FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

5FGC/5FDC18-30 Series. Please use this manual for providing quick, correct
servicing of the corresponding forklift models.

This manual deals with the above models as of August 1986. Please understand
that disagreement can take place between the descriptions in the manual and
actual vehicles due to change in design and specifications. Any change or
modifications thereafter will be informed by Toyota Industrial Vehicles' Parts &
Service News.

For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with this manual.

(Reference)
Repair manuals related to this manual are as follows:

TO YO TA INDUSTRIAL VEHICLE 4 Y ENGINE

REPAIR MANUAL (No. CE602)
TOY0TA INDUSTRIAL VEHICLE 2 J ENGINE
REPAIR MANUAL (No. CE603)

TOYOTA MOTOR CORPORATION

 SECTION INDEX

GENERAL
- - -

TORQUE CONVERTER
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
REAR AXLE
I STEERING
BRAKE
BODY
y 0

' MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
APPENDIX
 GENERAL

Page
VEHICLE EXTERIOR VIEWS .......................... 0-2
VEHICLE MODELS ...................................

ABBREVIATIONS & TIPS ON OPERATION ..........

STANDARD BOLT & NUT TIGHTENING TORQUE ...

PRECOAT BOLTS .....................................

HIGH PRESSURE HOSE FllTlNG
TIGHTENING TORQUE .............................

FRAME NUMBER ....................................

SAFE LOAD BY WIRE ROPE

SUSPENSION ANGLE .............................

WIRE ROPE SUSPENSION ANGLE LIST .............

CAPACITY AND TYPES OF
SPECIFIED LUBRICANTS ..........................

LUBRICATION ........................................
PERIODIC MAINTENANCE TABLE ...................

PERIODIC REPLACEMENT PARTS &

LUBRICANTS ......................................
VEHICLE EXTERIOR VIEWS

Vehicle Front View LAPI 8-8

Vehicle Rear View LAPI 8-4

VEHICLE MODELS

I Ser~es
I
Payload 1
I
Model
I
Mounted
englne
I1
E n g ~ n etype
I I
Power
transmlsslon
I
Remarks

I I
2ton
,I 1 7 5 i o n 5FGC18 4Y Gasollne 1 Torque converter as standard
I
I
serles
I I PS equ'pped
I
1
I
2 . 0 ton
I
42: nei;:g: i Torque converter

I I
i 225ton I 5FGC23 4Y Gasollne I Torque converter 1
I I I

1 1 5FGC25
5FDC25
I
42: nieE:: I
Torque converter I t

3 ton 2 7 5 ton 5FGC28 1 4Y Gasolne Torque converter

serles

3 0 ton
1
5FGC30
5FDC30
I

1 4Y
2J
' GasOilne
Diesel
Torque converter
i
ABBREVIATIONS
The abbrev~at~ons
used In thls manual are as follows:

I Abbreviat~on I / 1 I
,1
Meaning Abbrev~ation Meaning
1 1 I

ABDC 1 After bottom dead center 1 P/S 1 Power steering

I ASSY Assembly RH / Righthand I
ATDC 1 After drop dead center SAE
I

Soc~etyof Automot~ve
Engineers
BBDC
LH
LLC
11 Before bottom dead center
Lefthand
~ o n gl ~ i ecoolant
11 SST
STD
1
Special service tool
Standard

I
OHV Overhead valve Subassembly
I OPT Option SUB-ASSY
T= T ~ g h t e n ~ ntorque
g
I
Oversize OOT I Number of teeth (00)
Horsepower 1 Undersire

