Cab Body

CB
CAB BODY
CONTENTS
PRECAUTIONS FOR OPERATION ..............................................................CB-1
PRECAUTIONS FOR OPERATION ..........................................................CB-1
TOOLS...........................................................................................................CB-3
CAB BODY ....................................................................................................CB-4
REMOVAL AND MOUNTING ....................................................................CB-4
MODIFICATION AND REPLACEMENT ..................................................CB-18
INSTRUMENT PANEL AND CONSOLE RELATED PARTS .......................CB-24
DISASSEMBLY AND REASSEMBLY......................................................CB-24
GLASS.........................................................................................................CB-37
CONSTRUCTION ...................................................................................CB-37
REMOVAL AND INSTALLATION ............................................................CB-38
DOOR ..........................................................................................................CB-39
CAB MIRROR..............................................................................................CB-49
SERVICE DATA ...........................................................................................CB-55
SPECIFICATIONS...................................................................................CB-55
SERVICE DATA.......................................................................................CB-55
TIGHTENING TORQUE ..........................................................................CB-57
PRECAUTIONS FOR OPERATION

Precautions for installing and removing cab assembly
The cab needs to be tilted (5 m or more in height and 3 m or more
in space against the vehicle front part) when it is removed or
installed. Therefore, place the vehicle at the location where a crane
is useable and chock both the front and rear wheels.
Precautions for the cab section attached with black
films
<Section where black films are attached>
 End finisher panel under the front windshield
 Corner panel upper section
CB-1
Precautions for washing a vehicle with high-pressure

water and blowing with air
 Water injection and air blow should be conducted 1.5 m away
from the black film.
 Be sure to inject to the film edge portion at a right angle (90°).
When it is impossible due to any reasons, inject at an angle
larger than 45°. Never inject to the same portion for more than
5 seconds. If you fail to observe this, wrinkle or cracks may
occur on the films.
CAUTION
 When washing a vehicle with high-pressure water, make
sure that water pressure is less than 5 MPa (50 kg/cm2).
Precautions for wiping dirt

 Never wipe using thinner. Be sure to use white gasoline or
alcohols solvent.
Precautions for painting
 Never apply paint to black films.
 When applying paint in accordance with customer's strong
requests, apply paint after peeling off black films. When peel-
ing off black films, be sure to use sticker removing solvent
available in the market.
CAUTION
 When using sticker removing solvent, select and use
solvent which does not affect paint film adversely.
CB-2
TOOLS
TOOLS
Tool name and part No. Application Shape
SMJ bolt too Used when installing the stopper ring onto the Super
99782 Z0000 Multi-Junction (SMJ) bolt
Push bar
99886 Z0003
(6, 8, 10, 12 mm)
Use this to remove the nylon tube.
Push bar
99886 Z0004
(10, 12, 15 mm)
Cab lifter (for standard cab)

1. Cab hanger
99785 Z000A Used to lift the cab by setting the cab lifter hook on the
2. Chain link side rail upper section of the cab.
99783 Z000A NOTE
3. Cab lifter hook (LH)  When placing an order of any parts, refer
99786 Z000A to the part number of each single part.
4. Cab lifter hook (RH)
99786 Z000B
CB-3
CAB BODY
CAB BODY
REMOVAL AND MOUNTING
Key point of removal
<Operation before tilting up a cab>
NOTE
 Perform the works by properly arranging harness and
cables so that they will not excessively be bent or dam-
aged.
1. The cab needs to be tilted (5 m or more in height and 3 m or
more in space against the vehicle front part) when it is
removed. Therefore, place the vehicle at the location where a
crane is useable and chock both the front and rear wheels.
2. Stop the engine and turn the ignition switch OFF. Disconnect
the negative (–) cable from the battery.
3. Completely discharge air, refrigerant, and clutch fluid. As for

how to handle refrigerant gas for the air conditioner, see the
maintenance manual prepared by the air conditioner manufac-
turer.
4. Opening the front lid, disconnect the heater hoses.
NOTE
 Place a container under the heater hose connection to
collect the clutch fluid.
CB-4
CAB BODY
5. Disconnect air hoses, clutch hoses, and car cooler hoses.

