Owners Manual FUSO 2006 FE FG

Pub. No.
MH998808
Owner’s Manual
Owner’s Manual
2006 Model
2006 Model
Pub. No. MH998808 ’05-3
Pub. No. MH998808

MAR. ’05 Printed in Japan
FEFG.book Page 1 Thursday, March 10, 2005 7:30 PM
OWNER AND VEHICLE INFORMATION
OWNER NAME:
USER/COMPANY NAME:
MAILING ADDRESS:
CITY, STATE: ZIP:
VEHICLE IDENTIFICATION NUMBER:
DATE OF DELIVERY (WARRANTY START DATE): / /

MO. DAY YR.
SELLING DEALER IMPRINT HERE

Foreword
Thank you for purchasing a Mitsubishi Fuso FE, FG Truck.
This Owner’s Manual explains proper vehicle handling, simple maintenance practices, and the
periodical maintenance schedule to ensure that you are able to drive your vehicle safely and com-
fortably.
As improper use of the vehicle may result in a breakdown or cause an accident, we urge you to
read this handbook thoroughly before operating the vehicle.
Please keep this manual in the vehicle so it is always available for reference. If you sell the vehi-
cle, make sure the next owner receives this manual and is aware of its contents.
© 2005 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

Reading the handbook

Q The information in this manual is accurate as of the time of printing. Because of differences in specifica-
tions and improvements that may be added after preparation of this manual, some of the explanations
and illustrations in this handbook may not apply to your vehicle.
Q The following symbols are used throughout this handbook:
: optional equipment
: requests that reader should refer to the page of the number indicated.
Q This manual contains important cautionary instructions and supplementary information under the follow-
ing four headings which identify the nature of the instructions and information:
Precautions that should be taken when handling dangerous sub-

DANGER stances such as battery fluid in order to prevent a serious injury or
death
Precautionary instructions, which, if not observed, could result in
WARNING serious injury or death.
Precautionary instructions, which, if not observed, could result in
CAUTION damage to or destruction of equipment or parts.
NOTE: Suggestions or supplementary information for more efficient use of

equipment or better understanding.
Q California Proposition 65 Warning
DANGER
THIS PRODUCT CONTAINS OR EMITS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO
CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
CONTENTS
1. Recommendation to drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3. Opening and closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4. Seat and steering wheel adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5. Switches and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6. Instruments and warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. Starting and driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8. 4WD operation <FG models> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9. Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10. Interior equipment and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11. In cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12. Simple inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13. Useful advice for emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
14. Service data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15. Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
16. Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
17. Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Each chapter has a table of contents on its first page.

1-1
1. Recommendation to drivers
Chassis and engine numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Powerline label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Vehicle identification number (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Handling of the new vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Reporting safety defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Obtaining service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-2 Recommendation to drivers
Chassis and engine numbers
If presented at the time of repair or parts order, the

chassis number and engine number will facili-
tate the quick and smooth processing of your
requests.
1 Chassis number
The chassis number is indicated on the left frame,
near the left front wheel.
Example: FE84DD -
Chassis number
Vehicle model
2 Engine number
The engine number is indicated on the left side of
Z11767 the crankcase.
Example: 4M50 -
Engine number
Engine model
Powerline label
The powerline label located in the position shown

indicates the vehicle model, chassis number and
information relevant to the vehicle’s power trans-
mission components.
Z11768
1-3
Vehicle identification number (VIN)
The VIN is stamped on a plate that is located as

shown in the illustration.
The VIN comprises 17 numbers and letters, the
meanings of which are listed below.
Z11959
<Crew-cab model>
Z11769
J L 6 B B D 1 S 6 K
Country J: Japan
Make L: Mitsubishi Fuso
Type 6: Incomplete vehicle
Gross vehicle weight / Brake system
B: 14,001 to 16,000 lbs. / Hydraulic
C: 16,001 to 19,500 lbs. / Hydraulic
Line B: FE84D
C: FE85D
D: FE84 W
E: FG84D
Series (wheel base) C: 2.6 to 2.89 m (8.53 to 9.48 ft.)
D: 2.9 to 3.19 m (9.51 to 10.46 ft.)
E: 3.2 to 3.49 m (10.49 to 11.44 ft.)
G: 3.8 to 4.09 m (12.46 to 13.41 ft.)
H: 4.1 to 4.39 m (13.45 to 14.40 ft.)
J: 4.4 to 4.69 m (14.43 to 15.38 ft.)
Cab chassis type 1: Chassis cab
Engine S: 4.899 L Diesel turbo charged and charge air cooled
Check digit
Model year 6: 2006
Plant K: Kawasaki
Plant sequential number
Maintenance
Checking your vehicle at regular intervals is very

important for maximizing performance and extend-
ing service life. It is recommended that you make a
habit of performing the following inspections.
This manual describes simple maintenance checks
and procedures that can be carried out by the
owner. If you have difficulty or your vehicle needs
maintenance work that is not shown in this manual,
please refer to an authorized dealer.
1 New vehicle inspection

After you have driven the first 4,000 km (2,500
miles), your vehicle requires a special inspection
and adjustments to compensate for the initial settle-
ment of various parts. When the distance has been
reached, have your vehicle inspected by an autho-
rized dealer by showing them this Owner’s Manual.
NOTE:
The cost of oil, lubricants, parts and any work that is
not included in the new vehicle inspection must be
Z11771
borne by the owner.
2 Pre-operational check
Make a habit of checking your vehicle at the start of
every day’s operation. This will ensure safe and
comfortable operation. P. 12-8
3 Periodic inspection
In addition to maximizing the vehicle’s working life,
regular inspections also help prevent accidents.
Periodic inspection is based on either the distance
traveled (odometer reading) or period of use
(months/years).
The intervals between and content of periodic
inspections are as shown in the Maintenance
Schedule section. Please adhere to the mainte-
nance schedule carefully.
Z01367
1-5
Fuels
Use only diesel fuels conforming to the following

recommendations, without any additives, for diesel
engines installed in Mitsubishi Fuso trucks.
1 Diesel-fuel properties
Z01368 The following recommendations concerning diesel
fuel used with Mitsubishi Fuso diesel engines are
given for optimum fuel economy and performance.
Use condition Recommendation

Normal operation at ASTM D-975
temperatures above Grade Low Sulfur
–12°C (10°F). Grade 2-D*
Operation at tempera- ASTM D-975
tures below –12°C Grade Low Sulfur
(10°F), or long-hour no- Grade 1-D*
load operation.
NOTE:
* ASTM is an acronym for the American Society for
Testing and Materials which recommends fuel con-
taining 0.05% or less sulfur content.
Note that a sulfur content exceeding 0.05% deterio-
rates the performance of emission control device.
To meet fuel requirements exactly, it is necessary to
obtain cooperation from a reputable fuel oil supplier.
Both fuel suppliers and users are responsible for
keeping fuel clean.
2 Danger of fire and explosion by using

mixed fuel
Fuel containing 5% gasoline has a flash point as
low as 0°C (32°F), which can lead to a fire or explo-
sion while the engine is running.
DANGER
NEVER MIX DIESEL FUEL WITH GASOLINE,
GASOHOL OR ALCOHOL.
USE OF FUEL MIXED WITH ONE OR MORE
OF THESE COULD LEAD TO A FIRE OR
EXPLOSION INVOLVING SERIOUS INJURY,
DEATH OR PROPERTY DAMAGE. IF YOU
ACCIDENTALLY USE GASOLINE OR ALCO-
HOL WHEN REFUELING THE VEHICLE,
REMOVE ALL OF IT FROM THE FUEL SYS-
TEM.
3 Adverse effects of mixed fuel on engine

Using diesel fuel mixed with gasoline, alcohol, or
both, has the following adverse effects on the
engine:
• Fuel viscosity becomes lower, resulting in
excessive wear, damage, and failure of fuel sys-
tem parts.
• Difficulty in starting the engine will result due to
a reduced cetane number.
CAUTION
• The lower the cetane number, the more likely
internal engine damage will occur.
• Do not add antifreeze agents or other sub-
stances to the fuel. They could damage the
engine’s fuel injection system.
• If the fuel tank cap and breather (air hole)
become so dirty that the breather gets
blocked, the fuel tank may deform and the
fuel injection system may fail. Be sure to
clean them regularly.
4 Refueling
WARNING
• Stop the engine before fueling.
• Never smoke when fueling since diesel
fuel could ignite or explode.
Never operate lighters or other items that
emit sparks.
• If you inadvertently put gasoline in the fuel
tank, pump it all out. Running the engine
with gasoline in the tank could cause a fire
or explosion endangering your or other
people’s lives.
NOTE:
If you run out of fuel, refuel the tank. After fueling,
the fuel system must be primed before the engine
can be started. P. 13-23
1-7
• 125-liter fuel tank

<125-liter fuel tank> The fuel tank is on the left-hand side of the vehicle.
To open the cap, slowly turn it counterclockwise. To
close the cap, turn it fully clockwise.
Fuel tank capacity

125 liters (33 gallons)
• 113-liter fuel tank <optional for FE (except

Crew-cab models)>
<113-liter fuel tank> The fuel tank is at the rear of the vehicle. To open
the fuel tank cap, slowly turn it counterclockwise. To
close the cap, turn it clockwise until you hear a click.
Fuel tank capacity

113 liters (29.8 gallons)
WARNING
• When filling the fuel tank using a gun-type
Z11891 fuel pump, do not continue pumping after
the pump automatically stops. (The tank is
full at this point.) When filling the fuel tank
using any other method, stop as soon as
the surface of the fuel becomes visible
through the opening of the fuel filler. If you
supply so much fuel that it comes up to
the opening, fuel may leak though the
check valve when the vehicle starts
moving and when it stops moving. If fuel
leaks, carefully wipe it all up to prevent the
risk of fire.
• If the pointer of the fuel gauge is above the
“F” mark, do not add the fuel any more.
Handling of the new vehicle
The way the vehicle is handled when new greatly

affects its subsequent performance and service life.
Observe the following precautions when handling
the new vehicle.
1 Maintenance
Z12537
The “new vehicle inspection” is very important for
extending the service life of your vehicle. We
strongly recommend that you have this inspection
carried out by an authorized dealer. Be sure to give
the dealer this manual at that time.
During the initial run-in period, oil is quickly contam-
inated. Replace the following oils and oil filter ele-
ments at the time of the “new vehicle inspection”.
At 4,000 km (2,500 miles)

• Engine oil
• Manual transmission gear oil
• Transfer gear oil <FG>
• Front axle housing gear oil <FG>
• Rear axle housing gear oil
2 Maximum engine speed during run-in

period
To avoid overburdening a new engine, limit engine
RPM to that indicated below for the first 1,000 km
(600 miles).
Then, run in your vehicle step by step at various
speeds, beginning with low gears.
Maximum engine RPM during run-in period
Z08646 1,800 rpm
Reporting safety defects
If you believe that your vehicle has a defect that

could cause a crash or could cause injury or death,
you should immediately inform both the National
Highway Traffic Safety Administration (NHTSA) and
the Mitsubishi Fuso Truck of America, Inc. (MFTA).
If NHTSA receives similar complaints, it may open
an investigation, and if it finds that a safety defect
exists in a group of vehicles, it may order a recall
and remedy campaign. However, NHTSA cannot
become involved in individual problems between
you, your dealer, or MFTA.
To contact NHTSA, you may either call the Auto
Safety Hotline toll-free at 1-800-424-9393 (or 1-202-
366-0123 in Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation, Wash-
ington, D.C. 20590.
You can also obtain other information about motor
vehicle safety from the Auto Safety Hotline.
1-9
Obtaining service
At Mitsubishi Fuso Truck of America, Inc. (MFTA),

we are proud of the quality and workmanship that is
built into every MFTA Truck. We are equally proud
of our corporate commitment to promote the highest
possible degree of customer satisfaction with our
products and services.
Today’s trucks are extremely complex and are com-
prised of an enormous number of individual parts.
Occasionally, a failure of one of these parts may
occur. Should you experience such a failure, we are
confident that you will find an Authorized Dealer
prepared to provide you with high quality service.
Every Authorized Dealer has trained personnel,
plus the tools and equipment necessary to provide
for your various service needs. In the event that a
problems arises, we ask you to follow the procedure
outlined as follows, and in the sequence listed:
STEP 1: Contact your Nearest Authorized Dealer

This is the most direct and expedient way to obtain
service. Each Authorized Dealer has the ultimate
responsibility for providing the services and repairs
you may need. We recommend that you contact the
Service Manager of your nearest Authorized Dealer
for assistance. In the event that you feel additional
assistance is required, ask to speak to the General
Manager of the Authorized Dealer.
STEP 2: Contact MFTA

After the completion of Step 1, and in the event that
your nearest Authorized Dealer has been unable to
satisfactorily resolve the problem, please contact
MFTA’s Customer Service Representative at 1-877-
711-0707.
Please be prepared to provide the following infor-

mation when you call:
• Your Name, Company Name, Address, Tele-
phone Number
• Vehicle Model
• Vehicle Model Year
• Vehicle Identification Number
• Mileage
• Name of Dealer contacted under Step 1, if appli-
cable
• Details of the Complaint/Comment
You also may correspond with the Customer Ser-
vice Representative in writing, addressed to:
MITSUBISHI FUSO TRUCK OF AMERICA, INC.
CUSTOMER SERVICE REPRESENTATIVE
2015 CENTER SQUARE RD.
LOGAN TOWNSHIP, NJ 08085
2-1
2. Warning labels
Locations in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Locations outside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2 Warning labels
• The caution and warning labels show important

information. Be sure to read them before using
the vehicle.
• If any label has peeled so it is difficult to read, is
scratched or otherwise damaged, or has peeled
off completely, please inform an authorized
dealer. The warning and caution labels apply
only to the vehicle itself, not to any equipment
mounted on the vehicle. For information on cau-
tion and warning labels that apply to equipment
mounted on the vehicle, please refer to the
Owner’s Manual supplied by the manufacturer
of the equipment.
• The caution and warning labels are located in
the cab as shown below. Samples of these
labels are indicated in this and following pages.
Locations in cab
Z12495
Limited slip differential 113-liter fuel tank

<FE: other than Crew-cab models>
Z10690 Z12494
2-3
Voltage Hydraulic brake booster <FE85>
Z11770
Z11693
Transfer lever <FG> Towing <Automatic transmission vehicles>
Z12483 Z11666
Hydraulic brake booster Fuse

<FE85>
Z11694 Z12564
2-4 Warning labels
Engine inspection hatch Cab tilt function

<Crew-cab models> <Vehicles other than Crew-cab models>
Z11805 Z10697
2-5
Locations outside cab
Z12496
2-6 Warning labels
Engine oil Pressure cap
Z10084 Z08670
Automatic transmission fluid
Z12549
Battery
Z11680
Oil cooler <Automatic transmission vehicles> Oil cooler <Automatic transmission vehicles>
Z11844 Z11773
2-7
High-current fuse Air conditioner
Z11803 Z13208
Cab tilt function Cab tilt function

<Vehicles other than Crew-cab models> <Vehicles other than Crew-cab models>
Z11774 Z11804
125-liter fuel tank Limited slip differential
Z11678 Z10707
113-liter fuel tank

<FE: other than Crew-cab models>
Z12494
3-1
3. Opening and closing
Starter key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Central door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Entering and leaving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Door window glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-2 Opening and closing
Starter key
• There are two starter keys: a main key and a

sub key .
• Please make a note of the starter key number
. You can purchase more starter keys if you
inform an authorized dealer of this number.
Z08736
Doors
WARNING
• To help prevent accidents, always check
for vehicles and pedestrians approaching
from behind before opening the doors.
• Driving with a door ajar can be very dan-
gerous. Make sure the doors are com-
pletely closed before starting.
• Exercise caution when opening a door in
strong wind. Otherwise, the wind could
catch the door and suddenly blow it open.
• Exercise caution when opening a door on
a downward slope. Otherwise, the inclina-
tion of the vehicle could cause the door to
suddenly fall open.
• When leaving the vehicle, take with you
any child who was riding in the cab. Never
leave a child in the cab. A child left in the
cab could interfere with the vehicle, caus-
ing it to move or catch fire. Also, the cab
gets extremely hot in sunshine and in hot
weather so a child left in the cab could suf-
fer heatstroke.
3-3
1 From the outside

• To open, pull the outer handle toward you.
• Use the starter key to lock or unlock the door.
• It is possible to lock each door without using the
starter key. With the driver’s door or assistant
driver’s door, push the lock knob toward the
front of the vehicle then pull the outer handle
and keep it pulled as you close the door. With a
rear door, push the lock knob down then pull
the outer handle and keep it pulled as you close
Z10730 the door.
NOTE:
• If your vehicle is not a Crew-cab model vehicle,
locking the driver’s door using the starter key or
lock knob also causes the assistant driver’s door
to automatically lock.
On the other hand, unlocking the driver’s door
using the starter key or lock knob unlocks only
the driver’s door.
• When you leave your vehicle, be sure to remove
the starter key from the starter switch to prevent
theft.
• Be careful not to lock the doors with the starter
key inside the vehicle.
Z10731
2 From the inside

• To close, use the door waist bar . Close the
door completely.
• To lock the driver’s door or assistant driver’s
door, push the lock knob toward the front of
the vehicle. To lock a rear door, push the lock
knob down.
• To unlock and open the driver’s door or assist-
ant driver’s door, push the lock knob toward the
rear of the vehicle then pull the inner handle .
To unlock and open a rear door, pull up the lock
knob then pull the inner handle .
CAUTION
Closing the door by pulling any part other than
the door waist bar could damage the door
mechanism.
Z10732
Central door locks
<Vehicles other than Crew-cab models>

• When the “LOCK” side of the switch is
pressed, both doors are locked. When the
“UNLK” side of the switch is pressed, both doors
are unlocked.
• When the lock knob on the driver’s door is
pushed forward, the passenger’s door is also
automatically locked. If the lock knob on either
door is subsequently pushed rearward, only that
door is unlocked.
• When the driver’s door is locked from the out-
side using the starter key, the passenger’s door
is automatically also locked. If the starter key is
subsequently used to unlock either door, the
other door remains locked.
Z11819
Entering and leaving the vehicle
WARNING
• Always use the step to climb into or down
from the vehicle. Never put your foot on
the wheel or tire since it could easily slip
off.
• The step can become slippery in rain or
snow. Firmly hold the grip while climbing
into or down from the vehicle. Holding the
grip is particularly important when snow
has settled and frozen on the step.
• If the soles of your shoes are oily or
greasy, you could slip when climbing
down from the vehicle or when operating
the brake or clutch pedal.
Wipe any oil and grease off the soles of
your shoes before entering or leaving the
vehicle.
• When putting your foot on the step, make
sure your body is supported in three
places for safety.
• Do not hold luggage or other items in your
hands when entering or leaving the vehi-
cle since this can be dangerous.
• Do not jump down from the vehicle. Jump-
ing down from the vehicle could cause you
to fall or sustain an injury.
• Take care when entering or leaving the
vehicle on a slope or in a strong wind
since the door could open or close sud-
denly.
3-5
<FE> <FG>
<Rear doors: Crew-cab models>
Z12471
CAUTION
• Hold onto the grip when entering or leaving
the vehicle. Do not grasp any other part of
the vehicle since it could break.
• When entering or leaving an FG model truck,
do not place your feet or hands on the fender
. The fender could suffer damage. Also, the
fender can be dangerously slippery.
Hold the grip tightly and put your foot fully on the
step when entering or leaving the vehicle. If you
place your hand on the fender, put it on the non-slip
section .
Door window glass
WARNING
Do not allow a child to put its hands or head
out of a window. The child’s head or hands
could hit an object outside the vehicle, and
the child could be seriously injured in the
event of hard braking.
1 Power window switches <Vehicles other

than Crew-cab models>
WARNING
• Always make sure that no one has their
head or hands out of the window when
closing it. A body part could be injured if
caught in a closing window.
Never allow a child to open or close the
window.
• When a child is in the cab, be sure to press
the power window lock switch to prevent
the child from opening and closing the
assistant driver’s window. Otherwise, the
child may accidentally operate the power
window switch and get its hands or head
trapped.
The power window switches function only when the

starter switch is in the “ON” position.
On the driver’s door, there are two switches: switch
for controlling the driver’s window and switch
for controlling the assistant driver’s window.
Switch for assistant driver’s window.
Press the switch to open the window.
Raise the switch to close the window.
CAUTION
Do not keep any door or window open in rainy
weather, and be careful not to spill a drink on
any of the window switches. If water or any
other liquid gets on a window switch, it can
cause a malfunction.
Z10734
3-7
2 Power window lock switch <Vehicles

other than Crew-cab models>
WARNING
When a child is in the cab, be sure to press
the power window lock switch to prevent the
child from opening and closing the assistant
driver’s window. Otherwise, the child may
accidentally operate the power window
switch and get its hands or head trapped.
Press the power window lock switch to prevent

the assistant driver’s window from being opened or
closed.
Pressing the switch a second time releases the
lock.
CAUTION
Do not keep any door or window open in rainy
weather, and be careful not to spill a drink on
any of the window switches. If water or any
other liquid gets on a window switch, it can
cause a fault.
NOTE:
If a child is in your vehicle, it is important for safety’s
sake to press the power window lock switch to pre-
vent the child from opening or closing the assistant
driver’s window.
Z10735
3 Window regulator handle <Crew-cab

<Front doors>
models>
Turn the window regulator handle to open or
close the window.
Open
Close
CAUTION
The front door window glass lowering limit is
<Rear doors: Crew-cab models> near the door waist bar . Trying to lower it fur-
ther could damage the internal mechanism.
Z12531
4-1
4. Seat and steering wheel adjustments
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-2 Seat and steering wheel adjustments
Seats
WARNING
• Adjusting the seat while the vehicle is in
motion is dangerous as the seat may move
more than you intend. Be sure to stop the
vehicle and set the parking brake before
performing any adjustment of the seat.
• After you have adjusted the seat, gently
move or rock the seat to ensure that it is
locked in the desired position.
• When adjusting the seat, keep your hands
away from the bottom of the seat and from
moving parts of the seat. Otherwise, you
could suffer an injury by getting your
hands and fingers trapped.
• When adjusting the angle of the seatback,
keep your back or hand pressed against it.
Otherwise, the seatback could suddenly
return to its original position and injure
you by hitting your face or other body
parts.
1 Driver’s seat
1.1 Correct driving position
• Before driving the vehicle, adjust the seat with
reference to the following points:
Your back must touch the seatback, and you
must be able to see the warning lamps and
gauges.
You must be able to reach and firmly press
the pedals.
You must be able to operate the steering
Z11863 wheel and switches with ease.
You must be able to operate the shift lever
with ease.
You must be able to fasten the seat belt cor-
rectly.
• Adjust the steering wheel to a position at which
you can operate it comfortably with your arms
slightly bent.
4-3
1.2 Making adjustments

• Slide seat forward or backward while holding
slide adjustment lever raised. After making
the adjustment, release the lever and move the
seat back and forth slightly to lock it in position.
• To adjust the angle of the seatback , raise
reclining lever .
• Lower the armrest to use it. Turn the armrest
knob to adjust the height of the armrest in its
lowered position.
Up
Down
Z10741
2 Assistant driver’s seat

Assistant driver’s seat
Center seat
• Pulling the seatback lever allows the seat-
back angle to be adjusted. With the lever pulled,
grasp the top of the seatback and move it for-
ward or backward to adjust the seatback angle
as desired.
After adjusting the seatback angle or returning
the seatback to its original position after tipping
it forward, gently rock the seatback to make sure
it is locked in place.
• It is possible to tip the seatback fully forward.
With the lever pulled, grasp the seatback at the
top and tip it forward.
Z11806
3 Rear seat – Crew-cab models

Storage compartments are located under the rear
seat. The rear seat can be folded up for access to
them. When you wish to stow or remove something
from these compartments, release the hooks at
the base of the seat and raise the seat cushion .
To retain the seat cushion, use the retaining bands
that are attached to the seatback. Fit the loop
at the end of each retaining band over the corre-
sponding hook on the seat cushion.
Z12099
Seat belts
• To help prevent injury in the event of a sudden

stop or accident, the driver and all passengers
must wear their seat belts correctly.
• When wearing your seat belt, sit back in your
seat with your back straight. If a seat belt is used
Z11862 incorrectly, its effectiveness is greatly dimin-
ished and it could aggravate injuries in the event
of accident.
• For details of seat belt usage for children and
pregnant women, refer to “Children and babies”
and to “Pregnant women”. P. 4-6
WARNING
• Passengers must never be in the cargo
area while the vehicle is in motion. Unless
seated and properly belted up, the risk of
injury is greatly increased.
• Seat belts should be worn as low as possi-
ble over the hips. Wearing a seat belt
across the abdomen could be dangerous
since undue pressure would be placed on
internal organs in the event of a collision.
• Make sure that the seat belt is not twisted
when fastening it. A twisted seat belt could
be dangerous since its reduced width will
apply a larger force to a smaller part of
your body in the event of impact.
• Replace any seat belt that is cut or frayed,
or if its buckle does not work properly.
• Never use a single seat belt for more than
one person.
• It is dangerous to fasten or unfasten your
seat belt while driving since the momen-
tary diversion of your attention could lead
to a serious accident. Always stop the
vehicle first.
• The left and right seats feature 3-point lap and

shoulder belts with Emergency Locking Retrac-
tor (ELR), while the middle seat features a 2-
point lap belt.
1 Lap and shoulder belts with ELR
NOTE:
It is not necessary to adjust the length of these seat
belts.
An ELR seat belt extends and retracts automatically
as its wearer moves but locks automatically for pro-
tection in the event of a sudden stop or shock.
The belt’s tightness should be adjusted automati-
cally. If there is any looseness, lift the shoulder belt
gently and the mechanism will take up the slack.
With the belt properly tightened, the risk of it slip-
ping off in a collision is reduced.
4-5
• Fastening
1. Hold tang and gently extend the belt. If the
belt locks or is difficult to extend, let it retract and
pull it gently again.
2. Take care that the belt does not become twisted.
Insert the tang into the buckle until you hear a
click.
Z10760
3. Pull on the tang to confirm that it is locked in.

4. Adjust the belt so it is across your hips and
shoulder.
Z11726
• Unfastening
1. Press the red button to unlock the buckle.
2. The belt automatically retracts when unlocked.
To prevent the tang causing damage or injury,
hold it while the belt retracts.
3. Adjust the tang stopper to locate the tang in
an easy-to-reach position and prevent it from
slipping.
Z01351
2 Lap belt
• Fastening
1. Take care that the belt does not become twisted.
Insert the tang into the buckle until you
hear a click.
2. Pull on the tang to confirm that it is locked in.
3. Adjust the belt so it is low across your hips.
4. To adjust the belt’s length, hold the tang at 90°
to the belt.
Pull the belt end to shorten the belt or the tang
Z08774 to lengthen it.
To lengthen
To shorten
WARNING
For maximum protection in the event of an
accident, the belt must not be loose. A loose
belt could even aggravate injuries.
• Unfastening
1. Press the red button to unlock the buckle.
2. When the belt is not in use, insert its tang into
the buckle.
3 Children and babies

• When carrying children or babies, they must be
restrained properly to minimize the risk of injury
in the event of a sudden stop or accident. Never
allow children to stand or kneel on the seats. For
maximum safety, we recommend fitting and
using a restraint system that complies with Fed-
eral Motor Vehicle Safety Standards.
The use of child and/or baby restraint systems is
mandatory in some states. Please abide by your
state’s regulations.
• Older children may sit on the regular seats and
use the regular seat belts. However, make sure
that the shoulder belts do not cross their necks
or faces.
4 Pregnant women
Since a seat belt could exert undue pressure on the
abdomen in the event of an accident, pregnant
women should consult a doctor about the use of
seat belts before riding in the vehicle.
A pregnant woman should wear her seat belt as low
as possible across the hips, not across her abdo-
men.
5 Seat belt care

• Periodically, check the action of the mechanical
parts such as the buckles, tangs, and emer-
gency locking retractor (ELR) units. Check also
for any damage that could stop the seat belts
from functioning properly.
Replace seat belt unit if there is any malfunction
or damage.
• Replace any webbing that is cut, frayed, or oth-
erwise damaged.
• Replace any seat belt that has received a shock
due to a collision.
• Keep sharp or other potentially damaging
objects away from the seat belts, especially the
webbing.
• Keep the seat belts clean and dry. Use a mild
soap and lukewarm water to clean seat belts.
Such solvents as gasoline and thinner may seri-
ously affect the strength of the webbing.
P. 12-73
• Never attempt to bleach or dye the seat belts, as
this could weaken them considerably.
• Do not attempt to remove the seat belts or dis-
assemble the ELR units.
4-7
Steering wheel
WARNING
• After every adjustment, try to move the
steering wheel back and forth to make
sure that it is securely locked. Unless the
lever returns to its original position, the
steering wheel may move while the vehicle
is in motion and cause an accident.
• Make adjustments with the vehicle station-
ary. Adjusting the steering wheel while
driving is dangerous since it could detract
from your concentration or cause the
steering wheel to move more than desired.
The steering wheel can be adjusted to the preferred

height and tilted forward/backward. Adjust the
steering wheel as well as the seat to the best posi-
tions for easy safe driving.
• Pull the lock lever then adjust the steering
wheel to the height and angle that are most
comfortable for you.
• Push the lock lever back in to securely retain the
steering wheel.
Adjust
Retain
Z10764
5-1
5. Switches and controls
Arrangement of switches and

controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Warm-up switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Engine idling control volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Gearshift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Range selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Overdrive switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Parking brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Hazard warning lamp switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Rheostat control switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Van body dome light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Rearview mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Mirror heater switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-2 Switches and controls
<Manual transmission vehicles> Arrangement of switches and

controls
Starter switch
Engine idling control volume
Accelerator pedal
Brake pedal
Clutch pedal
Gearshift lever
Parking brake lever
Hazard warning lamp switch
Combination switch
(wiper and washer switch, exhaust brake switch:
Manual transmission vehicles)
Combination switch
(lighting switch, passing/dimmer switch, turn sig-
nal switch)
Front drive switch <FG> P. 8-3
Oil level check switch P. 12-19
Central door lock switch <vehicles other than
Crew-cab models> P. 3-4
Z12481 Warm-up switch
Range selector lever
Overdrive switch
<Automatic transmission vehicles> Shift lock release knob
Rheostat control switch
Van body dome light switch <vehicles other than
Crew-cab models>
Transfer lever <FG> P. 8-3
Mirror heater switch <option>
Z11821
5-3
Starter switch
WARNING
Never turn the starter switch to any position
other than the “ON” position while driving
the vehicle. Turning the starter switch to the
“ACC” position would be dangerous because
the engine would stop and the following
problems would occur:
• The braking force reduces extremely.
• The power steering system would stop
working so the steering action would
become extremely heavy.
• The electric circuits for the warning lamps
and meters would stop working, and elec-
tric parts could fail.
When the starter key is removed from the
starter switch, the steering wheel locks, mak-
ing steering impossible.
CAUTION
• Do not turn the starter switch to the “START”
position while the engine is running. Doing
so could damage the starter.
• The starter key cannot be turned from the
“ACC” position to the “LOCK” position
unless it is pressed in. Do not attempt to turn
it by force. Keep the key pressed in while
turning it from the “ACC” position to the
“LOCK” position.
• If you park the vehicle over an extended
period of time, always place the key in the
“LOCK” position and remove it from the
starter switch. Leaving the key in the “ON”
or “ACC” position could run down the bat-
tery.
• Avoid using the “ACC” position for long
periods, for example, for listening to the
radio, as the battery could be completely dis-
charged.
• LOCK
The starter key can be inserted and removed
in this position only. To place the key in the
“LOCK” position, turn it to the “ACC” position
then press it in. Keep it pressed in while turning
it to the “LOCK” position. When the key is
removed, the steering wheel locks.
The lighting switch, rheostat control switch, haz-
ard warning lamps, interior lamp, horn, central
door locks and turn signal lamps can be used.
• ACC
The engine is shut off or is not running in this
position.
The cigarette lighter can be used. Audio equip-
ment (radio, etc.) installed and connected in the
approved manner can also be used.
• ON
The engine is running in this position.
All electrical circuits are operable.
• START
The engine is turned over and started in this
position.
Z10782
Once the engine is running, release the key and
the switch will automatically return to the “ON”
position.
NOTE:
• Turn the key only after inserting it fully in the
starter switch.
• If you are unable to turn the key, gently turn the
steering wheel clockwise and counterclockwise
as you turn the key.
Warm-up switch
• To warm up the engine quickly or make the

heater work more effectively with the vehicle
stationary, turn ON the warm-up switch . The
warm-up system will begin to operate, and the
indicator lamp will illuminate.
Z11822 P. 5-10
• When the engine has finished warming up, the
warm-up system stops operating automatically
and the indicator lamp turns off.
• Once the engine has warmed up and/or the
heater is working satisfactorily, turn OFF the
switch.
5-5
NOTE:
• When you start driving, be sure to turn OFF the
switch to deactivate the warm-up system.
• The warm-up system is used to make the
engine warm up more quickly and to make the
heater work more effectively when the vehicle is
stationary on cold days.
When the warm-up system is turned ON, the
engine’s idling speed automatically increases
and the exhaust brake operates. As a result, the
coolant warms up more quickly.
Engine idling control volume
WARNING
Do not increase the engine speed using the
engine idling control volume and then drive
the vehicle; it will be impossible to control
the vehicle’s speed using the accelerator
pedal.
CAUTION
• Be sure to set the engine idling control vol-
ume to the AUTO position during driving.
If you drive with the engine speed raised by
the volume, abrupt starting or premature
wear of the clutch may occur.
• Turn the engine idling control volume gently,
as forcing it could damage the internal
mechanism.
• If the idling speed is set too low using man-
ual control, the engine may become exces-
sively noisy. Make sure the idling speed is
correct.
NOTE:
If the engine speed is raised by the engine idling
control volume with the Warm-up switch set to the
ON position, a black smoke may be produced.
Before turning ON the Warm-up switch, be sure to
set the engine idling control volume to the AUTO
position.
Automatic control
The engine is warmed up with the speed being
automatically controlled according to the engine
coolant temperature. (The engine speed automati-
cally decreases as the coolant temperature rises.)
Manual control
Turn the knob counterclockwise to reduce the
engine speed.
Turn it clockwise to increase the engine speed.
The engine idling control volume should normally
Z11843 be placed in the automatic control position.
Engine idling speed

