Toyota 42-5fg15 Forklift Service Repair Manual

remove engine clutch TORQUE converter set BOLT disconnect ton
<p>FOREWORD 
This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO- 
30/5FD 7 0-30 Series. Please use this manual for providing quick, correct 
servicing of the corresponding forklift models. 
These models on the market since August 7986 are subject to minor changes 
in September 7986. This manual deals with the models produced in the period 
between A ugust 7 988 and August 7 989 as well as the models as of September 
7 989 (after m~nor 
changes}. 
Any change or modifications thereafter will be informed by Toyota Industrial 
Vehicles' Parts & Service News. 
For the service procedures of the mounted engine, read the repair manuals 
listed below as reference together with this manual. 
(Reference) 
Repair manuals related to this manual are as follows: 
TOY0 TA INDUSTRIAL VEHICLE 4P ENGINE 
REPAIR MANUAL (No. CE604) 
TOYOTA INDUSTRIAL VEHICLE 4 Y ENGINE 
REPAIR MANUAL (No. CE602) 
TO YO TA INDUS TRIAL VEHICLE 2 J ENGINE 
REPAIR MANUAL (No. CE603) 
TO YO TA INDUSTRIAL VEHICLE 7Z ENGINE 
REPAIR MANUAL (No. CE60 7) 
TO YO TA INDUSTRIAL VEHICLE 5K ENGINE 
REPAIR MANUAL (No. CE67 7) 
TOYOTA INDUSTRIAL VEHICLE 7 DZ ENGINE 
REPAIR MANUAL (No. CE6 18) 
(Note: 2 -3 ton models mounted with 2J, IDZ diesel engine are only available 
in designated areas.) 
TOYOTA MOTOR CORPORATION 
GENERAL 
Page 
.............................. 
EXTERIOR VIEWS 
0-2 
VEHICLE LISTING .............................. 0-3 
ABBREVIATIONS ................................ 0-7 
............................. 
OPERATIONAL TIPS 
0-7 
STANDARD BOLT & NUT TIGHTENING 
TORQUE ..................................... 0-8 
HIGH PRESSURE HOSE FITTING 
........................ 
TIGHTENING TORQUE 
0-10 
FRAME NUMBER ............................... 0-11 
WIRE ROPE SUSPENSION ANGLE LIST ............ 0-14 
SAFE LOAD FOR EACH WlRE ROPE 
SUSPENSION ANGLE .......................... 0-14 
COMPONENT WEIGHT ........................... 0-15 
RECOMMENDED LUBRICANT QUANTITY 
& TYPE ...................................... 0-17 
LUBRICATION CHARTS .......................... 0-21 
....................... 
PERIODIC MAINTENANCE 
0-22 
PERIODIC REPLACEMENT LUBRICANTS 
.................................. 
AND PARTS 
0-29 
EXTERIOR VIEWS 
Front View (5FG15) 
LATI 4-16 
Rear View (5FG15) 
LAT14-18 
VEHICLE LISTING (1986.8 - 1989.8) 
Se- 
ries 
% 
. - 
L 
% 
C 
0 + 
- 
V) 
Q, 
.- 
L 
% 
0 + 
CU 
Pay load 
1.0 ton 
1.35 ton 
1.5 ton 
1.75 ton 
2.0ton 
Model 
5FG10 
02 - 5FG10 
40- 5FG10 
42- 5FG10 
5FD10 
02 - 5FD10 
5FG14 
02- 5FG14 
40- 5FG14 
42- 5FG14 
5FD14 
02- 5FD14 
5FG 15 
02 - 5FG15 
40- 5FG15 
42 - 5FG15 
5FD15 
02 - 5FD15 
5FG18 
02 - 5FG18 
40- 5FG18 
42- 5FG18 
5FD18 
02 - 5FD18 
5FG20 
02- 5FG20 
40- 5FG20 
42- 5FG20 
5F D20 
02- 5FD20 
60 - 5FD20 
62 - 5FD20 
Engine 
model 
4 P 
? 
4 Y 
f 
2 J 
f 
4 P 
f 
4 Y 
f 
2 J 
t 
4 P 
f 
4 Y 
f 
2 J  
t 
4 P 
f 
4 Y 
t 
2 J 
f 
4 P 
t 
4 Y 
t 
1 Z 
f 
2 J 
f 
Engine 
tY Pe 
Gasoline 
f 
f 
f 
D~esel 
T 
Gasoline 
f 
7' 
t 
Diesel 
.f 
Gasoline 
t 
f 
t 
Diesel 
t 
Gasol i ne 
? 
f 
f 
Diesel 
t 
Gasoline 
t 
t 
t 
Diesel 
t 
f 
f 
Drive system 
1 1 " clutch 
Torque converter 
1 1 " clutch 
Torque converter 
1 1 " clutch 
Torque converter 
I 1 " clutch 
Torque converter 
1 1 " clutch 
Torque converter 
1 1" clutch 
Torque converter 
I 1  " clutch 
Torque converter 
I 1" clutch 
Torque converter 
I I" clutch 
Torque converter 
11" clutch 
Torque converter 
1 I " clutch 
Torque converter 
11" clutch 
Torque converter 
1 1 " clutch 
Torque converter 
11" clutch 
Torque converter 
11" clutch 
Torque converter 
1 1 " clutch 
Torque converter 
Remarks 
P/S instal led 
as standard 
f 
f 
t 
f 
t 
f 
f 
7. 
f 
f 
t 
f 
t 
t 
f 
f 
f 
f 
f 
t 
t 
f 
f 
t 
I. 
t 
7- 
f 
f 
t 
f 
VEHICLE LISTING (1989.9 - 
Ser~es 
1 ton serles 
2 ton series 
Engine model 
5K 
4Y 
1 DZ 
5K 
4Y 
1 DZ 
5K 
4Y 
1 DZ 
5K 
4Y 
1 DZ 
5K 
4Y 
1 z 
1 DZ 
5K 
4Y 
Dr~ve 
system 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Load capac~ty 
1.0 ton 
1.35 ton 
1.5 ton 
1.75 ton 
2.0 ton 
2.25 ton 
Model 
5FG10 
02-5FG10 
40-5FG10 
42-5FG10 
5FD10 
02-5FD 10 
5FG14 
02-5FG14 
40-5FG14 
42-5FG14 
5FD14 
02-5FD14 
5FG15 
02-5FG15 
40-5FG15 
42-5FG15 
5FD15 
02-5FD15 
5FG18 
02-5FG18 
40-5FG18 
42-5FG18 
5FD18 
02-5FD 18 
5FG20 
02-5FG20 
40-5FG20 
42-5FG20 
5FD20 
02-5FD20 
60-5FD20 
62-5FD20 
5FG23 
02-5FG23 
40-5FG23 
42-5FG23 
Series 
2 ton series 
Load capacity 
2.25 ton 
2.5 ton 
Model 
5FD23 
02-5FD23 
60-5FD23 
62-5FD23 
5FG25 
02-5FG25 
40-5FG25 
42-5FG25 
5FD25 
02-5FD25 
60-5FD25 
62-5FD25 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
4Y 
3 ton series 
Engine model 
1 z 
1 DZ 
5K 
4Y 
1 z 
1 DZ 
Drive system 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
Clutch 
Torque converter 
2.75 ton 
3.0 ton 
5FD28 
02-5FD28 
60-5FD28 
62-5FD28 
5FG30 
02-5FG30 
5FD30 
02-5FD30 
60-5FD30 
62-5FD30 
1 Z 
1 DZ 
4Y 
1 Z 
1 DZ 
ABBREVIATIONS 
Abbreviations used in this manual are as follows: 
OPERATIONAL TIPS 
1. Safe operation 
( 1 )  Make sure that correct size wire is used for hoisting a heavy material 
(2) After jacking up, always support with rigid racks or stands. 
Meaning 
Power Steering 
Right Hand 
Society of Automotive Engineers 
(USA) 
Special Service Tool 
Standard 
Sub-assem bly 
Tightening Torque 
N um ber of Teeth (00) 
U ndersize 
With 
Abbreviation 
(Code) 
ABDC 
ASSY 
ATDC 
ATM 
BBDC 
LH 
L LC 
MTM 
OHV 
0 PT 
0 /S 
PS 
2. Preparation of SSTs and measuring tools 
( 1 ) Prepare SSTs and measuring tools before starting operat ion. 
3. Clearing and arrangement 
( 1  ) Always keep the workshop neat and orderly for easy operation. 
(2) Disassembly of hydraulic equipment shall always be done in a clean place using clean tools. 
Meaning 
After Bottom Dead Center 
Assem bl y 
After Top Dead Center 
Automatic Transmission 
Before Bottom Dead Center 
Left Hand 
Long Life Coolant 
Manual Transmission 
Overhead valve 
Opt ion 
Oversi~e 
Horsepower 
4. Genuine Toyota parts 
Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings. 
Abbreviation 
(Code) 
P/S 
RH 
SA E 
SST 
STD 
SU B-ASSY 
T = 
OOT 
U/S 
w/ 
5. Repairs on electrical system 
Before doing any repairs on the electrical system, disconnect the cables from the battery terminals. 
Be sure to disconnect the negative @ cable first. 
6. Tightening torque for irlstallation 
Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque ' 
listed in standard bolt & nut tightening torque. 