NOTE
 Place a container under the clutch hose connection to
collect the clutch fluid.
<Tilting up cab>
1. For lifting the cab, set a hook or rope on a specified position of
the cab.
 As for the cab, open both the right door and the left door and
set the nylon slinger (cross-section: approx. 50 8 mm) at the
upper rear corner of the door opening for lifting.
2. Setting a nylon slinger on the cab, lift it to tilt up slowly. Lift it to
the extent where load is not applied to the tilt stopper.
<Work after tilting up cab>

1. Disconnect joints for the parking brake air hose on both the
cab and the chassis.
2. Disconnect the chassis harness and the cab harness.

3. Disconnect the unit harness connector and remove the har-
ness from the clamp locked to the cab.
4. Scribe the matching marks on the steering gear box (the tip of
the worm shaft) and yoke before loosing the yoke bolt.
CB-5
CAB BODY
5. Disengage the transmission linkage.
6. Remove the nut and bolt which secure the sub-lever and cab
to the upper end of the tilt cylinder.
CB-6
CAB BODY
7. Hold the cab in the tilt-up position by using a crane.

WARNING
 As for the tilted-up cab, securely hold it by using a
crane.
<Lowering the cab in specified position>

1. Lock the tilt cylinder/cable/wire/hose by using sticky tape so
that they do not touch the cab.
2. Slowly lower the lifted cab to the mounting position by using a
crane.
3. Remove the wire or nylon slinger which is set on the cab.
<Work after returning cab to specified position>

1. Remove the cab suspension cap.
2. After disconnecting a SMJ (Supper Multi Junction) connector,

remove the harness clamp.
CB-7
CAB BODY
<Lifting and moving cab>

WARNING
 Never get into under the cab assembly while it is lifted
by a crane.
1. Opening the right and left doors, set the cab lifter on the side
rail upper section of the cab.
2. Release the cab tilt lock and fix it.
3. Lifting the cab slightly, make sure that the cab is held horizon-
tally and is not inclined in any direction.
4. Make sure that all joints between the chassis and cab are dis-
connected properly.
NOTE
 Keep the cab tilt lock in the released state.
5. Slowly moving the cab by using a crane, place it on a stable
stand.
Key point of removal work of first step
<When removing by tilting up first step>
1. Remove the first step cover (upper).
2. Remove bolts/nuts of the joint section of first step bracket/first
step hanger to remove the first step assembly.
CB-8
CAB BODY
<When removing without tilting up first step>

1. Remove the first step cover (lower).
2. Remove bolts/nuts/plastic rivets of the first step and the mud
guard.
3. Removing bolts of the first step cover (upper), remove the first
step while sliding it upward.
4. Remove the first step cover (upper).
CB-9
CAB BODY
Key point of removal work of the lid grille

NOTE
 When you remove the lid grille, the clip may remain on
the front lid. You can easily remove the clip remained on
the front lid by turning the clip 90 deg.
CB-10
CAB BODY
Key point of removal work of the lower grille

The lower grille is locked to the bracket at 6 points. Pinch the clip
with the pliers and remove the lower grille.
CAUTION
 If you pull the lower grille forcibly without removing the
clip, the clip and the lower grille may be damaged.
CB-11
CAB BODY
Key point of removal work of the bumper end cap

Remove the clip by using a screwdriver.
CB-12
CAB BODY
Key point of removal work of the assist grip

1. Notches are located on the lower sections of the caps at the
both ends of the assist grille. Insert the flat-blade screwdriver
into the notch and twist it to remove the cap.
2. After the pawl located on the lower side is disengaged, turn

around the inside of the cap so that the pawl located on the
upper side is not be damaged seriously.
CB-13
CAB BODY
Key point of removal work of the wiper motor

Aligning the bracket behind the motor with the motor opening,
remove the wiper motor.
NOTE
 There is no risk that the motor harness gets stuck or the
panel is damaged by the motor bracket.
CB-14
CAB BODY
Key point of removal work of the washer tube joint

As the dimension B is larger than the dimension A, the joint can be
removed when it is turned 90 °.
CB-15
CAB BODY
Key point of removal/installation work of the interior trim

