission, measure the
backlash between gears and end play in each gear. If the
measurement exceeds the limit, replace the defective parts.
22AA0015
Backlash Backlash
Backlash NV 0.09 to 0.21 NV 0.08 to 0.20
NV 0.04 to 0.17 L 0.5 L 0.5
L 0.5
5th 4th 3rd 2nd 1st Rev.
Backlash
NV 0.2 to 0.9
L 0.5
End play
NV 0.25 to 0.4
L 0.5
End play
NV 0.15 to 0.35 End play Backlash
L 0.5 NV 0.09 to 0.21 NV 0.09 to 0.21
L 0.5 L 0.5
22AA0309
o Check bearings for rotating condition.

o Check gears and splines for tooth contact, damage,
Play diametric and flaking and missing tooth.
direction after assembly
L 0.12 18
19 1
20
22 31
M5S5, M6S5
21 32
20 33
34
Bend
NV 0.05 or less
29 L 0.1
26
30 Clearance
BD 13
28 NV 0.02 to 0.07
27 36 L 0.15
3
35 2
5
4 6 Tilt of claw
Bend NV 0.1 or less
NV 0.3 or less L 0.2
L 0.06
Bend 7
25 NV 0.02 or less
Clearance Clearance
NV 0.05 to 0.20 L 0.04
24 NV 0.3 to 0.5
L 0.5 L 1.0
23 11
Clearance
13
Wear
NV 4.75 to 4.95 8
12
L 5.8
9
Wear
16 Play in turning direction
10 NV 0.052 to 0.148
L 0.3
10
Fit in counter shaft
14 in turning direction
NV T0.006 to L0.088
L 0.2
17 15
Play in diametric direction Clearance
after assembly NV 1.45 to 1.85
NV 0.105 to 0.150 L 0.2
L 0.3
VB43001
1. Main shaft O.D. gear 13 Synchronizer hub 25 Bearing
2. O.D. shift shaft 14 Synchronizer ring 26 Bearing
3 O.D. shift lever 15 Counter shaft O.D. gear assembly 27 Snap ring
4 O.D. shift rail B 16. O.D. gear sleeve 28 Snap ring
5. Set bolt 17. Thrust washer 29 Drive pinion assembly
6 O.D. gearshift rail C 18. Reverse shaft lock piece 30 Bearing
7 O.D. gearshift fork 19 Reverse gear shaft 31. Rear bearing retainer
8 Lock nut 20. Reverse gear side washer 32 Snap ring
9. Shifting key retainer 21 Reverse gear 33 Bearing
10. Shifting key spring 22 Needle bearing 34. Main shaft assembly
11 Synchronizer sleeve 23 Snap ring 35. Counter shaft assembly
12 Shifting key 24 Snap ring 36. Transmission case
-

Disassembly and Inspection Procedure that follows.
NOTE
1. Before disassembling the key type synchronizer, put matching mark at one location each in the
synchronizer hub and synchronizer sleeve where a key is inserted.
2. Before removing the main shaft assembly, extract the ball bearings at front and rear of the counter
shaft and let it fall down into the transmission case.
Disassembly and Inspection Procedure

1) Check the O.D. shift lever for alignment or bend.
If B is misaligned or bent exceeding the limit with reference to
A-A, replace the lever
A A A
VB43003
2) Check O.D. shift rail B and O.D. gearshift rail C for alignment
or bend. (Half of the dial indicator reading is the bend.)
If the limit is exceeded, correct or replace the part.
VB43005
3) Using the special tool, Single Spanner, remove the lock nut.
<M5S6, M6S6>
Single Spanner
MH061555
VB43007
4) Measure the clearance between the O.D. gearshift fork and

O.D. gearshift fork
synchronizer sleeve and replace the parts if the clearance ex-
ceeds the limit.
At the same time, check the shift fork claw for tilt.
If defects are evident, correct or replace the parts.
Synchronizer
sleeve
VB43009
5) Measure the clearance between the synchronizer hub keyway Shifting key
and shifting key. If the clearance exceeds the limit, replace the
parts.
Synchronizer hub
VB43011
6) Measure the synchronizer ring keyway width and shifting key

width to calculate the clearance. If the clearance exceeds the Synchronizer
limit, replace the parts
Shifting key
VB43013
7) Measure the clearance between the synchronizer ring and gear Feeler gauge
cone of the counter shaft O.D. gear assembly. If the limit is
exceeded, replace the parts.
NOTE
Press the synchronizer ring evenly and take measurement Synchronizer
ring
throughout the entire circumference.
Counter shaft O.D.
gear assembly
VB43015
Disassembly and Inspection Procedure

1) Mesure the synchronizer ring keyway width and shifting key Synchronizer ring
width to calculate the clearnce. If the clearance exceeds the

limit, replace the parts.
Shifting key
22AA0996
2) Before disassembling the reverse gear, check it for play in dia-

metric direction. If the play excceds the limit, replace the defec-
tive parts.
22AA1148
3) Remove the reverse gear shaft.
22AA0301
4) Remove the snap rings from the front end of the counter shaft.
22AA1344
5) Remove bearings from the front and rear ends of the counter
shaft.
22AA1345
6) Remove the snap rings on the drive pinion side.
22AA1346
7) Remove the drive pinion assembly together with the bearings.
Puller set
09431-83300
22AA1347
8) Remove the bearings from the drive pinion.

Puller set
09431-83100
22AA0317
9) Remove the snap ring from the rear end of the main shaft.
22AA1342
10) Remove the bearing from the rear end of the main shaft.
Puller set
09431-83100
22AA0141
Reassembly
10 11 13 16 14
12
15
8 9
40 Nm
(4.1 kgfm)
6
1
2
7
-
17 18 3 4 5 3
22AA1349
1) With supporting the front end of the main shaft drive the
bearings, to which snap rings have been attached, into the rear
end of the main shaft using special tool.
22AA0188
Dummy Bearing Re-

tainer
Dummy Bearing
Main Shaft Rear
Bearing Installer
22AA0155
2) Drive the bearing into the drive pinion assembly. Then, fit the
snap rings into position. Drift
NOTE:
Snap ring
Place the drive pinion assembly on a flat surface when
installing the bearing into it to prevent the drive pinion
assembly from being damaged. Bearing
Drive
pinion
assembly 22AA1351
3) Drive the bearing together with the drive pinion assembly into
position.
Drift
22AA0908
4) Hold the front end of the counter shaft with tools. Then, install
the bearing on the rear end with the groves outward.
Drift
22AA1352
5) Remove the tool from the front end of the counter shaft. Then
drive bearing, to which snap rings have been attached, into
position.
Drift
22AA1353
6) Fit the snap ring to secure the bearing in position.
22AA1344
7) Insert the reverse gear, to which the needle bearing and re-
Oil hole
verse gear side washer have been installed, from the side
40 Nm
washer have been installed, from the side and drive the re- (4.1 kgfm)
verse gear shaft into position with a plastic hammer. Then, se- Reverse Reverse shaft
gear shaft lock piece
cure the shaft with the reverse shaft lock piece. O-ring
Reverse gear Reverse gear Reverse gear

side washer side washer
22AA1354
8) Install the thrust washer so that its side having the oil groove
faces gear.
Oil groove
22AA1355
9) Mate the synchronizer hub with the synchronizer sleeve, en-

suring that the keyways at three places in the synchronizer Synchronizer
Synchronizer sleeve
hub are aligned with stub teeth at three places (indicated by *
hub
in Fig.) of the synchronizer sleeve.
NOTE
- Stub
If the synchronizer hub and synchronizer sleeve are reused, tooth
be sure to align the alignment marks when they are reas- Keyway
sembled together. 22AA1356
10) Fit shifting keys into keyways. Then, install the shifting key spring
so that gap between its ends is not located at the shifting key Shifting key Shifting Shifting key
spring key
spring
position.
Shifting key
22AA1000
11) Face the synchronizer ring to the synchronizer hub side having
oil grooves. Then, align keyway and fit synchronizer ring to syn- Synchronizer ring
chronizer hub.
Next, mount the assembly onto the counter shaft.
Oil groove
22AA0993
12) Install the shifting key retainer to the synchronizer hub, making
sure that the protrusions at two places in the retainer are fitted Protrusions
into the slots in hub.
22AA1357
13) Tighten lock nut to specification.

345 Nm
NOTE (35 kgfm)
After torquing the lock nut, bend tangs at four places of
the shifting key retainer over the lock nut.
Single spanner
Tang
22AA1358
14) After reassembly, check gears for backlash and end play.
NOTE
Check gears also for rotating condition.
22AA1339
MAIN SHAFT
Play in diametric direction NV ... Nominal Value
Fit in main shaft in after assembly
Clearance turning direction L ... Limit
NV 0.05 to 0.20 L 0.12
NV T0.006 to L0.088
L 0.5 L 0.2
15
Clearance Play in turning direction
NV 0.052 to 0.148 17
NV 4.75 to 4.95
L 5.8 L 0.3
11
13
9 12
16
Play in diametric direction 14
9 Clearance
after assembly
NV 1.45 to 1.85
L 0.12
Play in diametric direction L 0.2
after assembly
L 0.12
6
10 27
26
8 24
7
25 28
5
Play in diametric direction
after assembly
Play in diametric direction L 0.12
after assembly
L 0.12
23
19
Clearance
21 NV 0
20
L 1.5
Play in turning direction

NV 0.052 to 0.148
22 L 0.3
18
1
Fit in main shaft in
Clearance turning direction
NV 0 NV T0.05 to L0.017
L 1.5 L 0.2
3
2
Play in diametric direction
after assembly
29 L 0.2
Play in turning direction

4
NV 0.052 to 0.148
o Check bearings for rotating condition. L 0.3
o Check gears and splines for tooth contact, damage, and
flaking and missing tooth.
22AA0383
Disassembly sequence 20. 2nd and 3rd synchronizer assembly

1. 1st gear thrust washer 21. Main shaft 3rd gear bearing sleeve
2. Main shaft 1st and reverse gear 22. 2nd and 3rd synchronizer hub
3. Needle bearing 23. Main shaft 2nd gear assembly
4. Synchronizer sleeve 24. Needle bearing
5. Snap ring 25. Main shaft 2nd gear bearing sleeve
6. Pilot bearing 26. 2nd gear thrust washer
7. Lock nut 27. Main shaft 1st and reverse gear
8. Lock washer 28. Needle bearing
9. Synchronizer ring 29. Main shaft
10. Shifting key spring
11. Synchronizer sleeve For parts with an encircled number, refer to Disassembly and
12. Shifting key Inspection procedure that follows.
13. Synchronizer hub NOTE
14. Main shaft 4th gear assembly 1. Before disassembling the key type synchronizer, put
15. Needle bearing matching mark at one location each in the synchronizer
16. Main shaft 4th gear bearing sleeve hub and synchronizer sleeve where a key is inserted.
17. 4th gear thrust washer 2. Do not disassemble the 2nd and 3rd synchronizer assem-
18. Main shaft 3rd gear assembly bly of the pin type synchronizer, as its stem has been
19. Needle bearing staked over the ring. If it needs replacement, replace it as
an assembly.
1) Using the Snap Ring Expander, remove the snap ring.
Snap Ring Expander
22AA1359
2) Using the special tool, Puller set, remove the pilot bearing.
Puller set
09431-83100
22AA1104
3) Using the Single Spanner, loosen and remove the lock nut.
Single Spanner
22AA0187
4) To remove each bearing sleeve, make use of the weight of gear;

i.e., lightly hit the main shaft against a lead plate.
NOTE
Be sure to use a lead plate to prevent main shaft end from
being damaged.
Bearing sleeve
22AA1360
Inspection Procedure
1) Measure the play in diametric direction in each main shaft gear
and needle bearing.
If the play exceeds the limit, replace the needle bearing.
NOTE
1. If two needle bearings are used for one gear, use ones
of the same package color for replacement.
22AA575
2. If replacement of the needle bearing does not correct
the excessive diametric play, check each bearing sleeve
(except those in 1st and reverse gear) and main shaft
gear and replace any defective parts. Shifting key
2) Measure the clearance between the synchronizer hub keyway

and shifting key. Replace parts if the clearance exceeds the
limit
Synchronizer hub
22AA0997
3) Measure the synchronizer ring keyway width and shifting key

width to calculate the clearance between the two. If the limit is Synchronizer ring
exceeded, replace parts.
Shifting key
22AA0996
4) Measure the clearance between thew synchronizer ring and

the gear cone of main shaft 4th gear assembly. If the clear-
ance exceeds the limit, replace parts.
NOTE
Press synchronizer ring evenly and take measurement Feeler gauge
throughout the entire circumference. Main shaft 4th

Synchronizer ring Gear cone gear assembly
22AA0998
5) Measure the clearance between the synchronizer ring of 2nd

and 3rd synchronizer assembly and the synchronizer cone of
Synchronizer ring
main shaft 3rd/2nd gear assembly.
Synchronizer cone
Replace parts if the clearance exceeds the limit. Main shaft 3rd gear
assembly or main
2nd gear shaft
assembly
Clearance
22AA0993
Reassembly
11 12 14 21 18 22 24 26 23 27 28 2 1 29
10
245 Nm
(25 kgfm)
7
8 9 13 9 16 15 17 19 20 25 4 3
Assembly sequence
29→28→27→26→25→24→23→22→20→21→19→18→17→16→15→14→8→7→6→5→4→3→2→1
↑
13→11→12→10→9
For part with an encircled number, refer to Reassembly Procedure that followings.
22AA1362
Main shaft 3rd
1) Install the 4th gear thrust washer so that its side with a greater gear assembly side
contacting area faces the main shaft 3rd gear assembly.
Main shaft 4th gear

assembly side
22AA1363
2) Mate the synchronizer hub with the synchronizer sleeve, en-