7. Defect status grasp 
Do not start disassernbly and replacement as soon as a defect is found, but first grasp whether the 
defect requires disassembly and replacement. In the case of torque converter for example, do not 
attempt torque converter disassembly upon a failure in starting the vehicle, but first check such 
factors as the oil, pressure and rotation status causing the failure. 
STANDARD BOLT AND NUT TIGHTEN ING TORQUES 
How to judge tightening torque of a standard bolt or nut. 
1. How to judge tightening torque of a standard bolt. 
Find out the type of the bolt from the list below. 
Then, find the bolt tightening torque from the table. 
2. How to judge tighting torque of a standard unit. 
The nut tightening torque can be judged from the bolt type. (See the item above.) 
LIST OF BOLT TYPES AND STRENGTH 
1. Judging by part 
\ 
1 
Shape and class 
Hexagon 
head bolt 
@ Bolt head No* 
Hexagon 
flange bolt 
No mark 
Hexagon 
head bolt 
Hexagon 
Three protruding 
head bolt 
Two protruding 
lines 
Hexagon 
flange bolt 
Welded 
bolt 
@ l;') protruding 
Class 
2. Judging by part No. 
Hexagon head bolt 
Parts No, 
I 
91611-do625 
Length (rnrn) 
Diameter ( mm ) 
Diameter 
Parts No. 
~ e n ~ t h  
( r n m )  
Diameter ( m m  ) 
Diameter 
STANDARD BOLT TIGHTENING TORQUES 
PRECOAT BOLTS 
(Bolts with seal lock agent coating on threads) 
1. Do not use the precoat bolt as itisineither 
of the following cases: 
(a) After it is removed. 
(b) When the precoat bolt is moved Cloos- 
ened or tightened) by tightness check, 
etc. 
Note : 
. 
For torque check, use the lower limit of the 
Precoat ~~l~~ 
allowable tightening torque range. If the 
bolt moves, retighten it accordicg to the 
steps below. 
2. Method for reuse of precoat bolts 
(I) Wash ,the bolt and threaded hole. (The 
(2) Perfectly dry the washed parts by air 
threaded hole must be washed even for 
blowing. 
replacement of the bolt.) 
(3) Coat the specified seal lock agent to the 
threaded portion of the bolt. 
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with 
clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact 
surfaces before installation. 
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten 
the fitting. 
3. The maximum tightening torque must not exceed twice.the standard tightening torque. 
Nominal diameter 
of screw 
711 6 - 20'UNF 
9/16 - 18UNF 
314 - 16UNF 
7/8 - 14UNF 
11/16 - 12UNF 
15/16 - 12UNF 
PF1/4 
P F3/8 
PF112 
P F3/4 
PF1 
Hose inside 
d iarneter (mrn) 
6 
9 
12 
12 
19 
25 
9 
9 
12 
19 
25 
Standard tightening torque 
kg-m (ft-l b) 
Standard 
2.5 ( 18.1) 
5.0 ( 36.2) 
6.0 ( 43.4) 
6.0 ( 43.4) 
12.0 ( 86.8) 
14.0 (101.2) 
5.0 ( 36.2) 
5.0 ( 36.2) 
6.0 ( 43.4) 
12.0 ( 86.8) 
14.0 (101.2) 
Tightening range 
2.4 - 2.6 (17.4 - 18.8) 
4.8 - 5.3 (34.7 - 38.3) 
5.7 - 6.3 (41.2- 45.5) 
5.7 - 6.3 (41.2 - 45.5) 
11.4- 12.6 (82.4- 91.1) 
13.3 - 14.7 (96.2 -- 106.3) 
4.8 - 5.3 (34.7 -- 38.3) 
4.8 - 5.3 (34.7 - 38.3) 
5.7 -- 6.3 (41.2 - 45.5) 
11.4-12.6 
(82.4- 91.1) 
13.3 -- 14.7 (96.2 - 106.3) 
FRAME NUMBER (1986.8 -- 1989.8) 
Punching 
posit ion 
Vehicle series 
Engine model 
Vehicle model 
Punching format 
Vehicle series 
Eng~ne model 
Vehicle model 
Punching format 
Top on rear right frame 
- 
1 ton series 
1 Z 
- 
- 
- 
- 
- 
- 
- 
- 
- 
- 
4 P 
5FG10 
02- 5FG10 
5FG14 
02- 5FG14 
5FG15 
02- 5FG15 
5FG18 
02- 5FG18 
5FG18 - 
10001 
4 Y 
40- 5FG10 
42- 5FG10 
40- 5FG14 
42- 5FG14 
40- 5FG15 
42- 5FG15 
40- 5FG18 
42- 5FG18 
405FG18 - 
10001 
2 ton series 
2 J 
5FD10 
02- 5FD10 
5FD14 
02 - 5FD14 
5FD15 
02 - 5FD15 
5FD18 
02- 5FD18 
5FD18 - 
10001 
4 P 
5FG20 
02- 5FG20 
5FG23 
02 - 5FG23 
5FG25 
02 - 5FG25 
5FG25 - 
I0001 
1 Z 
5FD20 
02 - 5FD20 
5F D23 
02 - 5FD23 
5FD25 
02- 5FD25 
5FD25 - 
10001 
4 Y 
40- 5FG20 
42- 5FG20 
40- 5FG23 
42- 5FG23 
40- 5FG25 
42- 5FG25 
405FG25 - 
10001 
2 J 
60 - 5FD20 
62 - 5F D20 
60 - 5FD23 
62 - 5F D23 
60 - 5F D25 
62 - 5FD25 
605FD25 - 
10001 
Vehicle series 
Engine model 
Vehicle model 
Punching format 
3.0 ton series 
4 P 
- 
- 
- 
- 
- 
- 
2 J 
60- 5FD28 
62- 5FD28 
60- 5FD30 
62- 5FD30 
605FD30 - 
10001 
4 Y 
5FG28 
02- 5FG28 
5FG30 
02- 5FG30 
5FG30 - 
10001 
1 Z 
5FD28 
02- 5FD28 
5FD30 
02- 5FD30 
5FD30 - 
1000 1 
FRAME NUMBER (1 989.9 - 
1 
5FG14 
40-5FG14 
5FD14 
02-5FG14 
42-5FG 14 
02-5FD 14 
Vehicle model 
5FG15 
40-5FG15 
02-5FG15 
42-5FG 1 5 
02-5FD 1 5 
5FG18 
40-5FG 18 
02-5FG18 
42-5FG18 
02-5FD 18 
Punching 
format 
A5FG 1 8-400 1 1 
405FG 1 8-400 1 1 
A5FD 1 8-400 1 1 
2 ton series 
1 DZ 
60-5FD20 
62-5FD20 
60-5FD23 
62-5FD23 
60-5FD25 
62-5FD25 
A605FD25-40011 
1 Z 
5FD20 
02-5FD20 
5FD23 
02-5FD23 
5FD25 
02-5FD25 
5FD25-40011 
Engine model 
Vehicle model 
Punching 
format 
3 ton series 
5K 
5FG20 
02-5FG20 
5FG23 
02-5FG23 
5FG25 
02-5FG25 
A5FG25-40011 
4Y 
40-5FG20 
42-5FG20 
40-5FG23 
42-5FG23 
40-5FG25 
42-5FG25 
405FG25-40011 
1 DZ 
60-5FD28 
62-5FD28 
60-5FD30 
62-5FD30 
A605FD30-400 1 1 
A 
Engine model 
Vehicle model 
Punching 
format 
4Y 
5FG28 
02-5FG28 
5FG30 
02-5FG30 
5FG30-40011 
1 Z 
5FD28 
02-5FD28 
5FD30 
02-5FD30 
5FD30-400 1 1 
WlRE ROPE SUSPENSION ANGLE LIST 
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE 
Unit: ton (lb) 
Lifting 
angle 
0" 
30" 
60" 
Rope 
diameter 
6 mm 
(0.24 in.) 
8 mm 
(0.32 in.) 
10 mm 
(0.4 in.) 
12.5 mm 
(0.5 in.) 
14 mm 
(0.56 in.) 
Cutting 
load 
Tension 
1 .OO 
time 
1.04 
time 
1.16 
time 
Single-rope 
suspension 
Two-rope suspension 
Com pres- 
0 
time 
0.27 
time 
0.58 
time 
Four-rope suspension 
Suspension 
met hod 
Lifting 
angle 
90" 
120" 
w F 
2 t 
* 
I. 
