BodyGeneral

Specification ................................................. BD -2General Safety Information .......................... BD -4

Cap ExteriorCap Mounting

Removal .................................................. BD -5Bumper

Components ............................................ BD -9Removal .................................................. BD -9

Driver's DoorReplacement ........................................... BD -10Adjustment .............................................. BD -14

Outside Rear View MirrorRemoval .................................................. BD -15

Cap InteriorInstrument Panel

Components ............................................ BD -16Removal .................................................. BD -18

Window GlassComponents ............................................ BD -24Removal .................................................. BD -25Installation ............................................... BD -25

Interior TrimRemoval .................................................. BD -27

Driver's SeatComponents ............................................ BD -29Replacement ........................................... BD -31

Seat BeltComponents ............................................ BD -32Replacement ........................................... BD -32

GeneralSpecification

Item Specifications

Door

Construction Front hinged, Full door construction

Regulator system Wire drum type

Locking system Pin - fork type

Glass Thickness mm(in.)

Windshield glass 5.86(0.231)

Door glass 3.5(0.138)

Side window glass (super cab) 3.5(0.138)

Seat belt E.L.R type

CabItem Specifications

Type Tilt type with torsion bars, all steel welded construction with safety zone design

Mounting Rigid or Semi floating type

Windshield One piece type with laminated glass

Windshield Wipers Dual electric three speed (intermittent / low / fast) wipers & washer

Driver's Seat Urethane foam cushioned adjustable to the front & rear / reclining, Semi cloth material

Assistant's Seat Separate seat, bench seat, semi cloth material

Body typeItem Specifications

General Wooden body reinforced by steel structure

Floor

cross sill Steel square tube

board Wood plate

frame Bended steel (Angle)

Guard frame Bended steel structure

Side & Rear gate Steel panel

Tightening Torque

ItemTightening Torque

Nm Kgf.m Ib - ft

DoorDoor hinge to body 20~29 2.0~3.0 14.4~21.6

Door hinge to door 20~29 2.0~3.0 14.4~21.6

Seat belt

Upper anchor mounting bolt 39~54 4.0~5.5 28.9~39.7

Seat belt height adjuster mounting bolt 39~54 4.0~5.5 28.9~39.7

Retractor mounting bolt 39~54 4.0~5.5 28.9~39.7

Buckle mounting 39~54 4.0~5.5 28.9~39.7

SeatBolt 34~54 3.5~5.5 25.3~39.7

Nut 37.3~68.6 3.8~7.0 27.5~50.6

GENERAL SAFETY INFORMATIONPrecautions for electric welding

WARNINGWhen electric-welding the electronic parts which arecon nected directly to the battery, current in thewelding machine can flow through the groundingcircuit to these parts, thus damaging them. Followbelow procedures surely.1. Turn off all of the electric switches in vehicle.2. Remove the (-) Battery.3. Disconnect all of grounding circuits earthed in

vehicle, insulate the current using rubber and etc.

NOTICERefer the Electrical Troubleshooting Manual inrelation position of ground terminal.

4. Disconnect all ECU and controller connector.Engine control system : ECU or ECMBrake control system : ABS ECUThe other system : ETACS

NOTICERefer the Electrical Troubleshooting Manual inrelation position of ground terminal.

5. Do not earth grounding circuit in the welding machineto the fuel tank.

6. The welding spark should be contacted to the fueltank.

7. When tightening ground terminal to the body, cleanthe neighborhood of body and tighten it with specifiedtorque.

Item Outer Diameter of bolt(mm)Tightening torque.

Nm kgf·m lb-ft

Battery (+) cable tightening M8 88.3~137.3 9~14 65.1~101.3

Battery (+) terminal M8 88.3~137.3 9~14 65.1~101.3

Battery (-) cable tightening M10 137.3~156.9 14~16 101.3~115.7

Battery (-) terminal M6 39.2~58.8 4~6 28.9~43.4

Starter motor M8 98.1~117.7 10~12 72.3~86.8

Alternator "B" terminal M8 88.3~137.3 9~14 65.1~101.3

Engine grounding strap M10 186.3~274.6 19~28 137.4~202.5

Main Fuse box M8 88.3~137.3 9~14 65.1~101.3

Cab ExteriorCab MountingRemoval1. Place the wooden block (A) at rear wheel.