Synchro-
suring that the keyways at three places in the synchronizer nizer
Synchronizer hub
hub are aligned with stub teeth at three places (indicated by *
in Fig.) of the synchronizer sleeve.
sleeve
NOTE Stub
If the synchronizer hub and synchronizer sleeve are reused,
tooth
be sure to align the alignment marks when they are reas- Key way
sembled together. 22AA1356
3) Fit shifting key into keyways. Then, install the shifting key spring
Shifting key
so that the gap between its ends is not located at the shifting spring Shifting
key Shifting key
key positions.
spring
Shifting key
22AA1000
4) Install the lock washer to the synchronizer hub, making sure

that the protrusions at two places in the lock washer are fitted Protrusions
into the slots in the hub.
22AA1364
5) After assembling gears, use the Single Spanner, to tighten lock

nut to specification.
Single Spanner
22AA0187
6) Drive the pilot bearing onto main shaft.
22AA0154
7) Fit the snap ring into position.
Snap Ring Expander
22AA1359
8) Install the 1st gear thrust washer so that its side with oil grooves
faces gear. Oil groove
22AA1365
COUNTER SHAFT
Disassembly
3
2
1
1. Counter shaft constant-mesh gear
2. Counter shaft 4th gear
3. Counter shaft
22AA0384
Remove the counter shaft gear.
22AA0150
Reassembly
3
2 Apply sealant Assembly sequence
(THREEBOND 1375B or
3→2→1
equivalent) to the
periphery of shaft
22AA0315
Using a hydraulic press, install the counter shaft gear onto the
counter shaft then, press-fit the gear.
NOTE
Before installing the gears, apply sealant (THREEBOND 1375B
or equivalent) to the portions of the counter shaft over which
they are installed.
22AA0151
LOWER GEAR SHIFTER

Lost tension
2
Wear 3
1
Clearance form Defor-
synchronizer sleeve
mation 15 Cracks
NV 0.3 to 0.5 5
Tilt of claw
Deformation
NV 0.1 or less 4
L 0.2
Bend 9
Clearance from
NV 0.03 or less synchronizer sleeve
L 0.06 6 NV 0.3 to 0.5
L 1.0
7 11
Tilt of claw
8 NV0.1 or less
16
L 0.2
13
10 6
6 6
Bend
NV 0.02 or less
L 0.04 16 16
Clearance from
synchronizer sleeve 14 12
NV 0.3 to 0.5
L 1.0
6 L ... Limit
Tilt of claw
NV 0.1 or less Bend
L 0.2 NV 0.03 or less
L 0.06
1. Backup lamp switch 13. 4th and 5th gear shift rail jaw
2. Poppet spring 14. 4th and 5th gear shift fork
3. Interlock pin 15. Gearshift lower case
4. Dust plug 16. Steel ball
5. Expansion plug
6. Set bolt For parts with an encircled number, refer to Disassembly
7. 1st and reverse shift rail and Inspection procedure that follows.
8. 4th and 5th gear shift rail jaw
NOTE
9. 1st and reverse shift fork
1. Do not disasemble the lower case except when
10. 2nd and 3rd shift rail assembly
replacing the shift fork, shift rail, or shift rail jaw.
11. 2nd and 3rd gear shift fork
2. when disassembling the shift rail, use care not to
12. 4th and 5th shift rail
lose the interlock pin, steel ball, and poppet spring.
22AA0386
1) Check the shift rail for bend (A half of the dial gauge pointer
deflection is the bend). If the bend exceeds the limit, correct or
replace the parts.
22AA0194
2) Measure the clearance between the shift fork and synchro- Synchronizer sleeve
nizer sleeve and, if it exceeds the limit, replace the parts.
Clearance
Shift fork
22AA1361
3) Measure the displacement or tilt of claw of each shift fork with

reference to shift rail hole.
Replace parts if the limit is exceeded.
Shift rail hole
Displacement
22AA1366
Reassembly
49 Nm
(5 kgfm)
Apply sealant
1 B
(THREEBOND 1104jJ or equivalent)
to threads A
10
4
8
13 11
15
18
A B
16
12
5
3
9
2
14 29 Nm
7
(3 kgfm)
19 135 Nm
(13.6 kgfm)
6
Section A-A 17
Section B-B
Assembly sequence For parts with an encled number, refer to Reasembly

16→17 11→12 procedure that follows.
↓ ↓
NOTE
18→19→19→19→7→6→5→4→3→2→1
During reassembly, make sure of the correct installation di-
↑ ↑
rection of each shift fork.
13→15→14 9←10←8
22AA1367
Install the shift rail set bolt. After installation, stake threads at more
than three places by punching.
Set bolt
Stake threads at more than
three places by punching
22AA0198
UPPER GEAR SHIFT

1 4
5
8
12 9 Deterioration,
Deterioration 18 damage
10
19
20
3
11
14
2
Wear
16
6 Wear
15
17
Tension load/installed length
NV 85N (8.7 kgf)/27.6
L ... Limit
L 73N (7.4 kgf)/27.6
Disassembly sequence 10. Bushing

1. Air breather 11. Spring pin
2. Interlock switch 12. Gearshift lever
(vehicles with turbocharger) 13. Spring retainer
3. Gasket 14. Return spring
4. Lock pin 15. Gearshift sliding lever
5. Gear selecting lever B 16. Return spring retainer
6. Gear selecting lever A 17. Return spring
7. Shim 18. Dust seal
8. Washer 19. O-ring
9. Oil seal 20. Selector lever case
For parts with an encled number, refer to Reasembly procedure that follows.
NOTE
Do not remove bushing unless for replacement.
22AA1368
Selector lever case
To remove the bushing press-fitted into the selector lever case,
use a screwdriver.
NOTE
When removing the bushing, use utmost care to prevent dam-
age to the selector lever case.
Bushing
22AA1046
Reassembly
A B
20
5
12 13 14 13 16 17 16 18
17Nm
(1.7 kgfm)
B
C
Use shim to obtain
2 a 0.3 to 0.6 mm 11 19
Pack this area
15
1 A C axial play with grease
6 Section A-A [wheel bearing grease
8 4 7
(NLGI No. 2) Li soap]
2 3
Apply grease
(wheel bearing grease
10 (NLGI No 2.) Li soap]
9
Apply grease
(wheel bearing grease Apply sealant
(NLGI No 2.) Li soap] (THREEBOND
Apply sealant 1140J or
Section B-B (THREEBOND 1215J or equivalent)
equivalent)
Section C-C
Assembly sequence
20→10→9→16→17→16→15→13→14→13→11→6→8→7→5→4→3→2→1
↑
12→18→19
For part with an encircled number, refer to Reassembly Procedure that followings.
NOTE
When installing gear selecting lever A, turn the lever as may be
required to prevent oil seal lips from being damaged.
22AA1369
Drift
1) After cleaning the inner surfaces of the selector lever case,
press-fit the bushing into position.
At the time, using the special tool, Drift to the bushing and tap
the bar evenly with care not to gall the case. Also, coat the Bushing
facing side of the bushing with sealant before installation. Selector
Apply sealant lever case
NOTE (THREEBOND 1215
When applying sealant, keep the inside of the bushing free or equivalent)
22AA1047
of sealant.
2) Apply grease to oil seal lips and press the oil seal evenly into Lips
position, its lips facing down. Top
NOTE Bottom
Pack areas between lips with grease and make sure that Pack grease
Bushing [wheel bearings grease
the oil seal is installed in the correct direction. (NLGI No.20 Li soap]
Selector lever case
22AA1050
3) When installing the gearshift sliding lever to the gearshift lever,

Splines Selector lever case
align splines so that the two parts make the angle as shown.
Gearshift sliding lever Gearshift lever
22AA1370
REAR COVER
Vehicles with Center Park Brake
4
1
9
12
10
7 6 5
11
Backlash Clearance
NV 0.13 to 0.29 BD 12
L 0.36 NV 0.02 to 0.07
L 0.15
Disassembly sequence BD ... Basic Diameter

1. Lock nut NV ... Nominal Value
2. Parking brake drum L ... Limit
3. Companion flange
4. Support plate and shoe assembly
5. Speedometer gear bushing
6. Oil seal For parts with an encircled number, refer to Disassembly proce-
7. Speedometer gear dure that follows.
8. Rear cover
NOTE
9. Oil seal
Do not remove the oil seal and speedometer gear bushing A
10. Speedometer gear bushing A
unless for replacement.
11. Speedometer worm
12. Washer
22AA1371
Using the Socket Wrench, remove the lock nut. Socket Wrench
22AA0310
Speecometer
Measure the speedometer gear shaft O.D. and speedometer gear gear
bushing I.D. to calculate the clearance between the two. Replace
parts if the clearance exceeds the limit.
Speedometer
bushing
22AA1052
Reassembly
Vehicles with Center parking Brake
Apply sealant 4 Apply grease

2 40 Nm
(THREEBOND 1215 or [molybdenum disulfide (4.1 kgfm)
equivalent base grease (NLGi
to entire mating surfaces No.2) Li soap]
11 1
245 to 345 Nm
(25 to 35 kgfm)
12
3
9 145 Nm 5
(15 kgfm) 6
40 Nm
(4.1 kgfm) 7 10
8
Assembly sequence
12→11→7→4→3→2→1 NOTE
↑ ↑ When inserting bushing the speedometer gear, use care
8→10→9 6←5 not to damage the oil seal.
22AA1374
Rear cover Drift
1) To install speedometer gear bushing a into the rear cover, use
the special tool, Drift which has been machined to dimensions
shown.
Speedometer gear
bushing A
22AA1376
2) Drive oil seal evenly into the rear cover.
NOTE
Make sure that the oil seal is installed in the correct
direction.
Top
Bottom
Oil seal
22AA1290
3) To install oil seal into the speedometer gear bushing, using the
Drift
special tool, Drift round bar.
NOTE
Packing
Before installing the oil seal, pack the area indicated with
Top
grease. Make sure of correct installation direction.
Speedometer gear Bottom
Also apply grease to inner circumference of the packing. bushing Pack grease [wheel bearing
grease (NLGI No.2) Li soap]
22AA1094
4) Tighten the lock nut to specification.
245 to 345 Nm
(25 to 35 kgfm)
22AA0310
Transmission Control
11
13
8
6 7
12
14 4
10
9
15 1
16 2
17
18 19
20
1. Rear cross shaft bracket 11. Knob
2. Return spring 12. Boot
3. Rear cross shaft 13. Change lever
4. Shift D rod assembly 14. Change lever bracket
5. Select C rod assembly 15. Shift A rod assembly
6. Sleeve 16. Select rod A
7. Collar 17. Cross shaft bracket
8. Plate 18. Front cross shaft
9. Select lever 19. Shift B rod assembly
10. Collar 20. Select A rod assembly
VB43017
Adjusting after installation To displace the lever to right,

reduce length of rod
1) Adjustment of control rod To displace the lever to left,
increase length of rod
If the gearshift lever is displaced too far foward or backward, or
To displace the
to right or left, adjust the length of the rod. lever rearward,
increase rod
After adjustment, tighten the lock nut on each control rod to length
specification. To displace the
lever forward,
reduce rod length
VB43019
2) Installation of shift lever knob

The shift lever knob is provided with a self-tapping screw. The
knob has been removed, remount it by driving into position by
hand.
Reassembly
Apply grease
Cross shaft bracket, right
[chassis grease (NLGI No.1)
Ba-Al soap] Cross shaft support B
Rear housing assembly

Front cross shaft
Apply grease
[chassis grease (NLGI No.1) Apply grease
Ba-Al soap] Shift lever knob Rear housing [chassis grease (NLGI NO.1)
Apply LOCTITE #242 Ba-Al soap]
Shift rod assembly or equivalent
Rear cross Dust cover
shaft
Front mechanism set
Pack grease [chassis Ball bushing
Rear select
Select rod grease (NLGI No.1) Return
lever
Pack grease [chassis Ba-Al soap] sporing
grease (NLGI No.1) View A
Ba-Al soap]
Select rod assembly
Front select lever Select rod assembly
Cross shaft Bracket cross shaft stay
bracket, left
Front housing
Select rod assembly Shift rod assembly
Tightening of ball joints

Screw dimension Tightening torque
M8 x 1.25 19 to 27 Nm (1.9 to 2.8 kgfm)
M10 x 1.25 38 to 59 Nm (3.9 to 6.0 kgfm)
Shift rod and selected rod

Inscribed mark "L"
8.8 to 14 Nm (in the case of LH thread)
(0.9 to 1.4 kgfm)
Pack grease [chassis
grease (NLGI No.1)
Ba-Al soap]
Shift rod 8.8 to 14 Nm

(0.9 to 1.4 kgfm) Ball joint
VB43021
TROUBLESHOOTING
Transmission Defective control mechanism
slips out (insufficient shift stroke on transmission side)
of gear o Play in ball joint Replace ball joint
o Worn bushing Replace
o Bend rod Correct bend or replace
o Worn steel ball or groove in shift rail Replace worn part
o Insufficient shift rail poppet spring tension or broken spring Replace
Defective transmission
(Disassemble and check transmission assembly)
o Main shaft rear lock nut left loose Retighten to specifcation
o Worn main shaft thrust washer Replace
o Worn or damaged main shaft bearing Replace
o Worn splines in synchronizer ring and synchronizer sleeve Replace worn part
Hard Defective control mechanism
shifting (insufficient shift stroke on transmission side)
into gear o Play in ball joint Replace ball joint
o Ball joint insufficiently lubricated Lubricate
o Improper rod length Adjust
o Worn bushing Replace
o Shift rail not sliding smoothly Replace shift rail or
gearshift lower case
o Worn shift fork jaws Replace
o Bend shift fork Correct bend or replace
Defective transmission
(Disassemble and check transmission assembly)
o Main shaft rear lock nut left loose Retighten to specification
o Worn main shaft thrust washer Replace
o Worn or damaged main shaft bearing Replace
o Worn taper cone in synchronizer ring and gears Replace the worn part
o Defective clutch Adjust
o Cultch not releasing properly
o Improper clutch pedal free play
TROUBLESHOOTING TMa-43