Tension 
1.41 
time 
2.00 
time 
2t 
2t 
Compres- 
sion 
1 .OO 
time 
1.73 
time 
Suspension 
method 
2t 
2t 
b 
COMPONENTS WEIGHT 
(1986.8 -- 1989.8) 
unit: kg (Ib) 
Engine 
4P 
4Y 
2J 
1 Z 
Transmission ASSY 
Torque Converter ASSY 
Differential & Front 
Axle (w/ Brake 
Counter Weight 
Mast 
128 (282) 
134 (295) 
214 (471) 
237 (523) 
78 (172) 
AlSl N One speed 152 (335) 
AlSlN Twospeed 163 (359) 
1 ton series 
21 0 (463) 
2 ton series 
260 (573) 
3 ton series 
31 8 (701 ) 
1.0 ton Approx. 430 (950) 
1.35 ton Approx. 645 (1 420) 
1.5 ton Approx. 785 (1 730) 1.75 ton Approx. 91 5 (2020) 
2.0 ton Approx. 1 1 10 (2670) 2.25 ton Approx. 1225 (2700) 
2.5 ton Approx. 1430 (3 1 50) 2.75 ton Approx. 1670 (3680) 
3.0 ton Approx. 1860 (41 00) 
1 .O ton Approx. 400 (880) 
2.0 ton Approx. 500 (1 100) 
3.0 ton Approx. 600 (1320) 
COMPONENTS WEIGHT (1 989.9 - 
unit: kg (Ib) 
93 (205) 
134 (295) 
190 (41 9) 
237 (523) 
78 (1 72) 
152 (335) 
1 63 (359) 
2 10 (463) 
260 (573) 
318 (701) 
Approx. 430 (950) 
Approx. 645 (1 420) 
Approx. 785 (1730) 
Approx. 9 1 5 (2020) 
Approx. 1 1 1 0 (2670) 
Approx. 1 225 (2700) 
Approx. 1430 (3 1 50) 
Approx. 1670 (3680) 
Approx. 1 864 (4 1 00) 
Approx. 400 (880) 
Approx. 500 (1 100) 
Approx. 600 ( 1 320) 
. . 
Engine 
5K 
4Y 
1 DZ 
1 Z 
Transmission ASSY 
Torque Converter ASSY 
Differential & Front Axle 
(w/ Brake) 
Balance Weight 
Mast 
AlSlN 
One speed 
Two speed 
1 ton series 
2 ton series 
3 ton series 
1.0 ton 
1.35 ton 
1.5 ton 
1.75 ton 
2.0 ton 
2.25 ton 
2.5 ton 
2.75 ton 
3.0 ton 
1.0 ton 
2.0 ton 
3.0 ton 
RECOMMENDED LUBRICANT QUANTITY & TYPES 
(1 986.8 - 1989.8) 
Application 
4 P 
4 Y 
2 J 
1 Z 
MTM 
models 
AlSlN 
make 
1 ton series 
2 ton series 
3 ton series 
1 ton series 
2 ton series 
3 ton series 
1 ton series 
All models 
Attached Table 
Description 
Classification 
AP I 
SD,SE,SF 
AP I 
CC,CD 
AP I 
G L-4 
G L-5 
ATF 
AP I 
G L-4 
G L-5 
I SO 
VG32 
- 
LLC 
?- 
Quantity 
4.32 (1.14 USgal) 
4.0 Q (1.06 US gal) 
6.9 2 (1.82 US gal) 
9.0 P (2.38 US gal) 
4.0 2 (1.06 US gal) 
14 11 (3.70 US gal) 
5.8 Q (1.53 US gal) 
6.8 Q (1.80 US gal) 
9.0 Q (2.38 US gal) 
27 2 (7.1 US gal) 
34 2 (9.0 US gal) 
37 11 (9.8 US gal) 
Proper quantity 
Reservoir Tank 
0.2 Q (0.05 US gal) 
Proper quantity 
1 
Engine 
Type 
Motor oil 
SAE30 
(SAE20 in cold area) 
SA E20W-40 
(SAE 1 OW-30 in cold 
area) 
Diesel engine oil 
SAE30 
(SAE20 in cold area) 
SAE 1 OW-30 
Hypoid gear oil 
SAE85W-90 
GM 
Dexrono II 
Hypoid gear oil 
SAE85W-90 
Hydraulic oil 
#90 
SAE J-1703 
D OT- 3 
MP Grease 
"LLC 30-50% mix- 
ture (for winter or 
al I-season) 
a Coolant with rust- 
inhibitor (for spring, 
summer and autumn) 
? 
Gasoline 
Diesel 
Transmission 
Torque converter 
Differential 
Hydraulic oil 
Brake 
(1 .O-1.75 ton models) 
Chassis parts 
Coolant 
Coolant ( Reservoir 
Tank) 
Coolant volume 
All models 
1.1 Q (0.3 US gal) 
(at Full level) 
Attached Table 1 
Coolant volume 
unit: f (US gal) 
Engine 
4 P 
4 Y 
1 z 
2 J 
Drive method 
MTM 
ATM 
MTM 
ATM 
MTM 
ATM 
MTM 
ATM 
1 .O - 1.75 ton 
vehicles 
9.7 (2.56) 
11.5 (3.03) 
9.7 (2.56) 
1 1.5 (3.03) 
- 
- 
12.7 (3.35) 
14.5 (3.70) 
2.0 - 2.5 ton 
vehicles 
9.9 (2.61) 
11.2 (2.95) 
9.9 (2.61) 
11.2 (2.95) 
9.3 (2.46) 
8.6 (1 -01 
14.9 (3.93) 
14.2 (3.75) 
2.75,3.0 ton 
vehicles 
- 
- 
12.2 (3.22) 
1 1.8 (2.92) 
9.6 (2.53) 
9.2 (2.43) 
15.2 (4.01) 
14.8 (3.72) 
RECOMMENDED LUBRICANT QUANTITY & TYPES 
(1 989.9 - 
1 
Quantity 
4.0 Q (1.06 US gal) 
4.0 11 (1.06 US gal) 
6.511 (1.7 US gal) 
9.0 Q (2.38 US gal) 
4.0 Q (1.06 US gal) 
14.0 Q (3.70 US gal) 
5.8 Q (1.53 US gal) 
6.8 Q (1.80 US gal) 
9.0 Q (2.38 US gal) 
27.0 Q (7.1 US gal) 
34.0 Q (9.0 US gal) 
37.0 R (9.8 US gal) 
45.0 Q (1 1.9 US gal) 
65.0Q(17.2USgal) 
70.0 Q (1 8.5 US gal) 
45.0 Q (1 1.9 US gal) 
65.0 Q (1 7.2 US gal) 
70.0 R ( 1  8.5 US gal) 
Proper quantity 
Reservoir Tank 
0.2 R (0.05 US gal) 
Proper quantity 
1 
Application 
5K 
4Y 
1 DZ 
1 z 
MTM 
r~odels 
AlSlN make 
1 ton series 
2 ton series 
3 ton series 
1 ton series 
2 ton series 
3 ton series 
1 ton series 
Description 
Coolant 
(Reservoir Tank) 
Classification 
API 
SD,SE,SF 
API 
CC, CD 
API 
G L-4 
GL-5 
ATF 
API 
GL-4 
G L- 5 
IS0 
' 
VG32 
Engine 
2tonseries 
3 ton series 
Fuel tank 
1 ton series 
2 ton series 
3 ton series 
Brake 
1 ton series 
(1 .O-1.75 ton models) 
TY pe 
Motor oil 
SAE30 
(SAE20 in cold area) 
SAE20W-40 
(SAE1 OW-30 in cold 
area) 
Diesel engine oil 
SAE30 (SAE20 in cold 
area) 
SAE 1 OW-30 
Hypoid gear oil 
SAE85W-90 
GM Dexron@ I1 
Hypoid gear oil 
SAE85W-90 
Hydraulic oil #90 
Gasoline 
, 
Diesel 
Chassis parts 
Coolant 
t 
Transmission 
Torque converter 
Differential 
Hydraulic oil 
LLC 
(for winter or 
al I-season) 
Coolant with rust- 
in hi bitor (for spring, 
summer and autumn) 
t 
MP grease 
0" LLC 30-50% mixture 
Coolant volume 
All models 
Attached Table 
All models 
1.1 Q (0.3 US gal) 
(at Full level) 
Attached Table 1 Coolant volume 
unit: 2 (US gal) 
Engine 
5K 
4Y 
2.0 - 2.5 ton 
vehicles 
1 z 
1 DZ 
Drive method 
/ 
MTM 
ATM 
MTM 
ATM 
2.75, 3.0 ton 
vehicles 
1.0 - 1.75 ton 
vehicles 
5.5 (1.45) 
7.3 (1.93) 
7.5 (1.98) 
9.3 (2.46) 
MTM 
ATM 
MTM 
ATM 
5.7 (1.50) 
7.0 (1.85) 
7.7 (2.03) 
9.0 (2.38) 
10.0 (2.64) 
9.6 (2.53) 
9.7 (2.56) 
9.3 (2.46) 
8.3 (2.19) 
7.9 (2.09) 
9.4 (2.48) 
8.7 (2.30) 
5.8 (1.53) 
7.6 (2.01) 
8.0 (2.1 9) 
7.3 (1.93) 
LUBRICATION CHARTS 
2 
1 Chain 
2 Differential 
3 Front wheel bearing 
4 Brake master cylinder (1 .O-1.75 ton models) 
I 
5 Transmission case 
3 
6 Rear wheel bearing 
7 Steering knuckle kingpin 
8 Bell crank pin 
16 
9 Oil tank 
15 
10 Engine crank case 
11 Rear axle beam front 
4 
12 Rearaxlebeam rear 
13 Tilt steering universal joint 
13 
14 Tilt steering liocking meachanism 
15 Mast support bushing 
5 
16 Tilt cylinder front pin 
11 
17 Propeller shaft 
I 
lnspectevery8hours(daily) 
7 
I1 
Inspect every 40 hours (weekly) 
I11 
Inspect every 170 hours (monthly) 
6 
IV 
l nspect every 1000 hours (6 month1 y) 
V 
lnspectevery2000hours(annually) 
o 
lnspect and service 
Replace 
1 MP grease 
2 Engine oil 
3 Hypoid gear oil 
4 Hydraulic oil 
5 Gear oil 
6 Brake fluid (1 .O-1.75 ton models) 
Clutch Model Lubrication Chart 
LAOM136 
Chain 
Differential 
Front wheel bearing 
Brake master cylinder (1 .O-1.75 ton models) 
Torque converter case 
Rear wheel bearing 
Steering knuckle king pin 
Bell crank pin 
Oil tank 
Engine crank case 
Rear axle beam front 
Rear axle beam rear 
Tilt steering universal joint 
Tilt steering liocking meachanism 
Mast support bushing 
Tilt cylinder front pin 
Propeller shaft 
l nspect every 8 hours (daily 1 
lnspect every 40 hours (weekly) 
lnspect every 170 hours (monthly) 
lnspect every 1000 hours (6 monthly) 
lnspect every 2000 hours (annually) 
Inspect and service 
Replace 
MP grease 
Engine oil 
Hypoid gear oil 
Hydraulic oil 
Automatic transmission fluid 
Brake fluid (1 .O-1.75 ton models) 
Torque Converter Model Lubrication Chart 
PERIODIC MAINTENANCE 
INSPECTION METHOD 
I : Inspection. Repair or replacement if required. 