625 to 675 rpm
Starting the engine
WARNING
• Do not start or warm up the engine in a
garage or other closed area. When starting
the engine or entering or leaving a garage,
do not run the engine for longer than is
necessary as the accumulation of exhaust
gas in closed areas is very dangerous.
Exhaust emissions contain carbon monox-
ide (CO), which if breathed can cause
unconsciousness or death.
• If you smell exhaust gases inside the cab,
inspect the exhaust pipe and check
Z11944 whether exhaust gases are leaking
through holes or cracks caused by corro-
sion or damage. If exhaust gases are leak-
ing, have the exhaust pipe inspected by an
authorized dealer.
If exhaust gases that have leaked from the
exhaust pipe come into the cab, ventilate
the cab with fresh air by opening the win-
dows fully or by opening the doors.
• Make sure that there are no flammables
under or behind the parked vehicle, espe-
cially close to the exhaust pipe. A fire
could be started by the heat from the
engine or exhaust pipe.
• When you start the engine, be sure to sit in
the correct position on the driver’s seat to
wait for the engine to warm up. If you are
leaning out of the door window or other-
wise incorrectly seated and the vehicle
suddenly moves, a serious accident could
occur.
CAUTION
• It is dangerous to push-start the engine.
Only push-start the engine when it is
unavoidable. It is impossible to push-start an
automatic transmission vehicle, and
attempting to do so could damage the trans-
mission.
• Do not use ether or other vapor compound
type starting aids. Use of such fluid on this
engine could result in serious damage.
5-7
NOTE:
• When the engine has started, allow it to warm
up until the needle in the coolant temperature
gauge starts to move.
• Do not continue operating the starter for more
than 15 seconds as this could damage it or dis-
charge the battery.
• If you operate the starter continuously for 10
seconds and the engine still does not start, turn
the starter switch to the “ACC” position and wait
about 30 seconds for the battery to recover
before performing the starting procedure again.
• Use the engine idling control volume when
adjusting the engine speed immediately after
starting the engine. Doing so can prevent need-
less racing of the engine.
• On a vehicle that has not been operated for a
week or more, or after replacement of engine oil
or engine oil filter element, be sure to crank the
engine before starting it.
• If the indicator lamp does not illuminate in
cold weather, the fuse for the preheating circuit
may have blown and should be inspected.
P. 13-13
If the indicator lamp flashes, the preheating
circuit is malfunctioning. Have it inspected by an
authorized dealer.
• In a cold region, using a high-capacity battery
improves engine startability.
1 Pre-starting steps
1. Pull parking brake lever to fully apply the parking
brake.
2. Manual transmission vehicles:
Place gearshift lever in the neutral position.
Automatic transmission vehicles:
Place the range selector lever in the “P” posi-
tion.
Z11845
3. Turn the engine idling control volume to the

automatic control position.
Z11778
NOTE:
For safety, the engine in a manual transmission
vehicle cannot be started unless the gearshift lever
is in the neutral position.
In an automatic transmission vehicle, the engine
cannot be started unless the range selector lever is
in “P” or “N” position. It is safer to start the engine
with the range selector lever in the “P” position.
Start the engine with the range selector lever in the
“N” position only when absolutely necessary, for
example, if the engine stops while the vehicle is on
a level crossing.
2 Starting procedure
1. Turn the starter switch to the “ON” position.
Z08913
2. Check whether the indicator lamp illumi-

nates or not.
Z08914
• If the indicator lamp does not illuminate,

hold down the clutch pedal and turn the
starter switch to the “START” position to start the
engine. Do not depress the accelerator pedal.
Z08915
• If the indicator lamp illuminates, wait until it

goes off. After the lamp has gone off, hold down
the clutch pedal and turn the starter switch to
the “START” position to start the engine.
Z08915
5-9
3. After the engine has started, let it warm up until

the water temperature gauge needle begins to
move. P. 5-10
Z08917
3 Starting the engine when vehicle has

been parked over an extended period
When the vehicle is not used for a week or more or
the engine oil and oil filter are replaced, the engine
becomes starved of oil. Before the engine is started,
therefore, it must be cranked in accordance with the
following procedure to distribute oil to its various
components.
CAUTION
• To ensure maximum safety, be sure to pull
the parking brake lever fully to apply the
parking brake and block the wheels with
chocks thus preventing the vehicle from
accidentally moving.
• Performing the cranking is of essential
importance in terms of protecting the turbo-
charger.
1. Pull the parking brake lever to fully apply the

parking brake.
tion.
3. Without depressing the accelerator pedal, place
the starter switch in the “START” position and
crank the engine for roughly 15 seconds.
If the engine starts, release the starter key and
do not depress the accelerator pedal for roughly
15 seconds.
4 Starting the engine with the cab tilted

When you need to start the engine with the cab
tilted for inspection or servicing purposes, be sure
to observe the following safety precautions:
• Set the parking brake firmly and chock the

wheels.
• With a manual transmission vehicle, make sure
that the gearshift lever is in the neutral position.
With an automatic transmission vehicle, make
sure that the range selector lever is in the “P”
position.
• Make sure nobody is near the engine compart-
ment, then place the starter switch in the
“START” position to start the engine.
Z11846
Warming up the engine
WARNING
• Do not warm up the engine in a garage or
other closed area. When starting the
engine or entering or leaving a garage, do
not run the engine for longer than is nec-
essary as the accumulation of exhaust gas
in closed areas is very dangerous.
Exhaust emissions contain carbon monox-
ide (CO), which if breathed can cause
unconsciousness or death.
• If you smell exhaust gases inside the cab,
inspect the exhaust pipe and check
Z11944 whether exhaust gases are leaking
through holes or cracks caused by corro-
sion or damage. If exhaust gases are leak-
ing, have the exhaust pipe inspected by an
authorized dealer.
If exhaust gases that have leaked from the
exhaust pipe come into the cab, ventilate
the cab with fresh air by opening the win-
dows fully or by opening the doors.
• Make sure that there are no flammables
under or behind the parked vehicle, espe-
cially close to the exhaust pipe. A fire
could be started by the heat from the
engine or exhaust pipe.
CAUTION
Racing the engine immediately after it has
started causes excessive wear of cylinders and
pistons, leading to engine malfunction. Be sure
to warm up the engine to operating temperature
before full load operation according to the pro-
cedures described here.
5-11
NOTE:
Idling the engine for long time wastes fuel, and is
therefore detrimental to environmental protection
and resource conservation. So shut down the
engine whenever you leave the vehicle, even for a
short period.
After the engine has been idling for a relatively long
time, white smoke may be given off from the muffler
when driving off from a standstill and accelerating.
This is a normal effect of the catalytic converter that
is located in the muffler, and does not indicate any
abnormality. If you start to drive immediately after
starting the engine (while the engine is still cold),
you will encounter the following problems:
• In a cold region, the extreme coldness of the
engine will cause poor ignition of fuel, making
the engine prone to knocking.
• If the idling speed is too low, the engine will be
abnormally noisy. Be sure to return the idling
speed to the appropriate value.
With the engine idling control volume turned to the

automatic control position, the engine’s idling speed
is adjusted automatically. To make the engine warm
up more quickly, take the following steps:
1. After the engine starts, turn ON the warm-up
switch . The indicator lamp will illumi-
nate, the engine speed will start to increase, and
the exhaust brake will operate.
NOTE:
If the engine speed is raised by the engine idling
control volume with the Warm-up switch set to the
ON position, a black smoke may be produced.
Before turning ON the Warm-up switch, be sure to
set the engine idling control volume to the AUTO
Z11822
position.
2. Continue to let the engine warm up until the

water temperature gauge needle starts moving.
When the coolant temperature rises sufficiently,
the engine warming-up process stops automati-
cally and the indicator lamp then goes out.
Z08917
3. Turn OFF the warm-up switch.
Z11847
Stopping the engine
WARNING
• Never allow the vehicle to coast with the
engine stopped as braking may be danger-
ously sluggish and extremely difficult
steering may result. This may also cause
trouble in the fuel injection system.
• The engine and exhaust pipe are
extremely hot just after stopping the vehi-
cle. Avoid parking the vehicle where the
exhaust pipe could set fire to materials
such as dry grass.
CAUTION
• Allow the engine to idle for at least 3 minutes
before stopping it. Not doing so could result
in an engine malfunction.
• The engine should only be stopped from an
idle. Stopping it at a high RPM could result in
an engine malfunction.
1. Hold down the brake pedal and apply the park-

ing brake.
tion.
Z11845
3. Allow the engine to idle for more than 3 minutes

before stopping it.
More than When the vehicle is in motion, engine parts
3 minutes
become extremely hot. This is particularly true
during uphill or high-speed driving. Therefore,
let the engine cool down sufficiently by allowing
it to idle for a time before stopping it.
Z10800
5-13
4. Turn the starter switch to the “ACC” position to

stop the engine.
Z08812
Pedals
Accelerator pedal
WARNING
If you use a floor mat, lay it correctly and
make sure it is suitable for the size of the
vehicle. It is dangerous for a floor mat to
cover the accelerator pedal or for floor mats
to be laid in multiple layers since the acceler-
ator pedal may be prevented from returning
when released.
Z08813
Racing the engine also increases fuel consumption.
Brake pedal
WARNING
Allowing empty beverage cans or other
objects to get under the brake pedal is
extremely dangerous as they will interfere
with brake pedal movement. Keep the floor
free of any objects obstructive to operation
of the pedal.
• Illumination of the warning lamp while the

vehicle is being driven shows that the disc brake
pads are due for replacement. Have the disc
brake pads inspected by an authorized dealer.
The warning lamp always illuminates when
the starter switch is turned from the “ACC” posi-
tion to the “ON” position. Provided it goes off
approximately three seconds later, the disc
brake pads are normal.
• Use the brake pedal correctly. P. 7-7
Clutch pedal
<Manual transmission vehicles>
• Do not operate the vehicle with your foot on the
clutch pedal as doing so can shorten the service
life of the clutch. Driving with your foot on the
clutch pedal could prevent engine braking and
exhaust braking from taking place.
• Depress the clutch pedal fully when changing
gear. If you do not depress the clutch pedal far
enough, the clutch will slip, possibly damaging
the clutch discs.
Gearshift lever
CAUTION
• Shifting from a forward gear to the reverse
gear or vice versa, should be done only after
the vehicle has come to a complete stop.
When backing up, always double check to
make sure that there is nothing in your path.
• When the gearshift lever is in the neutral
position, never keep your hand on the lever,
as a forward or backward pressure resulting
from this practice could cause malfunction
of the transmission.
• When shifting, fully depress the clutch pedal
and then operate the gearshift lever. Other-
wise, damage to the transmission may
result.
• The gear pattern is inscribed on the top of gear-

shift lever.
• When the gearshift lever is placed in the reverse
(R) position, the backup lamps light up and the
backup buzzer sounds simultaneously.
Z10807
5-15
<Automatic transmission vehicles>

The range selector lever is used to select gear
ranges. Select lever positions carefully to ensure
proper engagement of each gear.
1 Using the range selector lever

Button
: While depressing the brake pedal, push the
button and move the range selector lever.
The lever cannot be moved unless the
starter switch is in the “ON” position.
: Push the button and move the lever.
: Move the lever without pushing the button.
NOTE:
• Never push the button for the range selector
lever movements indicated by the black arrows
Z11851
( ) in the illustration. With the button pressed,
the lever could unexpectedly slip into the “P”,
“R”, “3” or “2” position.
• For safety, the range selector lever cannot be
moved out of the “P” position unless the brake
pedal is depressed. Even with the brake pedal
depressed, the range selector lever cannot be
moved if the starter switch is in the “LOCK” posi-
tion or “ACC” position.
If the range selector lever cannot be moved out of
the “P” position even with the starter switch in the
“ON” position and the brake pedal depressed, move
the range selector lever while pushing the shift lock
Shift lock release knob.
release knob This problem can be caused by an electrical fault,
so have an inspection carried out by an authorized
dealer.
Z11852
2 Ranges
P: Used when stationary, for example, when start-
ing or warming up the engine. The starter key
can be removed with the range selector lever in
this position.
R: For backing up. The backup lamps illuminate,
and a warning buzzer sounds.
N: The engine can be started with the lever in this
position, but it is safer to use the “P” position.
D: For normal driving. With the overdrive switch in
the “ON” position, gearshifts are made automati-
cally using the 1st through 6th gears. With the
overdrive switch in the “OFF” position, gearshifts
are made automatically using the 1st through
4th gears.
3: Used when driving at low speeds or when pow-

erful engine braking is needed on a downhill
road. Gearshifts are made automatically
between the 1st through 3rd gears.
2: For driving on steep hills and through mud and
snow. This position provides the maximum
engine braking. Gearshifts take place automati-
cally using the 1st and 2nd gears.
CAUTION
When driving downhill with the range selector
lever in the “3” or “2” position, use the service
brakes as necessary to prevent the acceptable
engine revolutions being exceeded and the
tachometer needle entering the red zone.
For extra convenience, a shift indicator in the meter

cluster shows the position of the range selector
lever.
CAUTION
Shifting from a forward gear to the reverse gear
or vice versa, should be done only after the
vehicle has come to a complete stop.
When backing up, always double check to make
Z11853 sure that there is nothing in your path.
NOTE:
Control is implemented to accelerate warming-up of
the transmission when the weather is cold and the
temperature of the transmission fluid is low, and the
following conditions may occur as a result of this
action. Note that this control will be terminated
when the fluid reaches a suitable temperature.
• Difficulty may be experienced in making auto-
matic gear changes.
• If the fluid temperature is extremely low, the
transmission may remain fixed in 3rd gear when
the gearshift level is in the “D”, “3”, or “2” posi-
tion. Reverse will however be possible in the “R”
position.
If the fluid temperature is high, control is imple-
mented in order to protect the transmission, and this
may make it impossible to shift to 5th or 6th gear.
Once the temperature has dropped to a suitable
level, full functionality of the 6-speed automatic
transmission will be restored.
When travelling downhill, the incline and load condi-
tions will be determined automatically, and where
necessary, the transmission will be automatically
shifted to the appropriate speed. As a result, down-
shifting will be easier to perform on steeper inclines
and when carrying heavy loads.
5-17
OFF ON Overdrive switch
<Automatic transmission vehicle>

Overdrive can be switched on and off with the
switch located on the range selector lever.
When the switch is in the “OFF” position, an
indicator lamp illuminates.
Z11854
• Overdrive ON
Overdrive should be switched on as desired for nor-
mal driving and always for high-speed driving. In the
“D” range, gear shifts are made automatically
between the 1st and 6th gears, and fuel consump-
tion is minimized.
In cold weather, the transmission may not initially
make automatic shifts to the 5th and 6th gears
because of an excessively low fluid temperature.
This condition is normal and will be resolved as the
fluid temperature rises.
• Overdrive OFF
Overdrive should be switched off when engine brak-
ing is needed on a downhill road or when driving
uphill for a long period. In the “D” range, gear shifts
are made automatically between the 1st and 4th
gears.
NOTE:
Even with the overdrive switch in the “OFF” posi-
tion, the 5th and 6th gears will automatically be
selected if there is any risk of the engine overrev-
ving.
Parking brake lever
WARNING
• Do not use the parking brake when driv-
ing except in an emergency, like if the ser-
vice brakes have failed. Such use of the
parking brake may make the vehicle spin
or, at worst, roll over. It may also cause
faults in vehicle components.
• Illumination of the warning lamp does
not necessarily indicate that the parking
brake has been fully activated. Be sure to
pull the lever all the way.
Parking
The parking brake is activated when the parking
brake lever is fully pulled out. The warning lamp
lights up simultaneously.
Releasing
Raise the lever slightly, press the end button , and
lower the lever with the button still pressed. Make
sure that the warning lamp goes out.
• When parking, please bear in mind the cautions

in “Parking”, chapter 7. P. 7-12
CAUTION
• Before putting the vehicle in motion, com-
pletely release the parking brake lever and
check that the warning lamp is not illumi-
nated. If you accidentally drove the vehicle
with the parking brake applied, the parking
brake would wear prematurely and overheat,
leading to reduced effectiveness and the risk
of a fire.
Z11856 • When parking your vehicle on a slope, block
the wheels with chocks for added safety.
Combination switch
1 Arrangement of switches
Lighting switch
Passing/dimmer switch
Turn signal switch
Exhaust brake switch <Manual transmission
Z11857 vehicles>
Wiper and washer switch
2 Lighting switch
CAUTION
Keeping the headlamps on for a long period
without the engine running can drain the bat-
tery, making the engine impossible to start.
The lighting switch can be used with the starter

switch in any position.
Z11858 Turning the knob at the end of the lever controls the
illumination of lamps as follows:
5-19
Identification, clearance
and side marker, Headlamps
parking, tail, license, and
meter illumination lamps
OFF Off On*
position
On On*
position
On On
position
*: Illuminated by daytime running light system

NOTE:
Even when the vehicle is operated with the lighting
switch in the “OFF” or position, the daytime
running light system causes the low-beam head-
lamps to be lit. (The headlamps are dimmer than
when activated using the lighting switch.) The
indicator lamp is also lit. When the parking brake is
applied or the engine is stopped, the headlamps
and the indicator lamp go off.
3 Passing signal/dimmer switch

Passing signal
Pulling the lever up activates the high beams until
the lever is released. Use this to flash a signal when
overtaking another vehicle.
Dimmer
With the headlamps illuminated, pushing the lever
down activates the headlamp high beams and pull-
ing it back to the original position reactivates the low
Z11860 beams. When the high beams are on, indicator
lamp lights up.
4 Turn signal lamp switch

Turn signal
Moving the lever forward or backward activates the
corresponding turn signal causing it to flash. At the
same time, the corresponding indicator lamp or
flashes.
When the steering wheel is returned to the neutral
position after a right or left turn, the switch automat-
ically moves back to the neutral position and the
lamp stops flashing. After making a moderate turn,
Z11861 however, the switch will sometimes not return auto-
matically. In this case, put the switch in the neutral
position by hand.
Lane changer
Lightly pushing the lever forward or backward
causes the corresponding turn signal lamp to flash
while the lever is held in this position.
5 Exhaust brake
WARNING
Using the exhaust brake on a wet, frozen,
snow-covered, or otherwise slippery road
surface when the vehicle is lightly loaded or
not loaded can cause the tires to slip on the
road surface, resulting in a skid. Do not use
the exhaust brake on slippery road surfaces.
The exhaust brake enhances engine braking. Use it

as an auxiliary braking means on downhill stretches
or during high-speed driving.
Exhaust brake usage differs between manual and
automatic transmission vehicles. See the instruc-
tions below.
NOTE:
In a manual transmission vehicle, do not keep the
exhaust brake switch in the activation position at all
times. Frequent use of the exhaust brake reduces
fuel economy. Move the exhaust brake switch
between the activation and non-activation positions
as necessary according to road and traffic condi-
tions.
• Manual transmission vehicles

Pushing the lever forward activates the exhaust
brake. While the exhaust brake is activated, the
indicator lamp stays illuminated.
Deactivated
Activated
The exhaust brake will be temporarily disabled in
the following conditions. Full functionality will be
returned when the original conditions have been
restored.
Z10814
• The accelerator pedal is depressed.
• The gearshift lever is positioned in neutral for 10
seconds or longer.
• The ABS is operating.
• Automatic transmission vehicles

The exhaust brake activates if the accelerator pedal
is released while the vehicle is in motion. The
indicator lamp illuminates when the exhaust brake
is functioning.
The exhaust brake will be temporarily disabled in
the following conditions. Full functionality will be
returned when the original conditions have been
restored.
• The accelerator pedal is depressed.
• The gearshift lever is moved to “P” or “N”.
• The temperature of the transmission fluid is
high.
• The vehicle speed has dropped to 10 km/h (6
mph) or lower.
• Gear shifting is being carried out.
• The ABS is operating.
5-21
NOTE:
Do not place the range selector lever in the “P” posi-
tion or “N” position while the vehicle is moving.
Doing so could cause the transmission to fail.
6 Wiper and washer switch
WARNING
In cold weather, warm the windshield with the
heater before operating the washer since
washer fluid could otherwise freeze onto the
windshield and obstruct your vision.
CAUTION
• Operating the wipers when the windshield is
dry damages the windshield glass. If the
glass is dry, be sure to squirt it with washer
fluid before operating the wipers.
• Do not operate the wipers when the rubber
parts of the wiper blades are frozen onto the
windshield or otherwise stuck to the wind-
shield. The wiper blades could get damaged,
and the wiper motor could fail.
• When the wipers are not used for a long
time, dust, sand, and other substances can
collect between the wiper blades and wind-
shield. Clean the wipers before using them.
Otherwise, the windshield may get
scratched.
• Operating the washer continuously for more
than 20 seconds or when there is no fluid in
the reservoir could burn out the washer
motor.
• Rotating the grip at the end of the lever activates

the windshield wipers in one of the following
three modes:
HI
INT: Wipers operate intermittently at 3 to 5 sec-
ond intervals.
LO LO: Wipers operate at a slow speed.
HI: Wipers operate at a rapid speed.
INT OFF Replace the wiper blades if they start to work inef-
fectively. P. 12-63
Z10723
CAUTION
Wiper blade rubber can deteriorate over time,
causing the wipers to work ineffectively and
possibly causing the windshield to be
scratched.
• To activate the windshield washer, pull the lever

front.
• Refill the washer fluid reservoir before it is
empty. P. 12-64
Hazard warning lamp switch
CAUTION
The battery may be discharged and the engine
impossible to restart if the hazard warning
lamps are operated for an extended period of
time.
The hazard warning lamps may be used as a warn-

ing to other vehicles when you suddenly find it nec-
essary to stop your vehicle in emergencies.
The lamps can flash in any of the starter switch
positions.
Pressing switch causes all turn signal lamps to flash
simultaneously. At the same time, indicator lamps
start flashing.
Pressing the switch again causes the lamps to go
out.
Z10816
Rheostat control switch

Bright
Use the rheostat control switch to adjust the bright-
Dim ness of the meter cluster illumination lamps.
With the meter cluster lamps on, press and hold
either side of the switch to set the lamps to your
desired brightness, then release the switch.
Z11866 NOTE:
The lamps can be brightened and dimmed only
within a fixed range. Pressing the rheostat control
switch after the lamps have brightened or dimmed
to the limit will have no effect.
Van body dome light switch

This switch operates the lighting inside the van
body. With the starter switch in the “ON” position,
operate the van body dome light switch to turn the
van body interior lighting on or off. An indicator light
comes on in the switch when it is in the “ON” posi-
Z11867
tion.
CAUTION
Leaving the van body interior lighting on for an
extended period without the engine running can
drain the battery.
5-23
Rearview mirrors
The mirror stay can be swung manually in the direc-

tion indicated by the arrow.
Swing the stay to the inward position if the mirror is
obstructing free movement of the vehicle, for exam-
ple, when turning a tight corner, passing an oncom-
ing vehicle or parking in a narrow place.
Z11868
WARNING
• During normal driving, the mirrors must be
in their outward positions and adjusted so
that clear rear views may be obtained
through them.
• When turning right or left, bear in mind the
difference in tracking of the front and rear
inner wheels, and use the rearview mirrors
to confirm safety behind you.
• Pay attention to the extended rearview
mirrors when driving on narrow roads.
Take particular care to ensure that they do
not hit pedestrians.
• If rainy weather, drops of water can adhere
to the mirrors, detracting from rearward
visibility.
Stop the vehicle and wipe off the water to
restore visibility.
Mirror heater switch
When the mirrors are misted up, turn ON the switch

to activate the mirror heaters. The lamp in the
switch will illuminate at this time. Turn OFF the
switch when the mirrors are clear.
Z13628
CAUTION
Do not use the mirror heaters unless the engine
is running. Otherwise, the battery may become
drained, making it impossible to start the
engine.
6-1
6. Instruments and warning lamps
Arrangement of instruments and warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Warning/indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-2 Instruments and warning lamps
Arrangement of instruments and

warning lamps
Speedometer
Tachometer
Water temperature gauge
Fuel gauge
Warning/indicator lamps
Z11892
Speedometer
1 Speedometer
The speedometer indicates vehicle speed in miles
or kilometers per hour.
Odometer/Tripmeter
Z11893
2 Odometer/tripmeter
With the starter switch in the “ON” position, either
“ODO” (for “odometer”) or “TRIP” (for “tripmeter”) is
displayed. The display toggles between “ODO” and
“TRIP” each time the trip knob pressed.
• ODO (odometer)
The total distance covered by the vehicle is shown
to the nearest mile.
Z08790 • TRIP (tripmeter)

The distance covered by the vehicle from a selected
point to its present location is shown to the nearest
0.1 mile.
The tripmeter has two indications: TRIP “A” and
TRIP “B”, which can be set and displayed indepen-
dently of each other.
To zero the current indication, press the trip knob for
approximately 1 second or longer. The indication
will return to “0.0”.
Tachometer
• The tachometer indicates engine speed in revo-

lutions per minute.
• If the needle enters the red zone , the engine
is overrevved. Reduce the vehicle speed suffi-
ciently during downhill driving or downshifting to
Z13659
keep the needle from entering this zone.
P. 7-9
6-3
CAUTION
The term “overrev” refers to rotation of the
engine at an RPM exceeding the maximum limit.
This occurs when the engine is driven by the
wheels during downhill driving or downshifting.
Persistent overrevving can lead to an engine
breakdown.

Water temperature gauge
This gauge indicates the temperature of the engine

coolant.
With the engine running normally, the needle should
be in the center of the scale.
If the needle enters the red zone , the engine has
overheated. The warning lamp will illuminate at
this time. In this event, pull off the road as soon as
you can safely do so then let the engine cool down
<Automatic transmission vehicles> by running it at a speed slightly higher than its idling
speed. If the vehicle has an air conditioner, switch it
off.
When the gauge needle comes down to approxi-
mately the center of the scale, stop the engine and
perform the checks and corrective steps described
on this reference page: P. 13-7
CAUTION
Z12503
Be sure to stop the engine only after letting it
run at a speed slightly above the idling RPM
until the coolant cools down. Turning off the
engine immediately after stopping will cause the
coolant temperature to rise quickly and may
cause the engine to seize up.

Fuel gauge
The fuel gauge indicates the amount of fuel still

remaining in the fuel tank.
F: Full
E: Empty
When the needle approaches the “E” mark, refuel
as soon as possible.
If the vehicle completely runs out of fuel, air must be
bled out of the fuel system. P. 13-23
Z12504
6-5
Warning/indicator lamps
<Automatic
transmission
shift indicator>
Z12472
The illustration shows the standard arrangement of

the warning and indicator lamps. Some lamps
shown here, however, may not be installed on your
vehicle.
Illumination of certain warning lamps is accompa-
nied by sounding of a buzzer. If the parking brake is
applied, the buzzer will stop.
CAUTION
The red warning lamps, if illuminated, warn you
of vehicle component failures and possible dan-
ger of accident. Never drive the vehicle while a
red warning lamp is illuminated. If any of them
light up, stop the vehicle as soon as it is safe to
do so and make checks for locating the cause. If
necessary, have your vehicle repaired by an
authorized dealer.
NOTE:
The red warning lamps may also come on if the
engine is started when the battery’s performance
has decreased. In this event, either charge the bat-
tery or replace the battery with a new one.
Lamp Warning/indicator lamp If illuminated Ref. page

symbol
Turn signal indicator lamp Turn signals activated 5-19
Headlamp high beam indicator lamp Headlamp high beams illuminated 5-19
5-4,
Exhaust brake activated warm-up system
Exhaust brake indicator lamp 5-11,
in operation 5-20
Engine preheat indicator lamp Engine being preheated 5-8
Vacuum pressure warning lamp Excessively low vacuum in vacuum tank 6-8
<Other than FE85>
Brake fluid at an excessively low level, too

Brake warning lamp low power steering fluid pressure on FE85 6-8
(*) or parking brake activated
Charge warning lamp Problem in battery charging system 6-9
Engine oil pressure warning lamp Excessively low engine oil pressure 6-9
Cab lock warning lamp <Vehicles Cab tilted or not locked down 12-8
other than Crew-cab models>
LOW range indicator lamp <FG> Transfer LOW range gear selected 8-3
Automatic transmission fluid tempera- Automatic transmission fluid excessively

ture warning lamp 6-10
hot
Fuel filter warning lamp Excessive water in fuel filter 6-10
Disc brake warning lamp Disc brake pad worn 6-10
(Green) Engine oil level warning lamp Engine oil level normal
12-19
(Amber) Engine oil level warning lamp Low engine oil level
Fault in electronic control circuitry of fuel
(Red) Engine control warning lamp injection system
6-11
Fault in electronic control circuitry of fuel
(Amber) Engine control warning lamp injection system (functionality reduced)
4WD indicator lamp <FG> Four-wheel drive (4WD) mode selected 8-3
ABS warning lamp Fault in antilock braking system (ABS) 6-11
Automatic transmission warning lamp Fault in automatic transmission electronic 6-12

<Automatic transmission vehicles> control system
Headlamps (low-beam) illuminated by day-

Daytime running light indicator lamp 5-19
time running light system
6-7
Lamp Warning/indicator lamp If illuminated Ref. page

symbol
Engine overheating warning lamp Engine overheating 6-12
NOTE:
Illumination of any warning lamp marked (*) is accompanied by sounding of a buzzer.
The warning lamps shown below come on when the starter switch is turned from the “ACC” position to the
“ON” position but almost immediately go off.
Lamp Warning lamp Operation

symbol
Goes off when engine is started (except if park-

Brake warning lamp ing brake lever is pulled). <FE85>
Vacuum pressure warning lamp

<Other than FE85> Goes off when engine is started.
Charge warning lamp Goes off when engine is started.
Engine oil pressure warning lamp Goes off when engine is started.
(Red) Engine control warning lamp

Goes off when engine is started.
(Amber) Engine control warning lamp
Automatic transmission warning lamp Goes off a few seconds after starter switch is
<Automatic transmission vehicles> turned to “ON” position.
Automatic transmission fluid temperature Goes off a few seconds after starter switch is
warning lamp turned to “ON” position.
Disc brake warning lamp Goes off a few seconds after starter switch is
<Vehicles with disc brakes> turned to “ON” position.
Goes off a few seconds after starter switch is

ABS warning lamp turned to “ON” position.
1 Low vacuum warning lamp

<Other than FE85>
WARNING
Braking is dangerously sluggish when the
vacuum warning lamp is illuminated. For
safety, never drive with the vehicle in this
condition.
Z10909
This lamp illuminates when the starter switch is
turned to the “ON” position. As long as the lamp
goes out when the engine is started, the vehicle
may be driven. If illuminated while the engine is run-
ning, this lamp signals that the vacuum level in the
brake vacuum tank has dropped below the safe
limit.
This lamp, when illuminated, signals that the vac-
uum level in the brake vacuum tank has dropped
below the safe limit.
Since braking becomes sluggish under this condi-
tion, depress the brake pedal with full force to slow
down the vehicle, then pull off the road as soon as it
is safe to do so, and perform the following checks:
1. Let the engine run at intermediate RPM until the
warning lamp goes out.
2. Check piping and its connections for vacuum
leaks.
3. If the lamp does not go out or comes on again
soon after it has gone out, the vacuum system is
defective and must be repaired. Call an autho-
rized dealer.
2 Brake warning lamp
WARNING
If the brake warning lamp comes on owing to
an excessively low level of brake fluid (or low
power steering fluid pressure on FE85), the
brakes will not be fully effective and driving
will thus be dangerous. Do not drive the vehi-
cle in this condition.
Z10908
This lamp lights up when the parking brake lever is
pulled, when the brake fluid level drops below the
safe limit, or when the power steering fluid pressure
is too low on FE85. When the power steering fluid
pressure is too low on FE85, illumination of the
lamp is accompanied by sounding of a buzzer. The
buzzer stops when the parking brake is applied.
Should the lamp remain illuminated even after the
parking brake lever has been released or light up
during driving, pull off the road as soon as it is safe
to do so, and perform the checks below.
6-9
With the starter switch in the “ON” position and the

engine not running, the warning lamp will stay on
even if the parking brake lever is released. The
lamp will go out if the engine is started.
1. Check the brake fluid level.
Replenish the reservoir if the level is too low.
P. 12-28
2. Pump the brake pedal several times to make
sure that the fluid level does not drop.
3. If the fluid level drops, it indicates fluid leakage.
Call an authorized dealer.
4. If the warning lamp lights and the buzzer sounds
on FE85, never continue driving. Call an autho-
rized dealer.
3 Charge warning lamp

The charge warning lamp lights up when the starter
switch is turned to the “ON” position and goes out
as soon as the alternator starts charging the battery
after the engine has turned over.
The lamp also lights up if a problem occurs in the
battery charging system while the engine is running.
If this occurs, pull off the road as soon as it is safe to
do so, and perform the following checks.
1. Check for a broken V-belt. Also check belt ten-
Z10484 sion. P. 12-46
2. Check for a blown high-current fuse in the bat-
tery charging circuit. If blown, replace with a new
one. P. 13-12
3. If both the above checks have turned out nor-
mal, the problem is probably in the battery
charging system. Call an authorized dealer.
4 Engine oil pressure warning lamp

The engine oil pressure/level warning lamp lights up
when the starter switch is turned to the “ON” posi-
tion and goes out as soon as the engine is turned
over. If the lamp lights up while the engine is run-
ning, the cause may be an excessively low engine
oil pressure. Pull off the road as soon as it is safe to
do so, and perform the following checks.
1. Check the engine oil level. Add if insufficient.
P. 12-18
Z10476 2. Check various parts of the engine for any sign of
oil leaks.
3. If the oil level is normal and there are no oil
leaks, the problem is in the lubrication system.
Call an authorized dealer.
NOTE:
When it is cold, the engine oil’s viscosity is relatively
high and this may cause the warning lamp to stay
illuminated for a while even after the engine has
started. This is a normal condition.
CAUTION
Never continue driving with the lamp illumi-
nated. The engine could seize up.
5 Automatic transmission fluid tempera-

ture warning lamp
This lamp comes on when the starter key is turned
to “ON”. It should go out in a few seconds.
• This lamp illuminates if the automatic transmis-
sion fluid becomes excessively hot.
If the lamp illuminates while the vehicle is in
motion, pull over at the nearest safe place, put
the range selector lever in the “P” position, and
Z10987 run the engine at slightly higher than idling
speed.
• If the warning lamp goes out, it is safe to con-
tinue driving. If the lamp stays on or comes on
intermittently, there may be a fault in the cooling
fan (located on the left-hand side of the vehicle)
or fluid leak. Have the vehicle checked by an
authorized dealer.
6 Fuel filter warning lamp

If this lamp is illuminated, water is present in the fuel
filter in an amount exceeding the limit. Pull off the
road as soon as it is safe to do so and drain the fuel
filter of water. P. 12-38
If the warning lamp does not go out or lights up fre-
quently, have the vehicle checked by an authorized
dealer.
Z10843
CAUTION
Never continue driving with the lamp illumi-
nated as engine malfunction or fuel injection
system failure could result.
7 Disc brake warning lamp

<Vehicles with disc brakes>
This lamp illuminates if the disc brake pads become
worn beyond the safe limit and shows that the pads
must be replaced by an authorized dealer.
WARNING
Z10906 When the disc brake warning lamp is illumi-
nated, the brakes are dangerously ineffective
and could cause an accident.
6-11
8 Engine control warning lamp

to “ON”. It should go out when the engine starts.
8.1 Illumination of red lamp

Illumination of the red engine control warning lamp
indicates a fault in the electronic control circuitry of
the fuel injection system. The engine output may be
limited depending on the location of the fault.
If the lamp illuminates, place the starter switch in
Z11795 “ACC” or “LOCK” position for 5 seconds or longer to
reset the computer and then restart the engine. If
the lamp stays off, there is no problem. If the lamp
illuminates again, stop the engine and contact the
nearest authorized dealer.
8.2 Illumination of amber lamp

Illumination of the amber engine control warning
lamp indicates a fault in the electronic control cir-
cuitry of the fuel injection system that has caused
the system’s functionality to decrease. If the lamp
illuminates, place the starter switch in “ACC” or
“LOCK” position for 5 seconds or longer to reset the
computer and then restart the engine. If the lamp
stays off, there is no problem. If the lamp illuminates
again, have your vehicle inspected at an authorized
dealer in the earliest opportunity.
9 ABS warning lamp

to “ON”. It should go out a few seconds later. If the
lamp comes on again, this indicates there is a mal-
function in the antilock braking system (ABS).
Should this lamp illuminate during driving, stop the
vehicle in a safe place and perform the following
inspection.
1. Turn the starter key to the “OFF” position and
then to the “ON” position again.
Z10986 2. Determine the system condition as follows:
• The system is normal if the warning lamp goes
out a few seconds later.
• The system is faulty if the warning lamp stays on
for longer than a few seconds or it goes off but
comes on again.
• The system is normal if the warning lamp goes
off in a few seconds after the starter key is
turned to “ON”. The system is also normal if the
warning lamp does not go off a few seconds but
then goes off as soon as the vehicle is started.
3. If the system is found to be faulty, have the sys-
tem repaired by an authorized dealer as soon as
possible.
NOTE:
Even with the ABS faulty and the warning lamp
remaining lit, the normal brake system is still func-
tioning satisfactorily. Only the ABS function is lost.
Drive with great care on slippery surfaces with the
vehicle in this condition.
10 Automatic transmission warning lamp

The illumination of this lamp indicates a fault in the
automatic transmission electronic control system. If
the lamp illuminates, stop the vehicle in a safe
place, turn the starter key to the “ACC” position to
stop the engine, then start the engine again. In cer-
tain circumstances, the on-board computer may
Z10839 reset itself, allowing normal operation to continue.
If the fault does not rectify itself or the warning lamp
signals abnormal condition again soon later, have
an authorized dealer carry out a check.
Even with the electronic control system malfunction-
ing, the vehicle can be driven in a “limp-in” mode
whereby gearshifts will be made per the table
below.
Range Limp-in mode

selector Normal gearshift
gearshift
position
P Park Park
R Reverse Reverse
N Neutral Neutral
At high 1st ↔ 2nd ↔ 3rd
D speeds, fixed ↔ 4th ↔ 5th
to 5th. ↔ 6th
At low speeds,
3 fixed to 3rd. 1st ↔ 3rd only
After once
2 stopped, fixed 1st ↔ 2nd only
to 3rd.
11 Engine overheating warning lamp

This lamp illuminates if the engine overheats. With
the engine overheated, the needle in the coolant
temperature gauge is in the red zone.
Promptly stop the vehicle, then run the engine at a
speed slightly higher than the idling speed until the
coolant has cooled down. Also, take other steps
that are necessary following overheating of the
engine. P. 13-7
Z10486
WARNING
Driving with an overheated engine can dam-
age the engine or even cause a fire.
CAUTION
Be sure to stop the engine only after letting it
engine immediately after stopping will cause the
coolant temperature to rise quickly and may
cause the engine to seize up.
7-1
7. Starting and driving
Precautions when setting the vehicle in motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Precautions for driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tips for improving fuel economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Antilock braking system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
On uphill and downhill roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
On rough roads and in bad weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Vehicles with limited slip differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Loading cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-2 Starting and driving
Precautions when setting the

vehicle in motion
• Do not carry containers of fuel or spray cans in

the cabin.
WARNING
Z11316 Carrying fuel in the cabin is extremely dan-
gerous because an increase in the cabin tem-
perature could cause fuel vapor to catch fire
or cause the container to rupture.
• Do not attach any decorative panels or similar

items to the windshield.
WARNING
Attaching a decorative panel or similar item
to the windshield could impede driving and
visibility. In addition, any suction cup on
such an item could cause a fire by acting as a
lens.
• Check the immediate area around the vehicle,

using mirrors as necessary: there should be no
persons or obstacles under, in front of, on either
side, or behind the vehicle. Be particularly care-
ful when backing up.
If you wish to back up but cannot confirm safety
behind the vehicle using the mirrors, get out of
the vehicle and perform the check.
• Check that none of the red warning lamps are
illuminated. The warning lamp will go out
when the parking brake is released.
• Fully release the parking brake.
• Set manual transmission vehicles in motion
slowly. When pulling away, avoid racing the
engine and suddenly engaging the clutch. Sud-
den starts place undue strain on the vehicle and
should be avoided. Also, avoid slipping the
clutch for extended periods since this can dam-
age it.
• In an automatic transmission vehicle, depress
the brake pedal and move the range selector
lever out of the “P” position. The range selector
lever cannot be moved unless the brake pedal is
depressed. If the engine’s idling speed is too
high, selecting the “D” or “R” ranges may make
the vehicle lurch. Normalize the engine’s idling
speed before pulling away.
7-3
Precautions for driving
Observe the following precautions while driving.