Unusual Worn or damaged main shaft pilot bearing Replace or lubricate
noise Worn or damaged drive pinion bearing Replace
in neutral Excessive backlash between drive pinion Replace
and counter shaft constant-mesh gear
Worn or damaged counter shaft bearing Replace
Worn or damaged needle bearing in gears Replace
Excessive backlash between counter shaft Adjust with adjusting
4th gear and PTO idler gear gasket in PTO case or
replace gear
Unusual Worn or damaged main shaft and counter shaft bearings Replace
noise Worn or damaged main shaft pilot bearing Replace
in gear Worn or damaged needle bearing in gears Replace
Excessive backlash between gears in main Replace gears
shaft and counter shaft
Worn or damaged synchronizer sleeve Replace
Insufficient gear oil Add
Damaged gear Replace
Unusual Defective synchronizer
noise o Worn taper cone in synchronizer ring and gears Replacd worn part
in shifting o Worn shifting key Replace
o Damaged shifting key splines Replace
Worn splines in gears Replace gear
Worn synchronizer sleeve Replace
Clutch not releasing properly Adjust
TRANSMISSION
(KH10)
SPECIFICATIONS ............................................................................ TMb - 2
SERVICE STANDARDS ................................................................... TMb - 2
SERVICE PROCEDURES ................................................................ TMb - 3
Gear Shift Housing .................................................................... TMb - 8
Input and Output Shaft, Gears ................................................. TMb-16
Counter Shaft, Reverse Idler Shaft and Gear ......................... TMb-41
Transmission Control ............................................................... TMb-49
TROUBLESHOOTING ..................................................................... TMb-51
TMb-2 TRANSMISSION (KH10)
SPECIFICATIONS
Model KH-10
Transmission control type Floor shift, remote control type
1st 6.967
2nd 4.247
3rd 2.454
Gear ratio
4th 1.471
5th 1.000
rev. 6.492
Oil capacity 7.8 (without PTO)
8.3 (with PTO)
SERVICE STANDARDS
Maintenance item Norminal value Service limit Remedy and remarks
1st gear 0.023~0.101 0.016~0.055 Replace or check for
2nd gear 0.022~0.071 damaged tooth
Back lash 3rd gear 0.020~0.070 surface
4th gear 0.020~0.064

reverse gear 0.019~0.064
1st gear 0.15~0.3 0.15~0.60 Replace gear or
2nd gear washer
End play 3rd gear
4th gear
reverse gear 0.20~0.60

SERVICE PROCEDURES TMb-3
SERVICE PROCEDURES
COMPONENTS
1 3 2 5 4 6 7 8 9 10 11 12 13
22 23 21 20 19 18 17 16 15 14
1. Clutch release bearing 13. Main shaft

2. Synchronizer sleeve 14. Parking brake drum
3. 5th and input shaft 15. 1st, reverse synchronizer sleeve
4. 4th gear 16. Counter shaft
5. 4th, 5th shift fork 17. 2nd, 3rd synchronizer sleeve
6. 3rd gear 18. 3rd, 4th clutch hub
7. 2nd, 3rd shift fork 19. Counter 4th gear
8. Control cover 20. Transmission case
9. 2nd gear 21. Counter shaft drive gear
10. 1st gear 22. Clutch housing
11. 1st, reverse shift fork 23. Clutch release fork
12. Reverse gear
ATTM-700
Removal
1. Park the car on level ground.
2. Block the wheels with wooden block.
ATTM-701
3. Remove the drain plug and drain the transmission oil to the
suitable container.
ATTM-702
4. Mark assembly sign on flange and yoke.

5. Disassemble 4 nuts.
6. Remove center bearing fixing bolts and nuts.
7. Remove the propeller shaft.
ATTM-703
WARNING
• After removing propeller shaft, hold the parking brake
drum securely together with propeller shaft fixing bolt
and nut. Otherwise, parking brake drum may drop sud-
denly to result in the personal damage.
ATTM-704
8. Remove parking brake cable, speedometer cable and related

electric harnesses.
9. Remove the shift rod and select rod.
10. Remove the clutch booster.
CAUTION
• Place the plug on the removed clutch booster port and
pipes to prevent influx of dusts.
• Do not remove air tube or oil hose of clutch booster ATTM-705
not to do air bleeding in reassembling.
11. Remove the clutch-housing bolt.
ATTM-706
12. Place the jack under transmission.

13. Remove the remaining bolts of clutch housing.
14. Pull the transmission backward. Lower the jack slowly and re-
move the transmission.
ATTM-710
15. Remove the clutch housing.
ATTM-708
Installation
1. Install the clutch housing to the transmission.
Tightening torque : 2,200 ~ 3,200 kg.cm
ATTM-708
2. Apply the grease on the input shaft spline.
ATTM-709
3. Jack up the transmission, until main drive gear spline and clutch
disc spline aligns.
ATTM-710
4. Attach the transmission to the clutch housing.

5. Assemble the bolts around the clutch housing.
6. Lower the jack and put it aside.
7. Assemble the remaining bolts around clutch housing.
8. Tighten the transmission installation bolts.
Tightening torque : 380 ~ 500kg.cm
ATTM-706
9. Install shift rod and select rod.

10. Connect parking brake, speedometer cable and related elec-
tric harnesses.
ATBE-005
ATTM-705
11. Tighten the 4 nuts.

ATTM-703
12. Install propeller shaft to the center bearing holder.

13. Tighten the fixing bolts and nuts.
Tightening torque : 380 ~ 500 kg.cm
attm-711
14. Fill the oil to the level of filler plug hole of transmission.
15. Clean the drain plug and replace the gasket with new one and
tighten the plug.
Oil quantity : 6.8 liter
ATTM716A
16. Press the pedal and measure the distance that pedal travels
until resistance is felt.
Standard : 32 ± 5 mm
Limit : 30 mm
ATTM-713
17. Check every gear shift positions.
ATTM-714
Gear Shift Housing
COMPONENTS
33
33
32
17
28
15
23
1 2
19
16 19 29
7
18 5
20 21
28 11 12
25 30 29
26
31
27
8 22
3 10
13
24
11
12 6
23 14
9
11
13 12
23
1. Transmission case cover 13. Lockout plunger 25. Wire

2. 1st & reverse shift shaft 14. Pin 26. Shift lever
3. 2nd & 3rd shift shaft 15. Oil seal 27. Oil flange bolt
4. 4th & 5th shift shaft 16. Inner shift lever 28. Oil flange bolt
5. 1st & reverse shift head 17. Shift lever sub Ass'y 29. Bolt
6. 4th & 5th shift head 18. Compression spring 30. Key
7. 1st & reverse shift fork 19. Spacer 31. Dowel pin
8. 2nd & 3rd shift fork 20 Screw set 32. Power gear assembly
9. 4th & 5th shift fork 21. Air bleeder 33. Bolt
10. Compression spring 22. Expansion plug
11. Pin 23. Expansion plug
12. Spring pin 24. Steel ball
ATTM-715
DISASSEMBLY
NOTE
• Move each shift fork to see if any part is worn or abnor-
mally operating. Replace faulty part if any.
• Make sure that no pin and spring is left inside the gear
shift housing.
1. Remove air hose connected to power shift assembly.
2. Remove power shift assembly from control cover.
ATTM-602
3. Remove control cover from gear shift housing.
ATTM-716
4. After removing spring pin fixed to shift lever, remove shift lever
shaft from the control cover.
NOTE
• Take care so that the oil seal is not damaged by shift
lever shaft key.
5. Install the spacer and compression spring by using the special

tool.
ATTM-717
6. Remove selector lever and selection assembly after removing

the spring pin fixed to selector lever assembly.
ATTM-718
7. Remove compression spring, play washer, O-ring and spacer.
ATTM-719
8. Remove gearshift housing fixing bolts.
ATTM-720
9. Remove the gearshift housing.

10. Remove the back-up lamp switch.
11. Install the transmission case cover to the vise.
12. Remove the shift fork fixing pin and shift head by using tapping
rod of diameter 5 mm.
ATTM-721
13. Set the shift shaft into the neutral position.

14. Hold a copper rod against the end of the shift shaft and tap the
rod lightly to remove the shaft and its expansion plug. When
removing the shift shaft, remove the shift head and shift fork.
NOTE
• Take care not to damage the sliding surface of the in-
side gear shift housing.
ATTM-722
15. Remove the lock ball and compression spring.

NOTE
• Steel ball may pop up from the hole in removal of the
shift shaft. Install the safety glass and take care not to
lose lock ball and compression spring.
ATTM-723
16. Remove the inter-lock key plunger.

NOTE
• Take care not to lose the inter-lock plunger.
ATTM-724
17. Remove the inter-lock pin.

NOTE
• Take care not to lose inter-lock pin.
• Remove the other shift shaft, shift fork and shift head
with the same procedure.
ATTM-725
Inspection
1. Check the shift lever shaft and inner shift lever for any damage
or worn-out. Replace them if any damage or worn-out.
ATTM-726
2. Check any damage or worn-out for the following parts and re-
place them if any damage is detected.
Inter-lock pin, inter-lock plunger, compression spring, ball
ATTM-727
3. Check the clearance between the shift fork and shift sleeve.
4. If the clearance is bigger than the service limit, replace the
shift fork or shift sleeve with the new one.
Standard : 0.082 ~ 0.137 mm
Service limit : 1.0 mm
ATTM-728
5. Check the shift head, shift fork and shift shaft for the damage
and worn-out. Replace the part if any damage or worn-out is
detected.
ATTM-729
Assembly
Compression spring(5th gear)
1. Fix spacer, shift lever and shaft compression spring, and com-
press them by using special tool.
2. Align the key groove of spacers with the special tool. (Reverse
side)
3. Assemble the key into key groove of shift shaft.
4. Clean the control cover and apply the grease lightly on the
sliding surface inside control cover.
Compression spring(Reverse gear)
ATTM-730
5. Apply gear oil lightly on the gear shift lever shaft, and insert
the shaft into control cover. When the end of shift lever shaft is
inserted fully into the control cover, perform next operation.
ATTM-718
6. Assemble the compression spring and spacers. (Reverse side)
NOTE
• Assemble the spring and spacer while holding them
securely with the special tool (09703-1030).
ATTM-731
7. Assemble the inner shaft lever.

8. Assemble the compression spring and spacer (5th side)
NOTE
• Assemble the spring and spacer while holding them
securely with the special tool (09703-1010).
9. Install selection, O-ring, inner shift lever to control cover.
10. Install power shift assembly onto the control cover.
11. Apply the gear oil on shift shaft. ATTM-722
12. Align the shift fork and head and push to insert shift shaft.
NOTE
• Pay attention to the direction and position of shift fork
and shift head.
• Refer to the diagram below for the relative position of
component parts.
• Assemble the shift shaft, fork and head with the fol- A B C
lowing procedures. ATTM-732
A : 5th ~ 6th shift fork

B : 2nd ~ 3rd shift fork F
E
C : 1st ~ reverse shift fork
E : steel ball shift fork
F : compression spring
G : 4th ~ 5th shift shaft
H : 2nd ~ 3rd shift shaft
I : inter-lock plunger
J : inter-lock pin
K : 1st ~ reverse shift shaft G I H J K
ATTM-733
13. Install ball and spring into the hole.

14. Depress the spring and ball by using the special tool and slide
shift shaft over the ball.
NOTE
• Shift shaft must be in the neutral position.
ATTM-723
15. Fix the shift head and fork with cotter pins. Use 2 pins. Drive
both the large and the small pin into the fork and the head with
their slits positioned on opposite side.
ATTM-734
16. Install the inter-lock plunger.
NOTE
• Do not forget to install the inter-lock plunger.
ATTM-724
17. Install the inter lock pin.
NOTE
• Apply grease to the inter-lock pins and insert pins to
the shift shaft of 1st – 2nd and 3rd – 4th
ATTM-725
18. Install the expansion plugs in the shift shaft openings at each
end of the housing.
NOTE
• Apply sealing compound.
ATTM-735
19. Tighten the back-up lamp switch.

Back up lamp switch
Tightening torque : 350 ~ 400 mm
NOTE
• Apply thread-locking agent.
ATTM-736
20. Using an ohmmeter, check the continuity between the termi-

nals with in the neutral position (infinity) and with the gear shift
shaft in the reverse position (0 ohm). If faulty, replace the
switch.
ATTM-737
21. Check the relative position and direction of each shift fork and
shift head and check the interlock operations.
Distance :
A : 114.9 ± 0.5mm
+0.55
B : 114.1 - 0.45 mm
A B ATTM-738
22. Measure the shift stroke.

Shift Stroke :
(4th – 5th) A : 12.5mm
(2 -3 , Reverse-1 ) B : 12.0mm
nd rd st
A A B B C C
ATTM-739
23. Apply a sealing compound to the face of the transmission case.