KMTPA201A

2. Remove the battery (-) cable(A).

EMTEN02A

3. Withdraw the air conditioner refrigerant. (Refer to the"Heating ventilation and Air conditioning,Refrigerant")

4. Taking off the assistant seat crash pad lower panelscrew (A), remove the lower panel (B).

KBD1000A

5. Remove the main connector (A)

KMTBD110A

6. Opening the drain coke (A) of the radiator, drain outthe cooling water.

EMTBD5501A

7. Tilting the cab, remove the accelerator cable (A) andthe engine stop cable (B).

KMTBD111A

8. Remove the steering yoke(A).

KMTBD112A

9. Remove the transmission control cable (A).

KMTBD113A

10.Remove the parking cable. (Refer to the"Transmission")

11.Support the tilted cab with the hoist not to bedropped.

CAUTIONBe caution not to damage the cab with protectingthe parts contacted with the cab.

SUDBDA009L

12.Loosen the bolt(A), remove slowly the bolt(B) andnut. Then remove the bolt(A) and bracket(C).

SUDBDA010L

13.After removing the rear nut(A) for mounting the cab,lay down the cab.

KMTBD114A

14.Come down the cab with the hoist slowly.

SUDBDA009L

15.Remove the tightening bolt(A) of cab stay.

KMTBD115A

16.Support the cab with a jack.17.Remove the front grill (A).

SUDBD8010D

18.After removing the brake pipe (A) and clutch pipe (B),drain out the brake oil.

NOTICEBe careful the body is not contaminated by the brakeoil. If it is contaminated, clear out the oil with waterimmediately.

KMTBD117A

19.Remove the heater in and out hose (A).

KMTBD118A

20.Remove the high and low pressure pipe (A) of theair-con.

KMTBD119A

21.Remove the vacuum hose (A).

KMTBD120A

22.After taking off the front bolt (A) for tightening thecab, remove the cab.

KMTBD121A

23.The installation is performed in the reverse order ofremoval.

BumperComponents

SUDBDA012L

1. Tightening bolt of bumper2. Bumper

REMOVALNOTICE

• Using a screw driver or remover for removing work,wind a protection tape on it.

• Wear gloves for protect your hands.• Be careful that the trim and panel are not damaged.1. Disassemble the connector (A) of the both fog lamp.

KMTBD310A

2. After taking off the bolt (A), remove the bumper (B).

KMTBD311A

3. The installation is performed in the reverse order ofthe removal.

NOTICEBe ensured that the connector is firmly tightened.

Driver's DoorReplacement

NOTICE• Using a screw driver or remover for removing work,

wind a protection tape on it.• Wear gloves for protecting your hands.• Be careful that the trim and panel are not damaged.Replacement Of The Power Window SwitchAssembly1. Remove the screw (A) tightening the power window

switch assembly.

KMTBD410A

2. After removing the power window switch assembly(A) by lifting it from the front side to the rear side,remove the power window connector (B).

KMTBD411A

3. The installation is performed in the reverse order ofthe removal.

NOTICEBe ensured that the connector is firmly tightened.

Replacement of the Door Trim1. Remove the power window switch assembly. (Refer

to the "Replacement of the Power Window SwitchAssembly")

2. Loosening the screw (A) tightening the inside handlehousing, disassemble the inside handle housing (B)from the door trim (C).

KMTBD420A

3. Taking off the screw (A) and bolt (B) for tighteningthe door trim, remove the door trim (C).

KMTBD421A

4. The installation is performed in the reverse order ofthe removal.

Replacement of the Speaker1. Remove the door trim. (Refer to the "Replacement of

the Door Trim")2. Disassembling the speaker connector (A) and

loosening the tightening screw (B), remove thespeaker (C).

KMTBD430A

3. The installation is performed in the reverse order ofthe removal.

Replacement of the glass and regulator1. Remove the door trim and the speaker. (Refer to the

"Replacement of the Speaker")2. After taking off the screw (A) tightening the door pull

hand bracket, remove the door pull hand bracket (B).