Should you notice anything unusual about the vehi-
cle, immediately stop the vehicle and inspect the
relevant sections to find the cause of the trouble. If
you are unable to identify the cause of the trouble or
unable to do the repairs yourself, call your nearest
authorized dealer.
• Do not stop the engine while the vehicle is mov-
ing.
WARNING
Never place the starter switch in any position
other than the “ON” position while operating
the vehicle.
If you turn the starter switch to the “ACC”
position, the engine will stop. This is danger-
Z01410 ous.
If the engine stops during driving:
• The braking force reduces extremely.
• The power steering system becomes inop-
erative, rendering steering dangerously
sluggish.
• The electrical circuits of the warning
lamps, meters, etc. become inoperative,
causing electric components to malfunc-
tion.
Removing the starter key causes the steering
wheel to lock, making it impossible to steer
the vehicle.
• Should the engine stall while the vehicle is in

motion, do not panic. Simply depress the brake
pedal to slow the vehicle, and pull off the road
as soon as it is safe to do so.
• If a red warning lamp comes on, the buzzer
sounds, or the vehicle behaves abnormally, stop
the vehicle in the nearest safe place and investi-
gate the cause. P. 6-5
If you cannot identify the cause or cannot rectify
the problem, contact an authorized dealer.
• Avoid making sharp turns and braking hard
except in emergencies. Doing so during high-
speed driving could cause the vehicle to tip over.
• If you notice a strange noise, vibration, or smell,
or if steering or braking feels unusual, pull the
vehicle off the road as soon as it is safe to do so
and check for the source of the trouble. If you
cannot determine the cause of the problem and/
or cannot rectify it, contact the nearest autho-
rized dealer.
• When driving on narrow streets or when making
a turn, keep in mind that the tracking of the front
and rear inner wheels is different, and also
make sure of rearward safety using the rearview
mirrors.
• Remember that the mirrors protrude from the

vehicle body. Be careful not to hit pedestrians
and obstructions with the mirrors when driving
on narrow roads.
Looking at the mirrors while driving causes your
line of vision to move significantly. Be sure to
keep paying attention to safety ahead of the
vehicle.
• Do not keep the steering wheel turned fully to
either side for more than 10 seconds. Doing so
could cause the power steering system to mal-
function.
• Do not try to forcefully turn the steering wheel
when the front wheels are stuck against a curb-
stone or other object. Doing so could cause the
steering gearbox to fail.
• Continuous high-speed driving burdens the
engine and other vehicle parts. Allow yourself
enough time that you do not need to push the
vehicle too hard.
• Perform your pre-operation checks with particu-
lar care when you expect to drive at high
speeds.
When continuously driving at high speeds, your
sense of speed may become dull. Pay constant
attention to your speed, and maintain an ade-
quate distance from the preceding vehicle.
Z01413
• If a tire bursts or gets punctured while you are
driving at high speed, do not panic. Keep a firm
grip on the steering wheel and gradually reduce
your speed. Stop the vehicle in the nearest safe
place. Do not brake sharply. Braking sharply
would be dangerous because the steering wheel
would be pulled to one side with great force.
• When driving at high speeds in the rain, it some-
times happens that the tires ride on a film of
water and lose contact with the road surface.
This is known as “hydroplaning”. If this should
happen, you will lose control of both steering
and braking. Therefore, be sure to maintain
moderate speeds on rainy days.
Hydroplaning can easily occur if tire tread is
worn to the point where the tread pattern is very
shallow.
• Using the exhaust brake on a wet, frozen, snow-
covered, or otherwise slippery road surface
when the vehicle is lightly loaded or not loaded
can cause the tires to slip on the road surface,
resulting in a skid. Do not use the exhaust brake
on slippery road surfaces.
• Do not use a mobile telephone while driving. If
you wish to use a mobile telephone, first stop
the vehicle in a safe place. Using a mobile tele-
phone while driving could distract your attention
from the vehicle and from the road ahead,
resulting in an accident.
• Operate the radio and other items of equipment
in the cab when the vehicle is stationary. It is
dangerous to operate such items of equipment
or use a carphone (other than a hands-free
type) while driving.
7-5
• Do not allow a child to touch the driver’s controls

and other equipment. A child’s interference
could cause a fault or accident.
1 When driving a manual transmission

vehicle
• Avoid slipping the clutch excessively. Partially
depressing the clutch pedal while the vehicle is
in motion causes the clutch to slip and shortens
the service life of the clutch.
• Avoid suddenly releasing the clutch pedal since
this places undue stress on the vehicle and
shortens the service life of the clutch.
• Do not operate the vehicle with the clutch disen-
Z11317 gaged or the gearshift lever in neutral.
Doing so will render the engine braking and
exhaust brake features ineffective, forcing you
to rely only on the service brakes and overusing
them in the process.
• Before shifting down, wait for the tachometer
needle to drop below 2,000 rpm. Not shifting
down in this manner could cause the engine to
overrev.
CAUTION
“Overrev” refers to an operating state of the
engine in which it rotates at an RPM higher than
the recommended maximum RPM. Overrevving
the engine could lead to an engine failure.
2 When driving an automatic transmis-

sion vehicle
• For normal driving, select the “D” range and use
the overdrive switch depending on conditions.
P. 5-17
It is possible to pull away using the range selec-
tor lever in the same way as a manual gearshift
lever, starting in “2”, then upshifting through “3”
to “D”.
• Do not push the range selector lever into the “N”
or “P” position while the vehicle is in motion.
This would make engine braking and exhaust
braking impossible and force you to overuse the
service brakes. It could also damage the trans-
mission.
• When the vehicle is driving fast, shifting down
will be prohibited by a safety device. In such
cases, depress the brake pedal and reduce the
vehicle speed.
• If you stop the vehicle momentarily, for example,
at a red light, keep the brake pedal firmly
depressed. If you must wait for longer than
expected, select the “N” or “P” range and pull
the parking brake lever.
• If you stop temporarily when driving uphill,
depress the brake pedal and pull the parking
brake lever. Do not attempt to stop the vehicle
from rolling backwards with the accelerator
pedal.
Tips for improving fuel economy
Observe the following precautions to achieve maxi-

mum fuel economy and to extend tire life.
• Continue warming up the engine only to the
point at which the water temperature gauge
needle begins to move.
Z11318
• Avoid racing the engine as doing so not only
wastes fuel but also harms the engine.
• Avoid sudden starts, sudden acceleration, and
sudden braking.
• When accelerating, do not wind the engine out
before changing gears; instead, change gears
before engine speed reaches a high RPM.
• Fuel consumption can be minimized by keeping
the tachometer needle in the 1,500 to 2,000 rpm
range.
• With an automatic vehicle, fuel consumption can
be further minimized by setting the overdrive
switch to ON.
• Try to drive at moderate and constant speeds.
Unnecessary acceleration and deceleration
causes fuel waste.
• In a manual transmission vehicle, do not keep
the exhaust brake switch in the activation posi-
tion at all times. Frequent use of the exhaust
brake reduces fuel economy. Move the exhaust
brake switch between the activation and non-
activation positions as necessary for road and
traffic conditions.
• Always keep the air pressure in tires correctly
Z11319
adjusted.
• Try to load cargo in a way that minimizes wind
resistance. P. 7-15
• Be sure to perform the pre-operational checks
and periodic inspections.
7-7
Braking
When driving downhill, use engine braking as well

as exhaust braking in combination with the foot
brake. P. 7-9
Z01416 WARNING
• When warning lamps and/or
light up, immediately stop the vehicle and
perform necessary checks. P. 6-6
• Using the exhaust brake on a wet, frozen,
snow-covered, or otherwise slippery road
surface when the vehicle is lightly loaded
or not loaded can cause the tires to slip on
the road surface, resulting in a skid. Do
not use the exhaust brake on slippery road
surfaces.
• Sudden braking will wear down tires and
could cause malfunctions in other sec-
tions of the vehicle. Avoid sudden braking
except in emergencies.
Sudden braking could also result in an
injury due to shocks.
1. Use engine braking and exhaust brake to decel-

erate sufficiently before applying the brakes.
2. Depressing the brake pedal in two or three
stages contributes to stable braking.
Remember that the braking distance varies with
vehicle speed, load weight, and road conditions.
NOTE:
Engine braking is a braking effect realized when the
accelerator pedal is released during vehicle opera-
tion. The lower the transmission gear, the more
powerful the engine braking.
Antilock braking system (ABS)
The ABS operates automatically without need for

any manual control. However, you are requested to
read the following instructions and precautions to
ensure safe driving with your ABS-equipped vehi-
cle.
WARNING
Even the ABS cannot remove limitations on
the vehicle’s running and braking perfor-
mance. It is your responsibility to judge road
and other conditions properly and drive
safely on slippery surfaces.
NOTE:
When driving on slippery surfaces, activating the
brakes could lock the wheels and the vehicle is very
likely to lose directional control due to resulting
skids. The ABS minimizes such wheel locking by
electronically controlling the braking force of each
wheel.
• If the warning lamp illuminates during driv-

ing, it indicates that the ABS is faulty. The ABS
function will then be completely lost but normal
brake system will still function properly.
Z09032
P. 6-11
• On slippery surfaces, the braking distance for
vehicles with an ABS is generally shorter than
that for vehicles without it. This difference, how-
ever, varies with road surface conditions. It is
always important to maintain sufficient distance
from the vehicle ahead regardless of whether
your vehicle is equipped with an ABS or not.
Also, the braking distance of an ABS-equipped
vehicle on gravel or heavily snow-covered roads
may be longer than that for a vehicle without an
ABS. On these roads, therefore, be sure to drive
at reduced speeds. Also, avoid sudden maneu-
vering or braking on such roads to prevent colli-
sion with the vehicle behind you.
• Slight vibration will be felt on the vehicle body
and brake pedal when the ABS is in operation.
Also, the sound of motor operation may be
heard. These indicate the ABS is operating nor-
mally and do not indicate any abnormal condi-
tion. Keep fully depressing the brake pedal.
• When the ABS starts functioning after sudden
braking, the steering wheel may be pulled
slightly to one side because of braking power
distribution control made by the system. Espe-
cially in a condition where the traction is different
between the right and left wheels (on a road
covered by ice on one side and not on the other
side, for example), you may need to correct
direction with the steering wheel.
• The ABS cannot prevent the vehicle from over-
turning on a slippery surface that could result
from excessive speed being used in sharp turns.
Avoid driving at too high a speed or in a way
which requires quick operation of the steering
wheel.
• There is likelihood of skidding due to the effect
of engine braking on slippery surfaces when the
vehicle carries little or no load. In such a situa-
tion, it is recommended to depress the clutch
pedal first and then the brake pedal.
• If cargo is loaded only on the back half of the
cargo bed, the rear wheel brakes must share an
extremely large burden during braking to pre-
vent the front wheels from locking. On a snow-
covered or otherwise slippery, long downslope,
use engine/exhaust braking and minimize use of
the service brakes.
• The exhaust brake, if activated, is released tem-
porarily when the ABS comes into function.
7-9
WARNING
If the tires slip when driving around a slip-
pery curve or over a gap with the exhaust
brake working, the ABS will start functioning
and the exhaust brake will be temporarily
deactivated. Always slow down before enter-
ing a curve.
• Before you install a radio transmitter/receiver

equipment or tires of a size different from the
original ones, be sure to consult an authorized
dealer.
• Even if the ABS system fails and the warn-
ing lamp illuminates, the normal brakes still work
properly. You must, however, drive very carefully
on slippery roads. P. 6-11
On uphill and downhill roads
1 Uphill roads
• Downshift early when the speed begins to drop
to minimize the load on the engine.
• With an automatic transmission vehicle, down-
shifting can be performed either with the range
Z11320 selector lever or by depressing the accelerator
pedal hard. If you depress the accelerator pedal
to maintain a constant speed when driving
uphill, the transmission may shift down and the
engine speed increase.
2 Downhill roads
• If you are going to drive down a steep road or a
road with a long downhill grade, test the service
brakes and exhaust brake in advance to make
sure that they are functioning well.
• Place the vehicle in the gear used when driving
uphill and use engine braking and exhaust
brake to help slow the vehicle. Never drive
downhill at high speeds.
• If your vehicle is equipped with an automatic
transmission, leaving the range selector lever in
the “D” position will result in insufficient engine
braking, causing the vehicle to speed up too
much. Set the overdrive switch to OFF and add
engine braking by shifting down to “3” or “2”
depending on the steepness of the slope. Use
the service brakes to prevent the vehicle speed-
ing up excessively when the range selector
lever is in the “3” or “2” position.
• On slippery roads, avoid sudden engine braking
since this could cause a skid.
• Never coast downhill with the gearshift lever in

neutral (manual transmission vehicles) or the
range selector lever in the “N” position (auto-
matic transmission vehicles). Doing so makes
both engine braking and exhaust brake inopera-
tive, which in turn excessively burdens the ser-
vice brakes. This also causes the brakes to
overheat and the brake linings to wear out pre-
maturely.
In an automatic transmission vehicle, this can
also cause damage to the transmission.
Z11321
• Avoid overusing the service brakes as the
resultant overheating could cause undesirable
vapor lock and fading, both of which contribute
to poor braking.
NOTE:
• “Vapor lock” refers to the condition in which the
brake system overheats, causing the brake fluid
to boil and form bubbles that weaken hydraulic
pressure, resulting in poor braking.
• “Fading” refers to the condition in which the
brake linings or brake pads overheat to the point
where friction is significantly reduced. This also
results in poor braking.
WARNING
Except in an emergency, never apply the
parking brake while the vehicle is moving
since the vehicle could spin and/or overturn.
• First decelerate the engine sufficiently before

downshifting.
Downshifting more than two gears at a time or
downshifting at a high engine speed could
cause the engine to overrev.
Decelerate, as a rule, to roughly 2,000 rpm
before downshifting, and pay attention not to let
the needle enter the red zone during driving.
In an automatic transmission vehicle, shifting
down will be prohibited by a safety device if the
vehicle is driving fast. In such cases, depress
the brake pedal and reduce the vehicle speed.
NOTE:
“Overrev” refers to an operating state of the engine
in which it rotates at an RPM higher than the recom-
mended maximum RPM. Overrevving the engine
could lead to an engine failure.
7-11
On rough roads and in bad weather
• Use a low gear and try to drive at a constant

speed when driving on gravel roads or muddy
roads.
• Do not race the engine when attempting to
move out of mud. Racing the engine is useless
Z11323
and even worsens the condition as the spinning
wheels will make ruts deeper. Instead, place
thick waste cloth, gravel or the like under tires,
and engage the 1st and reverse gears alter-
nately or, in an automatic transmission vehicle,
shift the range selector lever into the “D” and “R”
positions alternately to move the vehicle back
and forth until you can drive out.
CAUTION
Do not operate an automatic transmission in
this way for more than 5 minutes since it causes
the transmission oil to heat up rapidly.
• Drive very slowly on bumpy roads and take care

not to allow the undercarriage to bottom out.
If the muffler strikes a rock or other obstacle, its
catalyst or other internal elements may be dam-
aged. Have it checked by an authorized dealer.
• Avoid sudden steering and sudden braking on
roads which are slippery from rain. Conditions
are especially dangerous just after it begins to
rain. Use engine braking and the exhaust brake
together with the wheel brakes to decelerate.
Note, however, that sudden engine braking can
cause a skid. Drive at a speed at which you can
stay comfortably in control of the vehicle.
• When the vehicle is driven through puddles or
washed with water, braking performance can be
reduced by water entering the brake drums or
splashed over the brake discs. In this event,
drive slowly with light pressure on the brake
pedal to dry out the brakes. Pay attention to
nearby vehicles while doing so.
• If you cannot avoid driving the vehicle into water
(for example, when the road is covered with
water because of torrential rain), first check the
depth of the water. If water gets into the engine,
it can cause engine damage. After driving
through water, check whether water has entered
the high-current fuse box. If water has entered
the high-current fuse box, remove the water and
have the vehicle inspected by an authorized
dealer. Water in the high-current fuse box could
cause a short circuit that results in a fire.
• In fog, drive carefully at low speeds, paying
attention to the center line and the vehicle
ahead of you.
• When driving in snow or on frozen roads, use
tire chains or snow tires and drive at a moderate
speed. Avoid sudden braking and sharp turns.
Parking
WARNING
• Park the vehicle on the flattest available
surface.
Avoid parking on slopes.
When you cannot avoid parking on a
slope, apply chocks to the wheels. You
can further improve safety by leaving the
steering wheel turned so the vehicle will
roll toward an obstacle (for example, a
Z11324 curbstone) in the unlikely event of move-
ment.
• Be sure to apply the parking brake fully.
• On an automatic transmission vehicle,
never park the vehicle without applying
the parking brake. Do not rely only on set-
ting the range selector lever in the “P”
position.
If you cannot avoid parking on a slope, be
sure to apply the parking brake securely
and apply chocks to the wheels. Depend-
ing on the condition of the vehicle, the
automatic transmission’s parking mecha-
nism (“P” position) may be damaged and
released, possibly leading to a serious
accident.
• The engine and exhaust pipe are
extremely hot immediately after the vehi-
cle has been driven. Do not park the vehi-
cle in any place where there is dry grass,
waste paper, or other flammable material.
• Always stop the engine before sleeping in
the cabin. You could otherwise cause an
accident by unintentionally moving the
accelerator pedal or shift lever while sleep-
ing. Also, you could suffer carbon-monox-
ide poisoning from exhaust gases if the
vehicle is parked in a closed space.
• Never leave lighters, cans of carbonated
drink, and spectacles in the cabin when
parking the vehicle in hot sunshine. The
cabin will become extremely hot, so light-
Z01422 ers and other flammable items may catch
fire and unopened drink cans (including
beer cans) may rupture. The heat may also
affect plastic spectacle lenses and other
spectacle parts that are made of plastic.
For example, the coating on the lenses
may crack and the lenses themselves may
become deformed.
• Always use the mirrors to confirm safety
before opening a door. Suddenly opening
a door is dangerous because the door may
obstruct cars, motorcycles, bicycles, and
pedestrians coming from behind.
7-13
1. In a manual transmission vehicle, put the gear-

shift lever in the neutral position when the vehi-
cle is stationary.
In an automatic transmission vehicle, pull the
parking brake lever while keeping the brake
pedal depressed, and then place the range
selector lever in the “P” position.
2. Pull the parking brake lever.
WARNING
Brake faults that would cause the warn-
ing lamp to illuminate have no effect on the
parking brake. If the warning lamp illumi-
nates, be sure to apply the parking brake.
3. Stop the engine by turning the starter switch to

the “ACC” position. P. 5-12
4. To help prevent theft and needless consumption
of electricity from the battery, be sure to remove
the starter key and lock the doors.
CAUTION
• Leaving the vehicle sitting for a long time
with the starter switch in the “ON” or “ACC”
position could result in a dead battery.
• Be sure to turn off all lights after parking to
prevent drainage of the battery.
5. If parking on a slope is unavoidable, block the

wheels securely with chocks and take any other
necessary measures to prevent the vehicle from
moving.
Vehicles with limited slip

differential
<Standard on FG>
The limited slip differential performs a special func-
tion in addition to the ordinary differential function
which is needed when the vehicle is in a turn. When
one wheel begins to spin on a slippery surface, the
limited slip differential provides most of the driving
force to the wheel which is not spinning, thus auto-
matically stopping the spinning and providing trac-
tion to the vehicle.
This function is effective when driving on bumpy or
snow laden roads, and useful when moving the
vehicle out of mud.
Z09030
WARNING
When you raise the vehicle on one side for
replacing a tire or any other purpose, never
rotate the raised wheel. Doing so is danger-
ous as power is transmitted to the wheel
which is on the ground and the vehicle could
move.
Z09031 CAUTION
Use only the special oil designed for limited slip
differentials if your vehicle is equipped with a
limited slip differential.
NOTE:
A vehicle with limited slip differential can be identi-
fied by precautionary stickers near its driver’s
seat and on the rear axle housing.
Z11347
The limited slip differential actions take place auto-

matically, but you are recommended to pay atten-
tion to the following points:
• On slippery road surfaces, excessively depress-
ing the accelerator pedal during a turn may
cause the vehicle to skid and lose balance.
Keep this in mind for your safety.
• Using tires different in air pressure or outside
diameter between the right and left wheels may
result in pulling the vehicle to one side during
acceleration or uneven wear of tires. Check the
tires regularly to make sure the right and left
ones are inflated to the same pressure and not
different in outside diameter.
• Distribute the load weight evenly. If the load is
heavier at the rear, the vehicle’s tendency to
move in a straight line will slightly increase.
7-15
Loading cargo
1 Do not overloading the vehicle.

• Overloading the vehicle causes braking per-
formance to deteriorate and can thus cause an
accident. Also, overloading the vehicle places
excessive stress on vehicle parts, shortening
their service lives. The vehicle is designed to
perform best when loaded within its Gross Vehi-
cle Weight Rating (GVWR) and within its front
and rear Gross Axle Weight Ratings (GAWR).
Try not to exceed these ratings.
• The vehicle’s GVWR, front GAWR, and rear
GAWR are listed on the VIN plate that is located
Z11959
as shown in the illustration.
NOTE:
Loading to a weight almost equal to a total of the
front and rear GAWRs may exceed the GVWR.
For example, a vehicle with a GVWR of 12,000 lbs.
(5,445 kg) has a front GAWR of 4,850 lbs. (2,200
kg) and a rear GAWR of 8,600 lbs. (3,900 kg).
Added together, the GAWRs total 13,450 lbs. (6,100
kg), thus exceeding the GVWR. Be sure neither the
4,850 lbs. 8,600 lbs. GAWRs nor GVWR are exceeded.
12,000 lbs. Z11958

WARNING
• Overloading the vehicle can damage the
vehicle and make safe driving difficult. For
safety, never overload.
• The GVWR and GAWRs pertain to the max-
imum load the vehicle can physically
carry. Please also abide by state and
regional loading limit requirements.
• Do not carry passengers in the cargo area
while the vehicle is in motion.
2 How to load cargo

Improperly loaded cargo not only is unstable but
also may result in uneven weight distribution which
could damage the cargo deck and frame.
WARNING
• When roping up cargo or covering it with a
tarpaulin, make sure that neither the rope
nor the end of the tarpaulin hang down
Z11325
between the cab and the cargo deck as a
loosely hanging rope or tarpaulin could
catch fire from the engine heat.
• When spreading the tarpaulin, take care
not to let it cover or be drawn into the
engine air intake duct.
• When loading heavy cargo, take adequate
measures to stop it from slipping. Also
use wire to secure it.
• Do not place wooden boards or other
items between the cargo bed and frame.
The heat from the exhaust pipe could set
fire to them.
• Place the cargo evenly on deck.
• If cargo is piled high, the vehicle is at risk of roll-

ing over upon being hit with a side wind or mak-
ing a turn.
• If you place supports under the cargo, position

them at equal intervals.
• Use suitable supports when loading long

objects. Avoid supporting long objects only with
the gate and the rear edge of the cargo deck.
• To prevent cargo from falling, strap it down

securely and cover it with a tarpaulin. Secure
the tarpaulin ends neatly so they do not flap.
Z11326
8-1
8. 4WD operation <FG models>
Control and indicator lamps for 4WD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Advice on use of the 4WD mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Precautions to be taken when selecting the 4WD mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8-2 4WD operation <FG models>
Control and indicator lamps for

4WD operation
Select the 2WD (rear-wheel-drive) mode or 4WD

(all-wheel-drive) mode as necessary for the condi-
tion of the road surface. The 4WD mode can be
used for extra traction on rough road surfaces and
on snow-covered road surfaces (in mountainous
regions, for example).
CAUTION
With a 4WD vehicle, power is applied to both the
front wheels and rear wheels; if incorrect tires
are fitted, they can prevent the vehicle from per-
forming to its full potential and can even cause
an accident. Incorrect tires can also adversely
affect powertrain components. Please observe
the following tire-related cautions:
• Make sure all of the tires are the specified
size and are identical in terms of manufac-
turer, brand, and tread pattern. Be particu-
larly careful when fitting snow tires or other
winter-use tires.
• Use tires that do not differ from each other in
terms of the extent of wear.
• Regularly check the tire inflation pressures
and keep them adjusted to the specified val-
ues.
• When tire replacement is necessary, replace
all of the tires at the same time.
• Use genuine wheels. Do not change the
wheel size.
• To ensure that the tires wear evenly, rotate
the tires every 10,000 km (6,000 miles).
For towing of the vehicle, raise the front wheels
off the ground and disconnect the propeller
shaft at the end closer to the rear wheels.
The 4WD mode is not recommended for driving
on dry paved roads as the tires may wear down
prematurely, the running noise may increase,
and more fuel may be consumed. Malfunction of
the drive train components may also result. Be
sure to drive in the 2WD mode on dry paved
roads.
1 Location of control and indicator lamps

HIGH-LOW selector lever
Front drive switch
4WD indicator lamp
LOW range indicator lamp
Z12473
8-3
1.1 Front drive switch

• The front drive switch is used to select either the
two-wheel drive (2WD) mode that uses only the
two rear wheels as driving wheels or the four-
wheel drive (4WD) mode in which the engine
power is transmitted to all four wheels. Pressing
the “ON” side of this switch selects the 4WD
mode, whereas pressing the “OFF” side selects
the 2WD mode. The indicator lamp lights up
when the 4WD mode is selected.
• The mode selection can be performed without
Z11339
depressing the clutch pedal.
CAUTION
Make sure that the free-wheeling hubs on both
the front wheels are in the “LOCK” position
when the 4WD mode is selected; in the “FREE”
position, the engine power is not transmitted to
the front wheels. P. 8-6
1.2 HIGH-LOW selector lever

• When the 4WD mode is selected, this lever
allows the driver to select either the high-speed
range or the low-speed range of the transfer
gear.
With the vehicle stationary and the clutch pedal
depressed, hold down the lever button and
move the lever to the high-speed range position
to select the high-speed range or to the low-
speed range position to select the low-speed
range. The indicator lamp comes on when
the low-speed range is selected.
• To change the range from one to the other, hold
down the clutch pedal with the vehicle stationary
and move the lever fully to the LOW range posi-
tion until the indicator lamp comes on or to
the HIGH range position until the lamp goes off.
After operating the lever, check that the lever is
locked in position by trying to move it back and
forth without pressing the button.
NOTE:
Do not operate the HIGH-LOW selector lever during
Z12476 driving.
Operation of the lever has no effect while the vehi-
cle is in motion. Always switch the transfer gear
range when the vehicle is stationary and after
depressing the clutch pedal.
2 Selecting drive mode-transfer gear

range combinations
You can select any desired drive mode and transfer
gear range combination from among those shown
in the following table. Select the most suitable com-
bination according to the driving conditions.
Illumi-
Mode-range nated
Driving conditions
combination indica-
tor lamp
2WD – HIGH – Normal road driving
Driving on snow-covered,
frozen, or sandy roads or
HIGH other difficult roads where
running in the two-wheel
drive mode is inappropri-
4WD ate.
Driving on steep uphill or
muddy roads or other
LOW roads where exceptionally
good traction is required.
Z11341
3 Switching the mode-range combination

• “2WD-HIGH” to/from “4WD-HIGH”
1. Make sure that the free-wheeling hubs on both
front wheels are in the “LOCK” position.
P. 8-6
2. Press the front drive switch either at the “ON”
side (4WD) or “OFF” side (2WD) when the vehi-
cle is either in motion or stationary.
Z11339
NOTE:
• You do not need to depress the clutch pedal
when switching from the 2WD-HIGH setting to
the 4WD-HIGH setting or vice versa.
• The mode-range setting cannot be switched
from 4WD-LOW to 2WD-HIGH. The 4WD-HIGH
setting must be selected before such switching
can take place.
• If it is difficult to switch from 2WD mode to 4WD
mode and vice versa, release the accelerator
pedal and then depress it again lightly. This will
Z11342
facilitate the switching.
• During switching from 4WD mode to 2WD
mode, the system may remain in 4WD mode
even after the indicator lamp has gone out.
If this happens, release the accelerator pedal
and depress it again lightly. The switching will
then take place.
8-5
• “4WD-HIGH” to/from “4WD-LOW”

1. Stop the vehicle and depress the clutch pedal.
Z11343
2. Move the HIGH-LOW lever while pressing the

button on it to the HIGH range position or
LOW range position .
Z12575
3. After moving the lever fully to the HIGH range or

LOW range position, make sure that the
indicator lamp has come on or gone off and then
release the clutch pedal. Check that the lever is
locked properly by trying to move it back and
forth without pressing the button.
NOTE:
• If the HIGH-LOW lever cannot be moved even
with the button pressed, release and re-depress
the clutch pedal. You will then be able to operate
the lever.
• If the vehicle refuses to move even with the
indicator lamp come on or gone off after operat-
ing the HIGH-LOW lever, release and re-
depress the clutch pedal, and then perform the
lever operation again.
CAUTION
When 2WD mode is selected, you cannot
change the range to LOW. In this mode the lever
is locked to the HIGH range and it cannot be
moved even if you press the button. Always
select 4WD mode before switching the range to
LOW.
4 Free-wheeling hub
• Even when the 4WD vehicle is running in the
two-wheel drive mode with the engine power
transmitted only to the rear wheels, the front
wheels are always connected to the power train
(differential, propeller shaft and transfer). The
free-wheeling hub is a device to release the
wheels from the power train to allow them to
rotate freely, thus saving energy and improving
power economy.
Z00446
• Set the free-wheeling hub as follows:

• For propulsion of the vehicle in the 2WD mode,
set each free-wheeling hub to the “FREE” posi-
tion .
• For propulsion of the vehicle in the 4WD mode,
set each free-wheeling hub to the “LOCK” posi-
tion .
When the 4WD mode is selected, ensure that the
free-wheeling hubs on both front wheels are set in
the “LOCK” positions. Should either or both of them
be in the “FREE” position, four-wheel driving is not
Z01026 possible.
WARNING
• Never drive with one free-wheeling hub in
the “FREE” position and the other in the
“LOCK” position. Doing so is very danger-
ous.
• The free-wheeling hub may be extremely
hot after driving. Do not touch it.
Advice on use of the 4WD mode
When you select the 4WD mode to drive on off-road

terrain (sandy or muddy ground) or snow-laden or
frozen roads, take sufficient care to avoid inappro-
priate operation.
1 Driving on snow-covered or frozen

roads
Select either the “4WD-LOW” or “4WD-HIGH”
mode-range combination according to the snow or
road surface condition. Start out slowly.
Tire chains cannot be used on both front and rear
wheels. You are advised to use snow or studless
tires.
Z09463
8-7
2 Driving on sandy or muddy ground

• Select the “4WD-LOW” setting if you find it
appropriate to do so after checking sand or mud
conditions. Start out slowly. Drive at low speeds,
keeping the speed as constant as possible.
• Avoid quick acceleration, sudden braking and
sharp turn as they can cause the vehicle to
become stuck in the sand or mud, making it
impossible to free the vehicle by yourself.
• Muddy conditions are generally difficult to judge
Z09464 and there is danger of becoming stuck in deep
mud. To prevent this, drive as slowly as possible
and, if necessary, get out of the vehicle and
check the conditions.
3 Climbing steep hills