TIPS ON OPERATION

1. Safe operation
( 1 ) Make sure that correct size wire rope is used when lifting a heavy material.
(2) After jacking up, always support with a rigid rack or stand.
2. Preparation of SSTs and measuring Instruments
( 1 ) Prepare necessary SSTs and measuring instruments before startlng repair
operation.
3. Neatness and underlines
( 1 ) Keep the working place neat and orderly to make operation easler.
(2) Hydraulic equipment should be disassembled with clean tools in clean places.
4. Genulne Toyota parts
Always use genuine Toyota parts even for packlngs, gaskets and o-rings which are
-replaced after each disassembly work.
5. Repairs on electrrcal system
Before doing any repair on the electrical system, disconnect the cables from battery
terminals.
Always disconnect the negative (-) terminal first.
6. Tightening torque at the time of installatron
Be sure to observe the tightening torque given In thls mannual. If not specified,
tlghten to the torque listed in "Standard Bolt & Nut t~ghteningTorques."
7. Grasplng the defect status
When a defect is found, do not immediately start disassembly and replacement. First
check if the defect needs disassembly and replacement for repair. For example, do
not disassemble the torque converter for a defect of vehicle starting failure but check
such factors as the oil status, hydraulic pressure and rotation which directly cause the
defect.
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and nut ttghtening torques are not ~ndicated
Therefore, judge the tightening torque as descr~bedbelow

1 Find out the type of bolt from the list below Then, judge the bolt tightenrng torque from the
tightening torque table
2 The nut tightening torque can be judged in the same way according to the type of the mating
bolt

DlSRlMlNATlON OF BOLT STRENGTH

1 Discriminat~onby actual bolt 2 Discrimination by part number

1 Shape and description

I
Strength
code
Hexagon bolt /
I

4=4T Part number example

1 Number in relief or 5=5T
I hallmark on head 6=6T 3 4 06 0
Hexagon -
7=7T
bolt I I I
Standard ; I
I I
head
I No mark
1
L- Nominal size
Hexagon (mm)
bolt

head I I
I
Hexagon 1 I 1 l ~ o m ~ ndlameter
a l
I Bolt with two relief
Standard I llnes on head
Length to bottom surface of head
bolt I
I
Hexagon I Stud b o l t 1
bolt I Bolt with two relief
Collar I n e s on head
6T
Part number example
head I

Hexagon
bolt
1 I
1 Boit w ~ t hthree relief
llnes on head
I
7T
9 2 1 3 2 - 4 06 14

I
I
! under head
imm)
Lnai;;; siz;

Strength code

Nomlnal d~ameter

Length

BAHS28 BAHS2
 --

TIGHTENING TORQUE TABLE

~ Standard t ~ g h t e n ~ ntorque
g kg-cm (ft-lb)

1 Standard
head
Collar
head
 - - - - - -

PRECOAT BOLTS I I1

(Bolts coated wrth seal lock agent on threads) I

1 Do not use the precoat bolt as it I S In

I
any of the follow~ngcases
I
(1) When the precoat bolt I S removed
(2) When the precoat bolt 1s moved
(loosened or tightened) rn tighten-
rng check etc
I
I
Reference : I
The tightening torque must be checked Precoat 601ts 84460

with the lower limit of the allowable

tightening toque range. If the bolt moves,
retighten it according to the following
procedure:

2. Reusing the precoat bolt

( 1 ) Clean the bolt and threaded hole. (2) Dry the precoat bolt sufficiently by
(Clean the threaded hole even alr blowing, etc
when the precoat bolt IS to be (3) Coat the specifred seal lock agent
replaced. j on the theaded hole for the bolt.

HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE

1. Before connecting a h ~ g hpressure hose, wipe the high pressure hose fitting and mating n ~ p p l e
contact surfaces with clean cloth to remove foreign matters and dirt. Check that there IS no
dent or other surface defect on the contact surface.
2. A l ~ g nthe high pressure hose f~ttingand nrpple and hold the hose In that the state during
tightening.
3. The maximum t ~ g h t e n ~ ntorque
g must not exceed twice the standard t~ghteningtorque.

