Body

General

Cap Interior

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

Cap Exterior
Cap Mounting
Removal ..................................................
Bumper
Components ............................................
Removal ..................................................
Driver's Door
Replacement ...........................................
Adjustment ..............................................
Outside Rear View Mirror
Removal ..................................................

BD -5
BD -9
BD -9
BD -10
BD -14
BD -15

Instrument Panel
Components ............................................
Removal ..................................................
Window Glass
Components ............................................
Removal ..................................................
Installation ...............................................
Interior Trim
Removal ..................................................
Driver's Seat
Components ............................................
Replacement ...........................................
Seat Belt
Components ............................................
Replacement ...........................................

BD -16
BD -18
BD -24
BD -25
BD -25
BD -27
BD -29
BD -31
BD -32
BD -32

General
Specification
Item

Door

Glass Thickness mm(in.)

Specifications

Construction

Front hinged, Full door construction

Regulator system

Wire drum type

Locking system

Pin - fork type

Windshield glass

5.86(0.231)

Door glass

3.5(0.138)

Side window glass (super cab)

3.5(0.138)

Seat belt

E.L.R type

Cab
Item

Specifications

Type

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

Mounting

Rigid or Semi floating type

Windshield

One piece type with laminated glass

Windshield Wipers

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

Driver's Seat

Urethane foam cushioned adjustable to the front & rear / reclining, Semi cloth material

Assistant's Seat

Separate seat, bench seat, semi cloth material

Body type
Item
General

Wooden body reinforced by steel structure

cross sill

Floor

Guard frame
Side & Rear gate

Specifications

Steel square tube

board

Wood plate

frame

Bended steel (Angle)

Bended steel structure
Steel panel

Tightening Torque
Tightening Torque
Item
Nm

Kgf.m

Ib - ft

Door hinge to body

20~29

2.0~3.0

14.4~21.6

Door hinge to door

20~29

2.0~3.0

14.4~21.6

Upper anchor mounting bolt

39~54

4.0~5.5

28.9~39.7

Seat belt height adjuster mounting bolt

39~54

4.0~5.5

28.9~39.7

Retractor mounting bolt

39~54

4.0~5.5

28.9~39.7

Buckle mounting

39~54

4.0~5.5

28.9~39.7

Bolt

34~54

3.5~5.5

25.3~39.7

Nut

37.3~68.6

3.8~7.0

27.5~50.6

Door

Seat belt

Seat

GENERAL SAFETY INFORMATION

Precautions for electric welding
WARNING
When electric-welding the electronic parts which are
con nected directly to the battery, current in the
welding machine can flow through the grounding
circuit to these parts, thus damaging them. Follow
below procedures surely.
1. Turn off all of the electric switches in vehicle.
2. Remove the (-) Battery.
3. Disconnect all of grounding circuits earthed in
vehicle, insulate the current using rubber and etc.
NOTICE
Refer the Electrical Troubleshooting Manual in
relation position of ground terminal.
4. Disconnect all ECU and controller connector.
Engine control system : ECU or ECM
Brake control system : ABS ECU
The other system : ETACS
NOTICE
Refer the Electrical Troubleshooting Manual in
relation position of ground terminal.
5. Do not earth grounding circuit in the welding machine
to the fuel tank.
6. The welding spark should be contacted to the fuel
tank.
7. When tightening ground terminal to the body, clean
the neighborhood of body and tighten it with specified
torque.
Tightening torque.
Item

Outer Diameter of bolt(mm)

Nm

kgfm

lb-ft

Battery (+) cable tightening

M8

88.3~137.3

9~14

65.1~101.3

Battery (+) terminal

M8

88.3~137.3

9~14

65.1~101.3

Battery (-) cable tightening

M10

137.3~156.9

14~16

101.3~115.7

Battery (-) terminal

M6

39.2~58.8

4~6

28.9~43.4

Starter motor

M8

98.1~117.7

10~12

72.3~86.8

Alternator "B" terminal

M8

88.3~137.3

9~14

65.1~101.3

Engine grounding strap

M10

186.3~274.6

19~28

137.4~202.5

Main Fuse box

M8

88.3~137.3

9~14

65.1~101.3

Cab Exterior
Cab Mounting
Removal
1. Place the wooden block (A) at rear wheel.