M : Measurement. Repair or adjustment if required. 
T : Retightening C : Cleaning 
L : Lubrication 
* : For new vehicle 
"1 : Soapy water 
"2 : Detector 
"3 : Flaw detector 
Inspection Period 
l tem 
Months 
Hours 
1 
170 
ENGINE 
Main body 
PCV system 
Governor 
Lubrication 
system 
Fuel system 
Cooling 
system 
Proper starting and abnormal noise 
Rotating condition at id1 ing 
Rotating condition during acceleration 
Exhaust gas condition 
Air cleaner element 
Valve clearance 
Compression 
Cylinder head bolt loosening 
Muffler rubber mount 
Clogging and damage in PCV valve and 
piping 
No-load maximum rpm 
Oil leak 
Oil level 
Clogging and dirt of oil filter 
Fuel leak 
Operation of carburetor link mechanism 
Dirt and clogging of fuel filter and element 
Injection timing 
l njection nozzle injection pressure and 
spray status 
Draining of sedimenter 
Coolant level in radiator and leak 
Rubber hose degradation 
Radiator cap condition 
Fan belt tension, looseness and damage 
Radiator rubber mount 
3 
500 
I 
M 
M 
I 
C 
M 
M 
T 
I 
I 
M 
I 
I 
I 
I 
I 
I 
M 
M 
I 
I 
I 
I 
I 
I 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0" 
0" 
6 
1000 
12 
2000 
0  
0  
0  
0  
0  
0  
0  
0  
0  
0  
- 
Inspection Period 
l tem 
Months 
Hours 
POWER 
Clutch 
Transmission 
Differential 
Torque 
converter and 
Propeller 
shaft and 
axle shaft 
DRIVE SYSTEM 
1 
170 
3 
500 
6 
1000 
TRANSMISSION SYSTEM 
Clutch pedal play 
Abnormal sound and functioning 
(connect ion) 
Clutch booster function and leak 
Fluid level 
Oil clutch mechanism function and leak 
Leak 
Fluid level 
Gear function and abnormal noise 
Leak 
Oil level 
Bolt loosening 
Lea k 
Fluid level 
Operating mechanism function and 
!ooseness 
Control valve and clutch functions 
Inching valve function 
Stall and hydrau l ic pressure measurement 
Loose joint 
Looseness at spline connections 
Looseness of universal joint 
Twisting and cracks of axle shaft. 
12 
2000 
0  
0  
0  
M 
I 
I 
I 
I 
I 
I 
I 
I 
I 
T 
I 
I 
I 
I 
I 
M 
T 
I 
I 
I 
Wheels 
0  
0  
0  
0 0 0 0  
0  
0 0 0 0  
0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 
Tire inflation pressure 
Tire cuts, damage and uneven wearing 
Loose rim and hub nuts 
tire groove depth 
metal chips, pebbles and other foreign 
matter trapped in tire grooves 
Rim, side bearing and disc wheel damage 
Abnormal sound and looseness of front 
wheel bearing 
M 
I 
T 
M 
I 
I 
I 
0  
0  
0  
0  
0  
0  
0 
0  
0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0  
0 0 0 0  
0 0 0 0  
0  
0  
0  
0  
0  
0  
0  
0  
0  
0  
0  
0 
inspection Period 
l tern 
Months 
Hours 
I 
I 
I 
M 
Wheel 
Front axle 
Rear axle 
A 
Abnormal sound and looseness of rear 
wheel bearing 
Cracks, damage and deformation of 
housing 
Cracks, damage and deformation of beam 
Looseness of axle beam in vehicle 
longitudinal direction 
STEERING SYSTEM 
Steering 
wheel 
Gear box 
Rods, links 
and arm 
Power 
steering 
Knuckle 
Steering 
shaft 
BRAKING 
1 
170 
0" 
3 
500 
0 0 0 0  
6 
1000 
Play and looseness 
Function 
Oil leak 
Looseness of mounting 
Clogging of re1 ief valve filter 
Looseness and damage 
Linkage wear and mounting condition 
Oil leak 
Mounting and linkage looseness 
Damage of power steering hose 
King pin looseness 
Cracks and deformation 
Wheel alignment 
Left and right turning angle 
SYSTEM 
12 
2000 
0  
0  
0  
Brake pedal 
Parking brake 
Brake pipe 
Reservoir tank 
I 
I 
I 
T 
C 
I 
I 
I 
I 
I 
I 
I 
M 
M 
Play and reserve 
Braking effect 
Operating force 
Braking effect 
Rod and cable looseness and damage 
Leak, damage and mounting condition 
Leak and fluid level 
0 
0 
Master cylinder or brake 
valve and wheel cylinder 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0  
0 0 0 0  
0  
I 
M 
I 
I 
I 
I 
I 
I 
Function, wear, damage, leak 
and rr~ounting 
looseness 
0  
0  
0 0 0 0  
0 0 0 0  
0 
0 0 0 0  
0 0 0 0  
0  
0  
0 
0 
0  
0  
0  
0  
0  
0  
0  
0  
0 
0  
0 
0  
0  
0  
0  
0  
0  
4 
Inspection Period 
l tem 
Months 
Hours 
M 
I 
I 
I 
I 
M 
I 
I 
T 
Brake drum 
and brake 
shoe 
Backing 
plate 
Clearance between drum and lining 
Wear of shoe sliding portion and lining 
Drum wear and damage 
Shoe operating condition 
Anchor pin rusting 
Return spring fatigue 
Automatic adjuster function 
Deformation, cracks and damage 
Loose mounting 
MATERIAL 
Forks 
Mast and 
fork 
bracket 
Chain and 
wheel 
Various 
attachments 
HYDRAULIC 
1 
170 
HANDLING SYSTEM 
Abnormality of fork and stopper pin 
Misalignment between left and right fork 
fingers 
Cracks at fork root and welded part 
Deformation and damage of each part and 
crack at welded part 
Mast and lift bracket looseness 
Wear and damage of mast support bush 
Wear, damage and rotating condition of 
rollers 
Wear and damage of roller pins 
Wear and damage of mast strip 
Tension, deformation and damage of 
chain 
Chain lubrication 
Abnormality of chain anchor bolt 
Wear, damage and rotating condition of 
chain wheel 
Abnormality and mounting condition of 
each part 
SYSTEM 
3 
500 
0 0 0 0  
I 
I 
I *3 
I 
I 
I 
I 
I 
I 
I 
I 
I 
I 
I 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
6 
1000 
I 
I 
I 
Cy I inder 
12 
2000 
0  
0  
0  
0  
0  
0  
0  
0  
Loosening and damage of cylinder mounting 
Deformation and damage of rod, rod screw 
and rod end 
Cylinder operation 
Natural drop and natural forward tilt 
(hydraulic drift) 
0  
0  
0  
0  
0  
, 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0  
0 0 0 0  
0 0 0 0  
0  
Inspection Period 
Months 
Hours 
I 
I 
M 
I 
I 
I 
C 
I 
I 
I 
I 
M 
I 
I 
I 
T 
l tern 
Cylinder 
Oil purrip 
Hydraulic 
oil tank 
Control 
lever 
Oil control 
* ~ a  
Ive 
Hydrau l ic 
piping 
ELECTRICAL 
Oil leak and damage 
Wear and damage of pin and cylinder 
bearing 
Lifting speed 
Uneven rnovemen t 
Oil leak and abnormal sound 
Oil level and contamination 
Tank and oil strainer 
Oil leak 
Loose l in kage 
Operation 
Oil leak 
Relief pressure measurement 
Relief valve and tilt lock valve functions 
Oil leak 
Deformation and damage 
Loose joint 
SYSTEM 
Ignition 
timing 
Starting 
rnotor 
Charger 
\ 
Battery 
Electrical 
wiring 
1 
170 
0 
Cracks on distributor cap 
Spark plug burning and gap 
Distributor side terminal burning 
Distributor cap center piece wear and 
darnage 
Plug cord internal discontinuity 
Ignition timing 
Pinion gear meshing status 
Charging function 
Battery fluid level 
Battery fluid specific gravity 
Darnage of wiring harness 
Fuses 
3 
500 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
1 
I 
I 
I 
I 
M 
I 
I 
I 
M 
I 
I 
6 
1000 
0  
0  
12 
2000 
0  
0  
0  
0  
0  
0 0 0 0  
0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0  
0 0 0 0  
0 0 0 0  
C 
0  
0  
0  
0  
0  
0  
0  
0  
12 
2000 
0 
0  
1 
170 
Months 
Hours 
1 
I 
I 
- 
l nspection Period 
l tem 
Preheater 
3 
500 
0 0 0 0  
Open-circuit in glow plug 
Open-circuit in intake heater 
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0 0 0 0  
0  
0 0 0 0  
SAFETY 
Head guard 
Back-rest 
Lighting 
system 
Horn 
Direction 
indicator 
l nstruments 
Backup buzzer 
Rear-view 
m i rror 
Seat 
Body 
Others 
6 
1000 
0  
0  
Engine stop- 
poing system 
1 Diesel engine key stop device function 
I 
I 
T 
I 
I 
I 
I 
I 
I 
I 
I 
I 
I 
T 
L 
DEVICES, ETC. 