NOTE
• The trace of the sealing compound should be
continuous. The sealing compound should be “THREE
BOND #1215” or equivalent. 4~6mm
24. Install the gear shift housing and tighten the bolts using a torque
wrench.
Tightening Torque : 400~500 kg.cm Sealing compound
ATTM-740
25. Install the control cover to the gear shift housing.

Tightening Torque : 400~500 kg.cm
26. Install the power gear assembly to the control cover.
ATTM-602
Input And Output Shaft, Gears
COMPONENTS
1
13 14
11
10
9
1
7
6 7
1
1 12 17
5
4 8
3 19
2
1 18
11
10 14
9 16
28
6 27
7
26
12 25
8 24
7 2
6 32
1
15 23
14 39
14
39 22 33
21 31
14
34
38 20 30
14
40
30
35
29
36
41 37
1. Retainer ring 15. 4th gear 29. Bearing retainer(front)

2. Cylindrical bearing 16. 3rd gear 30. Retainer gasket
3. Input shaft 17. Pin 31. Transmission case
4. Spacer 18. Output shaft 32. Speed gear bush
5. Roller bearing 19. 2nd gear 33. Speed drive gear
6. Synchronizer cone 20. 1st gear 34. Bearing retainer(rear)
7. Synchronizer ring 21. Constant hub 35. P.T.O cover
8. Synchronizer hub 22. 1st gear, reverse clutch sleeve 36. plug
9. Compression spring 23. Reverse gear 37. Magnetic plug
10. Synchronizer head 24. Oil seal 38. 1st, 2nd gear clutch hub
11. Synchronizer key 25. Dust deflector 39. Bushing
12. Synchronizer sleeve 26. Universal joint flange 40. Gasket
13. Synchronizer cone 27. O-ring 41. Soft washer
14. Needle roller bearing 28. Nut
ATTM-743A/ATTM-742
DISASSEMBLY
1. Remove the drum fixing nuts.
2. Remove the drum
ATTM-800
3. Lift the caulked part of lock nut completely out of the shaft
groove.
4. Using a special tool, remove the lock nut.
NOTE
• Before loosening the lock nut, engage two gears so
that the output shaft cannot be turned.
Special tool : Socket wrench (09839-4601)
ATTM-801
5. Remove the joint flange.
ATTM-802
6. Remove the parking brake assembly bolts.

7. Remove the parking brake assembly.
ATTM-803
8. Remove the rear-bearing retainer.

1) Remove assembly bolt of bearing retainer.
2) Remove bearing retainer.
ATTM-804
9. Remove the speedometer driven gear.

1) Remove bushing setting bolts of driven gear.
2) Remove the driven gear as the remov al of bushing.
ATTM-805
10. Remove oil seals.
ATTM-806
11. Remove the speedometer drive gear.
ATTM-807
12. Remove the fixing bolts.

13. Remove the front bearing retainer.
NOTE
• Oil seal is attached inside the front bearing retainer.
Cover (e.g. with aluminum foil) the spline of the input
shaft so as not to damage the lip of the oil seal when
removing retainer.
ATTM-808
14. Using special tool, remove the input shaft together with bearing.
Special tool :
Input shaft pulley (09650-2070)
Sliding Hammer (09420-1442)
ATTM-809
15. Using retainer ring flyer, remove the retainer ring from the in-
put shaft.
NOTE
• Be careful with the retainer ring that may pop up while
removal.
ATTM-810
16. Using a press, remove the cylindrical bearing.
ATTM-811
17. Using a screwdriver, remove the retainer ring from the groove
of the input shaft, and then remove the roller bearing from the
input shaft.
NOTE
removal.
ATTM-812
18. Remove the retainer ring from the output shaft rear bearing.
NOTE
removal.
ATTM-813
19. Install the special tool to the bearing.

Special tool :
Hook (096530-1190)
Puller (09650 – 1880)
NOTE
• Insert the hook’s click into the groove for the retainer
ring, and then fix the puller to the hook with bolts so
that bearing does not turn. Then rotate the bolt to pull ATTM-814
the bearing out.
20. Remove the rear bearing.
ATTM-815
21. Attach a jig to the end of the output shaft.

NOTE
• If the output shaft assembly is removed from the trans-
mission without jig, the reverse gear will drop from
the shaft and possibly result in personal injury.
ATTM-816
22. Remove the output shaft assembly from the transmission case.
When removing output shaft assembly, remove the synchro-
nizer ring and the cone of the input shaft gear.
ATTM-817
23. Remove the jig from the end of output shaft.
ATTM-818
24. Remove the reverse gear.
ATTM-819
25. Remove the reverse gear needle roller bearing.
ATTM-820
26. Remove the retainer ring at the front face of output shaft.
NOTE
removal.
ATTM-821
27. Remove the 4th – 5th synchronizer unit.
ATTM-822
28. Remove the synchronizer cone.
ATTM-823
29. Remove the needle roller bearing.
ATTM-824
30. Remove the retainer ring that fixes the 4th gear bushing to the
output shaft.
NOTE
removal.
ATTM-825
31. Remove the 4th gear housing.
ATTM-826
32. Remove the 4th gear.
ATTM-827
33. Remove the 4th gear needle roller bearing.
ATTM-828
34. Remove the pin.
ATTM-829
35. Remove the 3rd – 4th synchronizer unit.
ATTM-830
36. Remove the 3rd gear together with synchronizer ring.
ATTM-831
37. Remove the 3rd gear needle roller bearing and spacer.
ATTM-832
38. Press the main shaft rear end through the bushing and gears
by supporting the assembly on front face of the 2nd gear.
NOTE
Bush
• Stay away from the shaft. The shaft may drop suddenly
resulting in personal injury 1st gear
2nd gear
Supporter
ATTM-833
39. Remove the reverse gear bushing.
ATTM-834
40. Remove the constant hub.
ATTM-835
41. Remove the 1st gear.
ATTM-836
42. Remove the 1st needle roller bearing.
ATTM-837
43. Remove the 1st gear bushing.
ATTM-838
44. Remove the constant hub.
ATTM-839
45. Remove the 2nd gear.
ATTM-840
46. Remove the 2nd gear needle roller bearing and spacer.
ATTM-841
47. Remove the sleeves.
ATTM-842
48. Remove the synchronizer key and head.

NOTE
• Be careful with the spring that may pop up while
removal.
ATTM-843
49. Remove the compression spring.
ATTM-844
50. Remove the retainer that fixes the synchronizer ring to gear
(3rd , 4th gear)
NOTE
• Be careful with retainer ring that may pop up in
removal.
ATTM-845
51. Remove the synchronizer cone from the gear.
ATTM-846
Inspection
Gear and shaft inspection
1. Inspect crack and defect of every gear, and replace it if any
defect is found.
ATTM-847
2. Inspect damage and worn-out of input shaft and replace it if

any defect is found.
ATTM-848
3. Inspect damage and worn-out of output shaft and replace it if

any defect is found
ATTM-849
Synchronizer unit inspection

1. Inspect any damage or worn-out of assembling parts of syn-
chronizer unit. If any damage is found, replace the assembling
part.
ATTM-850
2. Inspect any damage or worn-out of the slanted parts and syn-

chronizer cone gear. And replace it if any damage is found.
ATTM-851
3. Measure the clearance between synchronizer ring and the

slanted part of synchronizer cone. If the measured clearance
lies within the service limit, replace the synchronizer ring and
cone.
Assembly standard : 1.2 ~ 1.8 mm
Maintenance criteria : 0.2 mm
ATTM-852
4. Inspect the contact between synchronizer ring and slanted part

of synchronizer cone. If the contact area is less than 90%,
replace the synchronizer ring and cone.
Total contact : more than 90%
ATTM-853
Bearing inspection
1. Inspect any damage or worn-out of cylindrical bearing, and
replace if any defect is found.
ATTM-854
2. Check the needle bearing for any damage or worn-out. If any

defect is found, replace the bearing.
ATTM-855
Oil seal inspection

Check the oil seal for any damage or worn-out. If any defect is found,
replace the oil seal.
ATTM-856
Speedometer gear inspection

Check speedometer drive gear and driven gear. If any damage or
worn-out is found, replace it.
ATTM-857
Assembly
1. Install compression spring.
NOTE
• Assemble the synchronizer unit.
ATTM-858
2. Install synchronizer key and head.

NOTE
• Be careful with compression spring that may pop up
during the assembly.
ATTM-859
3. Assemble the synchronizer sleeve.
ATTM-860
4. Install synchronizer cone on the 3rd and 4th gear.
ATTM-861
5. Fix the gear and synchronizer with the retainer ring.

NOTE
• Make sure to align the retainer ring to the groove of
gear.
• Be careful with the retainer ring that may pop out dur-
ing installation.
ATTM-845
6. Install spacer and 2nd gear needle roller bearing on output shaft.
NOTE
• Insert the spacer to each bearing.
• Apply the gear oil to each needle roller bearing and
gear.
ATTM-862
7. Install the 2nd gear.
ATTM-863
8. Assemble the 1st – 2nd synchronizer hub.

NOTE
• When assembling hub, place the side with the larger
chamfering close to the gear spline face of 1st gear.
(Chamfering : 1.5 mm). Besides, numbers are marked
at the hub side to prevent the mistake in assembly.
ATTM-864
9. Install the 1st gear bushing. Heat the bushing around 85C° with
heater and assemble it to the shaft end.
NOTE
• Do not touch the heated bushing with hands.
ATTM-865
10. Install the needle roller bearing for 1st gear.
ATTM-866
11. Install the 1st gear.
ATTM-867
12. Install the constant hub.
ATTM-868
13. Install reverse gear bushing. Heat the bushing around 85

with heater and insert it to the output shaft end.
NOTE
• Do not touch the heated bushing with hands.
ATTM-869
14. Install the needle roller bearing for reverse gear.
ATTM-870
15. Install the reverse gear.
ATTM-819
16. Hold the thrust washer with the jig

NOTE
• If output assembly is assembled to transmission with-
out using the jig, reverse gear may drop.
ATTM-818
17. Install the needle roller bearing and spacer for 3rd gear.
NOTE
• Place the spacer between 2 bearings.
ATTM-832
18. Install the 3rd gear.
ATTM-831
19. Install the synchronizer unit of 3rd – 4th gear.
ATTM-830
20. Install the pin.
ATTM-829
21. Install the 4th gear.
ATTM-827
22. Install the needle roller bearing for 4th gear.
ATTM-828
23. Install the bushing for the 4th gear.

NOTE
• Align the bushing grooves with pin.
ATTM-826
24. Install the retainer ring.

1) Select the retainer ring.
2) Install the retainer ring and make sure to be correctly
positioned.
NOTE
• Be careful with the retainer ring that may pop out
during installation.
3) Check the clearance. ATTM-825
Assembly standard : 0
Following types of retainer rings are available.
Thickness Color
2.35 mm -
1.45mm White
2.55 mm Green
2.65 mm Brown
NOTE
• Use only the new retainer rings.
ATTM-872
25. Install the gear needle roller bearing.
ATTM-824
26. Install the synchronizer cone.
ATTM-823
27. Assemble synchronizer unit for 4th – 5th gear.
ATTM-822

positioned.
NOTE
ATTM-821
3) Check the clearance.

There are 2 types of retainer rings
Thickness Color
1.9 mm -
2.00 mm White
NOTE
ATTM-873
29. Install output shaft assembly to the transmission case. When

assembling output shaft, assemble the synchronizer ring and
6th gear cone.
ATTM-817
30. Install the retainer ring to the bearing before installing rear
bearing.
31. Insert the bearing after installing the bearing side ring to out-
put shaft.
32. Apply the gear oil to the outer and inner race.
NOTE
• Be careful not to damage the inner race surface.
ATTM-874
33. Install the cylindrical bearing by using press.

1) Assemble the bearing after installing bearing side ring to
input shaft. When installing bearing side ring, place the
large chamfered side close to gear.
2) Apply the gear oil to the outer and inner race. Align it with
the correct angle and do not apply the pressure to the outer
race.
Note ATMT-900
• Be careful not to damage the inner race surface.
positioned.
Note
ATMT-901
Thickness Color
2.4mm -
2.5mm White
2.6mm Green
2.7mm Brown
NOTE
ATMT-902
35. Install the cylindrical bearing.

1) Apply the gear oil to the bearing.
ATMT-903
2) Install the spacers at both ends of bearing.

NOTE
? If needed, replace the bearing by unit of set.
ATMT-904
36. Be careful with the retainer ring that may pop out during in-
stallation
ATMT-905
37. Install the input shaft assembly.
ATMT-906
38. Install the oil seal.

NOTE
• Check whether oil seal is correctly installed.
ATMT-907
39. Install the front bearing retainer.

1) When installing bearing retainer, align the gasket notch
with oil drain hole to assemble the gasket.
2) Apply the grease to the oil seal and input shaft.
3) Apply the sealer to the both ends of gasket.
ATMT-908
40. Tighten the bolts.

NOTE
• Apply sealing tape or sealer to the bolt thread.
(A : bolt)
A
ATMT-909
41. Install the speedometer drive gear.
ATMT-910
42. Install the speedometer driven gear.

1) Apply grease to the O-ring, oil seal and driven gear shaft.
2) Assemble driven gear shaft to the bushing.
3) Install the speedometer driven gear together with bushing.
Note
• Be careful not to damage of O-ring and seal lip.
• Install the oil seal to its original position.
ATMT-911
Driven gear bush

Oil seal
ATMT-912
43. Speed gear set

Speed gear set is selected according to the final gear ratio of
the car.
Drive gear Driven gear Final gear ratio
9 19 4.333
7 15 3.636
16 3.909
6 15 4.333
44. Tighten the set screw

1) Align the speedometer driven gear bushing hole with the
hole of the rear bearing retainer
2) Tighten the screw.
ATMT-913
45. Install the oil seal

NOTE
• When installing the oil seal, check right angle align-
ment and take care not to damage the seal lip. Apply
grease to the lip
ATMT-914
46. Install the rear-bearing retainer, and tighten the fitting bolts.
NOTES
• Apply liquid sealer or sealing tape to the bolt threads.
• Apply liquid sealer to both sides of the gasket.
ATMT-915
47. Check the output shaft.