3. Withdraw the air conditioner refrigerant. (Refer to the

"Heating
ventilation
and
Air
conditioning,
Refrigerant")
4. Taking off the assistant seat crash pad lower panel
screw (A), remove the lower panel (B).

KBD1000A
KMTPA201A

5. Remove the main connector (A)

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

KMTBD110A
EMTEN02A

6. Opening the drain coke (A) of the radiator, drain out

the cooling water.

9. Remove the transmission control cable (A).

KMTBD113A
EMTBD5501A

7. Tilting the cab, remove the accelerator cable (A) and

the engine stop cable (B).

10.Remove the parking

"Transmission")

cable.

(Refer

to

the

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

dropped.
CAUTION
Be caution not to damage the cab with protecting
the parts contacted with the cab.

KMTBD111A

8. Remove the steering yoke(A).

SUDBDA009L

KMTBD112A

12.Loosen the bolt(A), remove slowly the bolt(B) and

nut. Then remove the bolt(A) and bracket(C).

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

KMTBD115A
SUDBDA010L

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

lay down the cab.

16.Support the cab with a jack.

17.Remove the front grill (A).

SUDBD8010D
KMTBD114A

14.Come down the cab with the hoist slowly.

SUDBDA009L

18.After removing the brake pipe (A) and clutch pipe (B),
drain out the brake oil.
NOTICE
Be careful the body is not contaminated by the brake
oil. If it is contaminated, clear out the oil with water
immediately.

KMTBD119A

21.Remove the vacuum hose (A).

KMTBD117A

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

KMTBD120A

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

KMTBD118A

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

air-con.

KMTBD121A

23.The installation is performed in the reverse order of

removal.

Bumper
Components

SUDBDA012L

1. Tightening bolt of bumper

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

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

Wear gloves for protect your hands.

Be careful that the trim and panel are not damaged.

1. Disassemble the connector (A) of the both fog lamp.

KMTBD311A

3. The installation is performed in the reverse order of

the removal.
NOTICE
Be ensured that the connector is firmly tightened.
KMTBD310A

Driver's Door
Replacement

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

Wear gloves for protecting your hands.

Be careful that the trim and panel are not damaged.

Replacement Of The Power Window Switch

Assembly
1. Remove the screw (A) tightening the power window
switch assembly.

KMTBD411A

3. The installation is performed in the reverse order of

the removal.
NOTICE
Be ensured that the connector is firmly tightened.

Replacement of the Door Trim

1. Remove the power window switch assembly. (Refer
to the "Replacement of the Power Window Switch
Assembly")
KMTBD410A

2. After removing the power window switch assembly

(A) by lifting it from the front side to the rear side,
remove the power window connector (B).

2. Loosening the screw (A) tightening the inside handle

housing, disassemble the inside handle housing (B)
from the door trim (C).

KMTBD420A

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

3. The installation is performed in the reverse order of

the removal.

Replacement of the glass and regulator

1. Remove the door trim and the speaker. (Refer to the
"Replacement of the Speaker")
2. After taking off the screw (A) tightening the door pull
hand bracket, remove the door pull hand bracket (B).
NOTICE
From the door inside handle lever, remove the
tightening screw(C) only.

KMTBD421A

4. The installation is performed in the reverse order of

the removal.

Replacement of the Speaker

1. Remove the door trim. (Refer to the "Replacement of
the Door Trim")
2. Disassembling the speaker connector (A) and
loosening the tightening screw (B), remove the
speaker (C).

