Nissan Truck (D21) - Service Manual / Repair Manual

NISSAN TRUCK (D21) - SERVICE MANUAL

- English Service Manual / Repair Manual to Nissan Truck (D21).

INDEX

FOREWORD
GI - General Information
MA - Maintenance
EM - Engine Mechanical
LC - Engine Lubrication & Cooling Systems
EC - Engine Control System
FE - Accelerator Control, Fuel & Exhaust Systems
CL - Clutch
MT - Manual Transmission
AT - Automatic Transmission
TF - Transfer
PD - Propeller Shaft & Differential Carrier
FA - Front Axle & Front Suspension
RA - Rear Axle & Rear Suspension
BR - Brake System
ST - Steering System
RS - Restraint System
BT - Body Trim
HA - Heater & Air Conditioner
EL - Electrical System
IDX - Alphabetical Index
FOLD OUT
COMMENT SHEET
QUICK REFERENCE CHART
GST Mode 6 - Test Value & Test Limit Chart
MA - Maintenance.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG"
Special Service Tool
GENERAL MAINTENANCE
PERIODIC MAINTENANCE
Schecule 1
Schedule 2
RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants
SAE Viscosity Number
Antifreeze Coolant Mixture Ratio
ENGINE MAINTENANCE
Checking Drive Belts
Changing Engine Coolant
Checking Fuel Lines
Changing Fuel Filter
Changing Air Cleaner Filter
Changing Engine Oil
Changing Oil Filter
Changing Spark Plugs
Checking EVAP Vapor Purge Lines
Changing Positive Crankcase Ventillation (PCV) Filter
CHASSIS AND BODY MAINTENANCE
Checking Exhaust System
Checking Clutch Fluid Level and Leaks
Checking M/T Oil
Changing M/T Oil
Checking Water Entry - For 4WD models
Checking A/T Fluid
Changint A/T Fluid
Checking Transfer Fluid
Changing Transfer Fluid
Checking Propeller Shaft
Checking Differential Gear Oil
Changing Differential Gear Oil
Balancing Wheels
Tire Roataion
Checking Brake Fluid Level and Leaks
Checking Brake System
Checking Disc Brake
Checking Drum Brake
Checking Steering Gear and Linkage
Checking Power Steering Fluid and Lines
Checking Steering Gear Oil Level and Leaks
Lubricating Hood Latches, Locks and Hinges
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters
SERVICE DATA AND SPECIFICATIONS (SDS
Engine Maintenance
Chassis and Body Maintenance
EM - Engine Mechanical.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG"
Parts Requiring Angular Tightening
Liquid Gasket Application Procedure
PREPARATION
Special Service Tools
Commercial Service Tools
OUTER COMPONENT PARTS
COMPRESSION PRESSURE
Measurement of Compression Pressure
OIL PAN
Removal
Installation
TIMING CHAIN
Removal
Inspection
Installation
OIL SEAL REPLACEMENT
Valve Oil Seal
Front Oil Seal
Rear Oil Seal
CYLINDER HEAD
Removal
Disassembly
Inspection
Assembly
Installation
ENGINE REMOVAL
Removal
Installation
CYLINDER BLOCK
Disassembly
Inspection
Assembly
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjusement
GI - General Information.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) "AIR BAG"
General Precautions
Precautions for Engine Oils
Precautions for Multiport Fuel Injection System or ECCS Engine
Precautions for Three Way Catalyst
Precautions for Fuel
Precautions for Air Conditioning
HOW TO USE THIS MANUAL
HOW TO READ WIRING DIAGRAMS
Sample/Wiring Diagram - EXAMPL -
Description
Connector Symbols
Switch Positions
Detectable Lines And Non-Detectable Lines
Multiple Switch
Foldout Page
Wiring Diagram Codes (Cell Codes)
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Work Flow