NOTE
 When the interior trim (rear/side finisher, mold headlin-
ing, carpet, etc.) is removed, there is a risk that clips and
other parts (4 parts described below) may be damaged.
When the clip is damaged, replace it with a new one.
CB-16
CAB BODY
Key point of installation

Installation sequence of the cab assembly is in the reverse order of
its removal.
CAUTION
 Replace the parts (rubber products etc.) which require
replacement with new ones.
1. For installation of the cab assembly, after adjusting so that the
dimensions A and B shown in the figure become equal, install
the cab suspension cap.
2. Install the yoke to the steering gear box and tighten the bolt.
NOTE
 To install the steering gear box and the yoke, match the
marks marked when they were removed.
Tightening torque [N•m {kgf•m}]: 51 - 61 {5.2 - 6.2}
CB-17
CAB BODY
3. When installing cables/wires/hoses, arrange so that they do

not contact each other. 
The SMJ connector bolt will fracture to protect the connector
and terminals from damage if it is tightened with excessive
torque 12 to 18 N•m {1.2 to 1.8 kgf•m}. It must be tightened
with the specified torque.
MODIFICATION AND REPLACEMENT

Procedure for replacing SMJ connector bolts
1. Remove the bolts while loosening them attached to the male

connector. When the bolt is broken, pull to separate the male/
female connectors in the direction shown by the arrow and
pinch the bolt remaining in the male connector with pliers and
remove the bolt while loosening it.
CB-18
CAB BODY
2. Insert a new bolt from the outer side of the male connector.
3. Place, on the surface plate, the male connector to which bolts

are inserted. When assembling the male connector, insert the
stopper ring into the bolt from the inner side and hammer the
stopper ring in the bolt by using the tool SMJ Bolt Tool (99782
Z0000).
4. When jointing the male/female connectors, be sure to tighten

with a specified torque.
NOTE
 The connector bolt will fracture to protect the connector
and terminals from damage if it is tightened with exces-
sive torque 12 to 18 N•m {1.2 to 1.8 kgf•m}. It must be
tightened with the specified torque.
5. After installing the SMJ connector, securely install the box

cover in order to prevent draft or water from entering.
NOTE
 Confirming that the waterproof grommet is properly
seated, attach the cover.
CB-19
CAB BODY
Procedure for assembling the wiper link

Assembly of the wiper link ball joint
CAUTION
 In order to ensure reliable work, perform the assembly
work of the ball joint after removing the wiper link.
 When the pivot assembly and the motor arm are reused,
clean the ball pin surface by using waste cloth and
make sure that flaws/wear/rust are not found. Never use
the ball pin with flaws/wear/rust.
1. Install the joint seal to the retainer at the link end.
NOTE
 Visually make sure that the entire circumference of the
joint seal is securely installed and the joint seal lip con-
tacts the outer circumference.
CB-20
CAB BODY
2. Scooping grease inside the retainer by using a clean stick

such as a toothpick, apply grease to the entire circumference
of the joint seal lip.
3. Bring the joint seal in contact with the top section of the ball pin
without deforming the joint seal.
4. Insert the ball pin into the joint seal without stopping so that air
inside the joint seal does not leak.
5. Confirming that the joint seal is properly installed to the

retainer and the ball pin neck section, press the retainer into
the ball pin.
NOTE
 Visually make sure that the retainer is securely installed
to the entire circumference of the joint seal and that the
joint seal lip contacts the retainer outer circumference.
6. Slide the link and make sure that the joint seal is properly
installed, inversion/twist do not occur, the joint seal is locked to
the retainer, and sliding properly takes place in the ball pin. If
sliding takes place on the retainer, slide the pivot arm while
pushing the joint seal against the retainer so that grease is
fully routed inside to enable sliding on the ball pin.
7. After the link is installed to the vehicle, make sure again that
the ball joint is properly installed and sliding takes place on the
ball pin.
CB-21
CAB BODY
8. Tighten the wiper link and the wiper arm with the specified
torque.
NOTE
 As excessive torque may cause failure of the bolts, be
sure to tighten with the specified torque.
Tightening torque
Item
N•m kgf•m
Wiper link mounting nuts 14 - 20 1.4 - 2.0
Wiper arm mounting nuts 19.6 - 23.5 2.0 - 2.4
CB-22
CAB BODY
Procedure for setting the wiper arm