KMTBD430A

KMTBD440A

3. Remove the door trim seal (A).

KMTBD441A

4. Taking off the glass tightening bolt (A), disassemble

the glass (B) with the regulator (C). Remove the
glass to upward by tilting the glass.
CAUTION
Be careful that the glass surface is not damaged.

KMTBD444A

7. The installation is performed in the reverse order of

the removal.

KMTBD442A

5. Disassemble the window motor connector (A).

NOTICE
When installing the regulator tightening nut, apply
the torque by which the regulator can have moving
clearances. And then, moving the glass up and
down for 2~3 times, tighten the nut with specified
torque.

Replacement of the Latch and Outside Handle

1. Remove the glass. (Refer to the "Glass and
Regulator")
2. Remove the rear panel (A).

KMTBD443A

6. Taking off the regulator tightening nut (A) and the

window motor tightening nut (B), removing the
regulator assembly (C).

KMTBD450A

3. After disassembling the door lock actuator connector

(A), remove the door lock actuator tightening bolt (B).

5. After disassembling the outside link rod (A) and lock

rod (B), remove the latch and door lock actuator
assembly.

KMTBD451A

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

KMTBD453A

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

KMTBD452A

KMTBD454A

7. After taking off the tightening bolt (B) of the outside

handle through the hole (A), remove the outside
handle (C).

Adjustment
1. When the gap between the door and body is
irregular, attach a tape at the edges of the hinge and
door. Using a special tool, loosen the door hinge
tightening bolt so that adjust the gap around the door
to be regular.

H7BD007V
KMTBD455A

8. The installation is performed in the reverse order of

the removal.
NOTICE
When installing the door latch tightening screw,
apply the torque by which the door latch can have
moving clearances. And then, opening and closing
the door for 2~3 times, tighten the door latch
tightening screw with specified torque.

2. To adjust the gap between the door and body is

performed loosening the door hinge tightening bolt
using a special tool.
3. The gearing between the striker and the door latch is
adjusted by increasing and decreasing the shim
being under the striker.

H7BD007W

Outside Rear View Mirror

REMOVAL
1. After taking off the outside rear view mirror rear cover
(A), remove the heat wire connector (B).
(LHD Type)

SUDBDA502L

(RHD Type)

SUDBDA011L

2. After taking off the tightening screw of the outside

rear view mirror, remove the outside rear view mirror.
3. The installation is performed in the reverse order of
the removal.

Cab Interior
Instrument Panel
Components
(LHD Type)

SUDBDA013L

1. Air vent bezel

2. Air vent duct
3. Crash pad lower panel
4. Column cover
5. Ashtray

6. Instrument crash pad

7. Glove box
8. Crash pad lower panel
9. Air vent duct
10. Side panel cover

(RHD Type)

SUDBDA001L

1. Air vent bezel

2. Air vent duct
3. Crash pad lower panel
4. Column cover
5. Ashtray

6. Instrument crash pad

7. Glove box
8. Crash pad lower panel
9. Air vent duct
10. Side panel cover

REMOVAL
1. Remove the steering wheel. (Refer to the Steering
System Group)

3. Remove the tightening screw (A) for instrument facia

panel.
(LHD Type)

2. Taking off the assistants seat crash pad lower panel

screw (A), remove the lower panel (B).
CAUTION
Using a screw driver or remover for removing
work, apply a tape on it to protect the parts.
(LHD Type)

KBD1001A

(RHD Type)
KBD1000A

(RHD Type)

SUDBDA504L

SUDBDA503L

4. Disassemble the emergency lamp connector (A), the

fog lamp connector (B), the heater mirror connector
(C), cigar light connector and the heater & air-con
control connector (D).

6. Taking off the cluster tightening screw (A) and

disassembling the connector, remove the cluster (B).

KBD1004B

KBD1002A

5. Disassemble the temperature controlling switch cable

(B) from the instrument facia panel (A).