Incident Simulation Tests
Circuit Inspection
Introduction
Testing for "Opens" In The Circuit
Testing for "Shorts" In The Circuit
Ground Inspection
Voltage Drop Tests
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
CONSULT CHECKING SYSTEM
IDENTIFICATION INFORMATION
Model Variation
Identification Number
Dimensions
Wheels & Tires
LIFTING POINTS AND TWO TRUCK TOWING
Pantograph Jack
Screw Jack
Garage Jack and Safety Stand
2-pole Lift
Tow Truck Towing
Towing Point
TIGHTENING TORQUE OF STANDARD BOLTS
SAE J1930 TERMINOLOGY LIST
LC - Engine Lubrication & Cooling Systems.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG"
Liquid Gasket Application Procedure
Special Service Tools
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Oil Pressure Check
Oil Pump
ENGINE COOLING SYSTEM
Cooling Circuit
System Check
Water Pump
Thermostat
Radiator
Cooling Fan
Overheating Cause Analysis
SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Lubrication System
Engine Cooling System
EC - Engine Control System.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
DIAGNOSTIC TROUBLE CODE INDEX
Alphabetical & P No. Index for DTC
PRECAUTIONS AND PREPARATION
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram
System Diagram
ECCS Component Parts Location
Vacuum Hose Drawing
System Chart
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Multiport Fuel Injection (MFI) System
Distributor Ignition (DI) System
Air Conditioning Cut Control
Fuel Cut control (at no load & high engine speed
EVAPORATIVE EMISSION SYSTEM
Description
Inspection
Evaporative Emission Line Drawing
POSITIVE CRANKCASE VENTILATION
Description
Inspection
BASIC SERVICE PROCEDURE
Fuel Pressure Release
Fuel Pressure Check
Injector Removal and Installation
Fast Idle Cam (FIC) Inspection and Adjustment
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Introduction
Two Trip Detection Logic
Emission-related Diagnostic Information
Malfunction Indicator Lamp (MIL)
OBD System Operation Chart
CONSULT
Generic Scan Tool (GST)
TROUBLE DIAGNOSIS – Introduction
Introduction
Diagnostic Worksheet
TROUBLE DIAGNOSIS - Work Flow
Work Flow
Description for Work Flow
TROUBLE DIAGNOSIS - Basic Inspection
Basic Inspection
TROUBLE DIAGNOSIS - General Description
Diagnostic Trouble Code (DTC) Inspection Priority Chart
Fail-Safe Chart
Symptom Matrix Chart
CONSULT Reference Value in Data Monitor Mode
Major Sensor Reference Graph in Data Monitor Mode
ECM Terminals and Reference Value
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
DTC P0100, Mass Air Flow Sensor (MAFS)
DTC P0105, Absolute Pressure Sensor
DTC P0110, Intake Air Temperature Sensor
DTC P0115, Engine Coolant Temperature Sensor (ECTS)
DTC P0120, Throttle Position Sensor
DTC P0125, Engine Coolant Temperature (ECT) Sensor
DTC P0130, Front Heated Oxygen Sensor (Front HO2S)
DTC P0130, Closed Loop Control
DTC P0135, Front Heated Oxygen Sensor Heater
DTC P0136, Rear Heated Oxygen Sensor (Rear (HO2S)
DTC P0141, Rear Heated Oxygen Sensor Heater
DTC P0171, Fuel Injection System Function (Lean side)
DTC P0172, Fuel Injection system Function (Rich side)
DTC P0180, Tank Fuel Temperature Sensor
DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire
DTC P0335, Crankshaft Position Sensor (CKPS) (OBD)
DTC P0340, Camshaft Position Sensor (CMPS)
DTC P0400, EGR Function
DTC P0402, EGRC-BPT Valve Function