Set A within the specified adjustment dimensions. B shows the ref-
erence values when the wiper was operated in the wet condition of
the window shield.
Unit: mm
Measured part Adjustment dimension Remarks
A 58 - 63
B 25 - 45 For reference
If the B wiper blade contacts the weather strip during wiper opera-
tion where A is set at the adjustment dimension, replace with the
new wiper link assembly.
Procedure for setting the injection point of washer

solution
Installation of the water nozzle assembly
Make sure that the washer solution target injection position A falls
within the values in the table below.
Unit: mm
Item B C D E
Wiper arm and blade on
35 109 28 17
the driver seat side
Wiper arm and blade in the
35 109 28 17
center
Wiper arm and blade on
50 48 35 25
the passenger seat side
When the washer solution target injection position A is not set prop-
erly, adjust angle of the nozzle section of the washer nozzle assem-
bly by using steel wire.
CAUTION
 Never damage the nozzle section of the washer nozzle
assembly while adjusting the angle.
CB-23
INSTRUMENT PANEL AND CONSOLE RELATED PARTS
INSTRUMENT PANEL AND

CONSOLE RELATED PARTS
DISASSEMBLY AND REASSEMBLY
<R.H.D. model>
CB-24
Disassembling sequence (Reassembly sequence is in the reverse order of disassembly.)

1 Cluster lid A 2 Finisher console front 3 Instrument lower panel (passen-
ger’s side)
4 Console center front (only with con- 5 Console center rear (only with con- 6 Escutcheon RH
sole center) sole center)
7 Cluster lid C 8 Instrument lower panel (center) 9 Instrument lower panel (driver’s
side LH)
10 Instrument lower panel (driver’s 11 Finisher console rear 12 Finisher console center
side RH)
13 Console side 14 Console driver 15 Finisher end (driver’s side)
16 Finisher end (passenger’s side) 17 Fuse lid 18 Instrument panel (driver’s side)
19 Instrument panel (passenger’s 20 Finisher console upper (manual
side) gear shift specification)
Key point of disassembly

1. Remove the cluster lid A.
 By holding the upper part, pull forward. (Remove 2 clips
located on the upper side)
 By holding the lower part, pull forward. (Remove 4 clips
located on the lower side.)
2. Removing the finisher console front.

 By holding the shift opening on the rear end, pull upward
toward the front. (Remove 2 clips on the rear.)
 By holding the right end, pull out sequentially by starting with
the right front. (Remove 4 clips on the front from the right)
 By holding the entire part, pull forward to remove the part.
CAUTION
 Be careful not to damage the finisher and surrounding
parts which are fragile.
 When pulling the parts forward, be careful not to hit the
shift lever and other parts.
 Never pull forcefully as the harness is connected to the
switch.
NOTE
 The finisher console upper of manual gear shift vehicles
can be removed/installed in the mounted state.
CB-25
3. Removing the instrument lower panel (passenger’s side).

 By inserting your hand into the air conditioner lower outlet, pull
forward. (Disengage 2 pawls located on the lower end.)
 By holding the right/left ends, pull forward. (Remove 4 clips
located on the both sides.)
 By holding the right/left ends, pull horizontally. (Remove 4 clips
located on the upper end.)
CAUTION
 When the clip is remaining on the counterpart, carefully
remove and install it to the lower panel.
4. Removing the console center front (with the console center).

 Remove 3 screws.
 By holding the entire part, pull upward. (Disengage the hook
located on the front.)
 Remove the part while moving it toward the passenger seat.
5. Removing the console center rear (with the console center).

 Opening the lid, remove 4 screws.
 By holding the entire part, remove by pulling upward.
6. Removing the escutcheon RH.

 By holding the left end, pull forward. (Remove 2 clips on the
left.)
 By holding the right/left ends, pull forward. (Remove 2 clips on
the right.)
CAUTION
CB-26
7. Removing the cluster lid C.

 Remove 3 screws located on the lower side.
 By holding the right end, pull forward. (Remove 2 clips located
on the right.)
 By holding the upper end, pull out sequentially by starting with
the right.
CAUTION
remove and install it to the cluster lid C.
8. Removing the instrument lower panel (center).