Standard t~ghtenrngtorque kg-cm (ft-lb) Hose ~ n s ~ d e

N~~~~~~
diameter
of screw
Standard Tighten~ngrange mm

7/16 -20UNF
9/16 -18UNF
3 / 4 -16UNF
1
I
2 5 1 181)
5 0 ( 362)
6 0 ( 43 3)
2 4 - 2 6 1 1 7 3 188)
4 8 - 531347- 383)
5 7 - 63141 2 - 4 5 5 )
6
9
12
7/8 -14UNF 6 0 ( 433) 1 5 7 - 63141 2 - 4 5 5 ) 12
11/16-12UNF 1 2 0 ( 866) 11 4 - 1 2 6 1 8 2 3 - 91 0) 19
15/16-12UNF 1 5 0 ( l O l 1) 1 133-,471960-1061) I 25

PFI / 4 5 0 1 362) 4 8 - 531347- 383) 9

PF3/8 ' 5 0 ( 362) 4 8 - 533347- 383) 9
PF1/2 5 7 - 63141 2 - 455) , 12
PF3/4
PF 1 I
1 2 0 ( 866)
140(101 1) 1 11 4 - 1 2 6 ( 8 2 3 -
133- 1471960-
91 0 )
1061)
19
25
FRAME NUMBER

1
top of rear pan of

Model serles
I

1 2.0 ton serles I 3.0 ton series

Eng~netype , 4Y 2J 4Y 2J

1
I
Model 5FGC 18 5FDC20 5FGC28 5FDC30
5FGC20 5FDC25 5FGC30 -
5FGC23 - - -
I 5FGC25 - - -
Frame ser~alnumber format 5FGC25-10001 5FDC25- 10001 5FGC30- 10001 5FDC30- 10001
'5FGC25E10001 "5FDC25E10001 '5FGC30E10001 '5FDC30E10001

. EEC spec. (1992. 1 1 -)

SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE Un~t.
ton (Ib)

Un~filar '
Rope Breakdown SusPen- B ~ f ~ l suspension
ar Cross sling~ng
d~ameter load sion
0" 0" 30" 60" 90" 0" 30" 60" 90"
6 rnm 2.18 0.31 0.62 0.6 0.53 0.44 1.24 1.2 1.06 0.88
(0.24 in) ( 4807) ( 683.6) ( 1 367) ( 1323) ( 1 169) ( 970) ( 2734) ( 2646) ( 2337) ( 1 940)

3.2 1 0.9 0.87 0.78 0.64 1.8 1.74 1.56 1.28

O m m 502 0 7 1 1 4 3 1 3 7 12 0 1
(1985) (1918) (1720) (1411 ) ( 3 9 6 9 ) ( 3837)( 3440) (2822)
2 8 2 7 2 4 2 0
( 0 4 in) 1 ( 1 1069) ( 1 565 6) (3153) (30211 (2646) (2205) 11 61 74) ( 5954) ( 5292) (4410)
1
12.5 mrn 7.84 1.12 2.2 ( 4.4 4.2 3.8 3.0
( 0 . 5 ~ n ) ( 1 7287) (2469.5)l(4851) ( 9702) ( 9261) ( 8379) (6615)

14 mrn . 9.83 1.4 2.8 2.7 2.4 1.9 5.6 5.4 4.8 3.8
1
( 0 . 5 6 In) (21675) ( 3 0 8 7 0 ) (6174) (5954) (5292) (4190) ( 1 2348) ( 1 1907) ( 1 0584) (8379)
 --

WIRE ROPE SUSPENSION ANGLE LIST

Suspen- Suspen Suspei I ~ompres- Suspen-
s~on
angle ,
Ten-
"On
C O ~ P ~ ~ S
slon
I strength
, ston
method
SIO~
angle
slon
sion
strength ,
slon
method
1
I
I I
I
I

I I
1
I
1
I
I I 1
I
I

30"
1 t o e
I 027 I
tme times 1 times
I

I
I

60" '
1 1 6 1 058
tmes , tme
/
1 I I
i I
CAPACITY AND TYPES OF SPECIFIED LUBRICANTS

Description Classification TYpe Application Quantity

API Motor oil
SD, SE, SF SAE30
(SAE20 in cold area)
Gasoline 4Y 4.01 (1.06 US gal)
SAE20W-40
Engine (SAE10W-30 in cold
area)
API Diesel engine oil
CC, CD SAE30 (SAE20 in
Deisel cold area) 2J 6.91 (1.82 US gal)

SAEl OW-30

Torque converter AT F GM Dexron@I1 All models 14.OP (3.70 US gal)