DTC P0420, Three Way Catalyst Function
DTC P0440, Evaporative Emission (EVAP) Control System (Small Leak)
DTC P0443, Evaporative Emission (EVAP) Canister Purge Control Valve/Solenoid Valve
DTC P0446, Evaporative Emission (EVAP) Canister Vent Control Valve
DTC P0450, Evaporative Emission (EVAP) Control System Pressure Sensor
DTC P0500, Vehicle Speed Sensor (VSS)
DTC P0505, Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve
DTC P0510, Closed Throttle Position Switch
DTC P0605, Engine Control Module (ECM)-ECCS Control Module
DTC P0705, Park/Neutral Position Switch
DTC P1105, Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve
DTC P1130, Swirl Control Valve Control Solenoid Valve
DTC P1165, Swirl Control Valve Vacuum Check Switch
DTC P1320, Ignition Signal
DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (COG)
DTC P1400, EGRC-Solenoid Valve
DTC P1401, EGR Temperature Sensor
DTC P1441, Vacuum Cut Valve Bypass Valve
DTC P1445, Evaporative Emission (EVAP) Canister Purge Volume Control Valve
DTC P1447, Evaporative Emission (EVAP) Control System Purge Flow Monitoring
DTC P1550, Torque Converter Clutch Solenoid Valve
DTC P1900, Overheat
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Injector
Start Signal
Fuel Pump
Power Steering Oil Pressure Switch
IACV-FICD Solenoid Valve
MIL & Data Link Connectors
SERVICE DATA AND SPECIFICATIONS
General Specfications
Inspection and Adjustment
FE - Accelerator Control, Fuel & Exhaust Systems.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
ACCELERATOR CONTROL SYSTEM
Adjusting Accelerator Wire
FUEL SYSTEM
Fuel Tank
Fuel Pump and Gauge
EXHAUST SYSTEM
CL - Clutch.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
CLUTCH SYSTEM
Clutch Pedal
INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal
Bleeding Procedure
HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder
Operating Cylinder
Clutch Damper
CLUTCH RELEASE MECHANISM
CLUTCH DISC AND CLUTCH COVER
Clutch Disc
Clutch Cover and Flywheel
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
MT - Manual Transmission.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PREPARATION
Special Service Tools
Commercial Service Tools
ON-VEHICLE SERVICE
Replacing Rear Oil Seal - 2WD Model
Position Switch Check
REMOVAL AND INSTALLATION
MAJOR OVERHAUL
Case Components
Gear Components - 2WD Model
Gear Components - 4WD Model
Shift Control Components
DISASSEMBLY
Case Components
Shift Control Components
Gear Components
INSPECTION
Shift Control Components
Gear Components
Gears and Shafts
Synchronizers
Bearings
ASSEMBLY
Gear Components
Shift Control Components
Case Components
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
AT - Automatic Transmission.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PREPARATION AND PRECAUTIONS
Special Service Tools
Precautions For Supplemental Restraint System (SRS) "AIR BAG"
Precautions
OVERALL SYSTEM
Circuit Diagram
Wiring Diagram
Cross-Sectional View
Hydraulic Control Circuits
Shift Mechanism
TROUBLE DIAGNOSIS - Basic Inspection
Remarks
A/T Fluid Check
Road Test
Shift Schedule
TROUBLE DIAGNOSIS - General Description
Symptom Chart
TROUBLE DIAGNOSIS FOR DTC P1550
Torque Converter Clutch Solenoid Valve
TROUBLE DIAGNOSES
Component Inspection
Final Check
TROUBLE DIAGNOSES - A/T Shift Lock System
Description
Shift Lock System Electrical Parts Location