 Remove 3 screws located on the right/left ends.
 By holding the left end, pull forward. (Remove 4 upper clips.)
 By holding the left/upper ends, pull out sequentially from the
left.
 Disengage the pawl on the right end.
CAUTION
NOTE
 As for vehicles equipped with the console box (passen-
ger’s side), implement work after removing the console.
9. Removing the instrument lower panel (driver’s side LH).

 Remove 2 places of push type clips. (Remove by pushing the
center of the clip.)
 By holding the left/upper ends, pull forward once and pull for-
ward while moving upward.
CAUTION
 Remove without hitting the brake pedal.
CB-27
10. Removing the instrument lower panel (driver’s side RH).

 Removing the instrument panel side grip (2 places of upper/
lower bolts)
 Remove a piece of push type clip. (Remove by pushing the
 By holding the right/upper ends, pull forward once and further
pull forward while moving upward.
CAUTION
 Remove while pulling forward the front lid opener lever.
 Remove without hitting the accelerator lever and accel-
erator pedal.
11. Removing the finisher console rear.
 By holding the front end, pull upward. (Remove 2 clips on the
front.)
 By holding the right end, pull upward. (Remove 2 clips on the
rear.)
CAUTION
remove and install it to the finisher console rear.
 When pulling the part forward, be careful not to hit the
hand control lever and other parts.
12. Removing the finisher console center.

 By holding the rear end, pull upward.
 By holding the right end, pull upward. (Remove the clip from
the rear.
CAUTION
13. Removing the console side.

 Remove 2 screws on the front and rear.
 Remove 2 places of push type clips on the front and rear.
(Remove by pushing the center of the clip.)
 Remove by pulling the part upward.
CB-28
14. Removing the console driver.

 Disconnect the joint between the instrument panel and the
console driver.
 By holding the entire part, pull upward.
CAUTION
NOTE
 After removing the instrument lower panel (center),
implement the removal work.
15. Removing the finisher end (driver’s side).

 Remove the instrument side grip. (2 bolts on the upper/lower)
 Remove a piece of screw on the bottom.
 By holding the lower end, pull forward. (Remove one clip in the
center)
CAUTION
remove and install it to the finisher end.
16. Removing the finisher end (passenger’s side).
 Remove the instrument side grip. (2 upper/lower bolts)
 Remove two screws on the right.
 By holding the right end, pull forward. (Remove one clip in the
center)
CAUTION
17. Removing the fuse lid.

 Depress the indication PUSH. (Disengage 2 latches on the
right/left)
 By holding the part end which has risen, pull upward.
CAUTION
 Remove the part after the latch is fully disengaged.
CB-29
18. Removing the instrument panels (driver’s/passenger’s sides).

 Remove 7 screws on the front and 8 screws on the rear.
 Remove the audio system.
 Remove the meter cluster.
 Remove the antenna lead for the radio located near the accel-
erator pedal.
 Remove the joint between the instrument panel and the center
console.
 Remove upward both the driver’s side instrument panel and
passenger’s side instrument panel at the same time.
 Remove the duct behind the instrument panel.
 Remove 5 screws which connect the driver’s/passenger’s side
instrument panels.
CAUTION
 Carefully remove as the air conditioning duct is
installed behind the instrument panel.
19. Removing the ventilator (passenger’s side).

 Remove 3 screws in the periphery of the ventilator case.
 By holding the entire part, pull forward.
20. Removing finisher console upper.

 By holding the rear end, pull upward. (Remove 2 clips on the
rear)
 By holding the front end, pull upward. (Remove 4 clips on the
front.)
CAUTION
shift lever or the other parts.
remove and install it to the finisher console upper.
NOTE
 Except the case of replacing parts of the finisher console
upper, perform work while they are installed on the fin-
isher console front.
Key point of reassembly

Installation sequence is in the reverse order of removal.
CB-30
<L.H.D. model>
CB-31
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1 Cluster lid A 2 Finisher console front 3 Instrument lower panel (passen-
ger’s side)
4 Console center rear (with console 5 Escutcheon LH 6 Cluster lid C
center)
7 Instrument lower panel (center) 8 Instrument lower panel (driver’s 9 Finisher console rear
side LH)
10 Finisher console center 11 Console side 12 Console driver
13 Finisher end (driver’s side) 14 Finisher end (passenger’s side) 15 Instrument panel (driver’s side)
16 Fuse lid 17 Instrument panel (passenger’s
side)
Key point of disassembly

1. Remove the cluster lid A.
 By holding the upper section, pull forward. (Remove 2 clips
located on the upper side)
 By holding the lower section, pull forward. (Remove 4 clips
located on the lower side)
2. Removing the finisher console front.