Differential API Hypoid gear oil

GL-4 SAE85W-90 All models 6.81 (1.80 US gal)
GL-5

Hydraulic oil IS0 Hydraulic oil # 9 0 2 ton series 27P (7.1 US gal)
VG32 3 ton series 281 (7.4 US gal)

Fuel tank All models 45P ( 1 2 US gal)

Chassis parts MP grease No.2 All models Proper quantity

Coolant LLC LLC 30-50% mixture

(for winter or
all-season) 4Y 9.OP (2.38 US gal)
Coolant with rust~nhi- 2J 9.51 (2.51 US gal)
bitor (for spring,
summer and autumn)
LUBRICATION

Cha~n Inspect every 8 hours (dally)

Differential lnspect every 4 0 hours (weekly)
Front wheel bearlng inspect every 1 7 0 hours (monthly)
Torque converter case lnspect every 1 0 0 0 hours (6monthly)
Rear wheel bear~ng V lnspect every 2 0 0 0 hours (annually)
Steering knuckle king pln 0 lnspect and service
Oil tank Replace
Engine crank case 1 MP grease
Rear axle beam front 2 E n g ~ n eoil
Rear axle beam rear 3 Hypoid gear 011
Tilt steerlng universal jolnt 4 Hydraul~coil
Tllt steerlng locking mechanism 5 Automat~ctransmission f u ~ d
Mast support bushing
T ~ lcylinder
t front pin
Propeller shaft

Lubr~cationChart UPM~
PERIODIC MAINTENANCE TABLE
INSPECTION METHOD
I . Inspect and Correct or replace as required. M : Measure and correct or adjust as requ~red
T . T~ghten C . Clean L : Lubricate
* . For new vehicle * ' . Soapy water '2 Detector "3 . Flaw detector

1 3 6 12 Months
Place
Inspection item Every 170 500 1000 2000 Hours
ENGINE

Engine Starting status and abnormal noise I C t t

proper Revolution in idling state M + + C

Revolution during acceleration M t C C

Exhaust gas I t t +

Air cleaner element C + + +

Valve clearance M* M
Compression M
Cylinder head bolt loosening T" T

Positive Clogging and damage of PCV valve I t C +

crankcase and piping

ventilation
(PCV)

Governor No-load maximum engine speed M t + C

Lubrication Oil leakage I + + +

system Oil level I + t +

Clogging and fouling of oil filter I + t C

Fuel Fuel leakage I C C +

system Carburetor link mechanism operation I t + +

Fouling and damage of oil filter I t t C

element
Injection timing M +

Injection nozzle injection pressure M

and spray status

Cooling Radiator cooling water level and I C C +

system leakage
Rubber hose deterioration I + + C

Radiator cap status I + + t

Fan belt tension, looseness and I + C t

damage
Damage and hardening of radiator I
rubber mount
 1 3 6 12 Months
Place
Every 170 500 1000 2000 Hours

LPG fuel Gas leakage from piping and joints 1*1 t + +

system Damage of pipng and joints 1'2 , t C

Vaporizer tar discharge C t +- +

Looseness and damage of gas I +-- + C

cylinder mounting

POWER TRANSMISSION SYSTEM

Differential Oil leakage I C + +

Oil level I + + +

Loose bolts T

Torque Oil leakage I

-
C C +

converter Oil level I + +

and Operating mechanism function and I + t +

transmis- looseness
sion Control valve and clutch functions I +- + t

I
Inching valve function
Stall test and oil pressure measure-
ment
C t

M -+

Propeller Loose joint I C t

shaft and ~oosenessat spline connection 1

axle shaft Looseness at flexible joint I
Axle shaft torsion and crack I
 1 3 6 12 Months
Place
Every 170 500 1000 2000 Hours