Wiring Diagram
Diagnostic Procedure
Key Interlock Cable
Component Check
ON-VEHICLE SERVICE
Control Valve Assembly and Accumulators Inspection
Rear Oil Seal Replacement
Parking Components Inspection
Governor Valve
Throttle Wire Adjustment
Inhibitor Switch Adjustment
Manual Control Linkage Adjustment
REMOVAL AND INSTALLATION
Removal
Installation
MAJOR OVERHAUL
Oil Channel
Locations of Needle Bearings, Thrust Washers and Snap Rings
DISASSEMBLY
Disassembly
REPAIR FOR COMPONENT PARTS
Oil Pump
Control Valve Assembly
Control Valve Upper Body
Control Valve Lower Body
Governor Valve Assembly
Parking Gear
Reverse Clutch
High Clutch
Forward and Overrun Clutches
Low & Reverse Brake
Forward Clutch Drum Assembly
Rear Internal Gear and Forward Clutch Hub
Band Servo Piston Assembly
Parking Pawl Components
ASSEMBLY
Assembly (1)
Adjustment
Assembly (2)
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Specifications and Adjustment
Vehicle Speed When Shifting Gears
Vehicle Speed When Performing and Releasing Lock-Up
Stall Revolution
Line Pressure
Return Spring
Accumulator O-Ring
Clutches And Brakes
Oil Pump And Low One-Way Clutch
Total End Play
Parking Gear
Reverse Clutch Drum End Play
Removal and Installation
TF - Transfer.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PREPARATION
Special Service Tools
Commercial Service Tools
Replacing Oil Seal
Center Case Oil Seal
Shift Shaft Oil Seal
Rear Oil Seal
REMOVAL AND INSTALLATION
TRANSFER GEAR CONTROL
MAJOR OVERHAUL
Case Components
Gear Components
Shift Control Components
DISASSEMBLY
REPAIR AND COMPONENT PARTS
Mainshaft
Front Drive Shaft
Counter Gear
Main Gear
Front Case
Shift Shaft Oil Seal
Front Case Cover
Cover Oil Seal
Bearing Retainer
Oil Catcher
Rear Case
Rear Oil Seal
Air Breather
Shift Control Components
ASSEMBLY
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
PD - Propeller Shaft & Differential Carrier.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PREPARATION
Special Service Tools
Propeller Shaft
PROPELLER SHAFT
On-vehicle Service
Removal and Installation
Inspection
Disassembly
Assembly
Final Drive
ON-VEHICLE SERVICE
Front Oil Seal Replacement (Front final drive)
Front Oil Seal Replacement (Rear final drive: Model H233B)
Rear Cover Gasket Replacement (Rear final drive: Model C200)
REMOVAL AND INSTALLATION (Front final drive)
REMOVAL AND INSTALLATION (Rear final drive)
R180A
FRONT FINAL DRIVE
DISASSEMBLY
Pre-inspection
Final Drive Housing
Differential Case
Extension Tube and Differential Side Shaft
INSPECTION
Ring Gear and Drive Pinion
Differential Case Assembly
Bearing
ADJUSTMENT
Side Bearing Preload
Pinion Gear Height and Pinion Bearing Preload
Tooth Contact
ASSEMBLY
Extension Tube and Differential Side Shaft
Differential Case
Final Drive Housing
H190A
REAR FINAL DRIVE
DISASSEMBLY
Pre-inspection
Differential Carrier
Differential Case
INSPECTION
Rear Gear and Drive Pinion
Differential Case Assembly
Bearing
LIMITED SLIP DIFFERENTIAL
Preparation for Disassembly
Disassembly
Inspection
Assembly
ADJUSTMENT
Side Bearing Preload
Pinion Gear Height
Tooth Contact
ASSEMBLY
Differential Case
Differential Carrier
C200
REAR FINAL DRIVE
DISASSEMBLY
Pre-Inspection
Differenital Carrier
Differential Case
INSPECTION
Ring Gear and Drive Pinion
Differential Case Assembly
Bearing
LIMITED SLIP DIFFERENTIAL
Preparation and Disassembly
Disassembly