 By holding the shift opening on the rear, pull forward. (Remove
2 clips on the rear.)
 By holding the right end, pull forward sequentially starting with
the right front. (Remove 4 clips on the front from the right.)
 By holding the entire part, pull forward and remove the part.
CAUTION
gear shift lever and other parts.
 Never pull forcefully as the harness is connected to the
switch.
3. Removing the instrument lower panel (passenger’s side).

 By inserting your hand into the air conditioner lower outlet, pull
forward. (Disengage 2 pawls located on the lower end.)
located on both sides.)
 By holding the right/left ends, pull horizontally. (Remove 4 clips
located on the upper end.)
CAUTION
CB-32
4. Removing the console center rear (with console center).

 Opening the lid, remove 4 screws.
 By holding the entire part, pull forward and remove the part.
5. Removing the escutcheon LH.

 By holding the left end, pull forward. (Remove 2 clips located
on the left.)
located on the right.)
CAUTION
6. Removing the cluster lid C.

 Remove 3 screws on the bottom.
 By holding the right end, pull forward. (Remove 2 clips located
on the right.)
 By holding the upper end, pull forward sequentially starting
with the right.
CAUTION
remove and install it to the cluster lid C.
7. Removing the instrument lower panel (center).

 Remove 2 screws on the right/left.
 By holding the left end, pull forward. (Remove 4 clips located
on the upper section.)
 By holding the left end and the upper end, pull forward
sequentially starting with the left.
 Disengage 2 pawls located on the right end.
CAUTION
NOTE
 As for vehicles equipped with the console center box
(passenger’s side), start works after removing the con-
sole.
CB-33
8. Removing the instrument lower panel (driver’s side LH).

 Remove 2 places of push type clips. (Remove by pushing the
 By holding the left end and the upper end, pull forward once
and pull forward while moving upward.
CAUTION
 Remove without hitting the clutch pedal.
 Remove the front lid opener lever while pulling it for-
ward.
9. Removing the finisher console rear.
 By holding the front end, pull upward. (Remove 2 clips located
on the front.)
 By holding the right end, pull upward. (Remove 2 clips located
on the rear.)
CAUTION
remove and install it to the finisher console rear.
10. Removing the finisher console center.

 By holding the rear end, pull upward.
 By holding the right end, pull upward. (Remove the clip from
the rear.)
CAUTION
11. Removing the console side.

 Remove 2 screws on the front/rear.
 Remove 2 places of push type clip on the front/rear. (Remove
by pushing the center of the clip.)
 Remove the part by pushing it upward.
CB-34
12. Removing the console driver.

 Disconnect the joint of the instrument panel on the front.
 By holding the whole part, pull upward.
CAUTION
NOTE
 After removing the instrument lower panel (center),
remove the console driver.
13. Removing the finisher end (driver’s side).
 Remove the instrument side grip. (2 places of upper/lower
bolts)
 Remove one screw on the bottom.
 By holding the lower end, pull forward. (Remove one clip in the
center.)
CAUTION
14. Removing the finisher end (passenger’s side).

 Remove the instrument side grip. (2 places of upper/lower
bolts)
 Remove 2 screws on the right.
 By holding the right end, pull forward. (Remove one clip
located in the upper center.)
CAUTION
15. Removing the fuse lid.
 Depress the indication PUSH. (Disengage 2 latches on the
right/left.)
 By holding the part end which has risen, pull upward.
CAUTION
 Remove the part after the latch is fully disengaged.
CB-35
16. Removing the instrument panels (driver’s/passenger’s sides).