1) Measure the backlash
Assembly standard :
1st, reverse gears : 0.08 – 0.16mm
2nd, 3rd gears : 0.1 – 0.2mm
4th, 5th gears : 0.04 – 0.12mm
Service Limit
ATMT-916
All gears : 0.4mm
2) Measure the free play
Assembly standard :
1st gear : 0.023 – 0.101mm
2nd gear : 0.022 – 0.071mm
3rd gear : 0.020 – 0.070mm
4th gear : 0.020 – 0.119mm
Reverse gear : 0.019-0.064mm
ATMT-917
Service Limit : 0.016-0.055mm
3) Measure the endplay
Assembly standard :
1st, 2nd, 3rd and 4th gears : 0.15 – 0.3mm
Reverse gear : 0.20 – 0.35mm
Service Limit : All gears : 0.15 – 0.60mm
ATMT-918
48. Install the parking brake to the transmission and tighten the
fitting nuts.
Tightening Torque : 900~1,200 kg.cm
ATMT-919
49. Install the flange coupling to the output shaft
ATMT-920
50. Install the O-ring to the flange coupling.
ATMT-921
51. Install the lock nut on the output shaft and tighten it.
NOTE
• Before tightening the lock nut, engage two gears so
that the shaft can not be turned
• Do not damage the O-ring.
Tightening Torque : 6,000~8,000 kg.cm
Special Tool : Socket wrench (09389-4601)
ATMT-922
52. Using a hammer and chisel, caulk the lock nut.

Follow the procedure below when caulking the lock nut
1) Caulk deeper than 1.5mm.
2) The caulking should fill the groove thoroughly.
3) The caulking should be done without rift
ATMT-923
53. Install the parking brake drum and adjust the drum with the
propeller shaft fitting nuts.
NOTE
• Be sure to secure the parking brake drum to the trans-
mission flange. Becareful not to drop the parking brake
drum.
ATMT-924
Counter Shaft, Reverse Idler Shaft And Gear
COMPONENTS
3
2
7
15
12
6
11
3 8 14
2 13
9
10
1
8
1. Seal cover 7. Woodruff key 13. Rock plate

2. Cylindrical bearing 8. Thrust washer 14. Bolt
3. Retainer ring 9. Reverse idler gear 15. Counter shaft
4. Counter drive gear 10. Needle roller bearing
5. Counter 4th gear 11. Reverse idler shaft
6. Counter 2nd & 3rd gear 12 O-ring
ATMT-925
DISASSEMBLY
1. Remove the retainer ring from the counter shaft.
NOTE
• The retainer ring may pop out of the groove during
removal.
ATMT-926
2. Remove the retainer ring from the rear cylindrical bearing.

NOTE
removal.
ATMT-927
3. Install special tools on the rear cylindrical bearing.

Special Tool : Hook (09653-1160)
Puller (09650-2080)
NOTE
• Insert the hook’s click into the groove for the retainer
ring then secure the puller to the hook with bolts.
Secure the puller so that it does not turn, then rotates
the bolt to pull the bearing out. ATMT-928
4. Pull out the cylindrical bearing.
ATMT-929
5. Tie a rope or hook around the counter shaft (between 3rd and
4th counter gear) and carefully pry the countershaft assembly
rearward until the front end of the shaft is clear of the front
cylindrical bearing.
6. Carefully lift the counter shaft assembly from the case.
ATMT-930
7. Using a tapping rod and a hammer, remove the bearing cover.
ATMT-931
8. Remove the front cylindrical bearing.
ATMT-932
9. Remove the inner race.

Using a special tool, pull out the cylindrical bearing inner race.
Special Tool : Puller (09650-1101)
ATMT-933
10. Remove the retainer ring
NOTE
removal.
ATMT-934
11. Using a press, remove the counter shaft drive gear.
ATMT-935
12. Using a press, remove the 5th gear.
ATMT-936
13. Remove the idle shaft lock bolt and lock plate from the case.
ATMT-937
14. Using a special tool, pull out the reverse idle shaft.
Special Tool : Sliding hammer (09420-1442)
ATMT-938
15. Remove the reverse idle gear, thrust washer and needle roller
bearing.
ASSEMBLY
1. Install needle roller bearing into reverse idle gear and install
thrust washers to both sides and place gear into case.
NOTE
• Apply gear oil lightly on needle roller bearing and thrust
washers before installation.
• Install the gear at the original position. ATMT-939
2. Install O-ring into gear shaft groove and install gear shaft into
case by hammer.
NOTE
• Apply grease on O-rings.
• Make sure that O-ring is installed into shaft groove.
3. Install lock plate on shaft and tighten it to the case by bolts.
ATMT-940
4. Select the suitable key according to the condition of the key

groove, and install the key in the groove.
Thickness(T): 10.015 ~ 10.024 mm

10.080 ~ 10.090 mm
ATMT-941
5. Using press, install counter shaft gear.
ATMT-942
6. Install the retainer ring on the counter shaft.

positioned.
NOTE
• Take care with the retainer ring that may pop out
ATMT-943
Thickness Color
2.4mm -
2.5mm White
2.6mm Green
2.7mm Brown
2.8mm Blue
NOTE
7. Install the front bearing inner race. Using the press, insert front
bearing inner race against the stepped part of the counter shaft.
8. Install the counter shaft in the gear case.
ATMT-944
9. Install the front bearing
NOTE
• Apply gear oil on inner and outer race.
• Be careful not to damage the inner race together with
roller bearing.
ATMT-945
10. “A” position distance check

ATMT-946
11. Install retainer ring first to the bearing before the assembling
rear bearing.
12. Insert bearing next to bearing side ring to the counter shaft.
When installing the bearing side ring, place the side with the
larger chamfering close to the reverse gear.
13. Apply the gear oil to outer and inner race.
NOTE
• Be careful not to damage the surface of inner race.
14. Installation of retainer ring.

Install the retainer ring to the counter shaft.
positioned.
NOTE
• Take care with the retainer ring that may pop out
during installation. ATMT-947
Thickness Color
2.4mm -
2.5mm White
2.6mm Green
2.7mm Brown
NOTE
15. Press the counter front cover and align it with the bearing.
16. Rotate the counter shaft by hands to check whether it turns
smoothly.
ATMT-948
17. Inspection of counter shaft and reverse idle gear.

1) Measure the backlash between reverse idle gear and
counter shaft reverse gear.
2) Measure the endplay of reverse idle gear.
Transmission Control
2kg·m
2kg·m
<Power shift lever>

1.5kg·m
"S1" N
"S2"
R,2,4,6 1, 3, 5
12.2
12
12.2 5th,6th
3rd,4th
1st,2nd
Rev ° 95° SHIFT STROKE
8.86 8. S1 S2
6°
17.8 al
° utr REV 16.58 - -
2 5 Ne
2ND 16.58 1ST 16.58
<Select lever> 4TH 17.27 3RD 17.27

6TH 17.27 5TH 17.27
5ttm-101
LEVER RATIO AND TIGHTENING TORQUE

1. Refill the grease on the fitting parts.
(Fitting parts : roller assembly, guide)
2. Lever ratio
Shift Select Remark
Lever ratio 7.44 5.52
Stroke 54 46 Max
3. Adjust the roller gap to be 0.2 ~ 0.6 mm by using the bias of

lower roller and upper roller of roller assembly.
4. Install the boot freely that assembled to roller assembly. Put
the shift lever in neutral.
5. Refer to the following table for the tightening torque of bolts
and nuts.
Model M8X1.0 M10X1.25 M12X1.5
Tightening torque 2.7~3.6 3.8~5.0 6.5~8.7
6. Adjust the position distance “A” of the select rod assembly.
Assembly standard : 147 mm
A
ATMT-950
TROUBLESHOOTING TMb-51
TROUBLESHOOTING
Abnormal noise Insufficient oil Add oil

The noise can be considered to Deterioration of oil quality Replace with oil of specified quality.
be from the transmission if the Worn bearing Adjust or replace.
noise is heard with the vehicle Wear of sliding surfaces of counter shaft gear. Replace
stopped and the engine idling, Wear of sliding surface of gears Replace
and then disappears when the Excessive gear backlash Replace
clutch pedal is depressed, or if Damaged gear teeth Replace
the noise is heard when the Influx of dust. Correct or replace
transmission is shifted.
Hard to shift change Bent change rod Replace
Insufficient grease in transmission control system Lubricate with grease
Insufficient oil Add oil
Deterioration of oil quality Replace oil with specified quality.
Wear or play of shift fork or shift rod Replace
Wear of synchronizer ring Replace
Wear of synchronizer cone of gear. Replace
Bad contact of synchronizer ring and cone of gear Replace
Excessive longitudinal play of gears Replace
Wear of bearing Adjust or replace
Wear of synchronizer key spring Replace
Improper disengagement of clutch Refer to CH group
Change release Bent change rod Replace
Weak or broken lock ball spring Replace
Wear of shift fork Replace
Wear of clutch hub Replace
Wear of gear sliding parts Replace
Excessive gear backlash Replace
Wear go bearing Replace
Incorrect installation of engine mounts or transmission Replace
mounts.
Rough or difficult operation of Sticking of control rod Replace
change rod Malfunction of ball joint of change rod Replace
Bent change rod Replace
Sub transmission is not Shift cable broken Change

working
Insufficient oil Refill
Oil seal defected Change oil seal
Worn-out or loosening of shift fork and shift rod Change or tightening
Worn-out or damage of synchronizer ring Change
Worn-out of input clutch cone and gear Change
Poor connection between synchronizer ring and cone Change
Cut or missing of snap ring Refer or change
Worn-out of bearing Change
Defect of synchronizer spring Change
Poor clutch release Refer to CH group
HEATER AND
AIR CONDITIONER
GENERAL ................................................................................ HA - 2
HEATER AND VENTILATION SYSTEM .................................. HA - 5
STRUCTURE AND OPERATION OF
AIR-CON AND HEATER .......................................................... HA - 7
MAIN COMPONENTS .............................................................. HA - 9
TROUBLE SHOOTING ............................................................ HA-17
SERVICE PROCEDURE .......................................................... HA-30
HA-2 HEATER AND AIR CONDITIONER
GENERAL
CAUTIONS IN HANDLING AIR-CONDITIONER AND
HEATER.
• Handle these items indoors where ventilates well and are no

combustible substances.
FPV97-001
• Since moisture does harm to air-conditioner, refrain from work-
ing in a rainy day.
While working on these items, do not touch the parts of brake

system, fuel system, and power steering system.
• Put the protection cover on the body so that the body is not
BODY
scratched or damaged.
FPV97-002
• When you have to work underneath the vehicle, be sure to put

the safety support.
• Be sure to remove the earth (-) wire before the work to prevent
electric damage.
• Put the key switch at “off” position or key off while working on the
vehicle.
FRV.OM117
• Put the gearshift in neutral position, and apply the parking brake.
• When engine is on, do not work close to rotating part like fan,
belts etc.
• While working, do not touch the heated parts like radiator,

exhaust manifold, exhaust pipe, muffler and catalytic converter.
• Smoking is prohibited while working.

FRV.OM201
GENERAL HA-3
PRECAUTIONS IN HANDLING REFRIGERANT.
• Refrigerant, having low freezing point, is highly volatile. A drop

on the skin of your hand may result in localized frostbite.
Therefore, be sure to wear protection goggles and gloves when
handling refrigerant.
• Since refrigerant is stored in high-pressure vessel, keep it away

from the engine or light.
• Do not remove refrigerant pipe before draining the refrigerant

fully.
• Air-con parts are sealed with protection cap to prevent the inflow
of dirt, dust and moisture. Be sure to remove this cap just before
the work and close it immediately after the work.
Refrigerant oil
• Especially ‘O” ring parts of hose and pipe should be free from dirt
and deformation. Check these parts before assembly and
replace it in case of defective. Union Nut
• Never reuse the “O” ring and apply refrigerant oil on to “O” ring
before assembly.
• As for the bolting, assemble them with bare hands first and
tighten it with 2 spanners.
• When replacing evaporator, compressor, or refrigerant pipes,

make sure to replace receiver drier too.
• When tightening connector, bolts and nuts, tighten them with the
tightening torques shown in the table below.
FPV97-003
TIGHTENING TORQUE
Unit : kg/cm²G
Bolt, Nut Flange bolt/ Nut

Diameter Pitch
4T 7T 4T 7T
M6 1.0 0.4~0.6 0.7~1.1 0.5~0.7 0.8~1.2
M8 1.25 0.9~1.4 1.7~2.6 1.0~1.5 1.8~2.8
M10 1.25 1.9~2.8 3.5~5.5 2.1~3.1 3.9~6.0
TIGHTENING TORQUE
Unit : kg/cm²G
Diameter 5/16(0) 3/8 1/2(12) 5/8(16) 3/4(19)

Type Items
Swival nut Torque 1.2~1.5 2.0~2.5 3.0~3.5 3.5~4.0
Joint Body side Torque 0.4~0.6 1.0~1.5
Flange Engine side Torque 2.0~3.0
Bolt M6 M8
HEATER AND VENTILATION SYSTEM HA-5
HEATER AND VENTILATION SYSTEM