NOTICEFrom the door inside handle lever, remove thetightening screw(C) only.

KMTBD440A

3. Remove the door trim seal (A).

KMTBD441A

4. Taking off the glass tightening bolt (A), disassemblethe glass (B) with the regulator (C). Remove theglass to upward by tilting the glass.

CAUTIONBe careful that the glass surface is not damaged.

KMTBD442A

5. Disassemble the window motor connector (A).

KMTBD443A

6. Taking off the regulator tightening nut (A) and thewindow motor tightening nut (B), removing theregulator assembly (C).

KMTBD444A

7. The installation is performed in the reverse order ofthe removal.

NOTICEWhen installing the regulator tightening nut, applythe torque by which the regulator can have movingclearances. And then, moving the glass up anddown for 2~3 times, tighten the nut with specifiedtorque.

Replacement of the Latch and Outside Handle1. Remove the glass. (Refer to the "Glass and

Regulator")2. Remove the rear panel (A).

KMTBD450A

3. After disassembling the door lock actuator connector(A), remove the door lock actuator tightening bolt (B).

KMTBD451A

4. Remove the tightening screw (A) for door latch.

KMTBD452A

5. After disassembling the outside link rod (A) and lockrod (B), remove the latch and door lock actuatorassembly.

KMTBD453A

6. After taking off the fixing pin (A) for the outside lockassembly, remove the outside lock assembly (B).

KMTBD454A

7. After taking off the tightening bolt (B) of the outsidehandle through the hole (A), remove the outsidehandle (C).

KMTBD455A

8. The installation is performed in the reverse order ofthe removal.

NOTICEWhen installing the door latch tightening screw,apply the torque by which the door latch can havemoving clearances. And then, opening and closingthe door for 2~3 times, tighten the door latchtightening screw with specified torque.

Adjustment1. When the gap between the door and body is

irregular, attach a tape at the edges of the hinge anddoor. Using a special tool, loosen the door hingetightening bolt so that adjust the gap around the doorto be regular.

H7BD007V

2. To adjust the gap between the door and body isperformed loosening the door hinge tightening boltusing a special tool.

3. The gearing between the striker and the door latch isadjusted by increasing and decreasing the shimbeing under the striker.

H7BD007W

Outside Rear View MirrorREMOVAL1. After taking off the outside rear view mirror rear cover

(A), remove the heat wire connector (B).(LHD Type)

SUDBDA502L

(RHD Type)

SUDBDA011L

2. After taking off the tightening screw of the outsiderear view mirror, remove the outside rear view mirror.

3. The installation is performed in the reverse order ofthe removal.

Cab InteriorInstrument PanelComponents(LHD Type)

SUDBDA013L

1. Air vent bezel2. Air vent duct3. Crash pad lower panel4. Column cover5. Ashtray

6. Instrument crash pad7. Glove box8. Crash pad lower panel9. Air vent duct10. Side panel cover

(RHD Type)

SUDBDA001L

1. Air vent bezel2. Air vent duct3. Crash pad lower panel4. Column cover5. Ashtray

6. Instrument crash pad7. Glove box8. Crash pad lower panel9. Air vent duct10. Side panel cover

REMOVAL1. Remove the steering wheel. (Refer to the “Steering

System Group”)2. Taking off the assistant’s seat crash pad lower panel

screw (A), remove the lower panel (B).

CAUTIONUsing a screw driver or remover for removingwork, apply a tape on it to protect the parts.(LHD Type)

KBD1000A

(RHD Type)

SUDBDA503L

3. Remove the tightening screw (A) for instrument faciapanel.(LHD Type)

KBD1001A

(RHD Type)

SUDBDA504L

4. Disassemble the emergency lamp connector (A), thefog lamp connector (B), the heater mirror connector(C), cigar light connector and the heater & air-concontrol connector (D).

KBD1002A

5. Disassemble the temperature controlling switch cable(B) from the instrument facia panel (A).

NOTICEWhen removing the temperature controlling switchcable, release the locking by pressing the cablefixing bracket (C) and lay down the cable (B) todownward.

