
lAll dimensions indicated in figures are actual ones.
lWhen using a tracking gauge, adjust both pointers to equal length. Make sure there is no free play.
lWhen a measuring tape is used, check to be sure there is no elongation, twisting or bending.
lMeasurements should be taken at the center of the mounting holes.
lAll measurements and mounting hole diameters are expressed in millimeters (mm).
lAn asterisk (*) following the value at the measuring point indicates that the measuring point on the other
side is symmetrically the same value.
lThe coordinates of the measurement points are the distances measured from the respective dimension
lines in the directions of ``x'', ``y'' and ``z''.
Dimension lines: ``x'' line Ð Center line of vehicle
``y'' line Ð Center line of front axle (Any measurement point in front of the dimension
line refers to a minus ``Ð'' value.)
``z'' line Ð Datum line (Any measurement point under the dimension line refers to a
minus ``Ð'' value.)
2W.SB: Short wheelbase (2WD)
2W.LB
: Long wheelbase (2WD)
4W.LB
: Long wheelbase (4WD)
BODY ALIGNMENT
BT-43

Injection Pump Calibration Standard
Injection pump assembly No.104780-4951/
104780-4961
Part No.16700 3S300/
106700 3S301Pump rotation: ClockwiseÐviewed from drive side
1. Test conditions
1 - 1 Nozzle: 105780-0060 (NP-DN0SD1510) 1 - 4 Injection pipe: 2 dia. x 6 dia. x 450 mm (0.08 dia. x 0.24 dia. x 17.72 in)
1 - 2 Nozzle holder: 105780-2150 1 - 5 Fuel oil temperature: 45
+5
0ÉC (113+9
0ÉF)
1 - 3 Nozzle opening pressure: 13,000+300
0kPa
(130.0+3.0
0bar,
133+3
0kg/cm2,
1,891+43
0psi)1 - 6 Supply pump pressure: 20 kPa (0.20 bar, 0.2 kg/cm
2, 2.8 psi)
2. SettingPump speed
rpmSettingsCharge air press
kPa
(mbar, mmHg, inHg)Difference in delivery
m!(Imp fl oz)
2 - 1 Timing device travel 1,100ON 3.4 - 4.2 mm (0.134 - 0.165 in)
OFF 1.8 - 2.2 mm (0.071 - 0.087 in)
ÐÐ
2 - 2 Supply pump pressure 1,100ON 471 - 549 kPa
(4.71 - 5.49 bar, 4.8 - 5.6 kg/cm
2,
68 - 80 psi)
OFF 402 - 461 kPa
(4.02 - 4.61 bar, 4.1 - 4.7 kg/cm
2,
58 - 67 psi)Ð
2 - 3 Full-load delivery 1,10046.9 - 47.9 m!
(1.65 - 1.69 Imp fl oz)/1,000 st3.5 (0.12)
2 - 4 Idle speed regulation 3755.1 - 9.1 m!
(0.18 - 0.32 Imp fl oz)/1,000 st2.0 (0.07)
2 - 5 Start 10045.0 - 80.0 m!
(1.58 - 2.82 Imp fl oz)/1,000 stÐ
2 - 6 Full-load speed regulation 2,50012.9 - 16.9 m!
(0.45 - 0.59 Imp fl oz)/1,000 stÐ
2 - 7 Load timer adjustment 1,100 0.1 - 0.5 mm (0.004 - 0.020 in) Ð
3. Test specifications Solenoid timer ON OFF
3 - 1 Timing deviceN = rpm
mm (in)1,100
3.3 - 4.3
(0.130 - 0.169)2,150
7.3 - 8.2
(0.287 - 0.323)700
Below 0.8
(0.031)1,100
1.7 - 2.3
(0.067 - 0.091)2,150
6.3 - 7.5
(0.248 - 0.295)
3 - 2 Supply pumpN = rpm
kPa (bar,
kg/cm
2, psi)1,100
392 - 471
(3.92 - 4.71,
4.0 - 4.8,
57 - 68)2,150
618 - 696
(6.18 - 6.96,
6.3 - 7.1,
90 - 101)
3-3Overflow deliv-
eryN = rpm
m!(Imp fl oz)/
min.1,100
310 - 570
(10.9 - 20.1)Ð
3 - 4 Fuel injection quantities
Speed control
lever positionPump speed
rpmFuel delivery
m!(Imp fl oz)/
1,000 stCharge air press
kPa (mbar,
mmHg, inHg)
Max. speed1,10046.4 - 48.4
(1.63 - 1.70)
Ð 50041.3 - 47.3
(1.45 - 1.66)*
2,15041.2 - 48.2
(1.45 - 1.70)*
2,50011.9 - 17.9
(0.42 - 0.63)
2,700 Below 5.0 (0.18)
Switch OFF
Magnet valve375 0 (0) Ð
Idling 3754.6 - 9.6
(0.16 - 0.34)Ð
3 - 5 SolenoidMax. cut-in voltage: 8V
Test voltage: 12 - 14V
ON: Solenoid timer is ON. *: Reference value
OFF: Solenoid timer is OFF.
If there is no designation in the specifications for the Solenoid Timer's ON-OFF position, then the position should be regarded as OFF.
4. Dimensions
K 3.2 - 3.4 mm (0.126 - 0.134 in)
KF 5.7 - 5.9 mm (0.224 - 0.232 in)
MS 0.9 - 1.1 mm (0.035 - 0.043 in)
BCS Ð
Pre-stroke 0.08 - 0.12 mm (0.0031 - 0.0047 in)
Control lever angle
a51.5 - 59.5 degree
b31.0 - 41.0 degree
gÐ
SERVICE DATA AND SPECIFICATIONS (SDS)TD
EC-234

VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or
replace if excessively worn.
lBefore repairing valve seats, check valve and valve
guide for wear. If they have worn, replace them. Then
correct valve seat.
lUse both hands to cut uniformly.
REPLACING VALVE SEAT FOR SERVICE PARTS
1. Bore out old seat until it collapses. Set machine depth stop
so that boring cannot contact bottom face of seat recess in
cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 (0.020)]: mm (in)
Intake 36.500 - 36.516 (1.4370 - 1.4376)
Exhaust 42.500 - 42.516 (1.6732 - 1.6739)
Use the valve guide center for reaming to ensure valve seat
will have the correct fit.
3. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF).
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool of the specified
dimensions. Refer to SDS, EM-92.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle ``a'':
45 deg.
Contacting width ``W'': mm (in)
Intake
1.6 - 1.7 (0.063 - 0.067)
Exhaust
1.7 - 2.1 (0.067 - 0.083)
VALVE DIMENSIONS
Check dimensions of each valve. Refer to SDS, EM-93.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
SEM227C
SEM795A
SEM008A
SEM892B
SEM188A
CYLINDER HEADKA
Inspection (Cont'd)
EM-31

REPLACING VALVE SEAT FOR SERVICE PARTS
1. Bore out old seat until it collapses or remove valve seats with
Tool.
Place a copper seat between contact surface of Tool and
cylinder head.
2. If the valve seat for the exhaust side is oversized, machine
its mating area (on the cylinder head side) to the dimensions
indicated in the table below. Refer to the figure at the left for
machining procedures.
Unit: mm (in)
Oversized valve
seatBore diameter ``d''
TD25
0.2 (0.008)38.695 - 38.710
(1.5234 - 1.5240)
0.4 (0.016)38.895 - 38.910
(1.5313 - 1.5319)
3. Place new valve seats on dry ice and allow them to cool for
five minutes.
WARNING:
Do not touch cooled valve seats with bare hand.
4. Heat cylinder head to 80ÉC (176ÉF).
5. Install cooled valve seats on cylinder head with Tool.
6. Stake exhaust valve seat at five places with punch.
When staking valve seat, select different places than those
staked before.
SEM631B
DEM031
SEM632B
SEM087
CYLINDER HEADTD
Inspection (Cont'd)
EM-58