OPERATION OVERVIEW
Ventilation outlets are defroster, heating floor and cooling vents on the whole as shown in the figure. In case of bi-level and
mix mode, blower and temperature are controlled properly and blown through these ventilation outlets for amicable climate
control.
FRV97-001
VENT
1. This mode is mainly used in air-con operation and interior air ventilation.
2. Blower is coming from vent register grille and it can be directed any where easily by adjusting the louver angle.
3. Fresh outside air, recirculation of inside air, temperature, airflow can be controlled arbitrarily. However recirculation of
inside air mode is used for the quick cooling and fresh outside air mode is chosen otherwise.
FLOOR
1. This mode is mainly used in heating.
2. Blower is directed outside the seat through the floor duct inside the car, and small quantity of air is directed toward
windshield glass.
3. Fresh outside air, recirculation of interior air, temperature, airflow can be controlled arbitrarily. However, fresh outside
air is used mainly.
BI-LEVEL (IT IS DISTINGUISHED INTO COOLING RANGE AND HEATING RANGE)

1. This mode is mainly used for the combined use of cooling and heating in spring or fall.
2. Blower is directed through floor duct, vent register grille and defroster (in case of heating range).
3. Though air intake, temperature and blower are arbitrarily chosen, as for the temperature, middle range is usually
selected.
MIX
1. This mode is mainly used to do heating and defrosting the front windshield at the same time.
2. Air is blown from floor duct and front windshield glass (defroster) outlet at the same time.
3. Fresh outside air mode is selected and temperature and blower is arbitrarily controlled. As for the temperature warming
(red zone) is usually selected.
DEFROSTER
1. This mode mainly used to defrost front windshield glass.
2. Air is blown from front windshield glass outlet.
3. Fresh outside air mode is selected and temperature and blower is arbitrarily controlled.
RECIRCULATION / FRESH
1. When recirculation is selected, air inside the vehicle recirculates. This mode is mainly used for quick cooling.
2. When fresh outside air mode is selected, fresh outside air is flown inside to ventilate.
TEMPERATURE CONTROL
As for the temperature control of the air from each outlet, temperature switches and buttons are properly selected to control
the temperature. Temperature control switch is dial type, and dial is distinguished into heating (red color) and cooling (blue
color). If the temperature control dial is set blue color range, air-mix door shuts airflow to heater core and cold air passing
evaporator is directly blown. If it is set at the red color range, air-mix door opens and heated air is blown passing heater
core. If the dial is set at in-between of red and blue, air mix door is located at the center of the passage to control and mix
the cold air and hot air.
BLOWER CONTROL
Blower control is selected by controlling blower button in the control.
STRUCTURE AND OPERATION OF AIR-CON AND HEATER HA-7
STRUCTURE AND OPERATION OF AIR-CON AND HEATER.

Air passed the evaporator is divided into the air to heater core and the air to elsewhere.
So this different air is mixed right before the outlet and sent to the outlet. Temperature is controlled by the air quantity by
the air mix damper. In other words, warm air and cold air are mixed properly. So temperature can be controlled continuously
from cooling to heating along with demoisturization. Since this is mixing control of warm and cold air, it is called air-mixing
type.
AIR-CON OPERATION.
When air-con switch is turned on, compressor operates cycling by repeating on and off by the evaporator pin temperature
sensor, which is to prevent evaporator core freezing. Air-con operates only when blower operates first.
SPECIFICATIONS
Items Specifications Remarks
Heating capacity 5000±10% kcal/h
Flow capacity 500±10% m³/h

Heater Power consumption 240±10% W
Blower rev. 3100±10% rpm
Blower control step 4step(RESISTER)
Cooling capacity 4700±10% kcal/h
Flow capacity 500±10% m³/h

Air
Conditioner Power consumption 240±10% W
Blower rev. 3100±10% rpm
Blower control step 4step(RESISTER)
Heater care Copper and Brass
Blower motor O.D. Ø76
Compressor HS-17 1700cc DC24V
Evaporator Laminated tank
Condenser Super compact condenser

Compo-
Condenser fan 2000±10% m³/h, 24V
nents
Safety system High/Low pressure switch, Fuse
Coolant temperature switch
Refrigerant (R-12) about 650g

(R134a) about 650g
Receiver drier Aeperated Drier and Sight glass
Capacity : 250 cc
MAIN COMPONENTS HA-9
MAIN COMPONENTS
HEATER UNIT ASSEMBLY
It is assembled at the center of vehicle inside instrument panel, whose housing is made of plastic case. And it consists of
heater core, in which engine coolant flows through the fascia, and mode door, which controls airflow, and temperature door,
which controls temperature. Heater coolant temperature sensor is installed at the lower side of heater core, which senses
engine coolant temperature flowing inside heater core.
EVAPORATOR UNIT
Evaporator unit is installed at the right side of heater assembly, whose housing is made of plastic case. It consists of
evaporator core and thermal expansion valve. Evaporator core evaporates refrigerant flown into case and thermal
expansion valve expands liquid refrigerant. And evaporator core pin sensor is inserted between core pins to prevent the
evaporator core freezing.
NOTE
• Do not adjust the thermal expansion valve since it is set to optimal performance when delivered. It may cause
a deterioration of cooling performance.
• Do not change the insertion point of evaporator core pin. It may cause the bad influence on the air-con system.
BLOWER UNIT
Its housing is made of plastic case. Ii consists of blower motor and wheels. Besides, there are conversion door between
circulation and fresh air inside modes, which is operated by electrically driven motor, and outside air temperature sensor,
which senses outside air temperature. Besides, HI blower relay is installed for air-con.
COMPRESSOR
Air-con is installed onto the engine, which intakes and compresses air-con refrigerant to recirculate the refrigerant. Magnetic
clutch operates and connected to engine pulley and belts by air-con switch operation
FPV97-005
Magnetic clutch
Adjustment bolt
Fixing bolt
Tension bolt
Compressor V-belt
FPV97-006 FPV97-007
CONDENSER
It is installed at the front of radiator, whose function is to compress the refrigerant after receiving from compressor. And it
is made of aluminum for the efficiency improvement and weight reduction.
NOTE
• Since it is made of aluminum, be careful not to damage and tear fins in handling.
FRV97-010
RECEIVER DRIER
It filters dirt and moisture in the refrigerant, which recirculating air-con system, stores refrigerant temporarily before
refrigerant flows into evaporator. It is installed between condenser and expansion valve. Besides, receiver tank consists
of Hi-low pressure switch, which shuts the system automatically in abnormally high or low pressure, and sight glasses, in
which we can check refrigerant filling and pressure outlet, which prevents high pressure in temperature increase.
OUT
Dual pressure
switch
IN
Moisture absorbent
FPV97-011
High-pressure switch operation diagram
2.25±0.3 27±2
ON
OFF
2.0±0.2
6±2
DIFF
(Unit : kg/cm2G) FPV97-012
NOTE
• Since receiver tank inlet and outlet are distinguished, assemble it between tube and liquid by checking in and
out marked on the label.
2-M6 x 1.0
View "A" FPV97-013

RELAY
Blower off relay, Hi
1. Blower off relay
As a relay to supply power to blower fan motor, it is installed to
blower unit case.
Compressor relay, condenser fan relay

1. Compressor relay
Mode actuator
Installed to the front heater unit, it controls 5th mode control from
2 1
vent to defroster by selecting mode switch.
6
3
5 4
FPV97-018
LEAD WIRE NO P1 P2 P3 P4 P5 P6 P7 P8
LEAD WIRE COLOR B L/G Y B/D B/W B/Y G/W
MODE M- M+ DEF D/F FOOT BI-L VENT
FPV97-018-1
Fresh air and recirculation actuator

Installed to the right side of blower unit, it operates damper to select
a
air intake (Fresh air, recirculation) by operating heater control push b
button.
SLIDING FPV97-019
a b
FPV97-023
INPUT OUTPUT
a b POSITION
+ - FRESH
- + RECIRCULATION
HEATER CONTROLLER (MANUAL)

Rotary and push button type.
Vent mode selection and switching between fresh outside air and recirculation are decided by damper motor operation, and
temperature is controlled by operating air-mix damper by the cable movement with rotary operation, which is installed to
the heater unit.
Control structure diagram
1. Control panel 6. Mode switch

2. Housing 7. Blower switch
3. Knob 8. Cable assembly
4. Wiring 9. Mode control switch(Fresh air, recirculation)
5. Temperature switch
FPV97-021
SWITCHES
1. Control panel(Front)
Mode switch
Blower switch Fresh air/ Recirculation switch Temperature switch
FPV.OM124
2. Control panel(Back)
Mode switch connector
Blower switch connector

Fresh air / Recirculation
illumination connector
FPV97-022
3. Blower switch terminal
Ground 3
COM 2
1 2 3 HIGH 4
4 5 6
M/H 1
M/L 5
LOW 6
FPV97-102
4. Mode select switch
Ground 6
VENT 3
B/L 1
1 3
FOOT 5
4 5 6 7
D/FOOT 4
DEF 7
FPV97-101
5. Fresh, recirculation switch
TERMINAL POSITION WIRE Sq

1 IGN 0.5 R
3 GND 0.5 LG
4 FRE 0.5 LR
5 REC 0.5 GW
6 TAIL+ 0.5 RG
2 TAIL- 0.5 B
1 2
3 4 5 6 1 4 3 5 6 2
FPV97-103
TROUBLE SHOOTING HA-17
TROUBLE SHOOTING
MANUAL TYPE
Symptoms
Air-con is not Temperature does Blower fan and Vent mode Air intake mode is
Check points
working when not drop when motor is not selection is not controlled
ignition switch air-con is working rotating impossible.
is on.
Fuse 1 1 1 1
Connector 2 2 2 2
Refrigerant volume 3 1
Compressor relay 4 4
Magnetic clutch 5 5
Dual pressure switch 6 2
Air-con switch 7
Blower relay 3
Blower motor 4
Switch 8 5
Blower resistance 6
Air intake control mode 10 3
damper motor
Mode selection damper 11 3

motor
Number means the checking points by sequence.

Symptoms Possible causes Repair
Air-con is not working when - Fuse blown Fuse replacement

ignition switch is on. - Harness or connector defective Repair harness or connector
- Refrigerant leakage or over charging Refrigerant refill or repair or leakage or discharge
- Compressor relay defective Replacement
- Magnetic relay defective Amateur plate, rotor or clutch oil
replacement
- Dual pressure switch defective Replacement
- Front air-con switch defective Replacement
- Front blower switch defective Replacement
Temperature does not drop when - Refrigerant leakage Refrigerant refill or repair leakage points
air-con is working - Dual pressure switch defective Replacement
- Compressor relay defective Replacement
- Magnetic clutch defective Replacement
Blower fan and motor is not - Fuse blown Replacement
rotating - Harness or connector defective Replacement
- Blower motor relay defective Replacement
- Front blower motor defective Replacement
- Front blower switch defective Replacement
- Blower resistance defective Replacement
Vent mode selection is - Fuse blown Replacement
impossible. - Harness or connector defective Replacement
- Mode selection damper motor defective Replacement
Air intake mode is not controlled - Fuse blown Replacement

(Fresh air and recirculation) - Harness or connector defective Replacement
- Air intake mode switch damper motor defective Replacement
FAULT DIAGNOSTIC TABLE
Check points
Magnetic clutch
Blower motor
Blower relay
Fuse
Register
Compressor relay
Dual pressure switch

Heater link
Wiring
(Fresh air outside, recirculation)
Condenser fan motor

Air-con control unit
Air intake damper actuator
Vent mode damper actuator
Refrigerant volume
Symptoms
Air-con is not working when
ignition switch is on.