TRAVELING EQUIPMENT

Wheels Tire cuts, damage and uneven wear I + t t

Loose rim and hub nuts T + + t

Tread depth M + C t

Metal fragments, stones or other I - t t

foreign matters on tires

Rim, side bearing and disc wheel I + + +
damage
Front wheel bearing abnormal sound I t + t

and looseness
Rear wheel bearing abnormal sound I - + +-

and looseness

Front axle Housing crack, damage and deforma- I

tion

Rear axle Beam crack, damage and deformation I

Looseness of axle beam in vehicle M* M
longitudinal direction

STEERING SYSTEM

Steering Play and looseness I t C +

wheel Operating status I + C t

Gear box Oil leakage I + + t

Looseness of installation T + + +

Power Oil leakage I t + +

steering Looseness of mounting and linkage I +- C C

Power steering hose damage I

 1 3 6 12 Months
Place
Inspection item Every 170 500 1000 2000 Hours

Knuckle King pin looseness I + C +

Crack and deformation I

Steering Wheel alignment M

axle Left and right turning angles M

BRAKING SYSTEM

Brake pedal Play and reserve M + + -

Braking effect I +- +- C

Parking Pull margin I + - t

brake Braking effect I t- + +

Looseness and damage of rod and I + t t

cable
Looseness and damage of level link I

Brake piping Leakage, damage and installation I + C t

status

Master Function, wear, damage, oil leakage I

cylinder or and loosening of installation
brake valve
and wheel
cylinder

Brake drum Clearance between drum and lining M e- +- t

and brake Wear at shoe sliding contact portion I

shoe and lining
Drum wear and damage I
Shoe operating state I
Anchor pin rusting I
Fatigue of return spring1 M
Automatic adjusting mechanism func- I
tion

Backing Deformation, crack and damage I

plate Looseness of mounting T
 1 3 6 12 Months
Place
Every 170 500 1000 2000 Hours
MATERIAL HANDLING SYSTEM

Fork Abnormality of fork and stopper pin I t + t

Left and right fork blade misalignment I t + +-

Crack at fork base and welded portion lX3

Mast and Deformation and damage of each I + + C

fork bracket part, crack at welded portion

Looseness of mast and lift bracket I + + t

Mast support bush wear and damage I

Roller wear, damage and rotation +-- C +

status
Roller pin wear and damage I
Mast strip wear and damage I + + +

Chain and Chain tension, deformation and I + C +

chain wheel damage

Chain lubrication I t + t

Abnormality of chain anchor bolt I + + t

Chain wheel wear, damage and I + +.- +

rotation status

Attachments Abnormality and installation status of

each attachment
I t - t

HYDRAULIC SYSTEM

Cylinder Looseness and damage of cylinder T + + t

mounting
Deformation and damage of rod, rod I + + +

screw and rod end

Cylinder operation I + C t

Natural drop and natural forward tilt M + + t

Oil leakage and damage I + t t

Wear and damage of pin and cylinder I + + t

bearing
Lifting speed M + t +-

Uneven movement I + + t

Oil pump Oil leakage and abnormal sound I +-- + t

Tank and oil strainer

Relief pressure measurement

Relief valve and tilt lock valve func-

Deformation and damage

Looseness of joints
Hose tension and torsion

Distributor side terminal burning

Wear and damage of distributor cap
center terminal

Pinion gear meshing

Deformation, crack and damage
PERIODIC REPLACEMENT PARTS & LUBRICANTS Replacement
Every Every six Every 12
month months months months
Every 1 7 0 Every 5 0 0 I Every 1,000 Every 2,000
hours hours hours 1 hours

1 E n g ~ n eoil
E n g ~ n e011filters
a
a
( V e w vehicle)

Cooiihg water (except for

LLC, every two years for
LLC)
Fuei filter

Torque converter oil

Torque converter oil f ~ l t e r
D ~ f f e r e n t ~oil
al

Hydraulic oil

Hydraul~coil filter

Wheel bearing grease

Spark plug
Cyclone air cleaner element
Brake valve rubber parts

Master and wheel cylinder

cups and seals

Power steering hose

a
(Every t w o years)

Power steering rubber parts

a
(Every t w o years)

Hydraulic hose
a
(Every t w o years)

Reservoir tank tube

a
(Every t w o years)

Fuel hose
a
(Every i w o years)

Torque converter rubber a

(Every t w o years)
hose
Chain
a
(Every three years)

Carry out accord~ngto operating hours or months, whichever comes earlier

 ENGINE

Page
GENERAL ....................................... 1-2

ENGINE PERFORMANCE ........................