Inspection
Adjustment
Assembly
ADJUSTMENT
Side Bearing Preload
Pinion Gear Height
Tooth Contact
ASSEMBLY
Differential Case
Differential Carrier
H233B
REAR FINAL DRIVE
DISASSEMBLY
Pre-inspection
Differential Carrier
Differential Case
INSPECTION
Ring Gear and Drive Pinion
Differential Case Assembly
Bearing
LIMITED SLIP DIFFERENTIAL
Preparation and Disassembly
Disassembly
Inspection
Adjustment
Assembly
ADJUSTMENT
Pinion Gear Height
Tooth Contact
ASSEMBLY
Differential Case
Differential Carrier
SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft
Final Drive
General Specifications
Inspection and Adjustment (R180A)
Inspection and Adjustment (H190A)
Inspection and Adjustment (C200)
Inspection and Adjustment (H233B)
FA - Front Axle & Front Suspension.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
FRONT AXLE AND FRONT SUSPENSION
ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts
Front Wheel Bearing
Preload Adjustment (2WD)
Preload Adjustment (4WD)
Front Wheel Alignment
Preliminary Inspection
Camber, Caster and Kingpin Inclication
Adjustment
Toe-In
Front Wheel Turning Angle
Drive Shaft
FRONT AXLE
FRONT AXLE (4WD)
Manual-lock Free-running Hub
Auto-lock Free-running Hub
FRONT AXLE
Wheel Hub and Rotor Disc
Knuckle Spindle
FRONT AXLE (4WD)
Drive Shaft
FRONT SUSPENSION
Shock Absorber
Torsion Bar Spring
Stabilizer Bar
Upper Link
Tension Rod or Compression Rod
Lower Link
Upper Ball Joint and Lower Ball Joint
SERVICE DATA AND SPECIFICATIONS
General Specifications
Inspection and Adjustment
RA - Rear Axle & Rear Suspension.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
REAR AXLE AND REAR SUSPENSION
ON-VEHICLE SERVICE

Rear Axle and Rear Suspension Parts
Rear Wheel Bearing
REAR AXLE
Components
Removal
Inspection
Installation
REAR SUSPENSION
Shock Absorber
Leaf Spring
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
BR - Brake System.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG"
Commercial Service Tools
CHECK ADJUSTMENT
Checking Brake Fluid Level
Checking Brake Line
Changing Brake Fluid
AIR BLEEDING
Bleeding Procedure
BRAKE HYDRAULIC LINE
CONTROL VALVE
Proportioning Valve (4WD)
Load Sensing Valve (2WD)
BRAKE PEDAL AND BRACKET
Adjustment
MASTER CYLINDER
BRAKE BOOSTER
On-vehicle Service
VACUUM HOSE
FRONT DISC BRAKE
Pad Replacement
REAR DRUM BRAKE
PARKING BRAKE CONTROL
Adjustment
REAR WHEEL ANTI-LOCK BRAKE SYSTEM
Purpose
Operation
System Description
System Components
Hydraulic Circuit
Removal and Installation
TROUBLE DIAGNOSIS
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Symptom Chart
Preliminary Check 1
Self-diagnosis
Component Parts and Harness Connector Location
Circuit Diagram
Wiring Diagram - ABS -
Diagnostic Procedures
Electrical Components Inspection
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
ST - Steering System.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG"
Steering System
Special Service Tools
Commercial Service Tool
ON-VEHICLE SERVICE
Steering System
Checking and Adjusting Drive Belts (For power steering)
Checking Fluid Level
Checking Fluid Leakage
Bleed Hydraulic System
Checking Steering Wheel Turning Force (For power steering)
Checking Steering Wheel Play
Checking Neutral Position on Steering Wheel
Checking Front Wheel Turning Angle
Checking Hydraulic System
STEERING WHEEL AND STEERING COLUMN
Steering Wheel
Steering Column