Inside temperature is not
going up
(Warm air is not coming)
Inside temperature does not
drop (Cold air is not coming)
Blower motor is not rotating
Blower motor does not stop.
Air intake mode is not

controlled
Vent mode damper is not
working
Condenser fan is not

working
represents the parts which needs repair, and the number means the priority number.
TROUBLE SHOOTING
No Symptoms Possible causes Repair
1 Air-con is not working when ignition Wire short or disconnection Wire repair
switch is on. Air-con control unit is damage Air-con control unit replacement
2 Inside temperature is not going up Temp damper stuck Temp damper repair and replacement
(Warm air is not coming) Wire short or disconnection Wire repair
Air-con control unit is damage Air-con control unit replacement
3 Inside temperature does not drop Damage of temp damper operation lever and damper connector Connector repair
(Cold air is not coming) Temp damper stuckv Temp damper repair and replacement
Wire short or disconnection Wire repair

Compressor relay damage Relay replacement
Refrigerant leakage Refrigerant refill or leakage repair
Magnetic clutch damage Replacement
4 Blower motor is not rotating Blower moter damage Blower motor replacement
Blower relay damage Relay replacement
5 Blower motor does not stop. Blower moter damage Power transistor replacement
Air-con control unit is damagev Air-con control unit replacement
6 Air intake mode is not controlled Air intake mode actuator damage Air intake mode actuator replacement
(Fresh air and recirculation) Linkage or damper damage Connector repair
7 Vent mode damper is not working Vent mode damper actuator damage Vent mode damper actuator replacement
Vent mode actuator linkage damage Connector repair
8 Condenser fan is not working while Condenser fan motor relay damage Relay replacement
air-con operating Condenser fan motor damage Condenser fan motor replacement
Maintenance procedures
1. Test procedures
1) Refrigerant charging level test of sight glass is done with the
refrigerant level indicator. To check the refrigerant charging
level, start the engine after cleaning sight glass. Operate the
compressor by pressing air-con button. Put the blower
switch at the high position put and temperature level at the
coldest position and check the sight glass.
a. When sight glass is cleaned, operate magnetic clutch.
If the compressor discharge line is warm and compres-
sor inlet is cold, it means that system is fully charged.
b. When sight glass is cleaned, operate magnetic clutch.
If there is no temperature difference between compres-
sor inlet and discharge line, it means that system lacks
refrigerant.
c. When a bubble is seen at the sight glass, charge the
system again.
2) Magnetic clutch
a. Remove the wiring from magnetic clutch.
b. Connect positive voltage of battery directly to magnetic
clutch wiring.
c. When magnetic clutch is normal, it will display “click”. If
the pulley or amateur is not connected to “click”, system
is in malfunction.
Magnetic clutch
wiring FPV97-031
3) Receiver drier
a. Receiver drier test
b. Hold receiver drier outlet and inlet, and check the pipe
temperature after operating the unit.
c. If there is temperature difference, check the receiver
drier and replace it, if needed.
4) Dual pressure switch (low pressure switch)

2.25±0.3 32±2
a. Close the valve by rotating the adaptor valve handle ON
fully, and install it to the low-pressure service valve.
b. Close the gauge manifold low-pressure maintenance
OFF
valve, and connect gauge manifold high-pressure side 2.0±0.2
charging hose to adaptor valve.
c. Tighten the adaptor valve handle and open the service 6±2
valve. DIF
kg/cm G
2
FPV97-012
d. When the side pressure of low-pressure is “on’ level of
dual pressure switch, and if there is continuity between
dual pressure switch terminals, switch is normal. Re-
place the switch otherwise.
1) Fin thermo sensor

Evaporator
a. Remove the sensor connector from evaporator case
and then measure the resistance using resistance tester.
If the sensor value lies within plus minus 10 % range,
Fin thermo
sensor is in normal operation. sensor
b. Even if the sensor is normal, replace it when the air-con
control unit is in malfunction.
FPV97-032
20
15
Resistance (
10
-10 0 10 20 30 40
Temperature(°C) FPV97-391
2. Charging procedures
1) Installation of charging equipments Adaptor valve Adaptor valve
(low-pressure side)
When using vacuum gauge.
a. Rotate the handle of adaptor valve and fully, Service
valve
and then install adaptor valve and to low
L/P H/P
pressure valve and high pressure valve respectively.
Refrigerant line
b. Tighten the adaptor valve and fully (valve or compressor
open), and then open low-pressure valve and high Charging hose Charging
hose
pressure valve.
Vacuum gauge
c. Connect charging hoses to adaptor valve and .
d. Tighten the adaptor valve fully (valve open), and
then install it to the low pressure charging hose.
e. Install the vacuum gauge to adaptor valve .
f. Install vacuum pump to high-pressure charging
hose. Adaptor valve Vacuum
NOTE pump
• Be careful not to be confused in connecting

FPV97-033
low-pressure and high-pressure. (Connect
the high pressure to condenser and then
connect the low-pressure to evaporator)
• “DIS” and “SUC” of compressor stands for
high pressure and low pressure respectively.
When using gauge manifold.

a. Turn adaptor valve handle counterclockwise, and
then install adaptor valve and, to low-pressure Shut High pressure valve
maintenance valve and vacuum valve. Shut

b. Install gauge manifold to low pressure and high
pressure. Adaptor valve
Low
c. Connect charging hoses to each adaptor. pressure
d. Open maintenance valve and vacuum pump by valve
Vacuum
rotating handle of adaptor and clockwise. pump
[REFERENCE]
• Be careful not to be confused in connecting
Adaptor valve
low-pressure and high-pressure. (Connect
the high pressure to condenser and then
Low pressure valve,
connect the low-pressure to evaporator) Refrigerant line
• “DIS” and “SUC” of compressor stands for or compressor
high pressure and low pressure respectively.
FPV97-034
2) Charging unit
Discharging
750mmHg or for 10 minutes
Stop discharging
Connector retightening Maintain for 5 minutes
Leakage Leakage test
Refrigerant charging
Leakage
Gas leakage test
Refrigerant charging
Refrigerant is discharged through outlet.

Charge with only R-134a.
R-134a can be used in a bulk tank and small can as well.
Please follow the preventive safety measures when han-
dling substances like R-134a.
3. Refrigerant charging
Adaptor valve Adaptor valve
1) Charging a small can. (low-pressure side) (high-pressure side)
When using a vacuum gauge.
Service
a. Operate vacuum pump. valve
b. Keep the vacuum pressure more than 750 mmHg L/P H/P
(discharging for more than 10 minutes) Refrigerant line
c. Turn clockwise the handle of high pressure adaptor or compressor
Charging
Charging hose hose
valve (valve closed)
d. Maintain the vacuum state for 5 minutes while
vacuum pump operation is stopped.
e. Check the leakage. (Good condition if vacuum state
is kept)
f. Turn the handle of charging valve backward
(valve open) and install it to charging can
Vacuum
g. Turn the handle of charging valve fully backward pump
(valve closed) and install charging can after remov-
ing vacuum meter. FPV97-035
h. Tighten the charging valve handle to pierce a
hole.
i. Turn the charging valve handle backward (valve
open), and tighten adaptor valve handle com-
pletely (valve open) and then charge the refrigerant.
j. When refrigerant is not circulating, turn the handle of
adaptor valve counterclockwise. (Valve closed)
k. Check the gas leakage using leak tester.
l. Start the engine
m. Turn the air-con on and put the switch at max cool
position.
n. Fix the engine speed at 1,500 rpm
o. Charge the refrigerant as needed by turning the
handle of adaptor valve completely clockwise
(valve open)
NOTE
• If the maintenance can is put upside down,
liquid refrigerant may flow down and dam-
age the compressor with the liquid
compression. Put the maintenance can up-
right so that the refrigerant can be filled as a
gas.
p. After charging, turn the adaptor valve handle fully
counterclockwise (valve closed)
When using gauge manifold

a. Operate vacuum pump
b. Keep the vacuum pressure more than 750 mmHg Shut
Shut
(discharging for more than 10 minutes)
c. Turn the handle of adaptor valve ¨è fully clockwise
(valve closed). Adaptor valve
d. Stop vacuum pump operation and keep the vacuum

state for more than 5 minutes.
e. Check the leakage. Vacuum
pump
Adaptor valve
Low pressure valve,

Refrigerant line
or compressor
FPV97-036
f. Tighten the handle of charging valve to the

maintenance can.
Shut
g. Tighten the handle of adaptor valve fully and Shut
open the charging valve. Adaptor valve
h. Charge the refrigerant to the low-pressure valve of
manifold gauge through charging hose.
NOTE
• If the maintenance can is put upside down,
Charging
liquid refrigerant may flow down and dam- valve
age the compressor with the liquid Charging hose Charging
can
compression. Put the maintenance can up-
right so that the refrigerant can be filled as a Adaptor valve
gas.
Low pressure valve,
i. When the refrigerant is not charging, turn the handle Refrigerant line
of adaptor valve counterclockwise. (Valve closed) or compressor
j. Check the gas leakage using gas leakage tester.

k. Start the engine. FPV97-037
l. Turn the air-con on and put the switch at max cool

position.
m. Fix the engine speed at 1,500 rpm
n. Charge the refrigerant as needed by turning the
handle of adaptor valve completely clockwise (valve
open)
o. After charging, turn the adaptor valve handle fully
backward (valve closed)
2) Removal of charging equipments

Close the charging valve (valve closed) Adaptor valve Adaptor valve
(low-pressure side) (high-pressure side)
Remove adaptor valve and from each service
valve.
Remove maintenance valve
Remove charging valve .
Remove adaptor
Charging
Remove adaptor Charging
hose
hose
Remove adaptor
Remove vacuum pump.
Adaptor valve
Adaptor valve
Vacuum
Charging pump
can
FPV97-038
2) Refill of low refrigerant level.

Turn the charging valve handle backward (valve open)
Adaptor valve
and install it to the maintenance can.
Tighten the handle and install the adaptor valve to Adaptor valve
charging valve. (Valve open)
Install the charging hose to adaptor valve
Charging
Turn the adaptor valve ¨è backward (valve closed) and hose
install the charging hose.
Turn the charging valve handle and pierce a hole in a can. Adaptor valve
Turn the handle of charging valve backward (valve
open), and operate it as the air should not leak from
adaptor valve. Charging
can
(Operation) Low pressure valve,
• Do not use high-pressure side. There is a risk of Refrigerant line
or compressor
refrigerant backward flow and subsequent dam-
age on charging can and hoses.
FPV97-039
Install adaptor valve to low pressure maintenance valve.

Adaptor valve Refrigerant
Start the engine charging unit
Turn the air-con on and put the switch at max cool
position.
Fix the engine speed at 1,500 rpm
After tightening handle of adaptor valve (valve open), L/P
Refrigerant line
charge the refrigerant as checking refrigerant charging or compressor
level with sight glass. FPV97-040
After charging, turn the adaptor valve handle fully
backward (valve closed)
Remove the adaptor valve ¨è from maintenance valve.
4) Charging equipment
Please refer to the unit operation manual for the use of refrigerant recovery unit equipment and recycling unit
equipment.
5) Proper refrigerant quantity of air-con system.
In charging, do not overcharge nor undercharge.
NOTE
• Charge properly, since overcharging or undercharging may cause air-con performance deterioration
or system malfunction.
Air-con specification Refrigerant quantity(g)
Manual 650±20g
6) Refill of refrigerant oil in air-con system.

When refrigerant oil is insufficient, compressor lubrication is not proper and causes malfunction accordingly. On
the contrary, if there is too much refrigerant oil, discharging temperature goes up and weaken the air-con
performance. When assembled in factory, 200 cc of refrigerant oil is charged. While air-con is in operation,
refrigerant oil flows throughout the system with the refrigerant. Since the refrigerant oil remains in many places, refill
the system with the proper quantity of refrigerant oil when the system components are replaced.
Refill quantity of refrigerant oil when replacing air-con system components
Items Quantity (cc)
Condenser 8
Evaporator 72
Receiver drier 6.4
4. Performance test
1) Park the vehicle to be tested in the shaded place.
2) Connect the tachometer
3) Turn the adaptor valve handle backward and then install the adaptor valve to high-pressure and low-pressure
maintenance valve respectively.
4) Connect the gauge manifold to adaptor valve.
5) Tighten adaptor valve handle and then open the service valve.
6) Start the engine.
7) Put the control at the following positions.
Items Position
Air-con switch Air-con on position
Mode selection Vent position
Temperature control Max cooling (max, cool position)
Air mode Recirculation position
Blower switch Hi position
8) Set the engine speed at 1,000 rpm so that air-con compressor turns on and off.
9) Warm up the engine after closing door and windows.
10) Install the thermometer at the center of air-con outlet (center of center vent grille) and start the engine for about 20
minutes.
11) Measure the discharging temperature
<Temperature table>
Ambient temperature(°C) 21 26.7 32.2 37.8 43.3

Discharging temperature(°C) 0.0~3.0 0.0~3.3 0.0~4.0 0.0~4.0 0.0~4.0
Compressordischargepressure(kg/cm²G) 6.5~7.0 7.4~7.9 9.8~10.2 11.5~12.0 13.2~13.7
Compressor suction pressure(kg/cm2G) 1.3~1.9 1.3~1.9 1.3~1.9 1.3~1.9 1.3~1.9
5. Repairing procedures of refrigerant leakage

1) Refrigerant leakage
When all refrigerant leaked away
Vacuum the system. (Refer to the vacuuming procedures)
Charge the system with about 1 pound of refrigerant
Check the leakage
Discharge the refrigerant
Repair the leaking point
Replace the receiver drier.
NOTE
• Receiver drier should be sealed when stored. Receiver drier, which is used in air-con system,
absorbs water quickly when exposed to the air. When installing the receiver drier, reassemble it as
quickly as possible without leaving it open for a long while.
Vacuum the system and charge it with refrigerant.
2) Insufficient charging
Repair the leakage if refrigerant charging is impossible. Since only small quantity of refrigerant is left in the system,
charge the refrigerant to increase the system pressure.
When repairing the leakage without discharging the remaining refrigerant in the system, follow the repair procedures
of low refrigerant charging level.
6. Tubing and fittings procedures

Refrigerant tubing or sharp bending in the refrigerant hose lines will greatly reduce the overall system performance.
System pressure becomes high, while operating. Make sure that all connections are tightened with proper torque. Be
careful so that any dirt and moisture contaminate the system when it is open for repair or replacement of lines or
components. Discharge the fitting completely before connecting it to the refrigerant system. The following precautions
must be observed. The system must be completely discharged before opening any fitting or connection in the
refrigeration system. Open fittings with caution even after the system has been discharged. If any pressure is detected
when disconnecting a fitting, allow trapped pressure to bleed off very slowly.
Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing. A good rule for
the flexible hose lines is keeping the radius of all bends at least 10 times of the hose outer diameter.
Sharper bends will reduce the flow of refrigerant.
The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold. It is good practice
to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed.
O-rings used on connections are not reusable.
7. Compressor noise check