Cracks at welded portion 
Deformation and damage 
Loosening of mounting 
Deformation, crack and damage 
Function and mounting condition 
Function and mounting condition 
Function and mounting condition 
Functions 
Function and mounting condition 
Dirt, damage 
Rear reflection status 
Loosening and damage of mounting 
Damage and cracks of frame, cross 
members, etc. 
Bolt looseness 
Grease up 
0  
G 
0  
0  
0  
0  
0  
0  
PERIODIC REPLACEMENT LUBRICANTS AND PARTS 
a : Replacement 
*' : for new vehicle *' : Every 2 years *3 : Every 3 years 
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier. 
l nterva l 
Item 
Engine 
Engine oil filter 
Engine coolant (every 2 years for LLC) 
Fuel filter 
Torque converter oil 
Torque converter oil filter 
Transmission oil 
Differential oil 
Hydraulic oil 
Hydraulic oil filter 
Wheel bearing grease 
Spark plugs 
Cyclone air cleaner element 
Brake va Ive rubber parts 
Cups and seals for master and wheel cylinders 
Brake fluid 
Power steering hoses 
Power steering rubbers parts 
Hydraulic hoses 
Reservoir tank tube 
Fuel hoses 
Torque converter rubber hoses 
Chains 
1 month 
170 hours 
a 
+ 1 
a 
3 months 
500 hours 
a 
a 
a 
6 months 
1000 hours 
a 
a 
a 
a 
a 
a 
a 
a 
12 months 
2000 hours 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a 
a*2 
a *2 
a*2 
a*2 
a*3 
A 
ENGINE 
........................................... 
GENERAL 
.......................... 
ENGINE PERFORMANCES 
ENGINE ASSY REMOVAL 
4P ENGINE VEHICLE (1 986.8 -- 1989.8) ........... 
25 ENGINE VEHICLE (1986.8 -1989.8) ............ 
.............................. 
I Z ENGINE VEHICLE 
4Y ENGINE VEHICLE .............................. 
5K ENGINE VEHICLE (1 989.9 - 
) ........... 
1 DZ ENGINE VEHICLE (1 989.9  ) .......... 
ENGINE ASSY DISCONNECTION 
............. 
TORQUE CONVERTER TYPE VEHICLE 
........................... 
CLUTCH TYPE VEHICLE 
ENGINE ASSY INSTALLATION 
4P ENGINE VEHICLE (1986.8 -- 1989.8) ........... 
2J ENGINE VEHICLE (1986.8 -- 1989.8) ........... 
1 Z ENGINE VEHICLE .................. ; ...... .'. ... 
.............................. 
4Y ENGINE VEHICLE 
5K ENGINE VEHICLE (1989.9 - 
) ........... 
1 DZ ENGINE VEHICLE (1 989.9 - 
) .......... 
ENGINE TUNE-UP 
...................... 
4P/4Y/5K ENGINE VEHICLE 
..................... 
2J/1 Z/l DZ ENGINE VEHICLE 
AIR CLEANER ....................................... 
RADIATOR .......................................... 
MUFFLER AND EXHAUST PIPE ...................... 
........................................... 
BAlTERY 
STARTING MOTOR .................................. 
ALTERNATOR ....................................... 
.............................. 
ACCELERATOR PEDAL 
Page 
1-2 
1-8 
GENERAL 
1 
I 
4P Engine Front View (1 986.8 -- 1989.8) 
KAF1-1 
I 
1 
4P Engine Rear View (1 986.8 - 1989.8) 
KAF25-32 
4Y Engine Front View 
KAJ 14-2 
1 
4Y Engine Front View 
KAJl4-16 
2J Engine Front View (1 986.8 - 1989.8) 
KAH2-2 
i 
2J Engine Rear View (1 986.8 - 1989.8) 
KAHI - 15 
12 Engine Front View 
KAG1-14 
1 Z Engine Front View 
1 
5K Engine Front View (1 989.9 - 
1 
KAPI-4 
5K Engine Front View (1 989.9 - 
1 
KAPI-5 
1 DZ Engine Front View (1 989.9 - 
1 
1 DZ Engine Front View (1 989.9 - 
1 
ENGINE PERFORMANCES (1 986.8 -- 1989.8) 
1.0 - 1.75 ton 
2.0 -- 2.5 ton 
Engine 
model 
4P 
4Y 
2 J 
4P 
4Y 
Tota I 
displacement 
cc 
1493 
2237 
248 1 
1493 
2237 
1 
1Z 
2953 
248 1 
2237 
2953 
248 1 
2.75 -- 3.0 ton 
No-load 
maximum governed 
speed rpm 
3050 
2450 
2300 
3050 
2600 
2J 
4Y 
1 Z 
2 J 
2600 
2600 
2600 
2600 
2600 
Rated 
horsepower 
PS/rpm 
35/2800 
4512 1 00 
4412700 
3512800 
5412400 
Maximum 
torque 
kg-m/rpm 
10.5/1800 
16.511 800 
14.512000 
10.511 800 
16.5/1800 
6012400 
5012500 
54/2400 
60/2400 
5012500 
18.5/1600 
14.512200 
1 6.5/1800 
1 8.511 600 
14.512260 
ENGINE PERFORMANCES (1989.9 - 
1 .O -- 1.75 ton 
2.0 - 2.5 ton 
1.75 -- 3.0 ton 
Engine 
model 
5K 
4Y 
1 DZ 
5K 
4Y 
1 Z 
1 DZ 
4Y 
1 Z 
1 DZ 
Total 
displacement 
cc 
1486 
2237 
2486 
1486 
2237 
2953 
2486 
2237 
2953 
2486 
No-load maximum 
governed 
speed rpm 
3050 
2600 
2600 
3050 
2600 
2600 
2600 
2600 
2600 
2600 
Rated 
horsepower 
PS/rpm 
38/2800 
54/2400 
55/2400 
38/2800 
54/2400 
60/2400 
55/2400 
54/2400 
60/2400 
55/2400 
Maximum 
torque 
kg-m/rpm 
1 1.5/2000 
16.5/1800 
17.0/1600 
1 1.5/2000 
16.5/1800 
18.5/1600 
1 7.0/ 1 600 
16.5/1800 
18.5/1600 
17.0/1600 
1-10 
PERFORMANCE CURVES 
Engine speed (rpm) 
4P Engine Performance Curve (1 986.8 - 1989.8) 
LAOM18 
-I 
14 2 
(kg-m 
I 
1 
6 
10 
14 
18 
22 
26 
XI 02 
Engine speed (rpm) 
(1 .O - 1.75 ton vehicle) 
2J Engine Performance Curve (1 986.8 - 1989.8) 
- 43- 
1 
- 
\19511000 
- - 
KAOM 19,20 
-300 5 
. - 
,280 '; 
E 
-260 2 
-240 
-220 5 
200 LL 
180 (glpsh) 
I- 
6 
10 
14 
18 
22 
26 
Engine speed (rpm) 
x1 02 
(2.0 - 3.0 ton vehicle) 
I:: (kg-m 
12 Engine Performance Curve 
- 44 - 
Engine speed (rpm) 
(1 .O - 1.75 ton vehicle) 
(kg-m ) 
4Y Engine Performance Curve (1 986.8 - 1989.8) 
LAOM1 1,12 
3 
\ 
u 
Fuel consumption 
v, 
Engine horsepower 
CI r 
y 
Shaft torque 
3 - 
~ 1 0 2  
Engine speed (rpm) 
5K Engine Performance Curve (1 989.9 - 
1 
1 
I 
I 
I 
10 
14 
18 
22 
1 
26 
~102 
Engine speed (rpm) 
1 DZ Engine Performance Curve (1 989.9 - 
1 
- 48 - 
ENGINE ASSY REMOVAL 
4P ENGINE VEHICLE (1 986.8 -- 1989.8) 
1. Engine hood removal 
(1) Disconnect the engine hood damper 
from the frame bracket. 