7. Taking off the screw (A) installing the audio,

disassemble the antenna jack and the audio
connector. Remove the audio unit (B).
(LHD Type)

NOTICE
When removing the temperature controlling switch
cable, release the locking by pressing the cable
fixing bracket (C) and lay down the cable (B) to
downward.

KBD1005A

KBD1003A

(RHD Type)

9. Taking off the tightening screw (A) of the glove box,

remove the glove box (B).
(LHD Type)

SUDBDA505L

8. Taking off the tightening screw (A) for glove box

linkage, remove the glove box out lead (B).
(LHD Type)

KBD1007A

(RHD Type)

SUDBDA008L

(RHD Type)

SUDBDA507L

SUDBDA506L

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

11.Remove the fuse box cover (A).

(LHD Type)

KBD1009A
KBD1008A

(RHD Type)

12.Remove the working lamp switch (A) and the choke

valve (B).
(LHD Type)

SUDBDA508L

KBD1010A

(RHD Type)

13.Remove the driver's seat side cover panel screw.

(LHD Type)

SUDBDA003L

KBD1012A

(RHD Type)

KBD1011A

SUDBDA004L

14.Remove the assistant's seat side cover panel screw

and the crash pad tightening bolt and screw.
(LHD Type)

KBD1013A

(RHD Type)

SUDBDA005L

15.Remove the instrument crash pad

16.The installation is performed in the reverse order of
the removal.

Window Glass
Components

SUDBDA014L

1. Weather strip
2. Wind shield glass
3. Rear window

Removal

Installation

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

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

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

of the wind shield glass, assemble the weather strip
to the glass.

CSBD117

2. Binding a strip to the gap of the weather strip, install

to the cab panel flange.
CAUTION
Pull the strip at the both ends to the center
portion.
G7BD025B

3. Apply some soap water to the contacting surface of

the body flange.

G7BD025C

4. As shown in figure, pull one end of the strip hanging

in the room side to the both side with maintaining
higher angle than the flange. At the same time, tap
the weather strip portion of the glass from the outside
in order to install to the glass.
A : Straight Line part 10m
B : Straight End portion
CAUTION
Pull the strip from the both ends of the wind
shield to the center portion and press from the
outside of the glass.

G7BD025D

G7BD025E

Interior Trim
2. Remove the weather strip(A).

Removal

(LHD Type)

1. Remove the door scarf plate(A).

(LHD Type)

VTBD039
VTBD037

(RHD Type)

(RHD Type)

SUDBDA510L
SUDBDA509L

3. Remove the rear back trim panel, the grip, the assist
handle and the front filler trim.

4. Remove the seat belt anchorage and the quarter low

& upper trim.

(LHD Type)

VTBD057
VTBD043

(RHD Type)

SUDBDA501L

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

VTBD045

6. The installation is performed in the reverse order of

the removal.

Driver's Seat
Components
<Drivers Seat>
(LHD Type)

EMTBD5001A

(RHD Type)

SUDBDA006L

<Assistants Seat>
(LHD Type)

EMTBD5002A

(RHD Type)

SUDBDA007L

Replacement
1. Loosen the seat tightening nut and bolt(A).
Tightening Torque
Nut : 37.3~53.9 Nm (3.8~5.5 kgfm, 27.5~39.8 lb-ft)
Bolt : 34.3~53.9 Nm (3.5~5.5 kgfm, 25.3~39.8 lb-ft)

VTBD051

2. The installation is performed in the reverse order of

the removal.

Seat Belt
Components

SUDBDA015L

1. Upper anchor
2. Seat belt

3. Retractor
4. Lower anchor

Replacement

2. Loosen the seat belt tightening bolt.

1. Remove the lower quarter trim.

Tightening Torque: 39.2~53.9 Nm (4.0 ~ 5.5 kgfm,

28.9~39.8 lb-ft)
3. The installation is performed in the reverse order of
the removal.

VTBD057