Disassembly and Assembly
Inspection
MANUAL STEERING GEAR (Model: VB66K)
Removal and Installation
Disassembly
Assembly and Adjustment
Inspection
POWER STEERING SYSTEM (Model: PB59K)
Description
POWER STEERING GEAR (Model: PB59K)
Removal and Installing
Power Steering Gear Component
Pre-disassembly Inspection and Adjustment
Disassembly
Assembly
POWER STEERING SYSTEM (Model: PB48S)
Description
POWER STEERING GEAR (Model: PB48S)
Removal and Installing
Power Steering Gear Component)
Pre-disassembly Inspection and Adjustment
Disassembly
Assembly
POWER STEERING OIL PUMP
Disassembly and Assembly
Pre-disassembly Inspection
Inspection
Disassembly
Assembly
STEERING LINKAGE
Removal and Installation
Disassembly
Inspection
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
RS - Restraint System.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG"
SEAT BELTS
Front Seat Belt
Rear Seat Belt
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions for SRS "Air Bag" Service
Special Service Tools
Description
SRS Component Parts Location
Maintenance Items
Diagnosis Sensor Unit and Crash Zone Sensor
Removal and Installation
Air Bag Module and Spiral Cable
Removal
Installation
Disposal of Air Bag Module
Checking Deployment Tool
Deployment Procedures for Air Bag Module (Outside of Vehicle)
Deployment of Air Bag Module While Mounted In Vehicle
Disposing of Air Bag Module
TROUBLE DIAGNOSES - Supplemental Restraing System (SRS)
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Schematic
Wiring Diagram - SRS -
Self-diagnosis
Diagnostic Procedures
Trouble Diagnoses for Air Bag Warning Lamp
Diagnostic Procedures
COLLISION DIAGNOSIS
SRS Inspection
BT - Body & Trim.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG"
GENERAL SERVICING
Clip and Fastener
BODY END
Front End
Rear End
Step Bumper
DOOR
Front Door
INSTRUMENT PANEL
INTERIOR TRIM
Side and Floor Trim - Passenger room
Roof Trim
EXTERIOR
SEAT
Front Seat
Jump Seat - King Cab Model
SUNROOF
Service Procedure
WINDSHIELD AND WINDOWS
Windshield
Back Window
Rear Side Window
MIRROR
Door Mirror
Rearview Mirror
CAB AND REAR BODY
Removal
Cab Body
Rear Body
Body Mounting
BODY ALIGNMENT
Engine Compartment
Underbody
HA - Heater & Air Conditioner.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS AND PREPARATION
Precautions for Supplemental Restraint System (SRS) "AIR BAG"
Introduction
Precautions for Working with R-134a
General Refrigerant Precautions
Precautions for Refrigerant Connection
Precautions for Servicing Compressor
Special Service Tools
R-134a Service Tools and Equipment
Precautions for Service Equipment
DESCRIPTION
Refrigeration Cycle
Component Layout
Discharge Air Flow
Control Operation
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Operational Check
Symptom Chart
Preliminary Check
Performance Test Diagnoses
Performance Chart
Trouble Diagnoses for Abnormal Pressure
Harness Layout
Circuit Diagram
Wiring Diagram - HEATER-
Wiring Diagram - A/C -
Mail Power Supply and Ground Circuit Check
Diagnostic Procedure 1
Electrical Components Inspection
Control Linkage Adjustment
SERVICE PROCEDURES
Checking Refrigerant Leaks
Refrigerant Lines
R-134a Service Procedure
Compressor Luibricant Quantity
Compressor Mounting
Belt Tension
Fast Idle Control Device (FICD)
Condenser
Compressor
Compressor Clutch
Thermal Protector
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