Select the “4WD-LOW” setting to make full use of
engine torque. Choose the path that has the least
stones, sand and bumps. At both the start and end
of a climb, moderate slopes are preferable.
Z09465
4 Descending steep hills

• Select “4WD-LOW” setting and descend slowly
using engine braking so that the wheels do not
slip.
• Quick braking can slip the wheels and result in a
loss of vehicle control. Check road conditions
before descending.
• Avoid gear shifting or clutch operation when
descending a hill. Select the best gear in
advance, and maintain the gear until the end of
Z09466 the descent.
5 Crossing a river
Even a 4WD vehicle is not fully water-resistant. Do
not drive in water for more than several minutes and
limit driving in water to the minimum. If it is abso-
lutely necessary to drive in water, select the “4WD-
LOW” setting and drive as described below.
• Choose a path where the water is no deeper
than the center of the wheels, and drive slowly
at a speed lower than 5 km/h (3 mph) to avoid
making waves.
Z09467 • After crossing, check the brakes. If the brakes
do not operate effectively, drive slowly and
lightly depress the brake pedal to dry the brakes
while remaining aware of any vehicles in front of
or behind you.
• After crossing, check the electric system for any
problems that the water may have caused. Also
observe the recommendations in the following
sub-paragraph describing precautions to be
taken when selecting the 4WD mode.
CAUTION
• Never drive in water deeper than the center
of the wheels; otherwise water may enter the
rear axle or other components.
• Never shift gears while crossing a river.
Precautions to be taken when

selecting the 4WD mode
• In the 4WD mode, you may feel the steering

wheel move differently from the way it does in
the 2WD mode.
Operate the steering wheel carefully until you
get the complete feel of 4WD operation.
• When turning a sharp corner at a low speed in

the 4WD mode, a condition resembling one that
would occur during braking can develop. This
condition called “sharp corner braking” is
caused by the fact that the four tires are moving
along circles of different radiuses and is a phe-
nomenon limited to 4WD vehicles. It does not
imply any abnormal condition exists. If you
experience this condition, either straighten
steering wheel or switch to the 2WD mode.
Z11346
1 If you have driven in water by necessity

• Immediately check engine, transmission, trans-
fer and differential oil. If the oil looks milky, it is
contaminated with water. Be sure to replace it.
• If water has entered the cab, dry the carpet, etc.
Leaving them wet can cause rusting.
2 After off-road driving, be sure to check

the following points:
• Check for damage caused by stones, etc.
• Check the brakes. If the brakes function poorly,
have them checked by an authorized dealer.
• Grease the propeller shaft and also the front and
rear suspension springs. P. 12-15
9-1
9. Heating and air conditioning
Front air outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Outside air inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9-2 Heating and air conditioning
Front air outlets
Z11960
1 Adjusting the airflow direction

• Adjust the left/right airflow direction from each
outlet as desired by moving the knob to the
left or right.
• Adjust the up/down airflow direction from each
outlet as desired by pressing the top or bottom
of the outlet.
Z11961
9-3
Heater
NOTE:
• The heater uses the heat produced by the
engine coolant. Warm air is, therefore, not avail-
able until the coolant temperature becomes suf-
ficiently high.
• When heating the cab while the engine is warm-
ing up and while the vehicle is parked, turning
“ON” the warm-up switch makes the heating
more effective.
1 Using the controls

Mode selector dial
Fan speed dial
Temperature adjustment dial
Air selector switch
Z11305
1.1 Fan speed dial

The fan speed dial allows you to adjust the fan
speed in four steps. Turn the dial in the direction of
arrow to increase the fan speed and in the direc-
tion of arrow to reduce it.
Z05610
1.2 Temperature adjustment dial

Turn the dial in the direction of arrow to increase
the air temperature and in the direction of arrow
to reduce it.
Z05611
1.3 Air selector switch

Pressing the air selector switch allows you to toggle
the setting between recirculation of inside air and
introduction of outside air. When recirculation is
selected, the indicator lamp in the switch comes
on.
• Outside air
Use this setting when driving in normal condi-
tions.
• Recirculation
Use this setting when the outside air is dirty.
Z05612 Using this setting when parking enables you to
prevent dust from entering the cab.
CAUTION
Using the recirculation setting for a long time
will cause air to become stale. If this happens,
switch to the outside air setting.
NOTE:
• Select outside air when driving in normal condi-
tions.
• Using the recirculation setting for a long period
when humidity is high makes the windows prone
to fogging.
1.4 Mode selector dial

Use the mode selector dial to select outlets as
desired.
• For airflow toward the upper body
Place the mode selector dial in the position.
Z11962
• For airflow toward the upper body and

toward the feet
Z11963
9-5
• For airflow toward the feet

Z11964
• For airflow toward the feet and toward the

windshield
1. With the dial in the position , most air is
directed toward the feet and the rest of the air is
directed toward the windshield.
Z11965
2. With the dial in the position , air is

directed equally toward the feet and windshield.
Z11966
• For airflow toward the windshield

Z11967

2.1 To heat the cab
Place the mode selector dial in the position
or in the position.
Z11307
2.2 For cool airflow toward the head and warm

airflow toward the feet
Place the mode selector dial in the position or
in the position.
Z11309
2.3 To defog the windshield

Place the mode selector dial in the position. If
you wish to defog the windshield quickly, use the
fan speed dial to select the maximum fan speed
and use the temperature adjustment dial to select
the maximum temperature.
Z11310
2.4 To ventilate the cab

Press the air selector switch to select outside air,
and place the mode selector dial in the position.
Z11312
3 Cleaning the air filter

Clean the air filter every 6 months.
A dust-loaded filter may cause malfunction of the
blower motor. P. 12-67
9-7
Air conditioner
WARNING
Never leave children alone in the cab espe-
cially when the air-conditioning is on. They
will suffer from dangerously high interior
temperatures should the air conditioning
accidentally stop.
NOTE:
• The heater uses heat produced by the engine
coolant. Warm air is, therefore, not available
until the coolant temperature becomes suffi-
ciently high.
• When heating the cab while the engine is warm-
ing up and while the vehicle is parked, turning
“ON” the warm-up switch makes the heating
more effective.
• In some vehicles, a fast idling device increases
the engine’s idling speed slightly when the air
conditioner is used. This prevents excessive
engine vibration. If the engine’s idling speed
does not increase automatically when the air
conditioner is used, the vehicle is not fitted with
a fast idling device. Therefore, the engine con-
trol knob must be used to raise the engine’s
idling speed to a speed slightly higher than the
normal idling speed when the air conditioner is
used.
A fast idling device can be fitted by the nearest
authorized dealer.

Mode selector dial
Fan speed dial
Temperature adjustment dial
Air selector switch
Air conditioner switch
Z11313
1.1 Fan speed dial

The fan speed dial allows you to adjust the fan
speed in four steps. Turn the dial in the direction of
arrow to increase the fan speed and in the direc-
tion of arrow to reduce it.
Z05610
1.2 Temperature adjustment dial

Turn the dial in the direction of arrow to increase
the air temperature and in the direction of arrow
to reduce it.
Z05611
1.3 Air selector switch

Pressing the air selector switch allows you to toggle
the setting between recirculation of inside air and
introduction of outside air. When recirculation is
selected, the indicator lamp in the switch comes
on.
• Outside air
Use this setting when driving in normal condi-
tions.
• Recirculation
Use this setting when the outside air is dirty.
Z05612 Using this setting when parking enables you to
prevent dust from entering the cab.
CAUTION
Using the recirculation setting for a long time
will cause air to become stale. If this happens,
switch to the outside air setting.
NOTE:
• Select outside air when driving in normal condi-
tions.
• Using the recirculation setting for a long period
when humidity is high makes the windows prone
to fogging.
9-9
1.4 Air conditioner switch

Pressing the air conditioner switch activates the air
conditioner, which has cooling and dehumidifying
functions. The indicator lamp in the switch comes
on at this time. Pressing the air conditioner switch
once more stops the air conditioner.
Z05613
1.5 Mode selector dial

Use the mode selector dial to select outlets as
desired.
• For airflow toward the upper body
Z11962
• For airflow toward the upper body and

toward the feet
Z11963
• For airflow toward the feet

Z11964
• For airflow toward the feet and toward the

windshield
1. With the dial in the position , most air is
directed toward the feet and the rest of the air is
directed toward the windshield.
Z11965
2. With the dial in the position , air is

directed equally toward the feet and windshield.
Z11966
• For airflow toward the windshield

Z11967

2.1 To heat the cab
Place the mode selector dial in the position
or in the position.
Z08867
2.2 For cool airflow toward the head and warm

airflow toward the feet
Place the mode selector dial in the position or
in the position.
Z08870
2.3 To defog the windshield

Place the mode selector dial in the position. If
you wish to defog the windshield quickly, use the
fan speed dial to select the maximum fan speed
and use the temperature adjustment dial to select
the maximum temperature.
Z08871
9-11
2.4 To ventilate the cab

Press the air selector switch to select outside air,
and place the mode selector dial in the position.
Z08873
2.5 To cool the cab

Press the air conditioner switch to activate the air
conditioner, then use the temperature control dial to
set a comfortable temperature. The indicator lamp
will be illuminated while the air conditioner is
operating.
Z08874
3 Checking the refrigerant level

If refrigerant is insufficient, the cooling efficiency will
be diminished. Therefore, check the refrigerant
level from time to time. Run the air conditioner so it
gives maximum cooling performance (place the fan
speed dial in the position and the temperature
adjustment dial in the position ). Observe the
receiver’s inspection window through the grille.
Check for the presence of bubbles. The refrigerant
is sufficient if no bubbles are visible through the
glass when the air conditioner is being operated. If
bubbles are visible, the amount of refrigerant is
insufficient. You can have your system charged at
your nearest authorized dealer.
Insufficient refrigerant
Refrigerant level normal
Excessive refrigerant, or no refrigerant
If you observe condition and the air condi-
tioner cools the cab poorly, have the air condi-
tioner inspected by an authorized dealer.
Z11983
CAUTION
• Running the air conditioner without refriger-
ant will damage the air conditioner compres-
sor. Check the refrigerant level if the air
conditioner stops working efficiently.
• To protect the environment, your vehicle’s
air conditioning system uses refrigerant
HFC-134a which does not harm the ozone
layer.
Since charging the system with this refriger-
ant requires a method different from the con-
ventional method, be sure to contact your
nearest authorized dealer if your system
needs to be serviced.
• Using any refrigerant other than the HFC-
134a will cause a malfunction of the air con-
ditioning system. Be sure to use only the
HFC-134a.
NOTE:
Do not release refrigerant into the atmosphere.
When necessary because of servicing or scrapping
of the vehicle, consult the nearest authorized dealer
in order to have the refrigerant properly removed.
4 Cleaning the air filter

Clean the air filter every 6 months.
A dust clogged air filter may cause a poor air condi-
tioning performance and blower motor malfunction.
P. 12-67
Outside air inlets
• Make sure the outside air inlets are not cov-

ered or otherwise obstructed. Remove any
object that is covering or otherwise obstructing
them. Unless the inlets are unobstructed, air will
not flow smoothly from the outlets when outside
Z11984
air is selected.
• Do not directly apply steam from a cleaner to the
outside air inlets. Water could enter the cab, and
the wiper motor could malfunction.
10-1
10. Interior equipment and accessories
Cigarette lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Ashtrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Coat hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Sun visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Interior lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Small article compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Using the radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10-2 Interior equipment and accessories
Cigarette lighter
The cigarette lighter can be used when the starter

switch is in the “ON” or “ACC” position.
Push the cigarette lighter all the way in. It will soon
pop back to the original position with its core red
hot. Pull out and use.
Z11985
WARNING
• Do not hold the cigarette lighter in the
pushed-in position since the wiring could
burn out and start a fire.
• Something is wrong with the lighter if it
does not pop out within approx. 30 sec-
onds. If this should happen, pull it out
manually and have the lighter inspected
by an authorized dealer. Leaving the
lighter unremoved in the socket could
cause a fire.
• Do not leave your vehicle with the ciga-
rette lighter pushed in. Doing so could
result in a fire.
• Do not allow a child to touch the cigarette
lighter. The child could get burned.
• Do not touch the metallic parts of the ciga-
rette lighter. You could get burned.
• Never use a cigarette lighter from another
vehicle. Your vehicle’s cigarette lighter is
designed for a 12 V power supply. Do not
use a 24 V cigarette lighter.
• Do not use a deformed cigarette lighter. If
deformed, the lighter will not pop out prop-
erly. Use of an improper lighter also
causes trouble. Be sure to use genuine
lighters or equivalents as replacements.
• Do not use electrical devices designed to
be plugged into the cigarette lighter
socket, as this could overload the circuitry
and overheat the wiring.
10-3
Ashtrays
Remove and empty the ashtrays when they

become full.
WARNING
• Be sure to put out cigarettes and match-
sticks before putting them in the ashtrays.
Close ashtrays completely.
• Put only cigarette stubs and matchsticks
in the ashtray. Empty the ashtray before it
becomes full completely as too many
stubs crammed into the ashtray could
catch fire.
• Do not throw cigarette ends out of the win-
dows since this is environmentally irre-
sponsible and could start a fire.
• When cleaning the ashtray, do not strike it
with a hard object since it could break. If
the ashtray breaks, stop using it and
replace it with a new one. Using a broken
ashtray could cause a fire.
1 Driver’s door ashtray and assistant

driver’s door ashtray
• Raise the lid to use the ashtray.
• When you wish to empty the ashtray, hold the lid
and pull the entire ashtray upward to remove it.
Z12530
2 Rear ashtray in crew-cab model

• Pull the lid of the ashtray toward you for use.
• When you wish to empty the ashtray, push down
the stopper and pull the ashtray out toward
you.
• To refit the ashtray, insert its bottom into the
groove then hold down the spring and push the
ashtray into place.
Z11986
Coat hooks

Use the coat hooks if you wish to hang up clothing
or similar items.
Z08840
CAUTION
Do not pull the coat hooks with excessive force
or hang heavy items on them. They could break.
Sun visors
The sun visor screens your eyes from sunlight.

Change its angle as needed. Unhook the inside
edge of the sun visor and swing it sideways to
reduce glare from the side. There is a ticket holder
on the back of the driver’s sun visor.
Z11377
Interior lamp
The interior lamp(s) can be used with the starter

switch in any position.
CAUTION
Leaving an interior lamp illuminated for a long
time with the engine not running can drain the
battery to such an extent that the engine cannot
be started. Always turn off the lamps before you
leave the vehicle.
1 Interior lamp
1.1 Other than Crew-cab models
• “ON” position
The lamp is illuminated regardless of the door
positions.
• “•” position
The lamp comes on when a door is opened and
goes off when the door is closed.
• “OFF” position
The lamp is off regardless of the door positions.
Z11987
10-5
1.2 Crew-cab models (front and rear seats)

• “ON” position
The lamp is illuminated regardless of the door
positions.
• “•” position
The lamp comes on when a door is opened and
goes off when the door is closed.
• “OFF” position
The lamp is off regardless of the door positions.
Z11389
Small article compartments
Z11988
WARNING
Always close the glove compartment before
operating the vehicle.
If left open, their covers could cause injury in
the event of a collision or sudden stop.
CAUTION
• Fuses, relays, and other electrical items are
located below the glove compartment and
tray . Do not splash water on the glove
compartment and tray, and do not put wet
objects in them.
• Do not use the console and tray to hold
items that are prone to rolling while the vehi-
cle is moving. Such items could create a haz-
ard by impeding driving.
Vertical compartment
Hook
Z11381
Door pocket
Center tray
Z11382
Center console box

Back panel console box
Cup holder
Pull out the cup holders to use them. Keep them
pushed in when they are not being used.
WARNING
• The contents in a cup or can held in the
cup holder may spill during movement of
the vehicle. Be careful of scalding if they
contain hot beverages.
Z11383 • A fusebox is located below the cup holder.
Be careful not to splash drinks on the
fusebox cover. If you accidentally splash a
drink on the fusebox cover, check that the
drink has not seeped into the fusebox.
Seatback trays
The assistant driver’s seat and center seat each
have a seatback tray. Each tray can be used
with the relevant seatback folded forward.
Glove compartment
Glove compartment
Tray
10-7
Card holder
The card holder can be used to hold express-
way tickets and similar items.
Z11989
Pocket
The pocket may be used as a radio or other
audio equipment mounting space.
Using the radio
The radio (optional) can be used with the starter

switch in the “ON” position or “ACC” position.
CAUTION
Using the radio for an extended period without
the engine running could drain the battery.
• Extend the antenna before using the radio.

Retract the antenna when it is likely to cause an
obstruction, for example, when tilting the cab.
Z12007
Accessories
• See an authorized dealer if you are considering

adding accessories to your vehicle.
• Your vehicle contains electronic devices. Even
though these are protected against interference
from electromagnetic emissions, you should
Z00020 refer to an authorized dealer before fitting equip-
ment that emits strong signals, such as mobile
telephones.
WARNING
To avoid the risk of overheating/fire or faulty
operation, have electrical accessories con-
nected by an authorized dealer. Never con-
nect them yourself.
11-1
11. In cold weather
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Other recommendations for cold weather operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Installing tire chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
11-2 In cold weather
Coolant
• When vehicles are shipped from the factory,

genuine FUSO DIESEL LONGLIFE COOLANT
is added to the coolant in their cooling systems.
This additive combines both antifreeze and anti-
rust capabilities to sufficiently protect the cooling
system from freezing up. However, for added
Z09270
safety, it is recommended that you have an
authorized dealer check that the coolant has a
proper concentration of the additive before win-
ter begins.
• Be sure to use coolant added with the FUSO
DIESEL LONGLIFE COOLANT or equivalent to
the recommended concentration. P. 12-39
CAUTION
Never mix FUSO DIESEL LONGLIFE COOLANT
with other brands of anti-freeze or anti-corro-
sion additives since these can detract from its
performance. If a different coolant additive has
been used and the FUSO DIESEL LONGLIFE
COOLANT is to be used, be sure to thoroughly
flush the cooling system.
Engine oil
The viscosity of the engine oil increases in cold

temperatures, sometimes making it hard to start the
engine, especially early in the morning. Therefore,
use an engine oil of a viscosity which suits the
weather conditions. P. 12-18
Z10758
Fuels
Ordinary diesel fuel gels in freezing temperatures,

making it impossible to start the engine.
If you are bound for a cold area, it is recommended
that you fuel your vehicle so that it burns more than
half the fuel by the time you reach your destination.
This allows you to refuel with a grade of diesel fuel
Z11189
appropriate to the colder weather conditions.
P. 1-5
11-3
Other recommendations for cold

weather operation
• If the engine fails to start, turn the starter switch

back to the “ACC” position or “LOCK” position
and wait for the battery to recover before trying
to start the engine again.
• As the temperature falls, battery performance
decreases. Check the battery electrolyte level
and its specific gravity. P. 12-64
• In cold weather, use a windshield washer fluid
additive in the concentration indicated by the
manufacturer’s instructions.
CAUTION
Do not use engine coolant or antifreeze since
these would damage the vehicle’s paint.
• Occasionally check the undercarriage and

fender wells, and if necessary remove snow and
ice taking care not to damage vehicle parts as
you do so.
• The brakes may be frozen up when the vehicle
is driven on snow-laden roads or during parking
in cold weather. Since frozen brakes are slug-
gish to function, drive your vehicle carefully
while paying attention to vehicles behind as well
as in front and checking normal function of the
brakes from time to time by slightly depressing
the brake pedal. If the brakes are sluggish,
depress the brake pedal repeatedly while driving
at a low speed until normal braking returns.
• When parking your vehicle, select a site not
directly exposed to wind or snow and face it
away from the wind.
• Do not apply the parking brake in extremely cold
conditions that could cause it to freeze up and
become impossible to release. In such condi-
tions, take the following steps:
1. Stop the vehicle and pull the parking brake
lever. Never park on a slope.
2. Block the wheels securely with chocks.
3. In a manual transmission vehicle, select first
gear or reverse.
In an automatic transmission vehicle, put the
range selector lever in the “P” position.
4. Release the parking brake lever.
• On vehicles with air conditioner, operate the air
conditioner at least once a month to maintain its
functions even during the cold season when it is
not being used.
11-4 In cold weather
Installing tire chains
<Vehicles other than FG models>

• On FG models, tire chains cannot be used on
both front and rear wheels.
• Make sure that tire chains are installed properly
so that they do not become loose and interfere
with other vehicle parts while the vehicle is in
motion.
• Use triple chains corresponding to tire size.
CAUTION
• Do not use chains on the front wheels on FE
models; instead, use of snow tires is recom-
mended.
• When fitting tire chains, refer to the instruc-
tions supplied with them.
• Drive at low speeds, desirably at speeds
lower than 30 km/h (19 mph), when chains
are installed on wheels.
• Driving on a dry road with chains installed
may damage the chains as well as the road
surface. Avoid doing so as far as possible.
• Make sure that the chains and their spring
bands are not excessively worn or otherwise
damaged.
• If you hear an abnormal noise while driving,
stop the vehicle in the nearest safe place and
check the tire chains.
1. Place the chains over the tires with the hook

ends of cross chains facing outward.
Z09325
2. Connect the hook of inside chain , leaving

no excess links. Then, take up the slack in the
inside chain by pulling cross chains for the
inside tire outward.
NOTE:
Pull the hook section outward to the possible maxi-
mum extent.
Z09326
11-5
3. Temporarily connect hook of outside chain

as shown.
Z11190
4. Pull the middle chain as far as possible and

connect its hook.
5. Pull both ends of outside chain as far as pos-
sible and connect hook .
Z11191
6. Ensure that hooks and are flat on the tire

sidewalls. Also make sure that the chains are
not twisted.
7. Fasten extra chain links with a metal wire to pre-
vent them from hitting against other vehicle
parts.
Z09329
8. Fit spring band . Attach the hooks of spring

band on the chain at even intervals with the
hook ends facing outward.
9. After driving the vehicle for 5 to 10 minutes,
check the chains for looseness or disconnected
hooks.
Z09330
12-1
12. Simple inspection and service
General precautions for servicing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

To reach the engine access opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Pre-operational checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Oils and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
Filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
Draining water from fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-38
Engine coolant – check and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
V-belts – check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
Range selector lever – check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-47
Steering wheel – check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
Service brakes – check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-49
Parking brake – check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-51
Clutch – check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-51
Tires – check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-52
Tire replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-55
Wheel nuts – check and retightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61
Tire rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-62
Wiper blade – replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-63
Windshield washer – fluid level check and refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-64
Battery – check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-64
Air filters – cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-67
Cleaning your vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-69
12-2 Simple inspection and service
General precautions for servicing

the vehicle
WARNING
• Never run the engine in a poorly ventilated
area. Exhaust emissions contain carbon
monoxide, which can cause unconscious-
ness or death if breathed.
• Never smoke when servicing your vehicle
since its fuel and the gases given off by its
battery are highly flammable.
• When tilting the cab, carefully follow the
instructions in this manual. Be sure to fit
the stopper into the notch in the lock lever
to prevent the cab from dropping.
Z11944 After letting the cab down, check that it is
locked securely in position. (Vehicles
other than Crew-cab models) P. 12-6
• The engine gets extremely hot when run-
ning and stays hot for some time after
being turned off. To avoid being burned,
do not touch the engine, exhaust manifold,
radiator, exhaust pipe, or other engine-
related parts until they have cooled down.
• Do not loosen the engine pressure cap
while the engine is hot. Wait for the engine
to cool down, then grip the cap with a
cloth and turn it slowly to release the inter-
nal pressure before removing it com-
Z12079 pletely.
• Never crawl under the vehicle when it is
supported only by a hydraulic jack since
the jack could slip out of position and
cause the vehicle to crush you.
• The battery cables and starter cables carry
extremely high voltages. Be careful not to
short-circuit them, e.g., with a tool, since
this could cause serious injury.
• Take great care when working near the fan
and fan belt. Never touch them when they
are moving.
• Be careful not to hurt yourself on the cor-
ners of the body when performing inspec-
tions.
• The oil cooling fan in an automatic trans-
mission vehicle switches on automatically
when the fluid temperature becomes high.
Keep your hands and tools clear of it.
• Keep oily rags and other flammable items
in a safe place.
• Put away all tools and rags after use. Items
left in the engine bay could get hot and
catch fire.
12-3
Please take the following precautions when servic-

ing your vehicle:
• Make sure the vehicle is on safe, level ground.
• Prevent the vehicle from moving by pulling the
parking brake lever and blocking the wheels
with chocks.
• Remove the starter key unless you need to run
the engine.
• Take off wristwatches, rings, and neckties, and
wear clothing that will not obstruct movement or
snag on parts of the vehicle.
• Wear all safety gear necessary for your task, for
example, hard hat or goggles.
• Use the correct tools for your task.
• Do not make adjustments or repairs unless you
know exactly what you are doing. For servicing
that is difficult or not shown in this manual, take
your vehicle to an authorized dealer.
• When servicing electrical equipment, disconnect
the negative terminal (–) of the battery.
CAUTION
• Replace filters and filter elements regularly.
Blocked or damaged filters and elements
can reduce the engine’s power and impair its
operation. Always use genuine parts for
replacements. Also, oils and greases should
be those recommended in this manual. Use
of non-genuine parts, or oil and grease not
recommended, may lead to failures.
P. 14-3
• When replacing the oil or coolant, be sure to
have a container suitable for catching
drained fluid ready.
• Dispose of drained oil and coolant in the
specified manner. Disposing of them irre-
sponsibly could cause environmental harm.
• The muffler contains a catalytic converter.
Do not kick or knock the muffler since the
catalytic converter could be damaged.
Water emitted by the exhaust pipe is slightly
acidic and should not be touched. If you
touch this water, rinse it off under a faucet.
To reach the engine access opening
<Crew-cab models>
There is an opening under the assistant driver’s
seat which provides access to the engine for
inspection and servicing.
Uncover and cover the opening as follows:
• To uncover the opening
1. Tip the seatback forward.
2. Fold back the floor mat, then release two clamps
by pulling down the handles of the clamps
then raising them while still pulling them.
3. Raise the seat cushion , then release the
retaining hook on the bottom of the seat cush-
ion.
4. Attach the retaining hook to the grip beside
the assistant driver’s seat to hold the seat in
place.
• To cover the opening
1. Remove the retaining hook from the grip while
Z10671 supporting the seat cushion to prevent it from
dropping.
2. Attach the retaining hook to the S-spring on the
bottom of the seat cushion to hold the hook in
place.
3. Gently lower the seatback and seat cushion,
then fasten the clamps to retain it.
4. Return the floor mat and seatback to their origi-
nal positions.
CAUTION
• Be careful not to trap the seat belt or floor
mat when lowering the seat cushion.
• Securely retain the seat cushion with the
clamps.
12-5
Tilting the cab

NOTE:
A Crew-cab cannot be tilted.
1 Preparation
WARNING
• Before tilting or lowering the cab, make
sure that the area around the cab is clear
of people and obstructions.
• Never tilt the cab when the vehicle is on
any kind of slope. The cab will move too
quickly under the effect of inertia if it is
tilted on a slope, possibly causing damage
to various vehicle components. Doing so
is dangerous as the hook may not engage
completely when the cab is lowered.
• Never tilt the cab with persons inside.
• The cab can drop suddenly if it has heavy
objects inside or is fitted with a roof deck.
You should be sufficiently aware of this for
your safety.
• Do not touch the steering wheel, gearshift
lever, parking brake lever, or any other
control in the cab while the cab is tilted.
• Park the vehicle on a flat and level surface and

stop the engine.
Tilting the cab on a slope is dangerous since the
cab could swing up unexpectedly. This could
also damage the mechanism because of the
huge, sudden stresses on it.
• Prevent the vehicle from moving by pulling the
parking brake lever and blocking the wheels
with chocks.
• In a manual transmission vehicle, put the gear
shift lever in the neutral position.
In an automatic transmission vehicle, put the
range selector lever in the “P” position.
• Remove water or other liquids from inside the
cab before tilting.
• Loose items left in the cab could fall and break
the windshield or other equipment. Take out or
safety stow all loose items before tilting the cab.
Any objects on the roof must be removed.
• Close both doors completely.
• Before tilting the cab, make sure there is ade-

quate clearance in front of the cab and above it.
Clearance in front 1 m or more (3.3 ft. or more)

Clearance above 1 m or more (3.3 ft. or more)
If there are any obstructions within the clear-

ance areas shown above, remove them.
• Retract the radio antenna.
2 Tilting the cab
CAUTION
Raise the cab gently. Raising it quickly with
great force could damage the cab tilt mecha-
nism.
1. Pull lever A . With lever A still pulled, pull up

lever B .
Z10672
2. Grasp tilt grip and pull lever C . The cab will

rise slightly.
Z10673
3. Use the tilt grip to raise the cab. After confirming

that the lock lever is hooked onto the cab stay
and the stay is secured, fit the stopper into
the notch in the lock lever.
WARNING
Be sure to fit the stopper into the notch in the
lock lever to prevent the cab from dropping.
Z10674
12-7
3 Lowering the cab
WARNING
• Be careful not to trap your hands or other
body parts.
• Before lowering the cab, make sure that
you have not left rags, tools, etc. in the
engine compartment. Flammable objects
left inside the engine compartment can
cause fires.
• The cab could come down too quickly if
there are heavy objects inside or on the
roof deck. Always lower the cab slowly
while supporting it.
• Hold the cab tilt grip when lowering the
cab. Holding the lever B or any other part
when lowering the cab could result in
damage.
• When you have unlocked the cab stay,
move your hands away from the lever. The
cab stay will tip toward the rear of the vehi-
cle, so your hands could otherwise get
trapped.
1. Release the stopper and retain it in the clip .
Z10675
2. Hold the tilt grip to support the cab. Lift the lock
lever and fold the cab stay .
Z10676
3. Still holding the tilt grip , lower the cab until the
hook on lever C engages with the cab mount
.
Z10677
4. Push down lever B until the pin engages

with the latch . Check that lever B cannot be
pulled up.
WARNING
If the lever B cannot be pushed down, tilt up
the cab again and repeat the lowering proce-
dure from the beginning.
Z10678
5. Turn the starter switch to the “ON” position, and

make sure that the warning lamp is not lit.
If the warning lamp lights and the buzzer
sounds, the cab is not locked completely. If this
happens, tilt up the cab, lower it, and lock it
again.
Z11895
Pre-operational checks
Be sure to perform the pre-operational checks for

the items listed below at the start of each day’s
operation in order to ensure safe and comfortable
driving. If you find anything unusual which you are
unable to repair yourself, you should have this cor-
rected at an authorized dealer before operating the
vehicle.
1 Before starting the engine
Z11896
12-9
Coolant level
Check that the coolant level is between the
“FULL” and “LOW” marks on the reservoir
tank.
P. 12-41
Z11188
V-belt tension and damage

Check the belt for proper deflection when a
force of 98 N (22 lbs., 10 kgf) is applied to the
point midway between the pulleys.
Check also that the belt is not nicked or other-
wise damaged.
P. 12-46
Z10749
Engine oil level

Check that there is sufficient engine oil using
the oil level gauge or oil level check button.
P. 12-19
Z10750
Leakage of coolant, fuel and oil

Check the underneath of the vehicle for any
sign of leakage.
Z10751
2 In the driver’s seat

First, check the range selector lever with the
engine stationary. Then, start the engine and per-
form the following checks and after while allowing
the engine to warm up.
Z12716

Set the starter switch in ON position but not start the
engine.
• Check if the range selector lever operates
smoothly and clicks at each range position
(“P” position through “2” position).
• Check if the shift indicator lamp in the meter clus-
ter indicates the selected range.
• Set the range selector lever to “P” position. Turn
the starter key to LOCK position and check if the
key can be removed from the key cylinder.
P. 12-47
Z12715
Engine conditions
Check the engine for smooth starting and quiet
running.
Z09197
Parking brake lever stroke

Check that the parking brake lever stroke is 7
to 9 notches.
P. 12-51
Z10681
Service brake pedal

Make sure that the brake pedal has 0.1 to 3
mm (0.0039 to 0.12 in.) free play when pressed
by finger.
Check also that when the brake pedal is fully
depressed, there is a gap of 20 mm (0.79 in.) or
more between the pedal and the floor.
P. 12-49
Z11955
Clutch pedal free play

With your hand, depress the clutch pedal and
make sure that it has 0.2 to 4 mm (0.0079 to
0.16 in.) of free play.
P. 12-52
Z11945
12-11
Brake fluid level

Check that the brake fluid level is between the
“MAX” and “MIN” marks on the reservoir tank.
P. 12-30
Z10682
Windshield washer fluid level

Confirm that the windshield washer fluid level is
above the bottom of the inspection window.
P. 12-64
Z11946
Steering wheel free play

Gently turning the steering wheel, check that its
play is more than 5 mm (0.2 in.) and less than
50 mm (1.97 in.).
P. 12-48
Z11947
Horn operation
Press the horn button to check that the horn is
working properly.
Z11948
Windshield wiper and washer operation

Check the washer for proper fluid spray direc-
tion and the wipers for normal action.
P. 5-21
Z11614
Defroster
Make sure that warm air blows properly onto
the windshield.
P. 9-3, 9-7
Z11696
Lighting system
Make sure that each lamp lights up or flashes
properly. Check lamp lenses for dirt and dam-
age.
P. 5-18
Z12505
Gauge, warning/indicator lamp operation

Check that gauges, warning lamps and indica-
tors are working properly.
P. 6-2
Z11949
Rearview mirrors
Seated in the driver’s seat, adjust the angles
for clear views of the sides and rear.
Make sure the mirrors are clean.
Z11950
Door locks
Push the lock knob and verify that the door
does not open even when the inner handle is
operated.
Z11951
12-13
Seat belts
Confirm that the seat belt buckles function cor-
rectly when fastening and unfastening.
Z11943
3 While walking around the vehicle
Z11952
Wheels and tires

Check the disc wheels for cracks and other
damage. Check the tires for inflation pressure,
tread groove depth, foreign objects in grooves,
cracks, and uneven wear.
P. 12-52
Z10752
Suspension springs
Check for broken springs and tilt of vehicle
body toward either side.
Z10753
License plate and reflector condition

Check the license plate and reflectors for
loose installation, damage, and dirt.
Z11953
4 While driving at slow speeds

Perform the following checks while driving in a safe
place at speeds lower than 20 km/h (12 mph).
Z10716
Steering wheel operation

Check that the steering wheel does not vibrate
or pull to one side and that it is not unduely
heavy. Also make sure that the steering wheel
returns to its neutral position smoothly.
P. 12-49
Z11954
Brake performance
Depress the brake pedal and check that the
brakes work effectively and evenly on all
wheels.
P. 12-50
Z10756
12-15
Lubrication
Application and replacement of lubricants at the

specified intervals is vital to the vehicle’s perfor-
mance, longevity, and safety. Following the mainte-
nance schedule will give optimum results.
P. 15-1
• If the vehicle is often used in demanding condi-
tions, for example, on unpaved roads, near the
coast, or in cold regions, lubricants should be
applied and replaced more quickly than speci-
fied in the maintenance schedule.
Consult an authorized dealer for the mainte-
nance schedule appropriate to your vehicle
operating conditions.
• Use only the lubricants specified. P. 14-3
• Special lubricants must be used if the vehicle is
used at temperatures below –23°C (–10°F). For
details, refer to an authorized dealer.
CAUTION
• Apply and replace lubricants regularly. Use
of lubricants beyond their designed service
life could cause bearings or other compo-
nents to seize up and cause an accident.
• Any checking, application, or replacement of
lubricants should be carried out with the
vehicle parked on level ground.
• Wipe all lubricant inspection windows and
filling ports carefully to prevent the entry of
mud, trash, water, or other contaminants.
• Never flush waste oil into the sewers or onto
the ground. Take it to a gas station or autho-
rized dealer.
Greasing
1 Grease nipples
Remove all dust and dirt from the grease nipples
before using them. Always use the recommended
grease.
CAUTION
Wipe away any grease that sticks to wires or
rubber hoses and any grease that overflows
from the grease nipples.
Every 10,000 km
Greasing intervals (6,000 miles)
<FE>
Z12034
<FG>
Z12506
12-17
Z09225 Z09226
Z09227 Z09228
Z09392 Z09498
Recommended lubricant:
Chassis grease
NLGI No. 1 (Li soap)
Rear spring pin, front (2 points each on both
sides)
Rear spring pin, rear (4 points each on both
sides)
King pin bearing (4 points in total on both sides)
Wheel bearing grease
Propeller shaft universal joint
Propeller shaft slip joint
Propeller shaft double cardan joint <FG>
NOTE:
The number of greasing points on the propeller
shaft differs from model to model.
2 Door hinge (4 points in total on both

sides; 8 points in Crew-cab models)
Every 10,000 km
Chassis grease
Z10719
3 Anchor hooks (two places)

<Not applicable to Crew-cab models>
Every 10,000 km
Chassis grease
Z10720
Atmospheric temperatures when engine is started.