(2) Disconnect the engine hood stay from 
the frame bracket. 
(3) Remove engine hood hinge set screws 
(2 pcs. on each side), and remove the 
engine hood. 
Removing the Engine Hood 
LA064-12 ,? 3 
Radiator cover and toe board removal 
Battery removal 
(1 ) Disconnect battery terminals. 
Caution : 
Always disconnect the negative terminal 
first. 
(2) Remove the battery cap. 
(3) Remove the battery. 
Removing the Battery 
LA054-6 
Battery case removal 
(1 ) Remove set bolts (3 pcs.), and remove 
the battery case. 
Electrical wiring and fuel hose disconnec- 
tion. 
(1) Disconnect the starting motor bond 
strap. 
(2) Disconnect each electrical wiring con- 
nector. 
(3) Disconnect the fuel hose. 
Removing the Battery Case 
LA054-9 
Air cleaner removal 
(1 ) Remove the hydraulic tank breather. 
(2) I-oosen the hose clamp for the air 
cleaner hose. 
(3) Remove air cleaner case set bolts (4 
pcs.) and remove the air cleaner. 
Removing the Air Cleaner 
- 49 - 
7. Radiator reserve tank removal 
( 1 )  Disconnect the reserve tank hose from 
the radiator. 
(2) Remove the reserve tank. 
Removing the Reserve Tank 
LA054-23 
Fan removal 
(1 ) Remove fan set bolts (4 pcs.) and re- 
move the fan. 
Coolant draining 
(1 ) Loosen the radiator drain plug to drain 
the coolant. 
(2) Loosen the engine drain plug to drain 
the coolant. 
Removing the Fan 
LA054-27 
Radiator removal 
( 1  ) Loosen the inlet and outlet hose clamps. 
(2) Disconnect the torque converter cooler 
hose (in torque converter vehicle). 
Caution: 
Identify the hose installed positions. 
(3) Remove radiator set bolts, and remove 
the radiator. 
Removing the Radiator 
LA054-29 
Exhaust pipe disconnection 
( 1 )  Remove flange set nuts (2 pcs.) and re. 
move the exhaust pipe. 
Accelerator cable disconnection 
(1 ) Disconnect the accelerator cable. 
Disconnecting the Exhaust Pipe 
Oil pump disconnection 
( 1  ) Remove oil pump set bolts (2 pcs.) 
(2) Disconnect 
the oil pump from the 
engine. 
Horn removal 
(1 ) Disconnect the horn wiring connector. 
(2) Remove set bolts (2 pcs.), and remove 
the horn. 
Removing the Oil Pump ASSY 
LA054-32 
Torque converter shift 
rod and inching 
cable disconnection 
(in torque converter vehicle). 
(1) Remove the set nut and disconnect 
the shift rod. 
(2) Disconnect the Inching Cable. 
Disconnecting the Rod and Cable 
LA059-26,28 
Clutch release cylinder removal 
(in clutch vehicle) 
(1 ) Disconnect the clevis. 
(2) Remove set bolts (2 pcs.) 
the clutch release cylinder. 
Accelerator peda l with pedal 
removal 
and remove 
toe board 
Removing the Clutch Release Cylinder 
LA054-15 
Oil control valve return hose removal 
(in clutch vehicle) 
(1 ) Loosen hose clamps at both ends of the 
hose and disconnect both ends. 
(2) Remove the bracket set bolt and remove 
the return hose. 
Removing the Return Hose 
Shift lever removal (in clutch vehicle) 
(1) Disconnect the shift lever rod on the 
transmission side. 
(2) Remove the shift lever set plate, and 
remove the shift 
levers (forward & 
reverse, and speed). 
(3) Remove the plate washer and spring. 
Disconnecting the Shift Lever R o d  
LA055-1 1 
Shift lever shaft removal (in clutch vehicle) 
( 1  ) Remove set bolts (4 pcs.), and remove 
the shift lever shaft. 
Removing the Shift Lever Shaft 
LA055- 10 
Propeller shaft disconnection 
(I 
) Remove set bolts (2 pa.), and remove 
the propeller shaft cover. 
(2) Remove propeller shaft set bolts (4 pcs. 
on one side), and disconnect the propel- 
ler shaft. 
Note : 
It may be disconnected on either of the 
differential or the transmission side. 
Disconnecting the Propeller Shaft ASSY 
LA055-7 
Parking brake cable clamp removal 
(in 
torque converter model) 
(1 ) Remove parking brake cable clamp set 
bolt, and re-move the cable from the 
transmission case. 
Disconnecting the.Parking Brake Cable 
LA063-28 
Mou 
( 1 )  
nting set bolt removal 
Remove the engine mounting set bolts 
left and right. 
Remove the torque converter & trans- 
mission mounting set bolts (in torque 
converter vehicle). 
Remove the transmission mounting set 
bolts (in clutch vehicle). 
Removing the Mounting Set Bolts 
LA052-6,7 
24. Stabili~er emoval (in clutch model) 
(1 ) Measure the stabilizer installed dimen- 
sions. Measure and record for both the 
stabilizer at the upper 
left and the 
stabilizer at lower right. 
Dimension A : 83 + 1 mm 
(3.27 k 0.04 in.) 
Dimension B : 198 2 1 mm 
(7.8 + 0.04 in.) 
i 
Measuring the Stabilizer Installed Dimensions LAOM166 
(2) Loosen the stabilizer bar lock nut. 
(3) Remove the set nuts at both ends, and 
remove the cushion rubber, plate, sta- 
bilizer stopper and stabilizer bar. 
25. Check that all electrical wiring, cables and 
links are disconnected. 
26. Engine ASSY with transmission removal 
- 
( 1  ) Use the SST and remove the engine 
Removing the Stabilizer 
LA052-4 
ASSY with transmission. 
SST 090 10-201 1 1 -7 1 
Weight of ecgine ASSY with trans- 
mission: 
With torque converter & transmission: 
approx. 240 kg (528 Ib) 
With transmission: 
approx. 270 kg (594 Ib) 
Caution : 
Try safe operation by fully considering 
the center of gravity in setting the wire 
ropes for hoisting. 
Removing the Engine with Transmission 
LA052-8 
2J ENGINE VEHICLE (1 986.8 -- 1989.8) 
1. Engine hood removal 
( 1  ) Disconnect 
the engine hood damper 
from the frame bracket. 
(2) Disconnect the engine hood stay from 
the frame bracket. 
(3) Remove the engine hood hinge set 
screws (2 pcs. on one side), and remove 
the engine hood. 
2. Toe board removal 
Removing the Engine Hood 
LAO 1-6 
3. Battery removal 
( 1  ) Disconnect battery terminals. 
Caution : 
Always disconnect the negative terminal 
first. 
(2) Remove the battery cap. 
(3) Remove the battery. 
Removing the Battery 
LAO1-10 
4. Battery case removal 
( 1  ) Remove set bolts (3 pcs. ), and remove 
the battery. 
5. Electrical wiring and fuel hose disconnec- 
tion. 
(1) Disconnect 
the starting motor bond 
strap. 
(2) Disconnect electrical wiring such as the 
injection pump solenoid cut wiring. 
(3) Disconnect the fuel hose. 
Disconnecting the Solenoid Cut Wiring 
LAO 1-20 
6. Fuelfilterwith bracketremoval 
( 1  ) Disconnect the fuel piping. 
(2) Remove the set bolts (2 pcs.), and re- 
move the fuel filter with bracket. 
Removing the Fuel Filter with Bracket 
LA01 -1 3 
- 
7. Air ( 
( 1  
(2) 
:leaner removal 
Remove the hydraulic tank breather. 
Loosen the hose clamp for the air 
cleaner hose. 
Remove air cleaner case set bolts (4 
pcs.), and remove the air cleaner. 
Removing the Air Cleaner ASSY 
LA01 -1 6 
Radiator cover removal 
(1) Remove the set knobs, and remove the 
radiator cover. 
Radiator reserve tank removal 
( I )  Disconnect the reserve tank hose from 
the radiator. 
(2) Remove the reserve tnak. 
Removing the Radiator Cover 
LAO 1-28 
Radiator removal 
( 1 )  Loosen the radiator drain plug to drain 
the coolant. 
(2) Loosen the engine drain plug to drain 
the coolant. 
(3) Disconnect the torque converter cooler 
hose (in torque converter model). 
Caution : 
Identify the hose installed positions. 
(4) Remove 
the radiator set bolts and 
remove the radiator. 
Coolant Drain Plugs 
L A O  1 -32,30 
Removing the Radiator 
- 55 - 
Exhaust pipe disconnection 
( 1 )  Remove flange set nuts (3 pcs.), and dis- 
connect the exhaust pipe. 
Accelerator cable disconnection 
(1) Disconnect 
the cable clevis 
injection pump side. 
(21 Remove the accelerator cable 
from the manifold. 
on the 
bracket 
13. Oil pump removal 
(1 ) Remove oil pump set bolts (2 pcs.). 
(2) Disconnect 
the oil pump from the 
engine. 
Disconnecting the Exhaust Pipe 
LA02-7 
Disconnecting the Accelerator Cable 
LA01 -14 
Removing the Oil Pump 
LA03-3 
Accelerator pedal with pedal toe board 
removal 
(1 ) Remove toe board set bolts, and remove 
accelerator pedal with pedal toe board. 