7. Cut or grind valve seat using suitable tool at the specified
dimensions as shown in SDS, EM-100.
8. After cutting, lap valve seat with a lapping compound.
9. Check contact condition of valve seat.
COMBUSTION CHAMBER
Check combustion chamber for cracks and other damage. If
necessary, replace.
REPLACING COMBUSTION CHAMBER
Usually combustion chamber should not be removed.
1. Remove combustion chamber so that cylinder head cannot
be damaged.
2. Install combustion chamber.
Identification of combustion chambers
Identification mark
(on combustion chamber)Outer diameter
``D'' mm (in)Engine
3 places 37 (1.46) TD25
(1) Cool combustion chamber with dry ice for approximately 5 to
10 minutes.
WARNING:
Do not touch cooled combustion chamber with bare hand.
(2) Align combustion chamber knock pin with cylinder head
notch, and drive in combustion chamber with a soft hammer.
3. Check amount of protrusion of combustion chamber.
Protrusion:
Standard
þ0.05 to 0.10 mm (þ0.0020 to 0.0039 in)
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to SDS.
When valve head has been worn down to 0.5 mm (0.020 in)
in margin thickness, replace the valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
SEM633B
DEM107
.
SEM634B
SEM188A
CYLINDER HEADTD
Inspection (Cont'd)
EM-59

GENERAL INFORMATION
SECTION
GI
CONTENTS
PRECAUTIONS......................................................... 1
Precautions for Supplemental Restraint
System (SRS) ``AIR BAG'' (4WD models)............. 1
Precautions for Supplemental Restraint
System (SRS) ``AIR BAG'' (2WD models)............. 1
Precautions for NATS ............................................ 2
General Precautions .............................................. 2
Precautions for Multiport Fuel Injection System
or ECCS Engine .................................................... 4
Precautions for Three Way Catalyst
(If so equipped) ...................................................... 4
Precautions for Engine Oils ................................... 4
Precautions for Fuel............................................... 5
Precautions for Air Conditioning ............................ 6
HOW TO USE THIS MANUAL.................................. 7
HOW TO READ WIRING DIAGRAMS...................... 9
Sample/Wiring Diagram - EXAMPL - .................... 9
Description ........................................................... 11
HOW TO CHECK TERMINAL................................. 18
How to Probe Connectors ................................... 18
How to Check Enlarged Contact Spring of
Terminal ............................................................... 19
Waterproof Connector Inspection ........................ 20
Terminal Lock Inspection ..................................... 20
HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT......................... 21
Work Flow ............................................................ 21HOW TO PERFORM EFFICIENT DIAGNOSIS...... 22
Incident Simulation Tests..................................... 22
Circuit Inspection ................................................. 25
HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES......................................... 31
How to Follow This Flow Chart ........................... 32
CONSULT CHECKING SYSTEM............................ 34
Function and System Application ........................ 34
Lithium Battery Replacement............................... 34
Checking Equipment ............................................ 35
Loading Procedure............................................... 36
CONSULT Data Link Connector (DLC) Circuit ... 36
IDENTIFICATION INFORMATION.......................... 37
Model Variation .................................................... 37
Identification Number ........................................... 40
Dimensions .......................................................... 44
Wheels and Tires ................................................. 46
LIFTING POINTS AND TOW TRUCK TOWING..... 47
Pantograph Jack .................................................. 47
Screw Jack........................................................... 48
Garage Jack and Safety Stand ........................... 49
2-pole Lift ............................................................. 50
Tow Truck Towing ............................................... 51
Towing Point ........................................................ 53
TIGHTENING TORQUE OF STANDARD BOLTS.. 54
SAE J1930 TERMINOLOGY LIST.......................... 55
SAE J1930 Terminology List ............................... 55
GI