EL - Electric System.pdf
QUICK REFERENCE INDEX
TABLE OF CONTENTS
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG"
HARNESS CONNECTOR
STANDARDIZED RELAY
POWER SUPPLY ROUTING
Schematic
Wiring Diagram - POWER -
Fuse
Fusible Link
Circuit Breaker Inspection
GROUND DISTRIBUTION
BATTERY
How to Handle Battery
Service Data Specifications (SDS)
STARTING SYSTEM
System Description
Wiring Diagram - START -
Starter
Pinion/Clutch Check
Service Data and Specifications (SDS)
CHARGING SYSTEM
System Description
Wiring Diagram - CHARGE -
Trouble Diagnoses
Generator
Diode Check
Disassembly and Assembly
Service Data and Specifications (SDS)
COMBINATION SWITCH
Combination Switch/Check
Combination Switch/Replacement
Steering Switch/Check
HEADLAMP
System Description (For USA)
Wiring Diagram (For USA) - H/LAMP -
Trouble Diagnoses (For USA)
System Description (For Canada)
Operation (Daytime light system for Canada)
Schematic (For Canada)
Wiring Diagram (For Canada) - DTRL -
Trouble Diagnoses (For Canada)
Bulb Specifications
Aiming Adjustment
EXTERIOR LAMP
Back-up Lamp/Wiring Diagram - BACK/L -
Parking, License, Tail and Stop Lamps/Wiring Diagram - TAIL/L -
Turn Signal and Hazard Warning Lamps/System Description
Turn Signal and Hazard Warning Lamps/Wiring Diagram - TURN -
Turn Signal and Hazard Warning Lamps/Trouble Diagnoses
Combination Flasher Unit Check
Bulb Specifications
INTERIOR LAMP
Illumination/System Description
Illimunation/Schematic
Illimunation/Wiring Diagram, - ILL -
Interior and Map Lamps/Wiring Diagram - INT/L -
Bulb Specifications
METERS AND GAUGES
Start Description
Combination Meter
Speedometer, Tachometer, Temp, and Fuel Guages/Wiring Diagram - METER -
Inspection/Water Temperature Guage
Inspection/Fuel Guage
Inspection/Tachometer
Inspection/Speedometer and Vehicle Speed Sensor
Inspection/Speedometer and Fuse
Fuel Tank Guage Unit Check
Fuel Warning Lamp Sensor Check
Thermal Transmitter Check
Oil Pressure Switch Check
Vehicle Speed Sensor Signal Check
WARNING LAMPS
System Description
Schematic
Wiring Diagram - WARN -
Diode Check
WARNING CHIME
System Description
Wiring Diagram - CHIME -
Trouble Diagnoses
WIPER AND WASHER
System Description
Wiring Diagram - WIPER -
Trouble Diagnoses
Wiper Amplifier Check
Installation
Washer Nozzle Adjustment
HORN, LIGHTER, CLOCK
Wiring Diagram - HORN -
AUDIO
System Description
Schematic
Wiring Diagram - AUDIO -
Trouble Diagnoses
ANTENNA
Location of Antenna
Window Antenna Repair
MIRROR
Wiring Diagram - MIRROR -
AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Component Parts and Harness Connector Location
System Description
Schematic
Wiring Diagram - ASCD -
Trouble Diagnoses
POWER WINDOW
Component Layout
System Description
Wiring diagram - WINDOW -
Trouble Diagnoses
POWER DOOR LOCK
System Description
Schematic
Wiring Diagram - D/LOCK -
Trouble Diagnoses
LOCATION OF ELECTRICAL UNITS
Passenger Compartment
Engine Compartment
HARNESS LAYOUT
How To Read Harness Layout
Outline
Main Harness and Air Bag Harness
Instrument Harness
Engine Harness
Chassis and Tail Harness
Front Door Harness
Room Lamp Harness
Foldout.pdf
QUICK REFERENCE INDEX
ELECTRICAL SYSTEM
SUPER MULTIPLE JUNCTION (SMJ)
INSTALLATION
Terminal Arrangement
JOINT CONNECTOR (J/C)
Location
FUSE BLOCK
Fuse Arrangement
CONTROL UNITS/MODULE
IDX - Index.pdf
QUICK REFERENCE INDEX