ENGINE PERFORMANCE CURVES ...............
ENGINE ASSY W/TORQUE CONVERTER
TRANSMISSION ................... .
.........
ENGINE ASSY ...................................
ENGINE SPEED ADJUSTMENT ..................
AIR CLEANER ...................................
RADIATOR ......................................
MUFFLER & EXHAUST PIPE ......................
BATTERY ........................................
STARTING MOTOR ..............................
ALTERNATOR ...................................
ACCELERATOR PEDAL ....................... ...
GENERAL

2J Engine Front View ~ ~ 4 . 7

2J Engine Rear View

- 26 -
4 Y Engine Front Righthand View

4Y Eng~neRear Lefthand View

ENGINE PERFORMANCE

1 Engne 1I Dspiace-
I
No-load
i
I

statlc maxlmum Rated output Max~mumtorque

ment
speed 1 PS/rpm kg-v/rpm
I 1

?-ton seres i !
I 23 2481 2600 50/2500 1 4 5/2200

1 4Y 2237 2700
I
54/2400
I
I
16.5/1800
3-ton series ,
1 2J
I
2481 , 2600 1 50/2500 1 14.5/2200
ENGINE PERFORMANCE CURVES

I I I I I
6 10 14 18 22 26
XI02
Engine speed (rpm)

2J Engine Performance Curves KAHM 19

- 29 -
 u
I I 1 I I I
6 10 14 18 22 27
x 102
Engine speed (rpm)
ENGINE ASSY W/TORQUE
CONVERTER TRANSMISSION
REMOVAL

[2J ENGINE MODELS]

1. Eng~nehood removal
( 1 ) Disconnect the engine hood damper
from the frame bracket.
( 2 ) D~sconnectthe engine hood stay from
the frame bracket.
Removing the Engine Hood LAPZ-'I
( 3 ) Remove the engine hood hinge set
screws (two on each side), and re-
move the englne hood.

2 Toe board removal

3. Battery ASSY removal

( 1 ) D~sconnectthe battery term~nals

Caution:
Always disconnect the battery negative (-)
terminal first.

(2) Remove the battery stopper Removing the Battery ~ ~ ~ 2 . 1 1

(3) Remove the battery ASSY.

4. Battery case removal

( 1 ) Remove the set bolts ( 2 pcs). and
remove the battery.

5 Electr~calwiring and fuel hose disconnec-

tion
(I)Disconnect the starting motor bond
strap
(2) .D~sconnectelectrical wlrings such as
the ~njectionpump solenold cut wir-
in9 Disconnecting the Solenoid Cut Wiring ~ ~ ~ 2 . 1 3
(3) Disconnect the fuel hose

6. Fuel fllter ASSY removal

(I) Disconnect the fuel piping.
( 2 ) Remove the set bolts ( 2 pcs.), and
remove the fuel filter ASSY.

Removing the Fuel Filter

-
 -

7 Air cleaner ASSY removal

( I ) Remove the hydraulic tank breather
( 2 ) Loosen the hose clamp for the alr
cleaner hose
(3) Remove the set bolts ( 4 pcs ) of the alr
cleaner case, and remove the alr
cleaner ASSY

Removing the Air Cleaner

8. Rad~atorcover removal
( 1 ) Remove the set knob, and remove the
fadlator cover.

9. Radiator reservoir tank removal

( I ) Dlsconnect the reservoir tank hose
from the radiator.
(2) Remove the reservoir tank.

Removing the Radiator Cover ~ ~ ~ 2 . 2 8

10. Rad~atorASSY removal

( I ) Loosen the radiator drain plug to drain
the cooling water.
(2) Loosen the engine draln plug to drain
the cooling water.

Cooling Water Drain Plugs 1~~2.33.31

(3) D~sconnectthe torque converter cool-

er hose.

Caution:
Identify the hose connecting positions.

(4) Remove the fan shroud set bolts. and

remove the fan shroud ASSY.

Removing the Fan Shroud ~ ~ 3 . 7

 (5) Remove the rad~ator set bolts, and
remove the radiator ASSY.