KBD1003A

6. Taking off the cluster tightening screw (A) anddisassembling the connector, remove the cluster (B).

KBD1004B

7. Taking off the screw (A) installing the audio,disassemble the antenna jack and the audioconnector. Remove the audio unit (B).(LHD Type)

KBD1005A

(RHD Type)

SUDBDA505L

8. Taking off the tightening screw (A) for glove boxlinkage, remove the glove box out lead (B).(LHD Type)

SUDBDA008L

(RHD Type)

SUDBDA506L

9. Taking off the tightening screw (A) of the glove box,remove the glove box (B).(LHD Type)

KBD1007A

(RHD Type)

SUDBDA507L

10.Remove the Front crash pad lower panel (A).(LHD Type)

KBD1008A

(RHD Type)

SUDBDA508L

11.Remove the fuse box cover (A).

KBD1009A

12.Remove the working lamp switch (A) and the chokevalve (B).(LHD Type)

KBD1010A

(RHD Type)

SUDBDA003L

KBD1011A

13.Remove the driver's seat side cover panel screw.(LHD Type)

KBD1012A

(RHD Type)

SUDBDA004L

14.Remove the assistant's seat side cover panel screwand the crash pad tightening bolt and screw.(LHD Type)

KBD1013A

(RHD Type)

SUDBDA005L

15.Remove the instrument crash pad16.The installation is performed in the reverse order of

the removal.

Window GlassComponents

SUDBDA014L

1. Weather strip2. Wind shield glass3. Rear window

Removal1. Remove the wiper arm. Using a screw driver or the

equivalent, remove the lip of the weather strip andthe wind shield glass or rear wind shield glass.

G7BD025B

Installation1. Aligning the mark of the wind shield molding with that

of the wind shield glass, assemble the weather stripto the glass.

CSBD117

2. Binding a strip to the gap of the weather strip, installto the cab panel flange.

CAUTIONPull the strip at the both ends to the centerportion.

3. Apply some soap water to the contacting surface ofthe body flange.

G7BD025C

4. As shown in figure, pull one end of the strip hangingin the room side to the both side with maintaininghigher angle than the flange. At the same time, tapthe weather strip portion of the glass from the outsidein order to install to the glass.A : Straight Line part 10mB : Straight End portion

CAUTIONPull the strip from the both ends of the windshield to the center portion and press from theoutside of the glass.

G7BD025D

G7BD025E

Interior TrimRemoval1. Remove the door scarf plate(A).

(LHD Type)

VTBD037

(RHD Type)

SUDBDA509L

2. Remove the weather strip(A).(LHD Type)

VTBD039

(RHD Type)

SUDBDA510L

3. Remove the rear back trim panel, the grip, the assisthandle and the front filler trim.(LHD Type)

VTBD043

(RHD Type)

SUDBDA501L

4. Remove the seat belt anchorage and the quarter low& upper trim.

VTBD057

5. Remove the hand grill, the sun visor, the interior light,the inside room mirror and the head lining.

VTBD045

6. The installation is performed in the reverse order ofthe removal.

Driver's SeatComponents<Driver’s Seat>(LHD Type)

EMTBD5001A

(RHD Type)

SUDBDA006L

<Assistant’s Seat>(LHD Type)

EMTBD5002A

(RHD Type)

SUDBDA007L

Replacement1. Loosen the seat tightening nut and bolt(A).

Tightening TorqueNut : 37.3~53.9 Nm (3.8~5.5 kgf·m, 27.5~39.8 lb-ft)Bolt : 34.3~53.9 Nm (3.5~5.5 kgf·m, 25.3~39.8 lb-ft)

VTBD051

2. The installation is performed in the reverse order ofthe removal.

Seat BeltComponents

SUDBDA015L

1. Upper anchor2. Seat belt

3. Retractor4. Lower anchor

Replacement1. Remove the lower quarter trim.

VTBD057

2. Loosen the seat belt tightening bolt.

Tightening Torque: 39.2~53.9 Nm (4.0 ~ 5.5 kgf·m,28.9~39.8 lb-ft)

3. The installation is performed in the reverse order ofthe removal.