Oils and fluids
1 Engine oil
Performance, life, and startability of the engine
depend to a large degree on the engine oil. Always
use oil of the specified grade and viscosity.
The proper engine oil viscosity numbers for various
Z02303 atmospheric temperature ranges are shown in the
diagram.
Inspection At the time of pre-operational

intervals check
Replacement Every 10,000 km
intervals (6,000 miles)
The first engine oil replacement during the run-in

period should be performed at the first 4,000 km
(2,500 miles).
CAUTION
Replace the engine oil earlier if the engine is fre-
quently used at high speeds or under high load-
ing.
Engine oil
API classification CD, CD/SF, CE, CE/SF, CF-4 or
JASO classification DH-1
SAE40, 30, 20W-20, 10W-30, 15W-40
12-19
CAUTION
Engine oil with an API classification of CC can-
not be used. Be sure to use engine oil with a
classification of CD or higher.
Quantity required:
FE Approx. 9 liters (9.5 qts)

Oil pan
FG Approx. 10 liters (11 qts)
Oil filter Approx. 1 liter (1.1 qts)
The engine oil level can be checked by using either

the oil level gauge or the oil level check button on
the instrument panel. The oil level check button is
for simple checking. Therefore, use of the oil level
gauge is recommended for precise checking.
NOTE:
Check the engine oil level with the vehicle parked
on a level place and the engine stopped. A correct
engine oil level cannot be determined when the
vehicle is tilted, or if the engine is running or the
time after stopping the engine is too short. Let the
engine stand at least 30 minutes after stopping it
before checking the oil level.
1.1 Checking by use of oil level check button

(simplified method)
1. Press the button before starting the engine. Esti-
mate the oil level from the color of the lamp
that comes on.
Green: Oil level is correct.
Amber: Oil level is too low.
2. If the amber lamp comes on, replenish with the
recommended engine oil.
NOTE:
Z12036 Provided the engine is not running, it is possible to
check the oil level using the oil level check button
regardless of the position of the starter switch. If you
check the oil level with the starter switch in the “ON”
position and the oil level is too low, the lamp
(amber) will come on and stay on. If the oil level is
normal, the lamp (amber) will come on and go
off and the lamp (green) will then come on.
1.2 Checking by use of oil level gauge

<Crew-cab models>
• Preparation
1. Tilt the cab.
<Crew-cab models>
1. Open the inspection cover in the rear floor
mat.
2. Release the lock , then open the hatch .
3. After inspection, close the hatch and inspection
cover by following the opening sequence in
reverse.
Observe the following caution, which is also printed
on the caution plate .
CAUTION
INSPECT CAREFULLY AS THIS COVER AND
INSIDE MAY BE EXTREMELY HOT.
Z12037

• Checking
1. Remove oil level gauge and wipe off oil with a
cloth.
2. Fully insert the oil level gauge in the crankcase,
and gently draw it out.
3. The oil level marked on the oil level gauge
should be between the upper and lower
notches.
If necessary, replenish with the recommended
engine oil.
If the engine oil is extremely dirty, replace it.
Z12038
4. After the check, insert the oil level gauge into
position and secure it properly.
Z10725
12-21
1.3 Adding oil

1. On Crew-cab models, the engine access open-
ing is located under the assistant driver’s seat.
Clean the area around oil filler cap to prevent
dust and dirt from entering the engine.
2. Remove the oil filler cap and add oil as neces-
sary.
3. Make sure that the oil level is correct. If the oil
level is checked immediately after adding, the
reading may be lower than the actual level
because all added oil may have not yet reached
the oil pan. Wait for at least 5 minutes after add-
ing oil. If you add too much oil, remove oil
through the drain plug on the oil pan to achieve
the correct level.
4. Install the oil filler cap.
WARNING
Take care not to spill engine oil as engine oil
on the exhaust manifold or other hot sec-
tions of engine could catch fire. Wipe clean
the oil if spilt.
CAUTION
• The added oil should be of the same grade
and viscosity as the oil originally placed in
the engine.
• Take care not to add more than the specified
quantity of oil. The engine can be severely
damaged if the correct engine oil level is not
maintained.
1.4 Replacement
1. Clean the surfaces around the oil filler cap
and remove the oil filler cap.
2. Remove drain plug from the oil pan to remove
the oil. Replace the oil filter at the same time.
P. 12-32
WARNING
The engine oil is extremely hot immediately
Z12039 after the vehicle has been operated. Take
care to avoid being scalded when draining
hot oil. Give the oil time to cool before drain-
ing it.
NOTE:
Oil removal is quicker if performed not so long after
the vehicle has been stopped and while the oil is
still warm.
3. After oil has been drained out, clean the area
around the drain plug hole.
4. Refit the drain plug.
39 N·m (29 ft.lbs.,

Tightening torque 4.0 kgf·m)
Z10767
5. Carefully pour fresh engine oil through the oil

filler.
6. Wait for more than 5 minutes and check the oil
level using the oil level gauge.
7. Crank the engine with the starter switch, then
start the engine. P. 5-9
8. Let the engine idle allowing oil to circulate
throughout the engine parts. Then, stop the
engine and wait for more than 30 minutes before
checking the oil level again. Also check for pos-
sible oil leaks.
9. After adding oil to the correct level, ensure that
the drain plug, oil filler cap and oil level gauge
are securely installed.
CAUTION
quantity of oil. The engine can be severely
damaged if the correct engine oil level is not
maintained.
• If the engine is frequently run at high speeds
or under heavy loads, the engine oil will
deteriorate quickly and must be replaced
sooner than specified.
WARNING
Take care not to spill engine oil as engine oil
on the exhaust manifold or other hot sec-
tions of engine could catch fire. Wipe clean
the oil if spilt.
2 Manual transmission gear oil
Every 10,000 km
Inspection intervals (6,000 miles)
Every 30,000 km
Replacement intervals (18,000 miles)
The first transmission gear oil replacement during

the run-in period should be performed at the initial
4,000 km (2,500 miles) point.
Recommended oil:
Gear oil
API classification GL-3
SAE80 (general)
GL-3 SAE90 (warm region)
GL-4 SAE90 (tropical region)
Engine oil
API Classification CC
SAE30 or 40
(long period of high-speed driving)
12-23
Quantity required:
Model Quantity
Approx. 3.6 liters
5-speed transmission (3.8 qts)
Approx. 4.4 liters
6-speed transmission (4.6 qts)
WARNING
Do not check or replace the gear oil immedi-
ately after operating the vehicle since the
engine, transmission, exhaust pipe, and
other components will be extremely hot.
2.1 Check
1. Remove inspection plug and make sure that
oil is topped off.
2. If insufficient, add oil through the inspection plug
hole until it is full to the brim.
CAUTION
The added oil should be of the same grade and
viscosity as the oil originally placed in the trans-
Z10770 mission.
3. Install the inspection plug.
68.6 ± 14.7 N·m (51 ± 11

Tightening torque ft.lbs., 7.0 ± 1.5 kgf·m)
2.2 Replacement
1. Remove inspection plug and drain plug to
let the oil flow out.
WARNING
The gear oil is extremely hot immediately
after the vehicle has been operated. Take
ing it.
NOTE:
still warm.
2. The drain plug is fitted with a magnet. Wipe off
any metal particles sticking to the magnet and
install the drain plug.
68.6 ± 14.7 N·m (51 ± 11

3. Add oil through the inspection plug hole until it

reaches the bottom of the hole.
68.6 ± 14.7 N·m (51 ± 11

3 Automatic transmission fluid
<Vehicles other than Crew-cab models> <Crew-cab models>
Level gauge
Z12049
Every 10,000 km
Every 40,000 km
Recommended fluid:
(Exxon Mobil: Mobil ATF3309 or equivalent)
Have the automatic transmission oil changed by an

authorized dealer.
3.1 Checking
NOTE:
Inspection of the fluid level should be carried out
when the fluid is at a high temperature after driving
and with the level gauge indicating “HOT”. The
“COLD” level is for reference purposes when the oil
temperature is low, and accurate measurement will
not be possible if the fluid temperature is low.
1. Park the vehicle on level ground. Prevent the

vehicle from moving by pulling the parking brake
lever and blocking the wheels with chocks.
2. Start the engine. With the engine idling and
brake pedal depressed, select each gear range
in turn, then put the range selector lever in the
“P” position.
12-25
3. Remove the level gauge that is located

behind the cab. If it is difficult to remove, tilt the
cab. On the Crew-cab models, open the inspec-
tion cover in the rear floor mat. Release the
lock , then open the hatch .
CAUTION
The inspection hatch may remain at high tem-
peratures for a certain period of time after the
engine has been stopped. Be careful not to be
burnt by the hatch or engine parts during
inspection.
NOTE:
In a Crew-cab model, the automatic transmission
fluid level gauge and engine oil level gauge
are close to each other. Be careful not to confuse
them.
4. Wipe the level gauge clean, reinsert it, then
slowly remove it again. Check the level of fluid
on the level gauge.
5. The fluid level should be in the “HOT” range.
6. If the fluid level is too low, add fluid via the level
gauge guide .
NOTE:
• Always carry out fluid level checks with the
engine idling.
• The fluid level rises as the fluid heats up.
CAUTION
quantity of fluid. The automatic transmission
can be severely damaged if the correct fluid
level is not maintained.
• To prevent foreign matters entering and
damaging the automatic transmission, add
fluid from a clean container.
4 Transfer gear oil <FG>
Every 10,000 km
Every 30,000 km
The first transmission gear oil replacement during

the run-in period should be performed at the initial
Recommended oil:
Gear oil
API classification GL-3 SAE 80 (general)
API classification GL-3 SAE 90 (warm regions)
API classification GL-4 SAE 90 (tropical regions)
Quantity required:
Quantity Approx. 3.1 liters (3.3 qts)
4.1 Check
oil is topped off.
CAUTION
viscosity as the oil originally placed in the trans-
Z12521 fer.
68.6 ± 14.7 N·m (51 ± 11

4.2 Replacement
WARNING
hot oil.
NOTE:
Oil removal is quicker if performed soon after the
vehicle has been stopped and while the oil is still
hot.

12-27
68.6 ± 14.7 N·m (51 ± 11


68.6 ± 14.7 N·m (51 ± 11

5 Axle housing gear oil
Every 10,000 km
Every 30,000 km
The first differential gear oil replacement during the

run-in period should be performed at the initial
Recommended oil:
Gear oil
API classification GL-5
Below 40°C (104°F) SAE90
40°C (104°F) or higher SAE140 or 85W-140
CAUTION
• Use oil conforming to GL-5, SAE140 or
SAE85W-140 if the vehicle is to be driven
under heavy load conditions as for example
driving up long uphill grades. Remember,
however, that this oil is to be used only when
the temperature is higher than 10°C (50°F).
• On vehicles with a limited slip differential, fill
the differential with Genuine Gear Oil, Part
No. 8149630EX (GL-5, SAE90).
Quantity required:
Model Quantity
FE Approx. 4.5 liters (4.8 qts)
Front axle Approx. 3.0 liters (3.2 qts)
FG
Rear axle Approx. 4.5 liters (4.8 qts)
These oil quantities are given only as guidelines. Be

sure to check the correct oil level by removing the
inspection plug as indicated below.
WARNING
Do not check or replace the gear oil immedi-
ately after operating the vehicle since the
axle and gear oil will be extremely hot.
5.1 Check
the oil is topped off.
CAUTION
viscosity as the oil originally placed in the dif-
Z09245 ferential gears.
Tightening 98 to 115 N·m (72 to 87 ft.lbs.,

torque 10 to 12 kgf·m)
5.2 Replacement
WARNING
ing it.
NOTE:
still warm.




6 Brake fluid

intervals check
Replacement Every 50,000 km (30,000 miles)
intervals or every 24 month
Have the brake fluid replacement performed by an

authorized dealer.
12-29
Recommended fluid:
Brake fluid SAE J1703
FMVSS No. 116, DOT3
NOTE:
With a manual transmission vehicle, the brake fluid
serves also as clutch fluid.
WARNING
• Be sure to use the recommended brake
fluid.
• Use only one brand of recommended
brake fluid. Mixing of different brands or
types of fluid will change the properties of
the fluid possibly resulting in a lower fluid
boiling point and damaged brake compo-
nents.
If you wish to change the brand of brake
fluid, replace all the existing fluid in the
brake system with the new brand fluid.
• Never allow engine oil, diesel fuel, gear oil,
automatic transmission fluid, or any other
mineral oil to mix with the brake fluid.
When mixed with the brake fluid even very
small in amounts, such oils will cause the
rubber parts of the brake system to swell,
and could cause brakes to become slug-
gish or to drag. Also, do not use contain-
ers which have been used for mineral oil
for brake fluid.
• Because brake fluid is highly hygroscopic,
it should be kept in a dry place both during
refilling and storage. If brake fluid absorbs
moisture, the boiling point is lowered, a
condition which could result in vapor lock.
This is very dangerous.
Do not open the reservoir tank cap when
checking the brake fluid.
• Brake fluid dissolves paint. If you spill the
fluid, wipe it clean or flush it off with water.
If not cleaned off, brake fluid can cause
discoloration, corrosion, or cracks in the
paintwork.
• If the brake fluid is used over long periods,
its boiling point drops significantly due to
the moisture it has absorbed, thereby
increasing the likelihood of dangerous
vapor lock. Therefore, be sure to replace
the brake fluid every 50,000 km (30,000
mile) or 24 months, whichever is sooner.
• When adding brake fluid, be careful not to
allow dirt and other foreign matter to enter
the reservoir tank. Any foreign matter
entering the reservoir tank could cause the
braking system to malfunction.
• If the brake fluid level drops abnormally,
brake fluid may be leaking from a pipe or
other component. Have the braking sys-
tem inspected by an authorized dealer.
6.1 Check
The fluid level should be between the “MAX” and
“MIN” lines on reservoir tank . Check whether the
reservoir tank contains foreign matter. If you see
foreign matter in the reservoir tank, have the reser-
voir tank inspected and cleaned by an authorized
dealer.
NOTE:
The warning lamp is illuminated when the
brake fluid level drops below the “MIN” line.
Z12050
CAUTION
Do not open cap of reservoir tank for inspec-
tion purposes.
6.2 Adding fluid

1. If the fluid level is lower than the “MIN” line,
remove cover , clean the surfaces around cap
of reservoir tank, open cap , and add the rec-
ommended brake fluid up to the “MAX” line.
2. Close the cap firmly.
WARNING
• The container used for adding brake fluid
Z12051 should be a clean one free of moisture,
mineral oil, and dust.
• Be extremely careful not to let dust and
other foreign matter enter the reservoir
tank, as foreign matter in the tank could
cause a failure of the brake system.
If you see foreign matter in the reservoir
tank, have it checked and cleaned by an
authorized dealer.
• Be careful not to exceed the “MAX” line
when adding brake fluid.
• If the fluid level is unusually low, there is a
fluid leak in the brake line. In this case,
have your vehicle inspected at an autho-
rized dealer.
7 Power steering fluid
Every 10,000 km
Every 50,000 km
Have an authorized dealer replace the fluid.
Recommended fluid:
Automatic transmission fluid DEXRON,
DEXRON II or DEXRON III type
12-31
CAUTION
When adding power steering fluid, be sure to
use fluid of the same brand as the existing fluid.
Mixing two or more different fluids will change
their properties and could cause a failure.
NOTE:
Inspect the power steering fluid level after stopping
the engine and allowing the power steering fluid to
cool. Increases in the fluid temperature cause
increases in the fluid level, so an accurate inspec-
tion of the level is not possible unless the fluid is
cold.
7.1 Inspecting and adding fluid

• Vehicles other than Crew-cab model
1. Make sure the parking brake is securely applied.
tion.
3. With the vehicle parked on level ground, place
the front wheels in the straight-ahead position
and stop the engine.
Z10729 4. Apply chocks to the wheels and make sure the
vehicle does not move.
5. Tilt the cab. P. 12-5
6. Observe the power steering fluid level in the res-
ervoir tank .
7. If the fluid level is between the “MAX” and “MIN”
lines, it is acceptable.
8. If the fluid level is below the “MIN” line, clean the
reservoir tank’s cap and the surrounding area
then open the cap and add power steering fluid
until it reaches the “MAX” line.
9. Securely fit the cap.
• Crew-cab model
tion.
3. With the vehicle parked on level ground, place
the front wheels in the straight-ahead position
and stop the engine.
4. Apply chocks to the wheels and make sure the
vehicle does not move.
5. Open the inspection cover in the rear floor-
mat. Release the lock , then open the hatch
.
CAUTION
In certain cases, the inspection hatch may
remain at high temperatures for a certain period
of time after the engine has been stopped. In
order to prevent burns, avoid touching this
hatch or other parts of the engine until the tem-
Z12566 perature has dropped sufficiently.
6. Clean the end of the guide pipe for the level

gauge with yellow painted mark , then with-
draw the level gauge and wipe off all the fluid
that is stuck to it. Next, insert the level gauge
and gently withdraw it. If the fluid level on the
level gauge is between the notches, it is accept-
able.
CAUTION
The power steering fluid level gauge has a yel-
low paint mark . Do not mistake it for the
engine oil level gauge.
7. If the fluid level on the level gauge is not

between the notches, add fluid through the
guide pipe. Add a little fluid at a time, checking
the new level with the level gauge each time.
8. When the fluid level is acceptable, insert the
level gauge and secure it in position.
CAUTION
• Use a clean container when adding the
power steering fluid. Never use a container
that has held any other types of oil or fluid.
Foreign matter in the fluid could result in a
failure.
• Avoid adding more fluid than specified.
• Insufficient oil can make the steering heavy
or noisy and can damage power steering
components.
WARNING
• Close the tank cap firmly; otherwise power
steering fluid will leak and could catch fire.
Also wipe clean spilt fluid.
• If the power steering fluid level becomes
abnormally low, fluid may be leaking. Have
the steering system inspected by an
authorized dealer.
Filter elements
1 Oil filter replacement

intervals or every 12 months
The first oil filter replacement during the run-in

period should be performed at the initial 4,000 km
(2,500 miles) point.
12-33
CAUTION
• Oil filter element must not be cleaned and
reused. Always replace the filter element
with a new one.
• Replace the oil filter element simultaneously
with engine oil change.
WARNING
• Spilt engine oil should be wiped off clean.
Oil remaining on the engine surface could
catch fire.
• Do not replace the oil filter immediately
after operating the vehicle since the
engine, transmission, exhaust pipe,
engine oil, and other items will be
extremely hot. If you try to replace the oil
filter immediately after driving the vehicle,
you may be scalded. Give the engine time
to cool before starting the job.

With a Crew-cab model, uncover the engine
inspection opening. P. 12-4
2. Clean the filter and the surrounding area to pre-
vent dirt from entering the new element.
3. Place a container under the oil filter. Remove
the drain plug from the bottom of the oil filter,
and allow the oil in the filter to drain out.
4. Turn filter element assembly in the direction
of the arrow (see figure) to remove it. If the
assembly is hard to turn, use a filter wrench
Z12052 (available from an authorized dealer).
5. Check the surface of the filter head that will
make contact with the new element for dirt and
contamination. If necessary, clean it.
6. Replace the filter element assembly with a new
one. The replacement part should be a genuine
part.
7. Install the filter element assembly using this pro-
cedure:
Apply a thin coat of engine oil to gasket on
the mounting surface of the filter element
assembly. Turn the assembly in the direction of
the arrow until the gasket touches the sealing
surface of the filter head.
From this point, additionally tighten the filter ele-
ment assembly by three-fourths of a turn.
The element assembly has four equally spaced
marks around its outside.
Tighten the assembly with reference to these
marks.
8. Refill with engine oil.
If the filter element assembly is replaced but the
engine oil is not replaced, add the amount of oil
shown below via the oil filler.
Amount of engine oil to Approx. 1 liter (1.1 qts)

be added
9. Start the engine and check for oil leakage.

10. Stop the engine and, after letting it stand for
more than 30 minutes, check the oil level.
2 Fuel filter replacement

intervals or every 12 months
WARNING
• Fuel is highly flammable and should be
kept away from hot objects and open
flames owing to the risk of fire or explo-
sion. Wipe up any spilt fuel.
• After installing the fuel filter, confirm that
no fuel is leaking out. Leaking fuel could
cause a fire or explosion.
• Use only the fuel filter specified for your
vehicle. Use of other filters could cause
fuel to leak and cause a fire or explosion.
• When replacing the fuel filter element, be
sure to use the special tool to remove and
reinstall the fuel filter. If the fuel filter is
tightened to an inappropriate torque when
reinstalled, fuel could leak and the filter
itself could become damaged, possibly
resulting in a fire and/or explosion. If you
do not have the special tool, please con-
tact an authorized dealer.
• Be careful not to damage the filter case, as
this could cause fuel leakage.
• Keep cigarettes and other sources of heat
away from the vehicle while replacing the
fuel filter. They are dangerous because
they could set fire to the fuel.
• When replacing the fuel filter, you will be
working in a tight space. Be careful not to
injure yourself on the edges of nearby
components.
CAUTION
• Fuel filter element must not be cleaned and
reused.
• Always replace with a new, genuine fuel filter
element. Do not use the filter element
beyond the recommended replacement inter-
vals. Failure to observe these may damage
the fuel injection parts.
12-35
1. Confirm that the parking brake lever is pulled.

Prevent the vehicle from moving by blocking the
wheels with chocks.
2. Clean the filter and the surrounding area to pre-
vent dirt from entering the new element.
3. Place a can under the fuel filter to catch fuel.
4. Disconnect the connector on the sensor .
5. Turn the sensor counterclockwise to loosen it,
and then extract all of the fuel from the filter
case . After the fuel has been extracted,
tighten the sensor by turning it clockwise.
6. Place the sensor and its harness inside the spe-
cial tool (available from an authorized dealer).
7. Remove the filter case using the special tool
(available from an authorized dealer), by turning
it in the direction of the arrow . Drain the fuel
from the filter case.
8. Remove the element and the sensor from the
filter case.
9. Replace the O-ring and O-ring with new
ones. Apply a thin coat of engine oil to each of
the new O-rings and install the O-ring on the
filter case and the O-ring on the sensor.
Z12053
10. Clean the surfaces of the filter head and fil-

ter case that will come in contact with the O-ring
. The O-ring groove on the filter case
should also be cleaned.
11. Install the element with the hole of its end facing
upward. Be sure to use a genuine replacement
element.
CAUTION
• Use the O-rings that are supplied with the
new replacement element.
• When installing the filter case, be careful not
to let the O-ring twist and be damaged.
• Do not reuse the element.
Z11924
12. Install the filter case by turning it in the direction

of the arrow . Tighten the filter case using the
special tool (available from an authorized
dealer) and a torque wrench to within the fol-
lowing torque range.
30 ± 2 N·m (22 ± 1.5 ft.lbs.,

Tightening torque 3 ± 0.2 kgf·m)
Z12054
CAUTION
Do not tighten the filter case too strongly. Over-
tightening could damage the filter case.
13. Install the sensor to the filter case and connect

the connector.
Sensor tightening 5 ± 1 N·m (3.7 ± 0.7 ft.lbs.,

torque 0.5 ± 0.1 kgf·m)
14. Bleed the fuel system. P. 13-23

15. Start the engine to test for fuel leakage.
3 Air cleaner cleaning and replacement
Every 5,000 km
Cleaning intervals (3,000 miles)
Every 40,000 km
WARNING
When cleaning air cleaner element, wear gog-
gles and a mask to protect your eyes and res-
piratory organs from dust.
And, use a dust collector to prevent dust
from dispersing into the surroundings.
CAUTION
Clean the air filter at the specified cleaning
intervals. Unnecessary frequent cleaning can
damage the element, allowing dust and other
foreign matter to be drawn into the engine.
NOTE:
Even if the cleaning interval has not elapsed, clean
or replace the element if clogging of the element
causes a decrease in engine output.
The air cleaner is located in the illustrated position.
Z12059
12-37
1. Undo the three clamps and remove the cover

.
2. Pull element straight down to remove.
Z12060
3. From the inside of the element, blow com-

pressed air evenly up and down along the pleats
of the filter paper.
CAUTION
• Keep the air pressure under 685 kPa (100
psi, 7 kgf/cm2) to prevent the element from
being damaged.
• Do not strike the element or hit it against
Z10773 another object.
• If the element is contaminated with oily soot
or dust, replace it regardless of the sched-
uled replacement time.
4. Place a light in the element and check the filter

paper for damage or places where it has worn
thin. Also check the packing for damage.
5. Clean the inside of case and cover with a
clean cloth.
6. Replace the element with a new one if the check
reveals a defective filter element or when the
recommended replacement interval expires.
Use a genuine filter element for replacement.
7. Install the element by reversing the order of
removal. Be sure to align match marks on the
Z10774 case and cover.
CAUTION
Install the element correctly.
If the packing is broken or the wing nut is loose,
the engine will suck in dust and premature pis-
ton and cylinder liner wear could result.
Draining water from fuel filter
If the warning lamp lights up, there is water in

the fuel filter in an amount exceeding the limit.
Drain the water as follows:
Z12062 WARNING
• Fuel is highly flammable and should be
kept away from hot objects and open
flames owing to the risk of fire or explo-
sion. Wipe up any spilt fuel.
• Keep cigarettes and other sources of heat
away from the vehicle while draining water
from the fuel filter. They are dangerous
because they could set fire to the fuel.
• Be careful not to injure yourself on the
edges of nearby components while drain-
ing water from the fuel filter.
1. Prepare a receiver for water.

2. Disconnect the connector on the sensor , then
turn the sensor in the direction of the arrow to
loosen it; the water will flow from the pipe at the
end of the sensor.
Operating priming pump helps quicken the
draining (press the pump handle approximately
7 times).
3. When fuel begins to flow out, close the drain
port by tightening the plug in the direction of the
arrow .
Connect the connector.
5 ± 1 N·m (3.7 ± 0.7 ft.lbs.,

Tightening torque 0.5 ± 0.1 kgf·m)
4. Bleed the fuel system. P. 13-23

5. Start the engine and check that fuel does not
leak.
WARNING
• The drain contains not only water but also
fuel.
Be sure to wipe clean the surfaces around
the fuel filter to remove all splashed fuel.
Fuel remaining on the surfaces could
cause a fire.
• Make sure fuel does not leak from the filter
or from related parts. Any fuel leakage
could cause a fire.
12-39
Engine coolant – check and

replacement
At the time of pre-oper-

Inspection intervals ational check
Replacement intervals Every 24 months
If the coolant becomes very dirty, replace it immedi-

ately regardless of the specified replacement inter-
vals.
1 Recommended coolant
Use a coolant containing the FUSO DIESEL
LONGLIFE COOLANT additive and soft water in the
specified proportions.
Having both corrosion preventive and anti-freezing
properties, the additive protects the cooling system
all year around.
Replace and top off the coolant only with water con-
taining FUSO DIESEL LONGLIFE COOLANT or an
equivalent.
2 Water used with coolant

Use soft water with the properties shown in the fol-
lowing table. Do no use hard water from wells and
rivers as it is liable to form scales and cause corro-
sion.
Total hardness 300 ppm or less

Sulfate SO –
4 100 ppm or less
Chloride Cl– 100 ppm or less
Total dissolved solids 500 ppm or less
pH 6 to 8
3 Using coolant additive

To prevent the cooling system freezing up and mini-
mize corrosion, use FUSO DIESEL LONGLIFE
COOLANT or an equivalent. FUSO DIESEL
LONGLIFE COOLANT is an ethylene-glycol-based
antifreeze (SAE J814-C) with both anti-freeze and
anti-corrosion properties. Dilute it with soft water to
the specified concentration.
Z09270
DANGER
• FUSO DIESEL LONGLIFE COOLANT IS
TOXIC. IF A PERSON HAS ACCIDEN-
TALLY SWALLOWED IT, FORCE HIM/HER
TO VOMIT AND CONSULT A DOCTOR
IMMEDIATELY. IF IT SPLASHES IN THE
EYES, IMMEDIATELY FLUSH THE EYES
WITH WATER FOR MORE THAN 15 MIN-
UTES, AND SEEK MEDICAL ATTENTION.
• SHOULD FUSO DIESEL LONGLIFE COOL-
ANT COME IN CONTACT WITH YOUR
SKIN, IMMEDIATELY WIPE IT OFF, AND
THEN THOROUGHLY WASH YOUR SKIN
WITH LOTS OF CLEAN WATER AND SOAP.
IF YOU FEEL UNWELL OR PAIN ON YOUR
SKIN, IMMEDIATELY SEEK MEDICAL
ATTENTION.
IN THE EVENT OF CONTACT WITH YOUR
CLOTHES, IMMEDIATELY FLUSH FUSO
LONGLIFE COOLANT WITH WATER AND
SOAP.
• DO NOT USE FUSO DIESEL LONGLIFE
COOLANT IN A CLOSED OR POORLY
VENTILATED SPACE. SHOULD YOU
INHALE A LARGE AMOUNT OF GAS OF
FUSO DIESEL LONGLIFE COOLANT,
MOVE TO A PLACE WITH FRESH AIR AND
KEEP YOURSELF WARM AND AT REST. IF
YOU FEEL NAUSEOUS OR OTHERWISE
ABNORMAL, IMMEDIATELY SEEK MEDI-
CAL ATTENTION.
• CLOSE THE CAP OF THE FUSO DIESEL
LONGLIFE COOLANT CONTAINER IMME-
DIATELY AFTER USING THE PRODUCT.
• DO NOT STORE FUSO DIESEL LONGLIFE
COOLANT WHERE CHILDREN COULD
REACH AND ACCIDENTALLY DRINK IT.
• FUSO DIESEL LONGLIFE COOLANT IS
FLAMMABLE; AVOID EXPOSING IT TO
OPEN FLAME.
• WHEN HANDLING FUSO DIESEL
LONGLIFE COOLANT, WEAR AN
ORGANIC GAS MASK, PROTECTION
GOGGLES, OIL-RESISTANT GLOVES,
AND/OR PROTECTIVE APRON AS NECES-
SARY.
CAUTION
Do not use methanol-based or methoxypro-
panol-based antifreeze products since these
can severely damage the engine. If a different
additive has been used and the FUSO DIESEL
LONGLIFE COOLANT is to be used, be sure to
thoroughly flush the cooling system.
12-41
Use the following table to determine the correct

concentration of FUSO DIESEL LONGLIFE COOL-
ANT according to the lowest temperature at which
your vehicle is to be operated.
FUSO DIESEL LONGLIFE COOLANT concentra-
tion (in volume percentage)
Lowest –10
temper- (14) –15 –20 –25 –30 –35 –40
ature or (5) (–4) (–13) (–22) (–31) (–40)
°C (°F) higher
Con-
centra- 30 35 40 45 50 55 60
tion (%)
Coolant quantity Approx. 16 liters (17qts)
NOTE:
Vehicles are shipped with a 50% concentration of
FUSO DIESEL LONGLIFE COOLANT and can
therefore be used at temperatures down to –30°C
(–22°F).
CAUTION
Use FUSO DIESEL LONGLIFE COOLANT at a
concentration of between 30% and 60%. The
proper concentration under normal tempera-
tures is 30%. At a concentration below 30%, this
additive performs poorly as an anticorrosive,
while at a concentration exceeding 60%, it per-
forms poorly as an antifreeze.
4 Check
NOTE:
• Always check the coolant level before starting
the engine when the coolant temperature is low.
When the coolant gets hot, it expands, making
the level look higher than it actually is.
• Deposition may occur in the reserve tank but
this will not cause any problem.
• The coolant level is sufficient if it is between the

<Crew-cab models> “FULL” and “LOW” marks on the coolant reser-
voir tank.
• If the coolant level is below the “LOW” line,
make sure coolant is not leaking from the cool-
ing system then add coolant until it reaches the
“FULL” line.
• Check for coolant leakage from the radiator and
radiator hoses.
If you find water on the ground from which your
vehicle has been moved after parking, coolant is
probably leaking.
• If the coolant level is abnormally low and quickly
Z12075 drops again when coolant has been added,
coolant may be leaking from the cooling system.
Have the vehicle inspected by your nearest
authorized dealer.
5 Adding coolant
CAUTION
• Coolant should normally be added through
the reservoir tank without opening the pres-
sure cap on the engine.
• When adding coolant, use new coolant addi-
tive of the same brand and concentration as
the additive that is already in the vehicle.
• Adding only water reduces the concentra-
tion of the coolant already in the system,
resulting in less protection against freezing
and corrosion. Additional coolant should
always contain the correct proportions of the
additive and soft water.
5.1 Adding coolant during pre-operation

checks
1. If the coolant level is below the “LOW” mark,
remove the cap from the reservoir tank, and refill
the tank with a mixture of FUSO DIESEL
LONGLIFE COOLANT and soft water to the
“FULL” mark.
2. Refit the cap securely after adding coolant.
5.2 Adding coolant following an engine over-

heat
If the engine overheats, the amount of coolant may
be insufficient not only in the reservoir tank but also
in the main body of the radiator.
1. Allow the engine to cool down by keeping it run-
ning at a speed slightly higher than the specified
idling speed. P. 5-5
2. When the needle in the coolant temperature
gauge has come down to approximately the
center of the scale, stop the engine and perform
the following checks and corrective steps:
• Check that coolant is not leaking from the
radiator hoses or from any related part.
• Check that the fan belt is not broken and that
its tension is normal. P. 12-46
If the vehicle is a Crew-cab model vehicle,
uncover the engine inspection opening.
P. 12-4
4. Undo the fastener then turn the pressure cap
counterclockwise to remove it. If the coolant
level is too low, add coolant until it reaches the
opening.
WARNING
Do not open the pressure cap before the nee-
dle in the coolant temperature gauge has
come down to approximately the center of
Z12449 the scale. If you open the pressure cap too
soon, hot coolant and steam will spray out
and scald you.
12-43
5. Refit the pressure cap by turning it clockwise,

then securely retain the fastener in the groove
on the engine.
6. Take the cap off the reservoir tank and add cool-
ant until it reaches the “FULL” line. Refit the cap
tightly.
6 Replacement
Be sure to flush the cooling system when replacing
the coolant.
WARNING
• Do not replace the coolant immediately
after operating the vehicle since the
engine, radiator, coolant, and other items
will be extremely hot. If you try to drain the
coolant immediately after driving the vehi-
cle, you may be scalded. Give the coolant
time to cool before starting the job.
• Before removing the pressure cap on the
engine, grip it in a cloth and loosen it
slowly to release the pressure.
Do not remove the pressure cap on the
engine when the coolant is hot since cool-
ant may gush out and scald you.
• Tighten the pressure cap before operating
the engine. If the engine speed is
increased with the pressure cap left open,
the coolant will overflow from the pressure
cap opening as its temperature rises.
1. Place a can under the engine drain plug and

a can under the radiator drain cock to receive
the coolant.
Z12078
2. Remove the cap from the reservoir tank .