Dimensions
Destination Except for Australia, the Middle East and Europe
Vehicle type 2-wheel drive model 4-wheel drive model
Wheelbase Standard Long Long
Cab or bed type Single cab Single cab Double cab Single cab Double cab
Overall length*1 mm (in) 4,675 (184.1) 4,975 (195.9) 4,885 (192.3) 4,975 (195.9) 4,885 (192.3)
Overall width mm (in) 1,690 (66.5) 1,690 (66.5) 1,690 (66.5) 1,820 (71.7) 1,820 (71.7)
Overall height mm (in) 1,630 (64.2) 1,625 (64.0)1,640 (64.6)
1,615 (63.6)*21,700 (66.9)1,715 (67.5)
1,705 (67.1)*3
Wheelbase mm (in) 2,650 (104.3) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1)
TreadFront mm (in) 1,395 (54.9) 1,395 (54.9) 1,395 (54.9) 1,525 (60.0) 1,525 (60.0)
Rear mm (in) 1,390 (54.7) 1,390 (54.7) 1,390 (54.7) 1,505 (59.3) 1,505 (59.3)
Ground clearance mm (in) 210 (8.3) 210 (8.3)210 (8.3)
185 (7.3)*2Z24S: 225 (8.9)
QD32: 210 (8.3)Z24S: 225 (8.9)
KA24E: 215 (8.5)
QD32: 210 (8.3)
200 (7.9)*3
*1: On step bumper equipped models, the bumper adds 155 mm (6.1 in) to the overall length above.
*2: ST model
*3: SE model
DestinationAustralia
Vehicle type 2-wheel drive model 4-wheel drive model
Wheelbase Long Long
Cab or bed type Single cab Double cab Single cab Double cab
Overall length* mm (in) 4,975 (195.9) 4,885 (192.3) 4,975 (195.9) 4,885 (192.3)
Overall width mm (in) 1,690 (66.5) 1,690 (66.5) 1,820 (71.7) 1,820 (71.7)
Overall height mm (in) 1,615 (63.6) 1,625 (64.0) 1,690 (66.5) 1,705 (67.1)
Wheelbase mm (in) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1)
TreadFront mm (in) 1,395 (54.9) 1,395 (54.9) 1,525 (60.0) 1,525 (60.0)
Rear mm (in) 1,390 (54.7) 1,390 (54.7) 1,505 (59.3) 1,505 (59.3)
Ground clearance mm (in) 200 (7.9) 200 (7.9)KA24: 230 (9.1)
QD32: 215 (8.5)KA24: 230 (9.1)
QD32: 215 (8.5)
*: On step bumper equipped models, the bumper adds 155 mm (6.1 in) to the overall length above.
IDENTIFICATION INFORMATION
GI-44

DestinationMiddle East
Vehicle type 2-wheel drive model 4-wheel drive model
Wheelbase Standard Long Long
Cab or bed type Single cab Single cab Double cab Single cab Double cab
Overall length* mm (in) 4,855 (191.1) 5,185 (204.1) 5,095 (200.6) 5,185 (204.1) 5,095 (200.6)
Overall width mm (in) 1,690 (66.5) 1,690 (66.5) 1,690 (66.5) 1,820 (71.7) 1,820 (71.7)
Overall height mm (in)Z24S: 1,610 (63.4)
TD27: 1,630 (64.2)1,605 (63.2)Z24S: 1,615 (63.6)
TD27: 1,640 (64.6)1,695 (66.7) 1,715 (67.5)
Wheelbase mm (in) 2,650 (104.3) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1)
TreadFront mm (in) 1,395 (54.9) 1,395 (54.9) 1,395 (54.9) 1,525 (60.0) 1,525 (60.0)
Rear mm (in) 1,390 (54.7) 1,390 (54.7) 1,390 (54.7) 1,505 (59.3) 1,505 (59.3)
Ground clearance mm (in)Z24S: 190 (7.5)
TD27: 210 (8.3)190 (7.5)Z24S: 185 (7.3)
TD27: 215 (8.5)225 (8.9) 225 (8.9)
*: The above dimensions include the length of the overrider and rear step bumper where applicable.
DestinationEurope
Vehicle type 2-wheel drive model 4-wheel drive model
Wheelbase Long Long
Cab or bed type Single Cab King Cab Double Cab King Cab Double Cab
Overall length*1 mm (in) 4,975 (195.9) 4,975 (195.9) 4,885 (192.3) 4,975 (195.9) 4,885 (192.3)
Overall width mm (in) 1,690 (66.5) 1,690 (66.5) 1,690 (66.5) 1,820 (71.7) 1,820 (71.7)
Overall height mm (in) 1,600 (63.0) 1,620 (63.8)*2 1,610 (63.4) 1,700 (66.9) 1,720 (67.7)
Wheelbase mm (in) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1)
TreadFront mm (in) 1,395 (54.9) 1,395 (54.9) 1,395 (54.9) 1,525 (60.0) 1,525 (60.0)
Rear mm (in) 1,390 (54.7) 1,390 (54.7) 1,390 (54.7) 1,505 (59.3) 1,505 (59.3)
Ground clearance mm (in) 190 (7.5)*3 200 (7.9) 190 (7.5)*3 230 (9.1) 230 (9.1)
*1: On step bumper equipped models, the bumper adds 155 mm (6.1 in) to the overall length above.
*2, *3: For models equipped with 195R14C tires, add 10 mm (0.4 in) to the overall height on ground clearance.
IDENTIFICATION INFORMATION
Dimensions (Cont'd)
GI-45