Removing the Pedal Toe Board 
Torque converter shlft rod and inching cable 
disconnection (in torque converter vehicle) 
( 1 )  Remove the set nut, and disconnect the 
shift rod. 
(2) Disconnect the clevis, loosen the cable 
set nut, and disconnect the inching 
cable. 
Disconnecting the Torque Converter 
LA03-8 
Link Components 
16. Clutch release cylinder removal (in clutch 
vehicle) 
(1 ) Remove set bolts (2 pcs.). 
(2) Extract the push rod, and remove the 
clutch release cylinder. 
Removing the Clutch Booster ASSY 
LA07-2 1 
17. Oil control valve return hose removal (in 
cluich vehicle) 
( 1  ) Loosen the hose clamps at both ends of 
the hose and disconnect both ends. 
(2) Remove the hose bracket set bolt, and 
remove the return hose. 
Removing the Valve Return Hose 
LA07-7 
18. Shiaft lever removal (in clutch vehicle) 
( 1 )  Dlsconnnect the shift lever rod from rhe 
transmission. 
(2) Remove the shift lever set plate, and 
remove the shift 
levers (forward & 
reverse, and speed). 
(3) Remove the plate washer and spring. 
Removing the Shlft Lever 
- 57 - 
19. Shift lever shaft rer~loval (in ( 
(1 ) Rernove set bolts (4 pcs. 
the shift lever shaft. 
:lu tch vehicle) 
) ,  and remove 
Removing the Shift Lever Shaft 
LA07-15 
Propeller shaft disconnection 
(1) Remove set bolts (2 pcs.), and remove 
the propeller shaft cover. 
(2) Remove propeller shaft set bolts (4 pcs. 
on one side), and disconnect the propel- 
ler shaft. 
Note: 
It may be disconnected on either the differ- 
ential or the transmission side. 
Disconnecting the Propeller Shaft 
LA03-16 
Parking brake cable calmp removal 
(I) Remove the parking brake clamp set 
bolt, and disconnect the cable from the 
transmission cal be. 
Disconnect~ng 
the Parking Brake Cable 
LA0126-31 
22. Mounting set bolt removal 
(1) Remove the engine mounting set bolts 
left and right. 
Removlng the Eng~ne Mounting Set Bolts 
LA01 26-32 
(2) Remove the torque converter & trans- 
mission mounting set bolts (in torque 
converter vehicle). 
(3) Remove the transmission mounting set 
bolts (in clutch vehicle). 
Stabiliter removal (in clutch vehicle) 
( 1  ) Measure the stabilizer installed dimen- 
tions. (measure and recored for both 
the stabilirer at upper 
left and the 
stabilirer at lower right.) 
m m  (in.) 
(2) Loosen the stabil~zer bar lock nut. 
(3) Remove set nuts at both ends, and 
remove the cushion rubber, plate, sta- 
bili~er 
stopper and stabilizer bar. 
Check that all electrical wiring, cables and 
links are disconnected. 
Dimension B 
198 + 1 
(7.8 
+ 0.04) 
205.5 2 1 
(8.1 
? 0.041 
Vehicle model 
1 .O " 2.5 ton series 
2.75-3.0 
tor series 
Removing the Mounting Set Bolts (1 ) 
LA03-22 
Dimension A 
83 ' 
(3.27 
2 0.04) 
90.5 
+_ 1 
(3,56 0.041 
Removing the Mounting Set Bolts ( 2 )  
LAO 126-34 
Measuring the Stabilizer Installed Dimension LAOM166 
Removing the Stab1 lizer 
- 59 - 
Engine ASSY with transmission removal 
(1) Use the SST and remove the engine 
ASSY with transmission. 
SST09010-20111-71 
Weight of engine ASSY with transmission 
With torque converter & transmission: 
330 kg (726 I b) 
With transmission : 
350 kg (770 Ib) 
Caution: 
Try safe operation by fully considering the 
Center of gravity in setting wire ropes for 
Removing the Engine ASSY with Transmission 
LA04-9 
hoisting. 
ENGINE VEHICLE 
Engine hood removal 
(1 ) Disconnect 
the engine hood damper 
from the frame bracket. 
(2) Disconnect the engine hood stay form 
the frame bracket. 
(3) Remove engine hood hinge set screws 
(2 pcs. on one side), and remove the 
engine hood. 
2. Radiator cover and toe board removal 
Removing the Engine Hood 
LA088-1 
Battery removal 
( 1  ) Disconnect battery terminals. 
Caution : 
Always disconnect the negative terminal 
first. 
(2) Remove the battery cap. 
(3) Remove the battery (2 pcs.). 
Removing the Battery 
LA088-5 
Battery case removal 
( 1 )  Remove set bolts (3 pcs.), and remove 
the battery case. 
Electrical wiring and fuel hose disconnection 
(1) Disconnect 
the starting motor bond 
strap. 
(2) Disconnect each wiring connector. 
(3) Disconnect the fuel hose. 
Removing the Battery Case 
LA096-4 
Coolant dra~ning 
(1 ) Loosen the radiator drain plug to drain 
the coolant. 
(2! Loosen the engine drain plug to drain 
the coolant. 
Radiator removal 
( 1  ) Rernove the radiator reserve tank. 
(2) Remove the torque converter cooler 
hose (in torque converter vehicle). 
Caution : 
Identify the hose instal led position. 
Disconnecting the Torque Converter 
LA096- 13 
Cooler Hose 
- 61 - 
(3) Disconnect the inlet and outlet hoses 
from the engine. 
(4) Disconnect the fan shroud from the 
radiator. 
Disconnecting the Fan Shroud 
LA096-14 
(5) Remove set bolts (2 pcs.), and remove 
the radiator. 
Removing the Radiator 
LA096-15 
Air cleaner removal 
(1 ) Remove the hydraulic tank breather. 
(2) Loosen the hose clamp for the air 
cleaner hose. 
(3) Remove air cleaner case set bolts (4 
pcs.), and remove the air cleaner. 
Removing the Air Cleaner 
LA096-18 
Exhaust pipe disconnection 
(1 ) Remove flange set nuts (3 pcs.), and dis- 
connect the exhaust pipe. 
Accelerator cable disconnection 
( 1  ) Disconnect the accelerator cable from 
the injection pump, 
Disconnecting the Exhaust Pipe 
LA096-19 
Torque converter shift 
rod and inching 
cable disconnection (in torque converter 
vehicle) 
( 1  ) Remove the set nut and disconnect the 
shift rod. 
(2) Disconnect the inching cable. 
Disconnecting the Shift Rod 
LA096-2 1 
12. Shift lever removal (in clutch vehicle) 
(1) Disconnect the shift lever rod on the 
transmission side. 
(2) Remove the shift lever rod set nut, and 
remove the plate and shift levers (for - 
ward & reverse, and speed). 
(3) Remove the plate washer and spring. 
Removing the Shift Lever 
LAO1 13-10 
Disconnect the oil pump (tandem pump) 
(2 - 3 ton clutch model) 
( 1 )  Disconnect the oil pump return hose 
from the hydraulic tank. 
Disconnecting theReturn Hose 
LA01 13-1 1 
(2) Remove oil pump set bolts (2 pcs.). 
(3) Disconnect the oil pump (tandem pump) 
from the engine. 
Disconnecting the Oil Pump ASSY 
LA01 13-12 
- 63 - 
Oil pump ASSY disconnection 
(All models excluding 2 " 3 ton clutch 
models) 
(1) Removeoil pump-set bolts (2 pcs.). 
(2) Disconnect the oil pump from the 
engine. 
Disconnecting the Oil Pump 
L A 0 8 8 - 1 9  
Clutch release cylinder removal (in clutch 
vehicle) 
(1 ) Diconnect the clevis. 
(2) Remove set bolts (2 pcs.) and remove 
the clutch release cylinder. 
Removing the Release Cylinder 
L A O  1 1 3-22 
16. Oil control valve return hose removal (in 
2.0 - 3.0 ton clutch vehicle) 
( 1  ) Loosen hose clamps at both ends of 
the hose. 
(2) Remove the return hose. 
Removing the Return Hose 
L A 0 1  13-13,14 
Propeller shaft disconnection 
( 1  ) Remove set bolts (2 pcs.), and remove 
the propeller shaft cover. 
(2) Remove propeller shaft set bolts (4 pcs. 
on each side) and disconnect the pro- 
pel ler shaft. 
Note: 
It may be disconnected on either the dif- 
ferential or the transmission side. 
0isconnect;ng the Propeller Shaft 
L A 0 9 6 - 2 8  
- 64 - 
Parking brake cable clamp removal 
(1 ) Remove the clamp set bolt at the lower 
part of the transmission case, and dis- 
connect the cable from the transmission 
case. 
Disconnecting the Parking Brake Cable 
LAO113-19 
Mounting set bolts removal 
( 1 )  Remove the engine mounting set bolts 
left and right. 
Removing the Engine Mounting Bolts 
LA01 13-21 
(2) Remove the troque converter & trans- 
mission mounting set bolts (in torque 
converter vehicle). 
(3) Remove 
the 
transmission mounting 
set bolts (in clutch vehicle). 