P. 12-4
4. Unlock the pressure cap by raising the fas-
tener . Remove the pressure cap by turning it
counterclockwise.
5. Open engine drain plug and radiator drain cock
to drain the coolant. Also drain the coolant in
reservoir tank.
<Crew-cab models> NOTE:
By connecting an appropriate hose to the drain cock
nipple , you can drain the coolant without it
splashing.
6. After the coolant has been completely drained,
close both engine drain plug and radiator drain
cock.
Tightening torque
Engine drain 24.5 ± 4.9 N·m (18.1 ± 3.6 ft.lbs.,
plug 2.5 ± 0.5 kgf·m)
Z12077
Radiator drain 1.5 ± 0.3 N·m (1.1 ± 0.2 ft.lbs.,
cock 0.15 ± 0.03 kgf·m)
7. Flush the cooling system.

Pour soft water (preferably after heating moder-
ately) through the pressure cap opening. Refit
the pressure cap tightly by turning it clockwise.
Lower the cab.
Start the engine, then run the engine at a
medium range RPM until the water temperature
gauge needle points the center of the scale, and
continue running the engine for about 10 min-
utes more from that point. Stop the engine and
discharge the water. Remember that the water
is very hot.
Repeat the above procedure until the water is
free of dirt.
CAUTION
If the radiator tubing is clogged or coolant is
more contaminated than usual, have your vehi-
cle inspected at an authorized dealer.
8. Make sure the radiator drain cock and engine

drain plug are securely fitted.
9. Tilt the cab. If the vehicle is a Crew-cab model
vehicle, uncover the engine inspection opening.
12-45
10. Pour coolant (FUSO DIESEL LONGLIFE

COOLANT plus soft water) up to the top of the
pressure cap opening. Pour the coolant slowly
to prevent air from mixing with it.
11. Check that the coolant level in the pressure cap
opening does not go down, then fit the pressure
cap (turn it clockwise until it is tight) and press
down the fastener to lock the pressure cap in
place.
Z12450 CAUTION
If air is not completely removed from the cool-
ing system, this may lead to reduced cooling
efficiency and engine parts failure. After replac-
ing the coolant, drive the vehicle and then check
the coolant level.
12. Lower the cab.

13. Fill the reservoir tank with the coolant (FUSO
DIESEL LONGLIFE COOLANT plus soft water)
to the “FULL” line, then replace the cap.
14. Start the engine and keep it running at a speed
slightly higher than the specified idling speed to
expel air from the cooling system. When the
needle in the coolant temperature gauge
reaches approximately the center of the scale,
allow the engine to idle for 10 more minutes
then stop it.
15. When the engine has cooled, open the pressure
cap and, if the coolant level is too low, add cool-
ant until it reaches the top of the pressure cap
opening.
16. Screw the pressure cap down tightly by turning it
clockwise.
Lock the pressure cap by pressing down the fas-
tener.
17. Run the engine a few more minutes to make
sure that there are no coolant leaks.
18. Make sure that the coolant level in the reservoir
tank is in the specified range. Add coolant if nec-
essary.
Z12076
7 Cleaning the intercooler and radiator

core
If the intercooler or front of the radiator core is
plugged with mud or dust, cooling efficiency will be
reduced leading to rust. Clean the radiator core at
regular intervals.
V-belts – check and adjustment
An excessively loose or tight belt could cause the

engine to overheat, the battery to be inadequately
charged, or the alternator or water pump to mal-
function. Always keep belts adjusted to the proper
tension.
V-belt At the time of pre-operational

inspection check and every 10,000 km
intervals (6,000 miles) or every 12 months
WARNING
Always stop the engine before inspecting or
adjusting belts.
Ensure that the engine cannot be started
while you are performing checks or adjust-
ments.
CAUTION
Prevent the V-belt from any contact with oil or
grease during check and adjustment.
If soiled with oil or grease, the belts will slip and
this will shorten their service life.
1 Check
1. Confirm that the parking brake lever is pulled.
Prevent the vehicle from moving by blocking the
wheels with chocks. Tilt the cab. P. 12-5
If the vehicle is a crew-cab model, uncover the
engine inspection opening under the assistant
driver’s seat. P. 12-4
2. Press the belt with an approximately 98 N (22
lbs., 10 kgf) force at the point midway between
the pulleys, and measure the amount of deflec-
Z11933 tion.
3. If the deflection is not as specified below, the
tension of the belt must be adjusted.
Belt tension
[Amount of deflection when the belt is pressed
with a 98 N (22 lbs., 10 kgf) force at the point
midway between the pulleys]
New belt (when installed):
Vehicles 9 to 11 mm (0.35 to 0.43 in.)
without air Used belt (when inspected
conditioner or reinstalled): 11 to 13 mm
Fan (0.43 to 0.51 in.)
belt New belt (when installed):
Vehicles 7 to 9 mm (0.28 to 0.35 in.)
with air Used belt (when inspected
conditioner or reinstalled): 10 to 11 mm
(0.39 to 0.43 in.)
12-47
4. Also, check the belts for damage.
2 Adjustment
WARNING
Never perform belt tension adjustments
when the engine is running.
2.1 Vehicles with air conditioner

P. 12-4
2. Slightly loosen the upper and lower alternator
mounting nuts .
3. Turn adjusting bolt to obtain proper belt ten-
sion. Turning the bolt clockwise increases the
tension.
4. After adjustment, firmly tighten the alternator
Z11935 mounting nuts.
2.2 Vehicles without air conditioner

P. 12-4
2. Loosen the tensioner pulley mounting nut
approximately half a turn by using a 22 mm (7/8
in.) offset wrench.
3. Turn adjusting bolt to obtain proper belt ten-
sion. Turning the bolt clockwise increases the
tension.
Z06454
4. After adjustment, firmly tighten the tensioner
pulley mounting nuts.
Range selector lever – check

If any abnormality is found in the following checks,
do not drive the vehicle. Contact to an authorized
dealer.
Z12715 At the time of pre-operational

Inspection check and every 30,000 km
intervals (18,000 miles) or every 6 months
NOTE:
Be sure to check with the engine stationary.
1. Confirm that the parking brake is fully applied.

2. Set the starter switch in ON position.
3. While shifting the range selector lever to each
position, check the following.
• Check if the range selector lever operates
smoothly and clicks at each range position
(“P” position through “2” position).
• Check if the shift indicator lamp indicates the
selected range.
4. Return the range selector lever to “P” position.

Turn the starter key to LOCK position and check
if the key can be removed from the key cylinder.
Steering wheel – check
The steering wheel is a safety-critical part of the

vehicle. If an inspection reveals any abnormality,
contact an authorized dealer and have the abnor-
mality rectified before you again drive the vehicle.
Driving the vehicle with the abnormality unrectified
could result in a serious accident.
At the time of pre-operational

WARNING
Perform the checks in a safe place that pro-
vides good visibility all around. During the
checks, be sufficiently attentive to surround-
ing traffic conditions.
1 Steering wheel play

2. If your vehicle is equipped with a manual trans-
mission, make sure that the gearshift lever is in
the neutral position. If your vehicle is an auto-
matic transmission vehicle, make sure that the
range selector lever is in the “P” position.
3. With the engine running, check the steering
wheel play as follows:
From its straight-ahead (neutral) position, turn
Z12232 the steering wheel clockwise and counterclock-
wise to the point where a resistance is first felt
for each direction, and measure the amount of
the steering wheel movement between these
points (steering wheel play). If the steering
wheel play is out of specification, contact an
authorized dealer.
Steering 5 to 50 mm (0.2 to 1.97 in.) or less

wheel play on the periphery of steering wheel
NOTE:
The above check must be performed with the
engine running.
2 Steering wheel looseness

1. Try moving steering wheel up and down and
also right and left to check for excessive loose-
ness.
2. If anything abnormal is found, contact an autho-
rized dealer.
12-49
NOTE:
Make sure the lock lever that is used for steering
wheel adjustment is securely locked.
3 Steering wheel operation

1. While driving slowly, make sure that the steering
wheel does not shake and the vehicle does not
pull to one side. Also check for excessive oper-
ating resistance and unsmooth return to the
neutral position.
2. If any abnormal condition is encountered during
the above check, call an authorized dealer for
inspection.
Service brakes – check
The service brakes are safety-critical parts of the

vehicle. If an inspection reveals any abnormality,
contact an authorized dealer and have the abnor-
mality rectified before you again drive the vehicle.
Driving the vehicle with the abnormality unrectified
could result in a serious accident.

intervals check
1 Brake pedal play

<Vehicles other than FE85>
1. Make sure the engine is not running.
4. Pump the brake pedal several times to release
Z09288 all the vacuum from the brake system (zero vac-
uum).
5. Measure the distance over which the brake
pedal moves when the center of the pedal pad is
pressed with light finger force to the point where
resistance is felt (brake pedal play). Check
whether the distance is within specification.
Brake pedal play 0.1 to 3 mm

(at center of pedal pad) (0.0039 to 0.12 in.)
6. If the brake pedal play is not as specified, have

the pedal inspected and adjusted by an autho-
rized dealer.
<FE85>
The FE85 has a hydraulic brake booster. Perform
the check as follows:

4. Measure the distance over which the brake
pedal moves when the center of the pedal pad is
pressed with light finger force to the point where
resistance is felt (brake pedal play). Check
whether the distance is within specification.
Brake pedal play 0.1 to 3 mm

5. If the brake pedal play is not as specified, have

the pedal inspected and ajusted by an autho-
rized dealer.
2 Brake pedal stroke

• Start the engine and allow it to idle.
• Fully depress the brake pedal. Check whether
the distance between the fully depressed pedal
and the floor is within specification.
Fully depressed brake 20 mm (0.79 in.) or

pedal to floor clearance more
• If the pedal-to-floor clearance is insufficient or

Z11612 the pedal feels spongy when depressed, brake
fluid leakage or presence of air in the brake
hydraulic system may be a cause.
Have the brake system inspected by an autho-
rized dealer if the above conditions are
detected.
3 Braking performance
Perform braking tests in a safe place. After check-
ing that warning lamp , or is not illumi-
nated, drive the vehicle at a low speed to make sure
that braking power is sufficient and even. If braking
seems in any way abnormal, operating the vehicle
could be dangerous. Ask an authorized dealer for a
more thorough inspection.
Z11178 WARNING
Perform brake tests in a safe place that pro-
tests, be attentive to surrounding traffic con-
ditions.
4 Hydraulic brake booster performance

<FE85>
Before starting the engine, depress the brake pedal
to check that the brake system auxiliary electric
pump operates. If the pump does not operate, have
an authorized dealer perform necessary inspection.
12-51
Parking brake – check and

adjustment

intervals check
1 Parking brake lever stroke check

1. Depress the brake pedal firmly so that the vehi-
cle cannot move.
2. Starting with the parking brake lever in the fully
released position, pull the parking brake lever
with a force of 295 N (66 Ibs., 30 kgf) until it
stops moving. Check whether the lever stroke
(the distance moved by the lever) is within spec-
ification. If the stroke is out of specification, have
the vehicle inspected by an authorized dealer.
Z11606
Parking brake lever 7 to 9 notches
stroke
3. Make sure the parking brake lever locks

securely in the pulled position.
2 Braking performance
Stop the vehicle on a dry downgrade, set the park-
ing brake and check to see if the parking brake can
hold the vehicle. If an appropriate downgrade is not
available, drive the vehicle at a low speed and acti-
vate the parking brake to make sure that it exhibits
satisfactory braking action.
If parking brake performance is in any way abnor-
mal, vehicle operation could be dangerous. Contact
an authorized dealer.
WARNING
Perform brake tests in safe place that pro-
tests, be sufficiently attentive to surrounding
traffic conditions.
Clutch – check

Check the clutch for condition. If anything abnormal

is found, see an authorized dealer.
1 Clutch pedal play
Clutch pedal play 0.2 to 4 mm


3. Make sure the gearshift lever is in the neutral
position.
4. To check clutch pedal play, use your finger to
Z11613 press the center of the pedal pad to the point
where resistance is felt and measure the dis-
tance over which the pedal has moved (play) .
If the degree of play is not as specified above,
adjustment is necessary.
Have any necessary adjustment made by an
authorized dealer.
2 Clutch operation
Make sure that the clutch pedal operates without
unusual noise or excessive resistance. Check also
that depressing the clutch pedal allows you to move
the gearshift lever easily to the various gear posi-
tions, and that the clutch engages smoothly without
slipping when the clutch pedal is released slowly.
Tires – check

1 Inflation pressure check

• Tire pressure should be checked and adjusted
before driving when the tires are still cool. Make
sure that the tire air valve caps are securely fit-
ted.
• You can roughly judge the air pressure from the
form of the tire tread, but need to use an air
gauge for precise measurement. If your vehicle
uses low-profile tires, the air pressure must be
checked using an air gauge.
Properly inflated
Excessively inflated
Insufficiently inflated
If the tires appear incorrectly inflated, make any

air pressure adjustments necessary before driv-
ing.
Z10801
12-53
Standard inflation pressure

Inflation pressure
Model Tire size kPa (psi, kgf/cm2)
LT215/85R16-10PR
FE84 550 (80, 5.5)
(Load Range E)
215/75R17.5 124/
FE85 123L (Load Range F) 690 (100, 7.0)
LT235/85R16-10PR
FG 550 (80, 5.5)
(Load Range E)
• There is a plate affixed to the driver’s door pillar

indicating standard inflation pressure.
WARNING
• Excessively low or high tire pressures not
only give a poor ride but also could cause
cargo to be damaged. Under-inflated or
over-inflated tires are also very dangerous
and can be easily damaged. Moreover, if
Z10802 the pressure is too low, tires could over-
heat and burst.
• Both the inner and outer tires on dual
wheels should be inflated to the same
pressure.
• You need not increase tire pressure before
high-speed driving.
• Tires should be handled with care due to
their high internal air pressure.
CAUTION
• Your vehicle’s tires will heat up during use,
with a corresponding increase in air pres-
sure. This is normal; do not release air from
the tires when they are hot.
Always check tire pressures before driving,
when the tires are cold.
• Pay particularly close attention to the air
pressure in new tires. New tires tend to
stretch slightly as they settle, with a corre-
sponding decrease in air pressure.
• Never fail to install tire valve caps after
checking or adjusting the air pressure.
Unless the valve caps are replaced, foreign
matter may interfere with the valves and
cause air to leak out.
NOTE:
• The tire inflation pressures will be higher just
after vehicle operation than before vehicle oper-
ation. The increases in pressure are not abnor-
mal; they occur because the air in the tires
expands as the tires get hot while the vehicle is
moving. Do not release air from the tires at this
time. The pressures will return to normal as the
tires cool down.
• The pressure drops naturally as time passes.
You should therefore check the tire pressure
regularly at least once a month using an air
gauge.
2 Checking tread depth

Check the entire circumference of each tire to make
sure that the remaining depth of the tread pattern on
the part that contacts the road surface is sufficient.
Tread groove depth 1.6 mm (0.06 in.)

limit
When the tread wears down, slip signs (inter-

rupted sections of the grooves) appear across the
tire at the locations corresponding to the marks.
Replace the tire as soon as the slip signs show up
as continued use is dangerous. P. 12-55
WARNING
If the remaining tread is too shallow, the tires
tend to skid and chances of “hydroplaning”
during high speed driving increase. Worn
tires should be replaced as soon as possible.
NOTE:
Hydroplaning can occur when driving on a wet
roads at high speeds. When a vehicle hydroplanes,
tires ride up on and slide over a film of water, caus-
ing the driver to lose control of both steering and
braking.
Z10804
3 Checking for cracks, damage, and

objects embedded in tread
Check both the tread and the sides of each tire for
cracks, damage, and excessive or unusual wear.
Check also for metal pieces, nails, and stones that
might be embedded in the tread or caught between
the tires of dual wheels.
WARNING
Z10805
Severely damaged or worn tires are suscepti-
ble to puncture during use and should be
replaced as soon as possible.
12-55
Tire replacement
1 Preparation for tire replacement

• Park the vehicle on a flat, hard surface. Pull the
parking brake all the way on. If your vehicle has
a manual transmission, place the gearshift lever
in the neutral position. If your vehicle has an
automatic transmission, place the range selec-
tor lever in the “P” position.
• Be sure to stop the engine.
• If you get a flat tire while on the road and need
to change it on the spot, pull up your vehicle in a
safe place where it will not block traffic, and
cause your hazard warning lamps to flash and
use a red or white flag or cloth to give warning to
passing vehicles.
• Have all passengers get out of the vehicle.
• Block the tire diagonally opposite to the tire to
be replaced with a chock.
Example:
Block the left front tire if the right rear tire is to be
replaced.
• Prepare a replacement tire.
NOTE:
• Your vehicle is not provided with a replacement
tire as standard equipment.
• Applicable tires are as follows.
Model Tire size

LT215/85R16-10PR
FE84 (Load Range E)
215/75R17.5 124/123L
FE85 (Load Range F)
LT235/85R16-10PR
FG (Load Range E)
2 Removing the wheel

2.1 Front axle jacking points
• FE
Bottom surface of the leaf spring at the rear of tie
rod.
Z12085
• FG
Jack support under the front axle.
Z12567
2.2 Rear axle jacking point

Bottom surface of the axle housing
Z12086
2.3 How to remove a wheel
WARNING
• After raising the vehicle slightly, confirm
that the jack is securely in position.
If the jack slipped out of position with the
vehicle fully raised, the vehicle could fall
and cause a serious injury.
• Apply the jack only to designated jacking
points. Applying the jack elsewhere could
damage the vehicle and cause the jack to
slip out of position.
• Never rock or climb below the vehicle
when it is jacked up since movement of
the jack could result in a serious injury or
in damage to the vehicle.
Never start the engine when the vehicle is
jacked up.
• It is dangerous to leave the vehicle jacked
up for long periods. If you need to raise
the vehicle for an extended period, sup-
port it with bricks or wooden beams
placed against the bottom surfaces of the
frame.
1. Securely apply the parking brake. Apply chocks

to the front and back (as seen from the side of
the vehicle) of the wheel diagonally opposite the
one that is to be jacked up.
2. Position the jack under the jacking point of the
vehicle and raise the vehicle to a point at which
the tire is still touching the ground.
NOTE:
Socket wrenches for use in jacking up the vehicle or
loosening/tightening the wheel nuts are not included
in the onboard tools.
12-57
3. Slightly loosen the wheel nuts by turning them in

the illustrated direction. Do not remove the nuts.
For right-hand wheel
For left-hand wheel
NOTE:
The wheel nuts on the right-hand wheel are marked
with “R” and have right-hand threads. Those on the
left-hand wheel are marked with “L” and have left-
hand threads.
Z12084
WARNING
• Fit the socket wrench securely on the
wheel nut. If fitted improperly, the wrench
will slip off the nut, and could cause injury.
• Do not loosen the wheel nuts too much or
you could damage the threads.
4. Jack up the vehicle until the tire is just clear of

the ground.
5. Remove the wheel nuts and then the tire.
6. To remove the tires of a rear dual-wheel, first
loosen the outer wheel nuts and remove outer
tire ; then lower the jack, loosen inner wheel
nuts and jack up the vehicle again to remove
inner tire .
Z09307
WARNING
• Do not rotate the jacked-up wheel if the
vehicle has a limited-slip differential.
Power would be transmitted to the wheel
in contact with the ground, and the vehicle
could move as a result.
• When removing wheels, be careful not to
damage the wheel bolts and the threads of
the inner wheel nuts.
Z09031
3 Mounting the tire

1. Clean the following sections before mounting
the wheel. If they are dirty, the wheel nuts could
become loose during driving.
Threads on wheel bolts and nuts
Spherical surface of wheel nuts
Disc wheel mounting surface
Disc wheel mating surface
Wheel nut contact surface on disc wheel
Disc wheel inside surface
Z09309 Guide sections on hub
WARNING
• If the above items are dirty, the nuts will
become loose during vehicle operation. If
wheel bolt or nut threads are damaged or
the disc wheel is cracked or otherwise
damaged, replace the wheel with a new
genuine part. A damaged wheel could
work loose and cause a serious accident
while the vehicle is in motion.
• Do not paint disc wheel mounting sur-
faces, dual wheel mating surfaces, wheel
nut seating surfaces, and wheel hub
mounting surfaces as resulting thicker
paint film could cause the wheel nuts to
loosen up.
2. Mount the wheel so that the wheel bolts line up

with the bolt holes in the disc wheel. Then,
tighten the wheel nuts to hold the disc wheel in
position. If the wheel nut has a spherical end ,
direct the spherical end toward the disc wheel.
NOTE:
The wheel bolts and nuts on the right-hand wheels
have right-hand threads, and those on the left-hand
wheels have left-hand threads.
The bolts and nuts have stamped marks for easy
Z09310 identification; an “R” mark for right-hand wheels and
an “L” mark for left-hand wheels.
3. Lower the vehicle gently until the tire makes

contact with the ground.
4. Tighten the wheel nuts in the order shown in the

4 illustration, repeating the tightening cycle 2 to 3
3 times. Finally, tighten the nuts to the specified
5 1 torque.
2 1
Tightening 440 to 540 N·m
torque (325 to 398 ft.lbs., 45 to 55 kgf·m)
2 6
5 3
4
Z09311
12-59
WARNING
• Do not jump or jerk on the wrench handle
when tightening the nut by using your own
weight. Doing so can overtighten the nut.
Overtightening the nuts could overstrain
the bolts or deform the disc wheel’s sur-
face.
• The wheel nuts must be tightened to the
specified torque. Unless the nuts are tight-
ened correctly, the wheel may work loose
while the vehicle is in motion, resulting in
a serious accident.
5. Mount dual rear wheels as described below.

4 3
5 1 WARNING
2 1
When replacing an outer wheel of a dual rear
wheel, be sure to retighten the inner wheel
nuts before tightening the outer wheel nuts.
2 6
5 3
4 NOTE:
Z09311 When installing dual wheels, make sure that the air
valve of the inner wheel is not lined up with the air
valve of the outer wheel.
Mount the inner wheel, then jack up the vehicle

again. Set the outer wheel such that the wheel
bolts are located in the centers of the disc
wheel’s bolt holes, then tighten the wheel nuts
just enough to eliminate looseness.
Lower the vehicle, then tighten the wheel nuts in
the illustrated sequence. Work through the
sequence two or three times, finally tightening
each wheel nut to the specified torque.
6. If only the outer wheel of dual wheels is

replaced, retighten the inner wheel nuts to the
specified torque before mounting the outer
wheel.
WARNING
• Be sure to tighten the wheel nuts to the
specified torque. Excessive torque could
elongate the bolt or deform the surface of
the disc wheel.
• When replacing the wheel, take care not to
damage the threads on the wheel bolts
and inner wheel nuts.
• As the vehicle is driven after a wheel has
been replaced, the wheel nuts loosen up
somewhat during the early stages of driv-
ing due to “wear-in.” Therefore, it is neces-
sary to retighten the wheel nuts to the
specified torque after driving 50 to 100 km
(30 to 60 miles). Thereafter, retighten the
nuts at regular intervals.
• Do not paint disc wheel mounting surfaces
, dual wheel mating surfaces , wheel
nut seating surfaces , and wheel hub
mounting surfaces as resulting thicker
paint film could cause the wheel nuts to
loosen up.
• Be sure to use the specified type of tires.
Mixing bias and radial tires results in poor
steering and should be avoided at all
costs.
Z09308
12-61
Wheel nuts – check and retightening
Every 10,000 km
With a new vehicle, perform the first inspection after

4,000 km (2,500 miles).
WARNING
After changing a tire, the wheel nuts will
loosen somewhat during the initial stages of
driving due to “wear-in.” Therefore, retighten
the wheel nuts to specification after you have
driven 50 to 100 km (30 to 60 miles).
Using a torque wrench, check for loose wheel nuts

and tighten as necessary.
Wheel nut 440 to 540 N·m

tightening (325 to 398 ft.lbs., 45 to 55 kgf·m)
torque
WARNING
• A loose wheel nut could cause broken
wheel bolts or a cracked disc wheel,
resulting in a tire coming loose or falling
off. Since this could cause a serious acci-
dent and render the vehicle undriveable,
be sure to check the wheel nuts regularly.
• Retightening wheel nuts on rear dual wheels

Retighten the wheel nuts in the following sequence:
Loosen outer wheel nuts.
Retighten inner wheel nuts to specification.
Tighten outer wheel nuts to specification.
WARNING
In the case of dual wheels, one often retight-
ens outer wheel nuts while forgetting to
Z09315 retighten inner wheel nuts. Always follow the
above procedure to tighten all the nuts.
NOTE:
The wheel bolts and nuts on the right-hand wheels
have right-hand threads, and those on the left-hand
wheels have left-hand threads.
The bolts and nuts have stamped marks for easy
identification; an “R” mark for right-hand wheels and
an “L” mark for left-hand wheels.
Same tread pattern on all tires

Tire rotation
The amount of wear on a tire depends on its posi-

tion on the vehicle. To equalize wear and extend life
as much as possible, rotate the tires at regular inter-
vals.
Front Rear Z12089 Every 10,000 km

Tire rotation intervals (6,000 miles)
Different tread patterns on front and rear tires • Use a tire of the same type on a single axle. If
different type tires are mounted on an axle, the
vehicle tends to pull to one side during braking,
and could cause you to lose directional control
of the vehicle.
• Applicable tires are as follows.
Model Tire size

LT215/85R16-10PR
Front Rear FE84
Z12090 (Load Range E)
215/75R17.5 124/123L
FE85 (Load Range F)
LT235/85R16-10PR
FG (Load Range E)
WARNING
• Be sure to use the specified type of tires.
Mixing bias and radial tires results in poor
steering and should be avoided at all cost.
• As the vehicle is driven after a wheel has
been replaced, the wheel nuts loosen up
somewhat during the early stages of driv-
ing due to “wear-in”. Therefore, it is neces-
sary to retighten the wheel nuts to the
specified torque after driving 50 to 100 km
(30 to 60 miles). Thereafter, retighten the
nuts at regular intervals.
CAUTION
• Break in new tires by driving 200 km (125
miles) or more at 60 km/h (37 mph) or less.
After this run-in period, check tire pressure.
• If using different tread patterns on the front
and rear wheels, select tires with a ribbed
tread for the front wheels and tires with a
traction-type tread for the rear wheels.
12-63
Wiper blade – replacement
1 Replacing wiper blade

1. Raise wiper arm , and then push clip spring
in the direction of the arrow (see figure).
Z05981
2. With the clip spring kept in the pushed position,

press wiper toward the wiper arm.
Z05982
3. The wiper blade will come off the wiper arm.

Install a new blade in the reverse order of
removal.
Use a genuine replacement part.
CAUTION
Do not bring the wiper arms back into position
or operate the wipers without wiper blades, as
this could scratch the windshield.
Z05983
2 Replacing blade rubber only

1. Raise the wiper arm.
Pinch both sides (indicated by arrows) of blade
rubber with your fingers and then pull the
blade rubber so that claws are unhooked from
grooves in the blade rubber.
2. Slide out the blade rubber.
3. Replace the old blade rubber with a new genu-
ine wiper blade rubber.
To install, reverse the removal procedure. Make
Z09332 sure that the claws fit into the grooves in blade
rubber.
Windshield washer – fluid level

check and refilling
1 Fluid level check

Check the washer fluid level through level check
window .
When the level has dropped to the lower part of the
window or is not visible at all, refill the tank with
Z12091 washer fluid.
2 Refilling
1. Open the assistant driver’s door.
2. Open windshield washer tank cap and pour in
a mixture of windshield washer fluid and tap
water until the level reaches the top of the check
window.
3. Close the cap tightly after refilling.
Windshield washer fluid Approx. 3 liters (3.2 qts)

quantity
CAUTION
Substituting soapy water for washer fluid could
result in clogged washer nozzles or spots on
painted surfaces.
NOTE:
When it is very cold, the ratio of windshield washer
fluid to water should be increased in order to pre-
vent the mixture from freezing up.
Battery – check
WARNING
• The battery generates flammable hydro-
gen gas and should be kept away from
open flame and spark.
• When removing the battery, always dis-
connect the negative (–) terminal first and
reconnect it last. A spark can occur if a
tool touches the positive (+) terminal and
frame with the negative (–) terminal con-
nected.
• When handling the battery, wear safety
goggles to protect your eyes.
• Perform all battery checks with the engine
turned off.
12-65
1 Removal and installation of battery

cover
1. Pull the stopper on the left side of the battery
to unhook it from the cover , and raise the left
end of the cover by about 50 mm (1.97 in.).
2. Slide the cover leftward to disengage it from the
right stopper .
3. Follow the above steps in reverse to reinstall the
battery cover. Check that the installed cover is
securely held in position.
Z12092
2 Inspecting the battery

The battery’s charge level is indicated by color of
the indicator on the top surface.
The battery is correctly charged when the indicator
is blue. If the indicator is white, the battery is not
Indicator correctly charged and the battery fluid level should
Blue White be checked as follows:
1. If the battery fluid level is below the “LOWER
LEVEL” line , remove the 6 vent plugs and
add distilled water via the vent plug holes until
Z12093 the battery fluid level is between the “UPPER
LEVEL” and “LOWER LEVEL” lines. Replace
the vent plugs and then change the battery.
2. If the battery fluid level is correct, or between the
“UPPER LEVEL” and “LOWER LEVEL” lines,
simply recharge the battery.
Replace the battery if the indicator does not turn
blue after charging.
DANGER
BATTERY FLUID IS DILUTE SULFURIC ACID
AND CAN HARM MOST THINGS IT
TOUCHES, INCLUDING HUMAN SKIN AND
CLOTHING. IF YOU GET IT ON YOUR SKIN
OR CLOTHING, FLUSH IT OFF WITH SOAP
AND WATER. IF YOU ACCIDENTALLY GET
BATTERY FLUID IN YOUR EYES, WASH
YOUR EYES WITH LOTS OF CLEAN WATER
THEN PROMPTLY SEE AN EYE DOCTOR
FOR TREATMENT.
WARNING
Do not use the battery with the fluid below
the “LOWER” level line. The battery would
deteriorate rapidly, and it could overheat or
explode.
CAUTION
• Whenever battery fluid has been added,
either charge the battery or run the vehicle
for a while. It is especially important in cold
weather as the battery can freeze up and be
damaged.
• Do not add so much fluid that the fluid in the
battery rises above the “UPPER LEVEL” line.
With the fluid above the “UPPER LEVEL”,
fluid could leak out and corrode the battery
terminals.
• If you do not use the vehicle for an extended
period, remove the battery.
3 Cleaning the terminals

Use warm water to remove any white powder
caused by corrosion.
If a terminal is seriously corroded, remove the bat-
tery cable and clean the terminal with a wire brush
or sandpaper.
After cleaning, apply a thin coat of grease to the ter-
minals.
CAUTION
If the battery needs to be charged, remove it
from the vehicle and remove the vent plugs
where possible before starting the procedure. If
it is charged in the vehicle due to unavoidable
circumstances, be sure to disconnect the nega-
tive (–) battery cable.
NOTE:
Follow the correct procedure when jump starting a
vehicle with a dead battery by connecting it to a live
battery using a booster cable. P. 13-22
4 Battery removal and installation

1. Disconnect the battery cables (each indicated
by an arrow in the illustration) from the bat-
tery terminals.
WARNING
When disconnecting the battery cables, dis-
connect the (–) cable first. When connecting
the battery cables, connect the (–) cable last.
Z12094 If you accidentally touched the (+) terminal
and the vehicle body with a tool with the (–)
cable connected to the battery, a dangerous
short circuit could occur.
12-67
2. Remove the battery support mounting nuts

(each indicated by an arrow in the illustra-
tion).
3. Remove the battery support , then remove the
battery.
4. Install the battery by performing these steps in
reverse. After installing the battery, make sure it
is securely retained.
Z12095 WARNING
Be sure to observe the following instructions
when storing a battery.
• Select a storage place where the battery
fluid will not freeze.
• The storage place must be free of any heat
source and well ventilated.
• The battery must be kept out of reach of
children.
• The battery must be placed with the termi-
nals facing upward. Do not place the bat-
tery on its side. Doing so could cause
battery fluid leakage and a fire.
CAUTION
Install the battery securely in position. If it is left
loose, shocks and vibrations from road surface
could damage the battery case and electrode
plates, shortening battery life.
Air filters – cleaning
Remove and clean the air filters (heater or air condi-

tioner filters) with water or compressed air to elimi-
nate dust and dirt at regular intervals (6 months or
so).
Clogged filters may cause inefficient heating or air-
conditioning, and even malfunction of the blower
motor.
WARNING
When cleaning the air filters, wear a dust
mask to avoid inhaling dust. Dust inhalation
can have adverse health effects.
CAUTION
Clean the air filters at shorter intervals if your
vehicle is used frequently in dusty areas.
1 Outside air filter

Disassembly is necessary before the outside air fil-
ter can be cleaned. Have an authorized dealer do
the job.
2 Dashboard air filter
Z11171
• Removal
1. Remove the four screws that retain the bot-
tom of the lower center panel and the bottom
of the lower panel .
2. Release the tabs on the lower panel and
lower center panel, then remove the lower
panel.
3. Remove the screw that retains the bottom of
the tray .
4. Open the glove compartment, then remove the
two screws .
5. Remove the three sets of plugs and screws ,
then remove the tray.
6. Withdraw the air filter .
Z11620
12-69
• Installation
1. Return the air filter to its original position by
inserting it with its front facing you. Press the air
filter securely into the guides (one on each
side at the top and two at the bottom).
2. Install the tray by performing the removal steps
in reverse.
3. Install the lower panel and lower center panel in
that order by performing the removal steps in
reverse.
Z11621
Cleaning your vehicle
WARNING
• Some cleaning fluids are poisonous or
flammable. Carefully follow the safety pre-
cautions shown on the container.
• Use solvent-based cleaning materials only
in a well ventilated area.
Open the windows when using solvent-
based cleaning materials in the cab.
• The following materials could injure you or
damage the vehicle, and should not be
used:
Acetone, lacquer thinner, enamel thinner,
nail enamel remover, and other volatile
solvents; laundry soap, bleach, deoxi-
dant, and other detergents; carbon tetra-
chloride, gasoline, benzene, naphtha, and
other petrochemicals.
1 Exterior cleaning
1.1 Cleaning glass surfaces
Keep the vehicle’s windows and screens clean at all
times. Use glass cleaner and wipe it off with a
sponge or soft cloth.
CAUTION
Never apply rubbing compound to glass since it
leaves scratches.
1.2 Washing
Using a hose, wash the mud and dirt off the body
surfaces. Wash not only the surfaces around the
cab, but also the wheel housings and the underside
of the chassis.
Especially after you have driven in a coastal area or
on salted road in the winter, your vehicle should be
given a thorough washing. Also try to wax the body
surfaces once a month.
WARNING
When washing the underside of the vehicle,
be careful not to hurt yourself on the edges
of panels and other parts.
CAUTION
• Wash the vehicle with luke-warm or cold
water. Do not use very hot water.
• Avoid leaving the vehicle in direct sunlight.
• Avoid splashing water on the air intake port
or the area where it connects to the engine.
Especially when the vehicle is washed with
the cab tilted, avoid allowing water to enter
the engine through the air intake port.
• When washing the engine compartment and
underside of the chassis, be careful not to
expose the starter, alternator, connectors,
and other electrical parts directly to steam or
high-pressure water.
• Do not use concentrated soap or synthetic
detergents.
• Rinse the detergent off with water. Take care
that none remains on the paintwork since it
could discolor the paint.
• Cleaning plastic parts with thinner or gaso-
line could result in cracking or discoloration.
• In cold weather, the key holes and rubber
parts of the door sometimes freeze, making
it hard to open the door. After washing,
remove moisture on and around the doors.
Applying silicone with antifreeze capabilities
is one solution to this problem.
• Do not clean the interior by splashing water
on it as this could damage relays, the com-
puter, and other electrical devices.
12-71
• When washing the underside of the vehicle,