Removing the Radiator ~ ~ ~ 3 . 1 0

1 1. Exhaust pipe disconnection

(1 ) Remove the flange set nuts (3 pcs.).
and disconnect the exhaust pipe.

Disconnecting the Exhaust Pipe 1~~3.11

1 2. Accelerator flex~blewire disconnect~on

(1) Disconnect the wire clevis from the
injection pump.
( 2 ) Disconnect, the accelerator cable
bracket from the manifold.

Disconnecting the Accelerator Wire LAP^-13.14

13. Oil pump ASSY removal

(1) Remove the oil pump set bolts (2
pcs.).
(2) Disconnect the oil pump ASSY from
the engine.

Removing the Oil Pump

33 -
1 4. Accelerator pedal W/accelerator bracket
removal
( 1 ) Remove the toe board set bolts, and
removal the accelerator pedal W/ac-
celerator bracket.

Removing the Accelerator Bracket ~~~3.17

15. Torque converter shift rod and inchrng

wire d~sconnect~on.
( 1 ) Remove the set nut. and disconnect
the shift rod.
(2) Drsconnect the clevis, loosen the wire
set nut, and disconnect the inching
wire.

Disconnecting the Torque Convener Link Portion ~~~3-rg.zo

16. Propeller shaft ASSY disconnection

( 1 ) Remove the set bolts ( 2 pcs.), and
remove the propeller shaft cover.
(2) Remove the propeller shaft set bolts ( 4
pcs. on each side), and disconnect the
propeller shaft.

Note:
The propeller shaft may be disconnected
on either the differential side or the
transmission side.

Disconnecting the Propeller Shaft 1-4~1-4.8

1 7 . Parkrng brake cable clamp removal

( I ) Remove the parkrng brake cable clamp
set bolt. and disconnect the cable
from the transmissron case.

Disconnecting the Parking Brake Cable up3-21

-
18. Mount~ngset bolt removal
( 1 ) Remove the engine mountlng set bolts
from the left and right sides.

Removing the Set Bolts LAP3-23

(2) Remove the torque converter trans-

mission mounting set bolts.

19.Check ~fany electr~calwiring, cable or link

IS left connected.

Removing the Set Bolts ~ ~ ~ 3 . 2 2

20. Englne ASSY W/torque converter trans-

mlsslon removal
( I ) Use the SST and remove the engine
ASSY W/transmission.
SST090t0-20111-71

Caution:
Carry out slinging in due consideration of
the center-of-gravity position for safe
operation.

Remov~ngthe Engine ~ ~ ~ 3 . 2 4
[4Y ENGINE MODEL]

1 Eng~nehood removal
( I )Dlsconnect the engine hood damper
from the frame bracket
( 2 ) Dlsconnect the engine hood stay from
the frame bracket
(3) Remove the englne hood hlnge set
bolts ( 2 pcs on each side), and re-
move the engine hood

2 Radlator cover and toe board removal

Removing the Engine Hood LAPIZ-9.10

3. Battery ASSY removal

(I) Disconnect the battery terminals.

Caution:
Always disconnect the battery negative (-)
terminal first.

( 2 ) Remove the battery stopper

( 3 ) Remove the battery ASSY.

4. Battery case removal

( 1 j Remove the set bolts ( 3 pcs.), and
remove the battery case. Removing the Battery ~ ~ ~ 1 2 . 1 7

5 Electr~calwirlng and fuel hose drsconnec-

tion
( 1 ) Disconnect the starting motor bond
strap
(2) Disconnect the connector of each
electrical wirlng
(3) Drsconnect the fuel hose

6. Horn ASSY removal

f l ) Disconnect the wiring at the connec-
tor.
(2) Remove the set bolts ( 2 pcs.) and Removing the Battery Case ~ ~ ~ 1 2 . 1 9

remove the horn ASSY.

7 . Air cleaner ASSY removal

( 1 ) Remove the hydraulic tank breather.
(2) Loosen the hose ciamp for the air
cleaner hose.
( 3 ) Remove the air cleaner case set bolts
( 4 pcs ), and remove the air cleaner
ASSY.

Removing the Air Cleaner

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