Removing the Transmission 
LA096-29,1 13-20 
Mounting Bolts 
Measuring the Stabilizer l nstalled Dimension LAOM1 66 
- 65 - 
20. Stabilizer removal (in clutch vehicle) 
(1 ) Measure the stabilizer installed dimen- 
sions. Measure and record for both 
the stabilizer at the upper 
left and 
stabilizer at lower right. 
mm (in.) 
I L 
_ _ 
._- 
.> 
I 
i 
i 
I 
I 
i 
L:, s,( 
I 
1 .g- 
- 
v- 
.. 
F -
 
I 
\ J L !  , 
Dimension B 
214.5 + 1 
(8.44 
t 0.04) 
205.5 
+- 1 
(8.1 k 0.04) 
t 
Vehicle model 
2.0 -2.5 
'On series 
2-75 " 3.0 'On 
. 
Demension A 
99.5 t 1 
(3.92 i 0.04) 
905k 1 
(3.56' ? 0.04) 
Loosen the stabilizer bar lock nut. 
Remove the set nuts at both ends, 
remove the cushion rubber, plate, 
bi I izer stopper and stabilizer bar. 
and 
sta- 
Removing the Stabilizer (Upper Left) 
L A 0 1  13-24 
21 . Radiator reserve tank bracket removal 
( 1  ) Remove set bolts (2 pcs.) and remc 
the reserve tank bracket. 
Removing the Stabilizer (Lower Right) 
L A O  1 13-27 
Fan removal 
( 1 )  Remove set bolts (4 pcs.), and remove 
the fan. 
Check that all electrical wiring, cables and 
l in-ks are disconnected. 
24 Engine ASSY with transmission removal 
Removing the Fan 
LAO 1 13-36 
( 1  ) Use the SST and remove the engine with 
transmission. 
SST 0901 0-20 1 1 1-7 1 
Weight of engine ASSY with transmission 
With torque converter & transmission: 
approx. 350 kg (770 lb) 
With transmission: 
approx. 380 kg (836 Ib) 
Caution : 
Try safe operation by fully considering 
the center of gravity in setting the wire 
ropes for hoisting. 
Engine ASSY with Transmission 
- 66 - 
ENGINE VEHICLE 
Engine hood removal 
( 1  ) Disconnect 
the engine hood damper 
from the frame bracket. 
(2) Disconnect the engine hood stay from 
the frame bracket. 
(3) Remove the engine hood hinge set 
screws (2 pcs. on one side), and remove 
the engine hood. 
2. Radiator cover and toe board removal 
Removing the Engine Hood 
Battery removal 
( 1  ) Disconnect battery terminals. 
Caution : 
Always disconnect the negative terminal 
first. 
(2) Remove the battery cap 
(3) Remove the battery. 
Removing the Battery 
LA064-2 1 
Battery case reomova l 
( 1  ) Remove set bolts (3 pcs.), and remove 
the battery case. 
Electrical wiring and fuel hose disconnection 
(1) Disconnect 
the starting motor bond 
strap. 
(2) Disconnect the electrical wiring con- 
nector. 
(3) Disconnect the fuel hose. 
Removing the Battery Case 
LA054-9 
Horn removal 
( 1  ) Disconnec; the wiring connector. 
(2) Remove set bolts (2 pcs.), and remove 
the horn. 
Accelerator pedal with pedal toe board 
removal 
(1 ) Remove toe board set bolts, and remove 
the accelerator pedal with pedal toe 
board. 
Removing the Accelerator Pedal with 
LA064 - 34 
Toe Board 
Air cleaner removal 
( 1 )  Remove the hydraulic tank breather. 
(2) Loosen the hose clamp for the air 
cleaner hose. 
(3) Remove air cleaner case set bolts (4 
pcs.), and remove the air cleaner. 
Removing the Air Cleaner ASSY 
LA057-5,6 
9. Oil ( 
(1 
:ontrol valve return pipe removal 
Loosen the hose clamps at both ends 
of pipe, and disconnect both ends. 
Remove the bracket set bolt, and re- 
move the return pipe. 
Removing the Return Pipe 
LA057 -3 
Accelerator cable discon nectio 
( 1  ) Disconnect the accelerato 
carburetor side. 
Exhaust pipe disconnection 
( 1 )  Remove flange set nuts 
remove the exhaust pipe. 
n 
r cable on the 
(2 pcs.), and 
Disconnecting the Exhaust Pipe 
LA057-11 
Radiator reserve tank removal 
(1 ) Disconnect the reserve tank hose from 
the radiator. 
(2) Remove the reserve tank. 
Removing the Reserve Tank 
- 68 - 
Coolant draining 
(1 ) Loosen the radiator drain plug to drain 
the coolant. 
(2) Loosen the engine drain plug to drain 
the coolant. 
Draining the Coolant 
LA057-21 
14. Radiator removal 
(1 1 Loosen the inlet and outlet hose clamps. 
(2) Rernove the radiator set bolts, and 
remove the radiator. 
Removing the Radiator ASSY 
LA058 -3 
15. Oil pump disconnection (tandem pump) 
(in 2.0 - 3.0 ton clutch model) 
(1) Disconnect the oil pump return hose 
from the hydraulic tank. 
.(2) Remove oil pump set bolts (2 pcs.). 
(3) Disconnect 
the oil pump from the 
engine. 
Removing the Oil Pump (Tandem Pump) 
LA062 -2 
16. Oil pump disconnection 
(All models excluding 2.0 - 3.0 ton clutch 
models) 
(1) Remove oil pump set bolts (2 pcs.). 
(2) Disconnect 
the oil pump from the 
engine. 
Removing the Oil Pump ASSY 
Clutch release cylinder removal 
(1 ) Disconnect the clevis. 
(2) Disconnect the piping. 
(3) Remove set bolts (2 pcs.), and remove 
the clutch release cylinder. 
Removing the Clutch Release Cylinder 
LA060-4 
18. Shift lever removal 
( 1 )  Clisconnect the shift lever rod on the 
transmission side. 
(2) Remove the shift lever set plate, and 
remove the shift 
levers (forward & 
reverse, and speed). 
(3) Remove the plate washer and spring. 
Removing the Shift Lever 
LA057-17 
Propeller shaft disconnection 
(1 ) Remove set bolts (2 pcs.), and remove 
the propeller shaft cover. 
(2) Remove the propeller shaft set bolts (13 
mm, 4 pcs. on each side), and discon- 
nect the propeller shaft. 
Note: 
It may be disconnected on either the dif- 
ferential or the transmission side. 
Removing the Propeller Shaft 
LA058-10 
20. Mounting set bolts removal 
( 1 )  Hemove the englne mount~ng set bolts 
left and right. 
(2) Remove the torque converter & trans- 
mission mounting set bolts. 
Removing the Mounting Set Bolts 
LA058-1 1,12 
21. Stabilizer removal 
(1 ) Measure the stabilizer instal led dimen- 
sions. Measure and record for both 
stabilizer stopper and stabilizer bar. 
mm (in.) 
(2) Loosen the stabilizer bar lock nut, 
(3) Remove the, set nut from both ends, 
and remove the cushion rubber, plate, 
stabilizer stopper and stabilizer bar. 
Check that all electrical wiring, cables and 
I inks are disconnected. 
Dimension B 
198k 1 
(7.8 t 0.04) 
205.5 + 1 
(8.1 t 0.04) 
L 
Vehicle model 
1.0 -2.5 ton series 
2.75 - 3.0 ton series 
23. Engine ASSY with transmission removal 
( 1 )  Use the SST and remove the engine 
ASSY with transmission: 
With torque converter & transmission: 
approx. 250 kg (550 Ib) 
With transmission: 
approx. 270 kg (594 I b) 
SST 0901 0-201 11-71 
Demension A 
83 t 1 
13,27 + 0,04) 
9055 1 
(3.56' 0.041 
Caution: 
Try safe operation by fully considering the 
center of gravity in setting wire ropes for 
hoisting. 
! 1 %Ijf 
I 
r-j-- i 
1 F -- - 
A?, 1 , r.. 
y 
:: 3.1 
Measuring the Stabilizer Installed Dimension 
LAOM166 
Removing the Stabilizer 
LA058-8,64-35 
Removing the Engine with Transmission 
LA058-13 
5K ENGINE VEHICLE (1 989.9 - 
1 
1 . 
Engine hood removal 
( 1 )  Disconnect the engine hood damper 
from the frame bracket. 
(2) Disconnect the engine hood stay from 
the frame bracket. 
(3) Remove engine hood hinge set screws 
(2 pcs. on each side), and remove the 
engine hood. 
Removing the Engine Hood 
lAT3-29 
Battery removal 
( 1  ) Disconnect the battery terminals. 
Caution: 
Always disconnect the negative terminal 
first. 
(2) Remove the battery cap. 
(3) Remove the battery. 
Removing the Battery 
lAT4- 1 
3. Battery case removal 
( 1 )  Remove set bolts (3 pcs.) and remove 
the battery case. 
Removing the Battery Case 
LAT4-2 
Air 
(1 
( 2 )  
cleaner ASSY removal 
Remove the hydraulic tank breather. 
Loosen the hose clamp for the air clean- 
er hose. 
Remove air cleaner case set bolts (4 
pcs.) and remove the air cleaner. 
Removing the air cleaner 
 
 
 
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