<Steering be careful not to direct water or steam from a
shaft> high-pressure cleaner toward the steering
shaft, the dust covers on the steering sys-
tem, or the dust covers on the front axle for a
long time at close range. Doing so could
cause a malfunction.
• When stepping onto the bumper to clean the
windshield, do not hold the wiper arms.
Doing so could cause a wiper malfunction.
• Do not use a vehicle-cleaning brush to clean
Z10792 the plastic lenses of the turn-signal lamps. A
brush could scratch the lenses. Wash the
<Dust cover on steering system, dust cover lenses with water, then wipe them with a soft
on front axle> cloth.
• Do not direct steam from a high-pressure
cleaner into the outside air inlets. Water
would get into the cab, and the wiper motor
could malfunction.
• When the vehicle is washed, braking perfor-
mance can be reduced by water entering the
brake drums or splashed over the brake
discs. In this event, drive slowly with light
pressure on the brake pedal to dry out the
brakes. Pay attention to nearby vehicles
while doing so.
Z11173
• There are ABS electric wiring located behind

<Front wheel> the wheels. When removing snow or ice hav-
ing adhered to the wheel areas after driving
on snow-covered roads, be careful not to
damage the ABS components and wiring.
Also, avoid exposing the ABS components
and wiring to high-pressure water or cleaner
steam as the system could be damaged and
not operate properly.
<Rear wheel>
Z11956
1.3 Waxing
Wax the vehicle once or twice a month or whenever
the wax on the vehicle ceases to repel water.
Apply wax out of direct sunlight and only when the
vehicle’s paintwork is cooler than human body tem-
perature.
1.4 Dirt caked on paintwork

The following contaminants can cause corrosion,
discoloration, or staining of the vehicle if not
washed off: calcium chloride and other salts; road
chemicals, oil; tar; tree sap; bird droppings; and
industrial soot.
If you cannot easily clean off these contaminants,
use a synthetic cleaner that does not scratch or oth-
erwise damage painted surfaces.
1.5 Small chips and scratches

Chips, cracks, and scratches caused by grit thrown
up off the road should be fixed as soon as possible.
If the body metal is visible, corrosion will quickly set
in and require expensive treatment. Your dealer can
supply touch-up paint for small chips and scratches.
2 Interior cleaning
• Dirt can leave marks or stains and should be
cleaned off as soon as possible.
• Clean the interior of the vehicle with a sponge or
soft cloth. Remove stubborn dirt with a soft
brush.
• Use the appropriate cleaning technique for each
interior item to avoid discoloration and stains.
• Do not water-wash the floor with the floor mat
left in place as this could cause the floor to rust
and could also damage the relays and other
electrical components.
• If water collects in the cab, either remove the
drain plug from the floor and allow the water to
drain out or wipe up all the water using a cloth.
2.1 Cleaning interior trim

Keep the vehicle’s interior trim clean at all times.
1. Clean out all dust on the trim with a vacuum
cleaner or soft brush.
2. Wipe vinyl trim areas carefully with cloth damp-
ened with water.
3. Wipe dirt and marks off the trim with a commer-
cially available cleaner.
2.2 General dirt

A multi-purpose powder-type cleaner is recom-
mended for cleaning general dirt. Soapsuds are
also usable.
1. Clean out all loose dust with a vacuum cleaner
or soft brush.
2. Dilute the cleaner in water to the specified con-
centration. The best results can usually be
obtained with a thinner solution.
When soapsuds are used, apply them with a
sponge or soft cloth.
3. Wipe up any remaining cleaner with a towel or
other absorbent cloth.
12-73
4. Finish cleaning by gently wiping the surface with

a dry soft cloth to polish it.
2.3 Grease and oil

Use this method to remove contamination by
grease, oil, butter, margarine, shoe polish, white
coffee, chewing gum, beauty cream, vegetable oil,
wax, crayon, tar, and asphalt.
• Wipe off the contamination, then apply a fabric
cleaning solution.
• Shoe polish, wax, crayon, tar, and asphalt can
stain the trim if not cleaned off quickly.
Carefully use cleaner because it dissolve these
contaminants and can cause a smudge.
2.4 Organic contaminants

Use this method to remove marks resulting from
tomato ketchup, black coffee, egg, fruit, fruit juice,
milk, cold drinks, wine, vomit, urine, and blood.
1. Wipe off the smudge, then wipe the area again
with a damp sponge.
2. If the area is stained, apply a multi-purpose
foam-type cleaner.
3. If the smell of vomit or urine lingers, dissolve 5
ml (0.17 fl oz.) of baking soda in 250 ml (8.5 fl
oz.) of luke-warm water and use the solution to
clean the affected area.
4. If necessary, lightly wipe the area with a fabric
cleaning solvent.
2.5 Other contaminants

Use this method to remove contamination by candy,
ice cream, mayonnaise, and chili sauce.
1. Carefully clean off the contamination, then wash
the area with water and dry it.
2. If any spot remains, clean with a fabric cleaning
solvent.
2.6 Cleaning vinyl surfaces

• Vinyl can usually be cleaned with warm water
and mild soap, e.g., saddle soap.
• Apply a little soapy water and leave it for several
minutes. Then, rub the area hard with a cloth
wet in water. Repeat this process until the area
is completely clean.
• Tar, asphalt, and shoe polish can leave stains if
not cleaned off quickly.
With a clean cloth impregnated with vinyl
cleaner, wipe the area clean.
2.7 Cleaning seat belts

• Keep your vehicle’s seat belts clean and dry at
all times. Clean them with mild soap and luke-
warm water. Never use gasoline, thinner, or
other flammable liquids since these will weaken
the webbing.
• Do not bleach or re-dye the webbing since this
would seriously weaken it.
2.8 Removing floor mat for cleaning

When removing the floor mat for cleaning, you must
raise the accelerator pedal by using the following
method.
1. Hold the hooked end of stopper with pliers
and pull the stopper toward the front of the vehi-
cle while twisting the hooked end through
approximately 15 degrees to disengage the end
from the pedal.
2. To return the pedal to the original state, fit accel-
erator arm inside the stopper, and force the
Z09336 hooked end of the stopper in the hole of the
pedal.
3. Check to ensure that the stopper does not dis-
engage.
15°
CAUTION
Do not use force to disengage the stopper from
the pedal. Always pull it while twisting.
After cleaning the floor mat, dry the felt backing

before putting the mat back on the floor. When fit-
Z12176 ting the floor mat back in the vehicle, make sure it
does not interfere with the accelerator pedal and
other moving parts.
13-1
13. Useful advice for emergencies
Possible failures, causes and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Stopping your vehicle in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
If the engine overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
When a fuse has blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
When a lamp has burn out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
When braking is sluggish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
If the engine stalls while the vehicle is in motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
If a tire goes flat while the vehicle is in motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
When the battery has run down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-22
When the fuel has run out (Bleeding the fuel system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
When the vehicle becomes stuck in soft ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
13-2 Useful advice for emergencies
Possible failures, causes

and remedies
Performing daily checks and good maintenance are

keys to preventing mechanical failures and the
resultant accidents. Be sure to check and service
your vehicle regularly.
Should your vehicle suffer a mechanical failure or
malfunction, the measures needed to correct the
problem can be found using the following chart.
If you are unable to correct the problem yourself or
the problem persists after you have attempted to
repair it, contact an authorized dealer for technical
assistance.
The engine does not start.

The starter does not turn over or turns over too slowly.
Possible cause Remedy Ref. page

The starter switch fuse or high-current fuse is Replace the blown fuse or high-current fuse 13-8
blown. with a new one of the specified amperage.
Battery has run down. Charge or replace the battery. 13-22
Battery cable is disconnected, loose or cor- Remove corrosion and connect the cable 12-66
roded. correctly.
Connection to ground terminal is open. Connect securely. –
Engine oil viscosity is too high. Replace the oil with an oil of proper viscosity. 12-18
The starter turns over normally.

Fuel has run out. Refuel and bleed the system. 13-23
Air is present in the fuel system. Bleed the system. 13-23
The fuel filter is clogged. Replace the filter element. 12-34
Fuel is frozen. Heat the fuel pipe with hot water
[60°C (140°F) or less]. –
The air cleaner is clogged. Clean or replace the element. 12-36

The engine preheating time is insufficient. Follow the preheating instructions. 5-8
The engine preheating circuit fuse is blown. Replace the fuse. 13-13
The fuel injection system is malfunctioning. Have an authorized dealer perform neces- –
sary inspection.
The engine starts but stalls immediately.

Idling speed setting is too low. Have an authorized dealer perform neces- –
sary inspection.
The air cleaner is clogged. Clean or replace the filter element. 12-36
13-3
The engine fails to stop.

The fuel injection system is malfunctioning. Have an authorized dealer perform neces- –
sary inspection.
The starter switch is malfunctioning. Have an authorized dealer perform neces- –
sary inspection.
Black smoke is emitted in exhaust.

The air cleaner is clogged. Clean or replace the air cleaner element. 12-36
The engine overheats.

The front of the radiator is plugged with dust Clean the radiator with a soft brush. 12-45
and dirt.
The coolant level is too low. Add coolant. 12-39
The engine pressure cap is not closed com- Install the cap firmly. –
pletely.
The fan belt is loose. Adjust the belt tension. 12-46
The coolant is contaminated. Flush the cooling system and replace the 12-39
coolant.
Engine oil pressure does not build up.

Insufficient quantity of engine oil. Add engine oil. 12-18
Engine oil viscosity is not adequate. Replace the engine oil with one of a proper 12-18
viscosity.
Fuel consumption is excessive.

There is a fuel leak. Check the fuel system and retighten connec- –
tions as necessary.
Tire pressure is too low. Adjust to the adequate inflation pressure. 12-52
The clutch disc is worn. Have an authorized dealer perform neces- –
sary inspection.
Engine oil consumption is excessive.

The wrong oil is being used. Replace the engine oil with a proper one. 12-18
There is too much oil. Adjust the quantity to the proper level. 12-18
There is an oil leak. Check the oil circuit and retighten connec- –
tions as necessary.

Engine oil replacement intervals are too long. Change the engine oil at prescribed intervals. 12-18
The oil filter is clogged. Replace the filter element. 12-32
Drive power is insufficient.

The parking brake is activated. Release the parking brake completely. 5-17
Air is present in the fuel system. Bleed the fuel system. 13-23
Clutch disc is worn. Have an authorized dealer perform neces- –
sary inspection.
The front of the radiator is plugged with dust Clean the front of the radiator. 12-45
and dirt.
The clutch disengages incompletely.

Clutch fluid is insufficient. Add clutch fluid (brake fluid). 12-28
Clutch pedal play is excessive. Adjust. 12-51
Braking is sluggish. <other than FE85>

Vacuum is insufficient. Increase the engine speed to boost vacuum. –
Brake fluid is insufficient. Add brake fluid. 12-28
There is vacuum leak. Check the vacuum circuit and retighten con- –
nections as necessary.
The disc brake pads or drum brake linings are Have an authorized dealer perform neces- –
worn. sary inspection.
There is air in the brake fluid. Have an authorized dealer perform neces- –
sary inspection.
Braking is sluggish. <FE85>

Brake fluid is insufficient. Add brake fluid. 12-28
Power steering system fluid pressure is insuffi- Have an authorized dealer perform neces- –
cient. sary inspection.
Power steering system fluid pressure is Have an authorized dealer perform neces- –
leaking. sary inspection.
Power steering fluid is insufficient. Add power steering fluid. 12-30
The disc brake pads or drum brake linings are Have an authorized dealer perform neces- –
worn. sary inspection.
There is air in the brake fluid. Have an authorized dealer perform neces- –
sary inspection.
13-5
The vehicle pulls to one side during braking.

Tires are not uniformly inflated. Inflate tires properly. 12-52
Tires wear unevenly. Change the tires. 12-55
Cargo is heavier on one side than the other. Load cargo evenly. 7-15
Steering is difficult.
Cargo is over-loaded on the front side. Load cargo evenly. 7-15
Power steering fluid is insufficient. Add power steering fluid. 12-30
Front tire pressure is insufficient. Inflate tires to recommended pressures. 12-52
The steering wheel vibrates.

Wheel nuts are loose. Tighten the wheel nuts to specification. 12-58
Tires are not uniformly inflated. Inflate tires properly. 12-52
Tires wear unevenly. Replace tires. 12-55
Tires are damaged. Replace tires. 12-55
Unbalance is in tires or brakes. Have an authorized dealer perform neces- –
sary inspection.
The steering wheel does not return to the straight ahead position smoothly.
Parts are insufficiently greased. Grease parts. 12-15
The lamp does not light up.

The bulb is out. Replace the bulb. 13-14
The fuse is blown. Replace the fuse with one of the correct 13-8
amperage.
There is an open circuit or defective ground- Have an authorized dealer perform neces- –
ing. sary inspection.
The battery frequently runs down.

The battery terminals are loose or corroded. Scrape off corrosion and tighten down termi- 12-65
nals.
The fan belt is loose. Adjust the belt tension. 12-46
The battery is short of electrolyte. Add battery electrolyte. 12-66
The life of the battery has expired. Replace the battery. –
Idling speed setting is too low. Have an authorized dealer perform neces- –
sary inspection.
Vehicle is used only at nighttime. Charge the battery. –
Switches are left on. Be sure to turn off the switches. –
Faulty alternator Have an authorized dealer perform neces- –
sary inspection.
Stopping your vehicle in an

emergency
Should a mechanical failure occur, do not panic.

Simply slow your vehicle while paying attention to
the vehicles behind you, and pull off the road at a
place where you do not hinder the flow of traffic.
WARNING
• Stopping your vehicle in a tunnel could be
dangerous. Wherever possible, drive out
of the tunnel before stopping the vehicle.
• Be sure to block the wheels with chocks
after stopping the vehicle as mechanical
failure may render the parking brake inop-
erative.
NOTE:
If the engine stops, it is not possible to move the
vehicle using only the starter.
1 Marking your vehicle

After you have pulled off the road, alert other drivers
as follows so that they do not run into your vehicle.
• Flash the hazard warning lamps.
• If your vehicle carries reflective triangles, erect
them by the side of the road behind the vehicle.
Z11259
2 Repair
Check the mechanical failure and if you judge it
readily repairable, fix it while paying attention to the
traffic. If you are unable to repair it, call an autho-
rized dealer for help.
WARNING
Never attempt to perform repairs on an
expressway or in a tunnel as doing so is very
dangerous.
13-7
If the engine overheats
WARNING
Open the pressure cap only after the coolant
temperature has dropped sufficiently. If the
cap is opened while the engine is still hot,
Z12079 boiling coolant could gush out, burning you
severely.
CAUTION
• Be sure to stop the engine only after letting it
engine immediately after stopping will cause
the coolant temperature to rise quickly and
may cause the engine to seize up.
• Suddenly pouring cold water into the radia-
tor could make the engine crack. Supply
cold water a little at a time.
If the needle in the coolant temperature gauge

enters the red zone , the engine has overheated.
Stop the vehicle in a safe place, and allow the
engine to cool by using the engine idling control vol-
ume or accelerator pedal to run the engine at a
speed slightly higher than the idling speed.
P. 5-5
When the needle in the coolant temperature gauge
has come down to approximately the middle of the
scale, stop the engine and perform the following
inspections and corrective steps:
Z09375 1. Check that coolant is not leaking from the radia-
tor hoses or from other parts.
2. Check that the fan belt is not broken and that its
tension is normal. P. 12-46
3. Check the coolant level. If the level is too low,
add coolant.
• Remove the pressure cap, then add coolant
until it reaches the top of the pressure cap
opening. P. 12-39
• Remove the reservoir tank cap, then add
coolant until it reaches the “FULL” line.
P. 12-39
4. Check that there is no dirt stuck to the front of
the radiator.
5. If coolant leaks or the engine repeatedly over-
heats, the cooling system is faulty. Have an
authorized dealer perform necessary inspection.
When a fuse has blown
• The fuse box is located under the center panel.

Fuses are also located in the high-current fuse
box.
• If a lamp fails to illuminate or electrical equip-
ment does not function, a fuse may have blown.
Check and replace fuses as necessary.
• Before checking or replacing fuses, turn the
starter switch to the “LOCK” position and push
all switches to the OFF position.
1 Removal and installation of fuse box

cover
1. Pull the bottom of the fuse box cover toward
you to remove the cover.
2. To install the cover, align and insert the tabs
at the top then press the bottom of the cover into
place.
Z11215
2 Removal and installation of high-current

fuse box cover
1. Pull down the clamps , then lift the cover
straight upward to remove it.
2. To install the cover, place it on the box and press
it straight downward. Align the holes of the clips
with the protrusions . While still pressing the
cover downward, retain it with the clamps.
CAUTION
When installing the high-current fuse box cover,
be sure to retain it with the clamps while press-
ing it straight downward. Pushing the cover
toward the inside of the vehicle with excessive
force could break it.
Z12080
13-9
3 Fuse replacement
1. To remove the fuse that is to be replaced, grip it
using the fuse puller in the fuse box. The
amperage and protected circuit of each fuse are
shown on the inside of the fuse box cover and
on the inside of the high-current fuse box cover.
Z11260
2. If a fuse is blown, be sure to select a spare fuse

of the specified amperage for replacement.
WARNING
Be sure to use fuses of the specified amper-
ages.
A fire could result if a fuse of incorrect
amperage is used.
Z11217
CAUTION
• If the cause of a blown fuse cannot be deter-
mined or the same fuse blows frequently,
have an authorized dealer perform neces-
sary inspection.
• Use care not to splash water on or around
the fuse box cover. Should water be
splashed over the fuse box cover, check the
inside of the fuse box for water.
<Fuse box> B13 B15
A2 * A4 * B14 B16 * *
A1 *
S1
B12
M1
B11
M2 B9
B7 B8
M3 M5 M9 B1 B3 B5
B6
M4 M8 B2 B4
M6 M11 Z12081
Fuse
<High-current fuse box> Amperage Protected circuit
No.
A1 15A Cigarette lighter
B30
B29 A2 10A Audio system
Auxiliary power supply
B28 A4 10A (starter switch ACC circuit)
B27 B1 15A Stop lamps
B2 10A Meter cluster
B36
B25 B3 15A Turn signal lamps
B34
B33 B4 10A (circuit directly connected
to battery)
B5 10A Audio system
B6 10A Interior lamps
B7 30A Power window (driver’s)
Power window (assistant
B8 30A driver’s)
Z12082
B9 20A Engine control unit
B11 20A Heater mirror
B12 10A Automatic transmission
B13 15A Tester
B14 20A Headlamps (high beam)
B15 20A Left headlamp (low beam)
Right headlamp
B16 20A (low beam)
B25 15A Tail lamps
13-11
Fuse Amperage Protected circuit

No.
B27 10A Horn
B28 10A Air conditioner
Air conditioner condenser
B29 25A fan
Air conditioner blower fan,
B30 30A
heater blower fan
B33 10A Van body dome light
Automatic transmission
B34 20A fluid cooler fan
B36 20A Engine drive unit
M1 10A Backup lamps
M2 10A Meter cluster
M3 15A Wipers
M4 10A (starter switch ON circuit)
M5 10A Relay control
M6 10A Automatic transmission
M8 10A Exhaust brake
M9 5A Engine control unit
M11 10A ABS
S1 10A Starter
5A
10A
* 15A Spare fuse
20A
30A
4 High-current fuse
There are high-current fuses between the battery
and fuse box, and between the battery and alterna-
tor. These protect circuits in the same way that ordi-
nary fuses do. If a high-current fuse is blown, most
of the vehicle’s electrical circuits become inopera-
tive.
4.1 Inspection
1. Pull down the clamps , then lift the cover
straight upward to remove it. To install the cover,
place it on the box and press it straight down-
ward. Align the holes of the clips with the pro-
trusions . While still pressing the cover
downward, retain it with the clamps.
The amperage and protected circuit of each
high-current fuse are shown on the inside of the
high-current fuse box cover.
Z12080
2. Check for a blown high-current fuse by looking

into the inside through inspection window .
If it is blown, immediately call an authorized
dealer and have them check your vehicle.
Z11258
13-13
Amperage
No. Protected circuit
(casing color)
Fuse box (S1, A1 – A5,
FH1 60A (yellow) M1 – M12)
Fuse box
FH2 60A (yellow) (B1 – B12)
Fuse box
FH3 40A (green) (B13 – B16)
Hydraulic brakes
FH5 60A (yellow) booster
FH5
FH7 40A (green) ABS motor
FH3
FH8 40A (green) ABS valve
FH2 FH8
BATT1 120A (white) Alternator
BATT2 120A (white) Alternator
FH1 FH7
BATT2 BATT1
WARNING
Z12083
Replacement high-current fuses should
always be of the specified amperage. Using a
high-current fuse of incorrect amperage
could cause a fire.
CAUTION
• Close the cover completely to prevent rain
water from entering the fuse box.
• When installing the high-current fuse box
cover, be sure to retain it with the clamps
while pressing it straight downward. Push-
ing the cover toward the inside of the vehicle
with excessive force could break it.
5 Engine preheating circuit fuse
WARNING
Fuses carry electric current constantly. For
safety, disconnect the negative battery cable
before replacing any fuse.
If the indicator lamp does not come on in cold

weather, check whether the glow relay fuse has
Z11262 blown. If it has blown, disconnect the (–) cable from
the battery and replace the fuse with a new one
(127A).
WARNING
Be sure to use fuses of the specified amper-
ages.
A fire could result if a fuse of incorrect
amperage is used.
When a lamp has burn out
Whenever replacing a lamp, be sure to place the

starter switch in the “LOCK” position and all other
switches in the OFF position.
WARNING
Use a lamp of the specified voltage and watt-
age shown in the following table. If a wrong
lamp is used, an excess of current flowing
through the wiring could blow a fuse or
cause the wiring to overheat and could pos-
sibly cause a fire.
CAUTION
• Do not directly touch the glass part of a halo-
gen bulb with your fingers. Any oil and other
substances contaminating the glass surface
could shorten the bulb’s service life.
• The turn signal lamps have plastic lenses.
Do not clean these lenses with alcohol or
thinner. Also, be careful not to splash brake
fluid on them when adding it to the braking
system. Contact with such a substance
could discolor or crack the lenses. If such a
substance gets on a plastic lens, immedi-
ately wipe it off or rinse it off with water.
• Burnt bulbs should be replaced as soon as
possible.
NOTE:
In rainy weather and when the vehicle is washed,
condensation can form on the inside surfaces of the
headlamp lenses. Just as the windows mist up in
rainy weather, the condensation forms owing to a
temperature difference between the inside and out-
side. This phenomenon does not affect the head-
lamps’ functionality. It disappears naturally.
13-15
Z12087
Ref. No. Lamp Bulb wattage Q’ty

Headlamp 12V-60/55W 2
Parking lamp 12V-5W 2
Front and side turn signal lamp 12V-21W 2
Stop/tail lamp (double filament) 12V-21/5W 2
Rear turn signal lamp 12V-21W 2
Backup lamp 12V-21W 2
License plate lamp 12V-7.5W 1
License plate lamp <Crew-cab or FG 12V-8W 2
models>
Clearance and side marker lamp 12V-7.5W 2
Identification lamp 12V-7.5W 3
Interior lamp 12V-10W 1
Interior lamp <rear seats of Crew-cab 12V-10W 1
models>
1 Headlamp bulb replacement

For safety and simplicity, bulb replacement is per-
formed with the headlamp removed. The front and
side turn signal lamp and dummy lamp must be
removed before the headlamp can be removed.
1.1 Headlamp removal and installation

• Headlamp removal
1. For removal of the headlamp , first remove the
screw and rivet , then move the lamp rub-
ber under the headlamp toward the centerline
of the vehicle and release it from the tabs .
CAUTION
When removing the lamp rubber, do not pull it
Z11264 with excessive force or the tabs could break.
2. Open the door, then loosen the screws

behind the front and side turn signal lamp and
the screw behind the dummy lamp until
they spin freely.
NOTE:
The screws are designed not to come out.
Z11265
3. Pull out screw toward you.
CAUTION
Unless the screw is pulled out, the front and
side turn signal lamp and dummy lamp will
catch on it and you will not be able to remove
them.
Z11266
4. Close the door.

5. Remove the front and side turn signal lamp
toward the outside of the vehicle, then remove
the connector .
CAUTION
• When removing the front and side turn sig-
nal lamp, do not pull it forward (toward the
front of the vehicle) or its tabs could break.
• Do not open the door with the front and side
Z11267 turn signal lamp moved outward (but not
completely removed) or the door could hit
and damage it.
13-17
6. Remove the screw at the bottom of the

dummy lamp , then remove the lamp toward
the outside of the vehicle.
Z11268
7. Remove the headlamp’s bolts and connectors

.
Z11269
CAUTION
• Do not turn the beam adjusting screw .
Turning the beam adjusting screw would
change the beam setting, thus creating a
nuisance for drivers of other vehicles. If you
accidentally turn the beam adjusting screw,
have an authorized dealer perform neces-
sary inspection.
Z11270 • When setting down the removed headlamp,
place it on a soft cloth to avoid scratching
the lens.
8. Raise the headlamp slightly to remove the tabs

from the holes , then pull it out toward you.
Z11271
• Headlamp installation
1. Insert the tabs on the headlamp into the
holes , and fit the headlamp in place.
Z11272
2. Fit the headlamp’s bolts and connectors .
Z11625
3. Pull out the screw in the vehicle.

4. Insert the stud pin on the dummy lamp into
the grommet hole , fit the dummy lamp in
place, and tighten the bottom screw .
CAUTION
Do not tighten the screw too tightly or the
mounting could get damaged.
Z11273
5. Install the connector on the front and side turn

signal lamp .
6. Pull out screws .
7. Align the tabs with the holes , then press
the lamp in toward the centerline of the vehicle.
Z11274
13-19
8. Open the door, then tighten the screws

behind the front and side turn signal lamp and
the screw behind the dummy lamp .
CAUTION
• Press the front and side turn signal lamp
fully in toward the centerline of the vehicle. If
the lamp was not pressed fully into place
and you opened the door, the door could hit
Z11624 the lamp and damage it.
• Do not tighten the screws too tightly or the
mounting could get damaged.
9. Fit the lamp rubber under the headlamp

onto the tabs by moving it toward the outside
of the vehicle.
10. Fit the rivet , then press in the screw .
Z11275
1.2 Headlamp bulb replacement

• Removal
1. Remove the cover by pressing it and turning it
in the direction of arrow .
2. Pull the connector toward you to remove it.
3. Remove the spring that retains the bulb .
4. Remove the bulb.
• Installation
1. Align the tabs on the bulb with the grooves ,
fit the bulb in place, and retain the bulb with the
Z09155 spring.
2. If the packing is dirty, clean it. If the packing is
twisted, untwist it.
3. Securely press the connector into place.
4. Fit the cover by pressing it and turning it in the
direction of arrow .
1.3 Parking lamp bulb replacement

1. Turn the socket in the direction of the arrow
to remove it.
2. Remove the bulb .
3. Perform installation by following the removal
steps in reverse.
4. If the packing is dirty, clean it.
Z11276
2 Front and side turn signal lamp bulb

replacement
1. Open the door.
2. Turn the socket in the direction of arrow to
remove it.
3. Press the bulb and turn it in the direction of
arrow to remove it.
4. Perform installation by following the removal
steps in reverse.
5. If the packing is dirty, clean it.
Z11278
3 Interior lamp bulb replacement

3.1 Other than crew-cab models
1. Insert a flat-blade screwdriver into the
notches and use it to release the tabs on
the bottom of the lens . Remove the lens.
2. Push the bulb retainer in the direction of the
arrow and remove the bulb .
3. To install the lens, insert the tabs on the bot-
tom of the lens, align the tabs on the top of the
lens, and press the lens into place.
Z11279
3.2 Crew-cab models <front and rear seats>

1. Insert a flat-blade screwdriver between the
lens and the interior lamp and use it to
release the tabs on the bottom of the lens.
Remove the lens.
2. Push the bulb retainer rightward and remove
the bulb .
3. To install the lens, insert the tabs on the top of
the lens and press the bottom of the lens into
place.
Z09125
4 Replacing other lamps

1. Loosen the screw that secures the lens then
remove the lens.
2. Turn the bulb counterclockwise while pressing it
and remove it.
3. Insert a new bulb and turn it clockwise.
4. Fit the lens, ensuring that the packing is cor-
rectly positioned. If the packing is incorrectly
installed or twisted, water can enter the lamp
and shorten its life. If the packing is dirty, clean
it.
5. Uniformly tighten the screws that retain the lens.
13-21
When braking is sluggish
Depress the brake pedal harder than usual, down-

shift to use engine braking and activate exhaust
braking to stop the vehicle. Apply the parking brake
when necessary. After the vehicle has been brought
into a stop, check parts, then have an authorized
dealer perform necessary inspection.
Z11281
WARNING
• Pulling the parking brake lever with full
force while driving could cause the vehicle
to topple over.
• Never continue driving with the brake sys-
tem malfunctioning or leaking fluid.
If the engine stalls while the vehicle

is in motion
The vehicle will be set into the following very dan-

gerous condition. Pull the vehicle over when safe to
do so and try to start the engine.
• The braking force reduces extremely. You must
exert additional force on the brake pedal to
Z11282
apply the brakes.
• The power steering system then becomes inop-
erative, making steering extremely difficult.
Additional force must be used when turning the
steering wheel.
If a tire goes flat while the vehicle is

in motion
Avoid sudden braking. Hold the steering wheel

firmly, and gradually slow down before pulling over
at a safe place.
To replace the tire, select a flat surface where your
vehicle will not hinder traffic. P. 12-55
Z11283
When the battery has run down
Perform the following procedure to start your engine

by connecting your battery to the well charged bat-
tery of another vehicle with booster cables.
CAUTION
• Use booster cables able to handle large cur-
rents.
• Your vehicle’s electrical system operates on
a 12V power supply. Confirm that the vehicle
giving the boost also has a battery or batter-
ies connected for 12V power supply.
1. Stop the engine of the vehicle giving the boost.