You must first know the conditions when the noise occurs. These conditions are: weather, vehicle speed, in gear or
neutral, engine temperature or any other special conditions. Noises that develop during A/C operation can often be
misleading. For example: what sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts,
mounting brackets or a loose clutch assembly. Verify accessory drive belt tension (power steering or alternator).
Improper accessory drive belt tension can cause a misleading noise when the compressor is engaged and little or no
noise when the compressor is disengaged.
Drive belts are speed-sensitive. In other words, at different engine speeds, and depending upon belt tension, belts can
develop unusual noises that are often mistaken for mechanical problems within the compressor.
a. Adjustment
1) Select a quiet area for testing. Duplicate conditions as much as possible. Turn compressor on and off several
times to clearly identify compressor noise. To duplicate high ambient conditions (high head pressure), restrict
airflow through condenser. Install manifold gauge set to make sure discharge pressure doesn’t exceed 21.4
kg/cm2.
2). Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt. Check to assure clutch
coil is tight (no rotation or wobble).
3). Check refrigerant hoses for rubbing or interference that can cause unusual noises.
4). Check refrigerant charge.
5). Recheck compressor noise as in Step 1.
6). If noise still exists, loosen compressor mounting bolts and re-torque. Repeat Step 1.
7). If noise continues, replace compressor and repeat Step 1.
SERVICE PROCEDURE
UNIT ASSEMBLY
Removal
1. Heater hose
2. In-outlet refrigerant pipe
3. Mounting nut
4. Control assembly
5. Audio assembly
6. Control panel
7. Passenger side under cover
8. Instrument assembly
9. Mounting bracket
Installation
Installstion is the reverse of removal.
Disassembly and assembly
Blower unit
Evaporator
Heat unit
FPV97-041
SERVICE PROCEDURE HA-31
HEATER UNIT
Removal
Disassemble after that heater unit removal
Installation

1. Disassemble as below illumination.
2. Assembly is the reverse of disassembly.
Heater care and mounting bracket

Temperature actuator and coolant temperature sensor
Wire clamp and bracket
FPV97-042
EVAPORATOR UNIT
Removal
Disassemble after that evaporator unit removal
Installation
Power transister(for Automatic Air-con)

Resister (for Manual A-con)
Thermist (for Automatic), Resistor(for Manual)
FPV97-043
1. Removal of case clip

To remove the case clip, insert the “-“ type screwdriver inside the
clip and pull it slowly not to damage the case.
Clip
FPV97-044
2. Removal of expansion valve

Loosen the swivel nut using 2 wrenches.
NOTE
• When installing an expansion valve, be careful with the
temperature sensor.
• Wrap it thoroughly with press-tight tape after fastening
the clips. Expansion
valve Clip Press tight tape
FPV97-045
O-ring
Expansion
valve
O-ring
FPV97-046
3. Check any damage of O-ring and apply the refrigerant oil before
connecting hose and pipes to the inlet and outlet of evaporator. 20
15 Upper limit
NOTE
Resistance (
• Check of evaporator pin thermo sensor. 10

Measure the resistance values of terminals more than
5
2 times at a different temperatures. If the value lies Lower limit
within the specification, sensor is normally operating. -10 0 10 20 30 40

Temperature(°C) FPV97-046-1
When measuring resistance values, temperature condition should

not exceeds the temperature range of the graph.
BLOWER UNIT
Removal
Disassemble after that blowr unit removal
Installation

1. Disassemble as below illumination.
2. Assembly is the reverse of disassembly.
Aspiration (for Automatic Air-con)

Ambient sensor (for automatic A-con)
FPV97-047
Check
Battery
FPV97-048
1. General check
Any deformation of bending of blower motor shaft
Any damage of wheel and blower case.
Operation state of air intake switch door motor.
Any malfunction of power relay
2. Blower motor assembly check

Remove the connector of blower motor.
Connect the connector to the blower motor directly and check whether blower motor turns smoothly.
Connect by changing the electrode and check whether the motor turns smoothly to the reverse direction.
Replace the motor if any fault is found.
CONDENSER
1. Exhaust hose assembly

2. Condenser assembly
3. Pipe assembly
4. Bolt
FPV97-050
Disassembling order.
1. Discharge hose and liquid tube (A)
2. Condenser bolts (4 ea)
3. Condenser
NOTE
• Discharge the refrigerant completely before disassembling condenser. Remove the radiator grille.
Assembly order
Assembly is done by the reverse order of disassembly.
NOTE
• Recharge the refrigerant to the specification after installing the condenser.
COMPRESSOR UNIT
Fin
Screw
Field coil assembly

Pulley assembly
Spacer
Bolt
Seal assembly Compressor assembly
Ring
Seal felt
Ring
Disc hub assembly
FPV97-051
Assembly and disassembly of compressor unit

1. Clutch and hub pulley
1) Removal
Remove the clutch hub supporting bolts with the span-
ner wrench.
FPV97-052
Pull the clutch hub and shim form the compressor shaft.
When the hub is not pulled from compressor shaft,
insert the bolt of 8 mm into the hub shaft hole and
remove the shaft.
FPV97-053
Remove the pulley supporting snap ring

Remove compressor pulley and bearing assembly
FPV97-054
2) Installation
Clean pulley bearing of compressor head to remove any
dirt or rust.
Install the compressor pulley and bearing
FPV97-055
Install the pulley snap ring as the slanted part faces outer
direction.
FPV97-056
Put one spacer shim of specified thickness inside hub

spool line opening, and slide down the hub to compres-
sor shaft end
FPV97-053
Put the new hub-supporting bolt on the compressor shaft

end and tighten it with the specified torques.
Tightening torque 1.1~1.4kg·m
NOTE
• Do not turn on the air-con.
FPV97-052
Check the clutch air gap between clutch hub and pulley
faces with dial gauge, and compare it with the
specification. Check it 3 times around pulley.
Items Standard
Clutch air clearance 0.4~0.7mm
If the clutch air gap exceeds the specification, adjust the

air clearance to the specification by trying the different
FPV97-057
shims.
2. Clutch field coil

1) Removal
Remove clutch hub and pulley
Install the shaft protection tool at the compressor open-
ing
Install the compressor pulley as shown in the figure.
Position the puller screw end at the concave part of shaft
protector and position the pulley jaw around the bottom
of the field coil.
Remove the coil out of compressor rotating the screw
with wrench.
NOTE
• Do not turn on the air-con.
FPV97-058
2) Installation
Clean the coil installation part of front head.
Position the compressor upright and put the coil at the
original position of the compressor front head. Check
whether electric connector of clutch coil is positioned
correctly.
Put the coil compression tools at the inner circle of
compressor nose and field coil. FPV97-055
Put the 2 pullers of 8 inches at the compressor and

compression tool respectively. Puller jaw should hold
tight the back of the installation part of front compressor,
and screw should be positioned at the center of com-
pression tool.
Tighten the screw with wrench as installing the coil tight
at the compressor front head.
Install clutch hub and pulley to the compressor.
FPV97-059
3. Shaft seal
Before replacing the compressor seal, remove the compressor from the vehicle and then discharge the refrigerant.
1) Removal
Remove the clutch hub from the compressor
Remove shaft seal felt from the compressor nose using proper equipment.
Blow out the dirt using the low-pressure compressed air, and wipe off the compressor nose in and out with no
shaggy clothe.
Remove shaft seal supporting snap ring from inside of compressor nose with snap ring remover as shown
below.
A B C
FPV97-060
a. Insert one end of the snap ring remover into a hole of the snap ring.(Figure A)
b. Turn the ring remover as the tool end snap ring hole approach to the compressor shaft.(Figure B)
c. Lift the snap ring remover quickly by leveraging the end onto the nose, and remove the snap ring.
(Figure C)
Put shaft seal remover at the compressor shaft and

slide it into compressor nose and down to shaft seal.
Grip the hexagonal part with bare hand and turn the tool
handle clockwise and insert tool end into inside the seal.
And then pull out the shaft seal form the compressor.
FPV97-061
2) Installation
Prepare the new shaft seal kit. Unpack it with care and
check the plastic shaft seal protector whether ma-
chined parts are damaged or rough.
Wipe off the shaft and seal pocket inside the compres-
sor nose with no shaggy clothe.
Dip the shaft seal protector and seal into the clean
refrigerant oil, and then put the seal onto the protector
as the seal rib faces bigger end of the protector.
FPV97-062
Install the seal protector installed with shaft seal at the

compressor shaft end.
FPV97-063
Install the shaft seal installer at the shaft seal protector

end, and then slide the shaft seal slowly into compres-
sor to be in a place.
Remove the seal installer and seal protector form the
compressor
Put a new seal supporting snap ring on the compressor
nose, and then insert the snap ring into the groove with
the remover.
FPV97-063-1
Turn the shaft about 10 revolutions with clutch hub, and
perform leak test the seal installation part.
Install the new felt at the compressor nose.
Install the compressor clutch hub
RECEIVER DRIER ASSEMBLY
1. Liquid tube (A) and (B)
2. Assembly bolts of receiver drier mounting
bracket (2 ea)
3. Receiver drier and bracket assembly
4. Receiver drier fixing bolt (1)
O - Ring 5. Receiver drier
6. Receiver drier mounting bracket
7
7. Dual pressure switch
2
3 5
4
Pipe connection part
O - Ring O - Ring
Compressor oil : FREOLS-83 SUNISO 5GS
FPV97-064
NOTE
• Discharge the refrigerant thoroughly, before the disassem-
bly of receiver drier.
Check
Assembly order is the reverse of disassembly order
NOTE
• Recharge the refrigerant with the specified quantity after
receiver drier installation.
Check
2.25±0.3 32±2
1. Dual pressure switch check ON
Measure the pressure at the high-pressure side. When dual
pressure switch is “On” as shown in the figure, if there is OFF
2.0±0.2
continuity between pressure switch terminals, then the system
is normal. If there is no continuity, replace the switch. 6±2
DIF
kg/cm2G FPV97-012
REFRIGERANT LINE
Removal and installation method
1. When removing, please refer to the cautions in removal below
2. When installing, please refer to the cautions in installation
below.
(Cautions in removal)
• Discharge the refrigerant thoroughly
• When removing the tubes and hoses, cover the hole so
that no dust and dirt get into them.
• When removing, be careful not to damage the other
parts like wiring and so on.
(Cautions in installation)
• Replace the O-ring at the connecting parts with new
one, and apply the refrigerant oil.
• Check the O-ring whether it is at the right place and
assemble.
• The designated torque on “P” must be applied.
• Swivel nut and joint flange type should be tightened
tentatively with bare hands first, and then fastened
tight with the tool.
• Tighten the connecting part first and then clamp it.
• Be careful not to cause any deformation, and check any
interference with other parts after installation.
• Recharge the refrigerant with the specified quantity
after installation.
• Check the air-con performance.
Removal order Pipe connecting parts

1. Discharge hose
2. Liquid tube (A)
3. Suction hose
4. Liquid tube (B)
5. Liquid tube (C) O-ring O-ring
6. Receiver drier and bracket assembly

Compressor oil :FREOL S-83 or SUNISO 5GS
7. Receiver drier mounting bracket FPV97-066-1
8. Receiver drier
9. Dual pressure switch
19
18
9
10
7
8 6
15
4
3 11
1
17 5
16
12
13
14
1. Condenser unit 8. Pipe mounting bracket 15. Suction pipe

2. Receiver drier bracket 9. Hose grommet 16. Pipe mounting bracket
3. Receiver drier 10. Discharge hose 17. Liquid hose
4. Crank pulley 11. Compressor 18. Liquid pipe
5. Nut 12. Suction hose 19. Evaporator unit
6. Drain hose 13. Liquid pipe
7. V-belt 14. Suction hose
EPV97-066

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What are the specifications of the engine?

What are the specifications of the engine?

What should be considered when reading disassembly and reassembly drawings?

What should be considered when reading disassembly and reassembly drawings?

GENERAL

Type Disel, 4cycle, lnline 6 cylinder,water cooled,direct injection

Aspiration Type Turbo charge Type

Compression ratio 17.6 : 1

Firing order 1-4-2-6-3-5

Direction of rotation Counter-clockwise viewed from fly wheel

Compression pressure 36-39kgf/cm2(280rpm)

Idle rpm 640±25rpm

Weight Approx. 580kg

Value seat angle Intake 30°

Value face angle Intake 30°

Close ATDC 13°

1. Nominal Value (Abbr.: NV)

NOTE, WARNING AND CAUTION

Table of Conversion Rate for Foot-pound Units into SI Units

Unit Sign of unit Sign of Foot-pound unit Conversion rate

General Precautions For Servicing

(1) Before performing the service procedures given in this manual,

(5) When servicing the electrical system, be sure to disconnect the

(7) Make alignment marks and keep disassembled part neatly

(9) Apply the specified grease to U-packings, oil seals, dust

(10) Special care must be taken in handling sensors and relays

(11) Connector handling precautions

(12) From a safety viewpoint, use utmost caution when handling

(13) When work requires an assistant or two, always make sure of

STANDARD BOLTS AND NUTS

Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or O) 8T (Head mark 4 or ⊕)

Flange bolts and nuts Unit: Nm (kgf m)

Dia. mm Pitch mm 4T (Head mark 4 or O) 7T (Head mark 7 or O) 8T (Head mark 8 or ⊕)

Identification marks of nut Identification marks of stud

3) Engine development order

4) Engine development version

6) Production sequence number

The nozzle tube accomplishes the function of holding the Piston

Combustion is accomplished by direct injection of fuel into the

A valve recess is machined on the top of the piston for providing

For more effective colling of the combustion chamber, water

Rocker shaft spring Inner valve spring

3. Crankcase and Cylinder Liner

4. Piston and piston ring

(b) Piston ring

5. Connecting Rod Bearing

6. Crankshaft and Main Bearing

By means of oil passages drilled through the pins and

An oil hole in each journal is through to that in pin, feeding

(b) Main bearing

A timing mark is a stamped on each gear.

Air compressor drive gear

Fuel injection pump

Power steering pump

Engine oil pump drive gear

A A : Match marks "1"

The ring gear tooth crests are induction-heardened for greater

SERVICE STANDARD Unit : mm

Inspection Item Standard Limit Remedy Inspection Procedure