<Connection>
2. Connect one end of the red booster cable to the
positive (+) terminal of the dead battery. Con-
nect the other end of the red booster cable to
the positive (+) terminal of the booster battery.
3. Connect one end of the black booster cable to
Booster the negative (–) terminal of the booster battery
battery and connect the other end of the black booster
cable to a section of frame on the vehicle with
Dead the dead battery at a point as far away as possi-
battery ble from the battery.
<Disconnection>
WARNING
• Check the battery’s fluid level before con-
necting booster cables. If the fluid is below
the “LOWER” level line, add battery fluid
or distilled water. If the battery was
Booster charged with an excessively low fluid
battery level, it would deteriorate rapidly and
could overheat or explode.
Dead • Be careful not to connect the booster
battery Z12096 cables in the wrong sequence. Sparks are
often produced when you connect the
booster cable to the vehicle’s frame.
Therefore, if the cable is connected to a
section of the frame near the battery, the
spark could set off the hydrogen given off
by the battery to cause an explosion. Be
sure to connect the cable end to a point as
far away as possible from the battery.
Also, keep cigarettes and open flames well
away from the battery.
• Unless absolutely necessary, avoid start-
ing the engine by towing or pushing the
vehicle. Doing so is dangerous because
the brakes work poorly and the steering
wheel becomes very difficult to turn.
Note that it is not possible to push-start an
automatic transmission vehicle.
13-23
4. After the above connections have been com-

pleted, start the engine of the vehicle with the
booster battery and let it run at an RPM slightly
higher than idling speed. Then, attempt to start
the engine of the vehicle with the dead battery.
If the engine starts with difficulty because of cold
weather or a dead battery, let it draw a charge
for several minutes from the vehicle from which
you are receiving the boost before attempting to
turn over the engine.
5. After the engine of the vehicle with the dead bat-
tery has been started, disconnect the booster
cables by reversing the order of connection.
When the fuel has run out

(Bleeding the fuel system)
When the vehicle runs out of fuel and the engine

stalls, also when the fuel filter has been replaced, or
if water has been drained from the fuel filter, air that
has entered the fuel system prevents the engine
from being started even if the engine has been refu-
eled after running dry.
In these cases, bleed the fuel system by performing
the following steps.
WARNING
• A fire could result if there is a fuel leak or if
spilt fuel is not removed. Always wipe off
spilt fuel after air bleeding. Also be sure to
check for fuel leakage.
• The working space for air-bleeding is tight.
Be careful not to injure yourself on the
edges of nearby parts.
CAUTION
The fuel injection system may fail if the engine
stops due to lack of fuel.
1. Connect a hose with an inside diameter of 8

mm (0.31 in.) to one of the air vent plugs of
the fuel filter.
NOTE:
• Use whichever of the two air vent plugs is the
most convenient; both plugs provide the same
effect. Do not use both plugs together.
• Use a transparent hose so you can easily check
for air bubbles in the drained fuel.
• If no hose is available, cover the air vent plug
Z12088 area with a clean cloth and perform air bleeding.
2. Loosen air vent plug on the fuel filter by using a
wrench.
3. Operate manual pump to pump fuel.
4. Fuel containing air bubbles comes out from the

air vent plug.
Operate the manual pump a few dozen times
more until the emerging fuel no longer contains
bubbles.
5. When fuel is bubble-free, firmly tighten the air
vent plug. Then, operate the manual pump sev-
eral more times until it becomes hard to press.
When the fuel is cold, the manual pump may not
become hard to press. Even so, you must oper-
ate the manual pump several times after tighten-
ing the air vent plug.
10 ± 2 N·m (7.2 ± 1.4 ft.lbs.,

Tightening torque 1 ± 0.2 kgf·m)
6. After the fuel system has been completely bled,

wipe off spilt fuel and start the engine.
7. Check that there is no fuel leakage.
Towing
If you are forced to tow the vehicle, take the follow-

ing precautions:
• Disconnect either the propeller shaft or the rear
axle shaft, whichever is easier.
If you disconnect the rear axle shaft, cover the
opening to prevent oil and grease from escap-
ing.
CAUTION
Before towing an automatic transmission vehi-
cle, disconnect the propeller shaft or rear axle
shaft. Alternatively, tow the vehicle with its rear
wheels off the ground. Towing the vehicle with-
out taking these precautions would damage the
automatic transmission.
13-25
• To prevent damage to the front bumper when

raising the front wheels, attach an L-shaped pro-
tection plate.
• Attach the towing chain securely to the front
axle.
CAUTION
• Do not attach the chain to the bumper since
L-shaped the bumper would be damaged upon raising
protection Chain the front wheels or towing.
plate • Before raising the front wheels or towing,
confirm that the chain will not damage the
stabilizer or any other part of the vehicle.
If the chain looks likely to cause damage,
use a thicker L-shaped protection plates to
hold the chain further from the vehicle.
• Tow the vehicle only with a specially
designed towing truck.
• If you disconnect the rear axle shaft to tow
the vehicle, the axle housing gear oil may be
depleted. Check the axle housing gear oil
and add more if necessary. P. 12-28
Z12074
• Never use the tie-down hook(s) under the

<FE>
frame for towing purpose. The tie-down hook
is to secure the vehicle when transporting it.
If the hook is used for towing, damage to the
front bumper or frame may result.
<FG>
Z12565
When the vehicle becomes stuck in

soft ground
<FG>
If the vehicle becomes stuck in sand, mud, or snow,
free it by driving forward and backward.
P. 7-11
If this method is not successful, free the vehicle by
towing it as described below.
CAUTION
• Use the towing method described in this
section only to free the vehicle from soft
ground. To tow the vehicle in the event of a
breakdown, use the method described in the
previous section.
• The stranded vehicle must be unloaded com-
pletely.
• Never use the tie-down hook(s) under the
<FE> frame for towing purpose. The tie-down hook
is to secure the vehicle when transporting it.
If the hook is used for towing, damage to the
front bumper or frame may result.
<FG>
Z12565
1. Tow the stranded vehicle using a vehicle whose

gross weight is equal to that of the stranded
vehicle (14,050 lbs., 6,375 kg). Attach the rope
or wire rope to the towing hook of the towing
vehicle.
13-27
2. Attach the other end of the rope or wire rope to

the towing hook of the stranded vehicle. If nec-
essary, use another towing hook that is located
behind the left-hand side rail.
WARNING
To avoid the risk of a serious accident, make
sure the rope or wire rope is strong enough
Towing hook to tow the stranded vehicle and make sure it
Z12524 does not slip off either vehicle’s towing hook.
3. For the sake of safety, the angle formed by the

15° tow rope when hooked up should be limited to
15° the range indicated in the illustration. Do not tow
a vehicle under conditions which could impose
sudden undue stress on the hooks (for instance,
towing a vehicle out of a ditch) as doing so could
break the hooks.
4. Start each vehicle’s engine and prepare to start
15° driving.
5. If the rope or wire rope is slack, eliminate the
15° slackness by moving the towing vehicle.
Z11290 6. Slowly drive both vehicles forward. Do not race
either vehicle’s engine.
7. When the towed vehicle becomes free, promptly
stop it each vehicle by applying the brake pedal.
To make the rope or wire rope easy to remove
from the towing hooks, let it become slightly
slack before stopping the towed vehicle.
14-1
14. Service data
Recommended lubricants/hydraulic fluids and quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Service data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
14-2 Service data
Recommended lubricants/hydraulic fluids and quantities
1 Quantities of lubricants/hydraulic fluids

liters (qts)
Item Quantity
FE Approx. 9 (9.5)
Oil pan
Engine FG Approx. 10 (11)
Oil filter Approx. 1 (1.1)
5-speed Approx. 3.6 (3.8)
Manual transmission
6-speed Approx. 4.4 (4.6)
Automatic Total quantity Approx. 12.9 (14)

transmission Replacement quantity Approx. 6.4 (6.8)
Transfer <FG> Approx. 3.1 (3.3)
FE Approx. 4.5 (4.8)
Axle housing Front axle Approx. 3.0 (3.2)
FG
Rear axle Approx. 4.5 (4.8)
Models other than FE85 Approx. 1.9 (2.0)
FE
Power steering FE85 Approx. 2.3 (2.4)
FG Approx. 1.8 (1.9)
Brake fluid (for both brakes and clutch) As required
CAUTION
The indicated oil and fluid quantities should be used only as a guide at the time of replacement. To
ensure correct oil and fluid levels, use the oil level gauge, inspection plug holes, and level lines as
appropriate.
14-3
2 Recommended lubricants/hydraulic fluids

Be sure to use the specified lubricants.
Viscosity
Parts Category Classification Atmospheric SAE viscosity
temperature number
Below 0°C (32°F) 10W–30
Above –15°C (5°F) 15W–40
API CD, CD/SF, CE, –15 to 15°C 20W–20
Engine Engine oil CE/SF, CF-4 or JASO (5 to 59°F)
classification DH-1
–5 to 40°C
(23 to 104°F) 30
Above 30°C (86°F) 40

General 80
API GL-3
Gear oil Warm region 90
Manual transmission API GL-4 Tropical region 90
Transfer <FG>
Engine oil
Long period of high-
<not applicable to API CC speed driving 30 or 40
transfer>
Exxon Mobil:
Automatic transmis- Automatic transmis- Mobil ATF3309 or – –
sion sion fluid
equivalent
Below 40°C (104°F) 90
Axle housing *1 Gear oil API GL-5
Above 40°C (104°F) 140 or 85W–140
Limited-slip API GL-5
differential <vehicles Gear oil for limited-
with limited slip differ- slip differential Genuine Gear Oil, – 90
Part No. 8149630EX
ential>
Power steering Automatic transmis- DEXRON, DEXRON – –

sion fluid II or DEXRON III type
SAE J1703,
Brake, Clutch Brake fluid FMVSS No. 116 – –
(Grade DOT3)
Chassis grease
nipples (rear spring NLGI No. 1 (Li soap)
pin, king pin) Consistency 310 to
Door hinge Chassis grease 340 (at 25°C or 77°F) – –
Anchor hooks Dropping point 130°C
<Vehicles other than (266°F) or higher
Crew-cab models>
Wheel hub bearing NLGI No. 2 (Li soap)
Propeller shaft Wheel bearing Consistency 265 to
grease
(universal joint, slip (Multipurpose type 295 (at 25°C or 77°F) – –
joint, double cardan Dropping point 185°C
joint <FG>) grease) (365°F) or higher
Consistency 220 to
250 (at 20°C or 68°F)
Propeller shaft center Dropping point 250°C
Bearing grease – –
bearing (482°F) or higher
Usable temperature
range –40 to 150°C
(–40 to 302°F)
*1: At ambient temperatures higher than 10°C (50°F), use an oil conforming to GL-5, SAE140 or SAE85W-140 if the vehi-
cle is used under such a heavy load conditions as continuous upgrade climbing.
14-4 Service data
Service data
Description Standard value

Engine idling speed 625 to 675 rpm
New belt (when installed):
9 to 11 mm
(0.35 to 0.43 in.)
Vehicles without air
conditioner Used belt (when inspected
or reinstalled):
Belt tension [amount of deflection 11 to 13 mm
under a 98 N (22 lbs., 10 kgf) pres- (0.43 to 0.51 in.)
sure at the point midway between pul- Fan belt New belt (when installed):
leys] 7 to 9 mm
(0.28 to 0.35 in.)
Vehicles with air
conditioner Used belt (when inspected
or reinstalled):
10 to 11 mm
(0.39 to 0.43 in.)
Approx. 14.4 liters
Coolant quantity (15.2 qts)
0.2 to 4 mm
Clutch pedal play (at center of pedal pad) (0.0079 to 0.16 in.)
0.1 to 3 mm
Brake pedal play (0.0039 to 0.12 in.)
Fully depressed brake pedal to floor clearance 20 mm (0.79 in.) or more
Parking brake lever stroke 7 to 9 notches
5 to 50 mm
Steering wheel play (as measured on the periphery of steering wheel) (0.2 to 1.97 in.)
Tire tread groove depth 1.6 mm (0.06 in.) or more
440 to 540 N·m
Wheel nut tightening torque (325 to 398 ft.lbs.,
45 to 55 kgf·m)
LT215/85R16-10PR 550 kPa
FE84 (Load Range E) (80 psi, 5.5 kgf/cm2)
215/75R17.5
Tire inflation pressure 690 kPa
FE85 124/123L (100 psi, 7.0 kgf/cm2)
(Load Range F)
LT235/85R16-10PR 550 kPa
FG (Load Range E) (80 psi, 5.5 kgf/cm2)
15-1
15. Maintenance schedule
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
15-2 Maintenance schedule
Regular maintenance is vital to maximizing your vehicle’s performance, service life, and safety.
Following the maintenance schedule will give optimum results.
The preceding sections describe simple maintenance checks and procedures that can be carried out by the
owner. If you have difficulty or your vehicle needs maintenance work that is not shown in this manual, please
take the vehicle to an authorized dealer.
1 Maintenance schedule
For the replacement intervals of lubricants and fluids, see the section entitled “Lubrication schedule”.
: Exhaust emission items.

: Noise control items.
Time of inspection and maintenance
Inspection interval
New vehicle at 4,000 km/
Every 250,000 km/

Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Ref.
Item Working procedures page
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
ENGINE
Leakage of Check the underneath of
coolant, fuel and × the vehicle for any sign of –
oil leakage.
Check the engine for
Engine
conditions × smooth starting and quiet –
running.
Check inlet exhaust mani-
Manifold bolts and
nuts torque × fold bolts and nuts for –
looseness.
Check and
Check valve clearance with
adjust valve clear- × × thickness gauge. –
ance
Oil filter Every 10,000 km/6,000 miles or Replace oil filters. 12-32
replacement 12 months
Fuel filter Every 20,000 km/12,000 miles or Replace fuel filter. 12-34
replacement 12 months
Inspect the fuel tank, cap
Every 20,000 km/12,000 miles or
Fuel line and lines for damage caus- –
12 months ing leakage.
Belts tension Every 10,000 km/6,000 miles or Inspect belts for crack, wear
and damage × 12 months and tension. 12-46
Check radiator and pres-

sure cap for sealing perfor-
mance and mounting
condition.
Inspect hoses for loose-
Cooling system × ness, deterioration, damage –
causing leakage.
Remove dust and foreign
matter deposit from radia-
tor and intercooler front.
15-3

Inspection interval

Every 250,000 km/

Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Ref.
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
Check that the coolant level

is between the “FULL” and
Coolant level × “LOW” marks on the reser- 12-41
voir tank.
Coolant Every 24 months Replace coolant. 12-39
replacement
Turbocharger Check turbocharger rotor
rotor play × play. –
Clean air cleaner element

Air cleaner Every 5,000 km/3,000 miles by blowing clean com- 12-36
element pressed air.
Air cleaner
Replace air cleaner
element replace- × element. 12-36
ment
Inspect the exhaust system
Exhaust for damage, corrosion and
system × loose connection causing –
leakage.
POWER TRAIN
Check the clutch pedal for
Clutch pedal play × play 12-52
Check the pedal for free

Clutch pedal and
clutch disc wear × play. 12-51
Check clutch disc wear.
Range selector Check the operate perfor-

Every 30,000 km/18,000 miles
lever × or 6 months mance of range selector 12-47
lever
Propeller shaft Check flange yoke bolts for
flange torque and
universal joint
× looseness and universal –
joint for play.
looseness
Check center bearing if
Propeller shaft trace of grease flowing out
center bearing × is evident. –
Check center bearing for
wear, damage and play.
FRONT AND REAR AXLE
Wheel hub Check wheel hub bearing
bearing × for play. –
When wheel hub bearing

Wheel hub bear- grease is replaced, also
ing hub seals × replace the wheel hub bear- –
replacement ing hub seals.

Inspection interval

Every 250,000 km/

Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Ref.
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
Check disc wheel for corro-

sion, deformation and
cracks.
Measure inflation pressure
with tire gauge.
Check tire tread and side
× × wall for cracks and damage. 12-52
Wheel and tire Measure tire tread groove
depth to make sure it is
deep enough.
Check tire tread for uneven
wear, stepped wear and
other abnormal wear.
× Rotate all tires. 12-62
Check wheel nuts for loose-
ness.
Retightening
wheel nuts × × Check at the first 50 to 100 12-61
km/30 to 60 miles after
changing a wheel.
SUSPENSION SYSTEM
Suspension Check for broken springs

springs × and tilt of vehicle body –
toward either side.
Check U-bolt nuts for loose-
ness.
Retightening Check at the first 1‚000 km/
U-bolts × × 600 miles after removing –
and retightening U-bolt
nuts.
BRAKING SYSTEM
Service brake Check brake pedal play and
pedal × stroke. 12-49
Depress the brake pedal

Brake and check that the brakes
performance × work effectively and evenly 12-50
on all wheels.
Disc brake pad Check disc brake pad and
and disc × disc for damage and wear. –
Check lining for wear

Brake lining × through inspection hole.
Disassemble and check –
Brake drum × drum for wear, crack and
damage.
Parking brake Check parking brake lever
lever stroke × stroke. 12-51
15-5

Inspection interval

Every 250,000 km/

Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Ref.
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
Inspect brake lines and

hoses looseness, play and
Looseness, play damage.
and damage of
brake system × Inspect wheel cylinder and –
brake master cylinder for
parts looseness, play and dam-
age.
STEERING SYSTEM
Turn steering wheel right
Steering wheel and left to measure play at
play × steering wheel rim. Mea- 12-48
sure while engine is run-
ning.
Check that the steering
wheel does not vibrate or
Steering wheel pull to one side and that it is
operation × not unduely heavy. Also 12-49
make sure that the steering
wheel returns to its neutral
position smoothly.
Check steering system for
looseness, steering wheel
play and operating condi-
Steering system × tion. Inspect for oil leaks, 12-48
booster and oil pump func-
tion.
CAB
Make sure that warm air 9-3,
Defroster × blows properly onto the 9-7
windshield.
Seated in the driver’s seat,
adjust the angles for clear
Rearview mirrors × views of the sides and rear. –
Make sure the mirrors are
clean.
License plate and Check the license plate and

reflector condition × reflectors for loose installa- –
tion, damage, and dirt.
Push down the lock knob
and verify that the door
Door locks × does not open even when –
the inner handle is oper-
ated.
Confirm that the seat belt
buckles function correctly
Seat belts × when fastening and unfas- –
tening.

Inspection interval

Every 250,000 km/

Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Ref.
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
ELECTRICAL SYSTEM
Press the horn button to
Horn operation × check that the horn is work- –
ing properly.
Confirm that the windshield
Windshield washer fluid level is above
washer fluid level × the bottom of the inspection 12-64
window.
Windshield wiper Check the washer for

proper fluid spray direction
and washer opera- × and the wipers for normal 5-21
tion
action.
Make sure that each lamp
lights up or flashes properly.
Lighting system × Check lamp lenses for dirt 5-18
and damage.
Gauge, warning/ Check that gauges, warning
indicator lamp × lamps and indicators are 6-2
operation working properly.
15-7
2 Lubrication schedule
: Exhaust emission items.

Inspection interval
New vehicle at 4‚000 km/

Every 20,000 km/

Every 10‚000 km/
Every 30‚000 km/
Every 40‚000 km/
Every 50‚000 km/

Item Reference page
12,000 miles
18‚000 miles
24‚000 miles
30‚000 miles
2‚500 miles
6‚000 miles
Engine oil level ×
12-18
Engine oil replacement × ×
Manual transmission oil level ×
12-22
Manual transmission oil replacement × ×
Automatic transmission fluid level × 12-24
replacement × –
Transfer gear oil level <FG> ×

12-26
Transfer gear oil replacement <FG> × ×
Rear axle housing gear oil level ×
Rear axle housing gear oil replacement × ×
Front axle housing gear oil level <FG> × 12-27
Front axle housing gear oil replacement

<FG> × ×
Hub bearing grease replacement × –

Front axle birfield joint grease
replacement <FG> × –
Front axle kingpin bearing grease

Front axle steering knuckle grease

Brake fluid level × 12-30

Brake (and clutch) fluid replacement × –
Power steering fluid level × 12-30
Power steering fluid replacement × –
Center bearing × –
Universal joint, slip
Lubrication of joint × 12-15
propeller shaft
Double cardan joint
<FG> × 12-15
Lubrication of rear suspension spring

pin ×
12-15
Lubrication of kingpins ×

Inspection interval
New vehicle at 4‚000 km/

Every 20,000 km/

Every 10‚000 km/
Every 30‚000 km/
Every 40‚000 km/
Every 50‚000 km/

Item Reference page
12,000 miles
18‚000 miles
24‚000 miles
30‚000 miles
2‚500 miles
6‚000 miles
Lubrication of door hinge × 12-18
Lubrication of anchor hook
<Vehicles other than Crew-cab models> × 12-18
16-1
16. Alphabetical index

16-2 Alphabetical index
4WD operation FG models> ............................. 8-1 Fuse ................................................................ 13-8

Accelerator pedal ............................................ 5-13 Gearshift lever ................................................ 5-14
Air cleaner ..................................................... 12-36 Greasing ....................................................... 12-15
Air conditioner ................................................... 9-7 Handling of the new vehicle .............................. 1-7
Air filters ........................................................ 12-67 Hazard warning lamp switch ........................... 5-22
Antilock braking system (ABS) .......................... 7-7 Heater ............................................................... 9-3
Ashtrays .......................................................... 10-3 HIGH-LOW selector lever ................................. 8-3
Assistant driver’s seat ....................................... 4-3 Indicator lamps ................................................. 6-5
Automatic transmission fluid ......................... 12-24 Interior lamp .................................................... 10-4
Axle housing gear oil .................................... 12-27 Jacking points ............................................... 12-55
Battery .......................................................... 12-64 Lamp ............................................................. 13-14
Battery has run down .................................... 13-22 Lane changer .................................................. 5-19
Brake fluid ..................................................... 12-28 Lighting switch ................................................ 5-18
Brake pedal ..................................................... 5-13 Limited slip differential .................................... 7-13
Brakes ........................................................... 12-49 Loading cargo ................................................. 7-15
Braking .................................................. 7-7, 13-21 Lubrication .................................................... 12-15
Card holder ..................................................... 10-7 Maintenance record ....................................... 17--3
Central door locks ............................................. 3-4 Maintenance schedule .................................... 15-1
Chassis number ................................................ 1-2 Manual transmission gear oil ........................ 12-22
Cigarette lighter .............................................. 10-2 Mirror heater switch ........................................ 5-23
Cleaning your vehicle .................................... 12-69 New vehicle inspection ..................................... 1-4
Clutch ............................................................ 12-51 Obtaining service .............................................. 1-9
Clutch pedal .................................................... 5-14 Odometer .......................................................... 6-2
Coat hooks ...................................................... 10-4 Oil filter ......................................................... 12-32
Combination switch ......................................... 5-18 Oil level check button .................................... 12-19
Coolant ............................................... 11-2, 12-39 On rough roads and in bad weather ............... 7-11
Cup holder ...................................................... 10-6 On uphill and downhill roads ............................. 7-9
Dimmer switch ................................................ 5-19 Overdrive switch ............................................. 5-17
Door window glass ............................................ 3-6 Parking ........................................................... 7-12
Doors ................................................................ 3-2 Parking brake ............................................... 12-51
Draining water from fuel filter ........................ 12-38 Parking brake lever ......................................... 5-17
Driver’s seat ...................................................... 4-2 Passing signal ................................................ 5-19
Engine idling control volume ............................. 5-5 Periodic inspection ............................................ 1-4
Engine number ................................................. 1-2 Possible failures, causes and remedies ......... 13-2
Engine oil ............................................ 11-2, 12-18 Power steering fluid ...................................... 12-30
Engine overheats ............................................ 13-7 Power window lock switch ................................ 3-7
Entering and leaving the vehicle ....................... 3-4 Power window switches .................................... 3-6
Exhaust brake ................................................. 5-20 Powerline label ................................................. 1-2
Free-wheeling hub ............................................ 8-6 Precautions for driving ...................................... 7-3
Front air outlets ................................................. 9-2 Precautions when setting the vehicle in
motion ............................................................... 7-2
Front drive switch .............................................. 8-3
Pre-operational check ............................. 1-4, 12-8
Fuel filter ....................................................... 12-34
Range selector lever ............... 5-15, 12-10, 12-47
Fuel gauge ........................................................ 6-4
Rear seat .......................................................... 4-3
Fuel has run out ............................................ 13-23
Recommended lubricants ..................... 14-2, 14-3
Fuels ....................................................... 1-5, 11-2
Reporting safety defects ................................... 1-8
Alphabetical index 16-3
Rheostat control switch ................................... 5-22

Seat belts .......................................................... 4-4
Seats ................................................................. 4-2
Service data .................................................... 14-4
Small article compartments ............................. 10-5
Speedometer .................................................... 6-2
Starter key ......................................................... 3-2
Starter switch .................................................... 5-3
Starting the engine ............................................ 5-6
Steering wheel .................................................. 4-7
Stopping the engine ........................................ 5-12
Sun visors ....................................................... 10-4
Tachometer ....................................................... 6-2
Tilting the cab .................................................. 12-5
Tips for improving fuel economy ....................... 7-6
Tire chains ...................................................... 11-4
Tire replacement ........................................... 12-55
Tire rotation ................................................... 12-62
Tires .............................................................. 12-52
To reach the engine access opening .............. 12-4
Towing .......................................................... 13-24
Tripmeter ........................................................... 6-2
Turn signal lamp switch .................................. 5-19
Van body dome light switch ............................ 5-22
V-belts ........................................................... 12-46
Vehicle identification number (VIN) ................... 1-3
Warming up the engine ................................... 5-10
Warm-up switch ................................................ 5-4
Warning labels .................................................. 2-1
Warning lamps .................................................. 6-5
Washer switch ................................................. 5-21
Water temperature gauge ................................. 6-3
Wheel nuts .................................................... 12-61
Window regulator handle .................................. 3-7
Windshield washer ........................................ 12-64
Wiper blade ................................................... 12-63
Wiper switch .................................................... 5-21
FEFG.book Page -3 Thursday, March 10, 2005 7:30 PM
17. MAINTENANCE RECORD
NOTE:
The symbols and prefixed to some check items
stand for Exhaust Emission Control item and Noise
Control item respectively.
17-1
New Vehicle: 4,000 km/2,500 Miles

FREE INSPECTION AND SERVICE CERTIFICATE
(NVI)
Owner’s Name:
Address:
City, State: Zip:
Vehicle identification number
J L
Date NVI was Performed:
Mileage at time of NVI:
Dealer Code of Servicing Dealer:
Dealer Reference R.O./Dealer Claim No.:
Dealer imprint / Dealership Name and Address
I certify the above identified truck has been thoroughly inspected and adjusted in accordance
with the “4,000 km/2,500 miles free inspection and service” procedures prescribed by MFTA.
FE/FG
Dealer Representive Signature Date
(MFTA COPY)

(NVI)
Owner’s Name:
Address:
City, State: Zip:
J L
FE/FG
(DEALER COPY)

(NVI)
Owner’s Name:
Address:
City, State: Zip:
J L
FE/FG
(OWNER COPY)
NEW VEHICLE: 4,000 km / 2,500 miles

SERVICE OPERATIONS
Owner’s name: Date:
Address:
Vehicle identification number:
Lubrication Inspection and maintenance

Engine oil replacement Engine
Manual transmission oil replacement Check and adjust valve clearance
Transfer gear oil replacement <FG>
Front and rear axle
Rear axle housing gear oil replacement
Retightening wheel nuts
Front axle housing gear oil replacement <FG>
Suspension system
Retightening U-bolts
10,000 km / 6,000 miles 10,000 km / 6,000 miles

SERVICE OPERATIONS SERVICE OPERATIONS

Owner’s name:
Address:
Lubrication
Date: Engine oil replacement (or 12 months)
Transmission oil level
Transfer gear oil level <FG>
Address: Rear axle housing gear oil level
Front axle housing gear oil level <FG>
Power steering fluid level
Lubrication of universal joints, slip joint
Lubrication of double cardan joint <FG>
Lubrication of rear suspension spring pin
Lubrication of king pins
Lubrication of door hinge
Total mileage: Inspection and maintenance
Engine
Oil filter replacement (or 12 months)
Servicing dealer’s name: V-belts tension and damage (or 12 months)
Air cleaner element cleaning
Power train
Clutch pedal and clutch disc wear
Propeller shaft flange torque and universal joint
looseness
Front and rear axle
Address:
Wheel and tire
Braking system
Disc brake pad and disc
Brake lining
Looseness, play and damage of brake system parts
Signature: Steering system
Steering system
1
20,000 km / 12,000 miles 20,000 km / 12,000 miles


Owner’s name:
Address:
Lubrication
Transmission oil or fluid level
Engine
Servicing dealer’s name: Fuel filter replacement (or 12 months)
Fuel line (or 12 months)
V-belts tension and damage (or 12 months)
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Signature: Suspension system
Spring U-bolt nuts
Braking system
Brake lining
Steering system
Steering system
3
30,000 km / 18,000 miles 30,000 km / 18,000 miles


Owner’s name:
Address:
Lubrication
Manual transmission oil replacement
Address: Transfer gear oil replacement <FG>
Wheel hub bearing grease replacement
Front axle birfield joint grease replacement <FG>
Front axle kingpin bearing grease replacement <FG>
Front axle steering knuckle grease replacement <FG>
Total mileage: Lubrication of rear suspension spring pin
Servicing dealer’s name: Lubrication of anchor hook
Inspection and maintenance
Engine
Address:
Power train
Operate performance of range selector lever
(or 6 months)
Front and rear axle
Wheel hub bearing
Signature: Wheel hub bearing hub seals replacement
Wheel and tire
Braking system
Brake lining
Brake drum
Steering system
Steering system
5
40,000 km / 24,000 miles 40,000 km / 24,000 miles


Owner’s name:
Address:
Lubrication
Transmission oil level (Manual)
Address: Automatic transmission fluid replacement
Rear axle housing gear oil level
Total mileage: <Vehicles other than Crew-cab models>
Engine
Servicing dealer’s name: Oil filter replacement (or 12 months)
Fuel filter replacement (or 12 months)
Cooling system
Air cleaner element replacement
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Signature: Retightening wheel nuts
Suspension system
Braking system
Brake lining
Steering system
Steering system
7
50,000 km / 30,000 miles 50,000 km / 30,000 miles


Owner’s name:
Address:
Lubrication
Address: Rear axle housing gear oil replacement
Brake (and clutch) fluid replacement
Power steering fluid replacement
Lubrication of propeller shaft center bearing
Total mileage: Lubrication of anchor hook
Servicing dealer’s name: Engine
Manifold bolts and nuts torque
Check and adjust valve clearance
Coolant replacement (24 months)
Address:
Power train
Propeller shaft center bearing
Front and rear axle
Wheel and tire
Signature: Braking system
Brake lining
Steering system
Steering system
9
60,000 km / 36,000 miles 60,000 km / 36,000 miles


Owner’s name:
Address:
Lubrication
Transmission fluid level (Automatic)
Engine
Address:
Cooling system
Exhaust system
Power train
Signature: Operate performance of range selector lever
(or 6 months)
looseness
Front and rear axle
Wheel hub bearing
Wheel hub bearing hub seals replacement
Wheel and tire
11 Continued on reverse side

Suspension system
Braking system
Brake lining
Brake drum
Steering system
Steering system
12
70,000 km / 42,000 miles 70,000 km / 42,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Address: Retightening wheel nuts
Braking system
Brake lining
Steering system
Steering system
Signature:
13
80,000 km / 48,000 miles 80,000 km / 48,000 miles


Owner’s name:
Address:
Lubrication
Automatic transmission fluid replacement
Address: Transfer gear oil level <FG>
Engine
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Suspension system
Braking system
Brake lining
Steering system
Steering system
15
90,000 km / 54,000 miles 90,000 km / 54,000 miles


Owner’s name:
Address:
Lubrication
Front axle gear oil replacement <FG>
Engine
Address:
Power train
(or 6 months)
Front and rear axle
Wheel hub bearing
Wheel and tire
Braking system
Brake lining
Brake drum
Steering system
Steering system
17
100,000 km / 60,000 miles 100,000 km / 60,000 miles


Owner’s name:
Address:
Lubrication
Address:
Cooling system
Exhaust system
Power train
Signature: Propeller shaft flange torque and universal joint
looseness
Front and rear axle
Wheel and tire
Suspension system

Braking system
Brake lining
Steering system
Steering system
20
110,000 km / 66,000 miles 110,000 km / 66,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
Signature:
21
120,000 km / 72,000 miles 120,000 km / 72,000 miles


Owner’s name:
Address:
Lubrication
Transmission oil or fluid replacement
Total mileage: Lubrication of king pins
Servicing dealer’s name:
Engine
Address:
Cooling system
Exhaust system
Power train
Signature: (or 6 months)
looseness
Front and rear axle
Wheel hub bearing
Wheel and tire
Suspension system

Braking system
Brake lining
Brake drum
Steering system
Steering system
24
130,000 km / 78,000 miles 130,000 km / 78,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
Signature:
25
140,000 km / 84,000 miles 140,000 km / 84,000 miles


Owner’s name:
Address:
Lubrication
Engine
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Spring U-bolt nuts
Braking system
Brake lining
Steering system
Steering system
27
150,000 km / 90,000 miles 150,000 km / 90,000 miles


Owner’s name:
Address:
Lubrication
Total mileage: Lubrication of universal joints, slip joint
Servicing dealer’s name: Lubrication of king pins
Engine
Address:
Power train
Signature: Clutch pedal and clutch disc wear
(or 6 months)
Front and rear axle
Wheel hub bearing
Wheel and tire

Braking system
Brake lining
Brake drum
Steering system
Steering system
30
160,000 km / 96,000 miles 160,000 km / 96,000 miles


Owner’s name:
Address:
Lubrication
Engine
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Suspension system
Braking system
Brake lining
Steering system
Steering system
31
170,000 km / 102,000 miles 170,000 km / 102,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
Signature:
33
180,000 km / 108,000 miles 180,000 km / 108,000 miles


Owner’s name:
Address:
Lubrication
Engine
Address:
Cooling system
Exhaust system
Power train
Signature: Operate performance of range selector lever
(or 6 months)
looseness
Front and rear axle
Wheel hub bearing
Wheel and tire

Suspension system
Braking system
Brake lining
Brake drum
Steering system
Steering system
36
190,000 km / 114,000 miles 190,000 km / 114,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
Signature:
37
200,000 km / 120,000 miles 200,000 km / 120,000 miles


Owner’s name:
Address:
Lubrication
Automatic transmission oil replacement
Total mileage: Lubrication of door hinge
Servicing dealer’s name: Inspection and maintenance

Engine
Address:
Cooling system
Exhaust system
Power train
Signature: Clutch pedal and clutch disc wear
looseness
Front and rear axle
Wheel and tire
Suspension system

Braking system
Brake lining
Steering system
Steering system
40
210,000 km / 126,000 miles 210,000 km / 126,000 miles


Owner’s name:
Address:
Lubrication
Engine
Address:
Power train
(or 6 months)
Front and rear axle
Wheel hub bearing
Wheel and tire
Braking system
Brake lining
Brake drum
Steering system
Steering system
41
220,000 km / 132,000 miles 220,000 km / 132,000 miles


Owner’s name:
Address:
Lubrication
Engine
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Spring U-bolt nuts
Braking system
Brake lining
Steering system
Steering system
43
230,000 km / 138,000 miles 230,000 km / 138,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
Signature:
45
240,000 km / 144,000 miles 240,000 km / 144,000 miles


Owner’s name:
Address:
Lubrication
Transmission oil or fluid replacement
Total mileage: Lubrication of king pins
Servicing dealer’s name:
Engine
Address:
Cooling system
Exhaust system
Power train
Signature: (or 6 months)
looseness
Front and rear axle
Wheel hub bearing
Wheel and tire
Suspension system

Braking system
Brake lining
Brake drum
Steering system
Steering system
48
250,000 km / 150,000 miles 250,000 km / 150,000 miles


Owner’s name:
Address:
Lubrication
Lubrication of center bearing
Turbocharger rotor play
Address:
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
49
260,000 km / 156,000 miles 260,000 km / 156,000 miles


Owner’s name:
Address:
Lubrication
Front axle gear oil level <FG>
Engine
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Spring U-bolt nuts
Braking system
Brake lining
Steering system
Steering system
51
270,000 km / 162,000 miles 270,000 km / 162,000 miles


Owner’s name:
Address:
Lubrication
Engine
Address:
Power train
(or 6 months)
Front and rear axle
Wheel hub bearing
Wheel and tire
Braking system
Brake lining
Brake drum
Steering system
Steering system
53
280,000 km / 168,000 miles 280,000 km / 168,000 miles


Owner’s name:
Address:
Lubrication
Engine
Cooling system
Exhaust system
Address:
Power train
looseness
Front and rear axle
Wheel and tire
Suspension system
Braking system
Brake lining
Steering system
Steering system
55
290,000 km / 174,000 miles 290,000 km / 174,000 miles


Owner’s name:
Address:
Lubrication
Engine
Power train
Front and rear axle
Wheel and tire
Braking system
Brake lining
Steering system
Steering system
Signature:
57
300,000 km / 180,000 miles 300,000 km / 180,000 miles


Owner’s name:
Address:
Lubrication
Total mileage: Lubrication of universal joints, slip joint
Servicing dealer’s name: Lubrication of king pins
Engine
Address:
Cooling system
Signature: Coolant replacement (24 months)
Exhaust system
Power train
(or 6 months)
looseness

Front and rear axle

Wheel hub bearing
Wheel and tire
Suspension system
Braking system
Brake lining
Brake drum
Steering system
Steering system
60

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Pub. No.

Pub. No. MH998808

OWNER AND VEHICLE INFORMATION

CITY, STATE: ZIP:

VEHICLE IDENTIFICATION NUMBER:

DATE OF DELIVERY (WARRANTY START DATE): / /

SELLING DEALER IMPRINT HERE

© 2005 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

Reading the handbook

Precautions that should be taken when handling dangerous sub-

NOTE: Suggestions or supplementary information for more efficient use of

Q California Proposition 65 Warning

1. Recommendation to drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Each chapter has a table of contents on its first page.

Chassis and engine numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Recommendation to drivers

Chassis and engine numbers

If presented at the time of repair or parts order, the

The powerline label located in the position shown

Vehicle identification number (VIN)

The VIN is stamped on a plate that is located as

1-4 Recommendation to drivers

Checking your vehicle at regular intervals is very

1 New vehicle inspection

Use only diesel fuels conforming to the following

Use condition Recommendation

2 Danger of fire and explosion by using

1-6 Recommendation to drivers

3 Adverse effects of mixed fuel on engine

• 125-liter fuel tank

Fuel tank capacity

• 113-liter fuel tank <optional for FE (except

Fuel tank capacity

Handling of the new vehicle

The way the vehicle is handled when new greatly

1-8 Recommendation to drivers

At 4,000 km (2,500 miles)

2 Maximum engine speed during run-in

Maximum engine RPM during run-in period

Z08646 1,800 rpm

Reporting safety defects

If you believe that your vehicle has a defect that

At Mitsubishi Fuso Truck of America, Inc. (MFTA),

STEP 1: Contact your Nearest Authorized Dealer

STEP 2: Contact MFTA

Please be prepared to provide the following infor-

Locations in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Warning labels

• The caution and warning labels show important

Limited slip differential 113-liter fuel tank

Voltage Hydraulic brake booster <FE85>

Transfer lever <FG> Towing <Automatic transmission vehicles>

Hydraulic brake booster Fuse

2-4 Warning labels

Engine inspection hatch Cab tilt function

Locations outside cab