 Remove 7 screws located on the front and 8 screws located on
the rear.
 Remove the audio system.
 Remove the meter cluster.
 Remove the antenna lead for the radio located near the accel-
erator pedal.
 Remove the joint between the instrument panel and the center
console.
 Remove upward both the driver’s side instrument panel and
passenger’s side instrument panel at the same time.
 Remove the duct behind the instrument panel.
 Remove 5 screws which connect the driver’s side/passenger’s
side instrument panels.
CAUTION
 Carefully conduct this removal work as the air condi-
tioning duct is installed behind the instrument panel.
17. Removing the ventilator (passenger’s side).
 Remove 3 screws located in the periphery of the ventilator
case.
 By holding the entire part, pull forward.

Installation sequence is in the reverse order of removal.
CB-36
GLASS
GLASS
CONSTRUCTION
Part name
1 Front weather strip 2 Front glass 3 Rear weather strip
4 Rear glass 5 Side glass finisher
CB-37
GLASS
REMOVAL AND INSTALLATION

1. Installing the front glass and rear glasses
Fit the weather strip to the edges of the glass and fit a strong string
(5 to 8 mm dia. and 5 to 7 m long) into the outer edge of the
weather strip. Pass the string through a copper pipe (10 mm inner
dia.) and use the pipe as a guide to facilitate.
NOTE
 Placing the end of the string inside the compartment,
align the glass with the cab flange. While pressing the
glass from the outside and tapping it with your palm, fit
the weather strip over the cab flange by pulling the string
from the inside of the compartment.
NOTE
 Do not use a rubber-faced hammer to tap the laminated
glass. Be sure to use your palm.
 Do not tap any glass part other than the hatched area in
the figure.
 Do not tap the part near the weather strip.
2. Always install the front/rear/side weather strips so that the

water drain hole is located at the bottom.
CB-38
DOOR
DOOR
Inside the right door (R.H.D. model)
 When installing the weather strip, use soap water.
CB-39
DOOR
Outside the right door (R.H.D. model)
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.

1 Cap 2 Handle escutcheon 3 Switch finisher
4 Switch assembly 5 Glass protector 6 Door moulding
7 Ash tray 8 Ash tray bracket 9 Door finisher
10 Glass runner 11 Inside handle escutcheon 12 Inside handle
13 Inside handle bracket 14 Waterproof film 15 Door glass
16 Glass runner lower 17 Power window motor assembly 18 Door lock assembly
19 Protector 20 Grommet 21 Outside handle
22 Outside handle bracket 23 Key cylinder assembly 24 Door sash (lower)
25 Lower cover 26 Step light 27 Side turn signal light assembly
28 Harness (for ash tray) 29 Harness assembly 30 Door striker assembly
31 Door hinge assembly 32 Check link 33 Door panel assembly
CB-40
DOOR
Inside the left door (R.H.D. model)
 When installing the weather strip, be sure to use soap water.
CB-41
DOOR
Outside the left door (R.H.D. model)

10 Striker 11 Glass runner 12 Inside handle escutcheon
13 Inside handle 14 Inside handle bracket 15 Waterproof film
16 Door glass 17 Glass runner lower 18 Power window motor assembly
19 Door lock assembly 20 Protector 21 Grommet
22 Outside handle 23 Outside handle bracket 24 Key cylinder assembly
25 Door sash (lower) 26 Lower cover 27 Step lamp
28 Side turn signal light assembly 29 Harness assembly 30 Door striker assembly
31 Door hinge assembly 32 Check link 33 Door panel assembly
CB-42
DOOR
Inside the left door (L.H.D. model)
 When installing the weather strip, be sure to use soap water.
CB-43
DOOR
Outside the left door (L.H.D. model)

10 Striker 11 Glass runner 12 Inside handle escutcheon
13 Inside handle 14 Inside handle bracket 15 Waterproof film
16 Door glass 17 Glass runner lower 18 Power window motor assembly
19 Door lock assembly 20 Protector 21 Grommet
22 Outside handle 23 Outside handle bracket 24 Key cylinder assembly
25 Door sash (lower) 26 Lower cover 27 Side turn signal light assembly
28 Harness assembly 29 Door striker assembly 30 Door hinge assembly
31 Check link 32 Door panel assembly 33 Door panel assembly
CB-44
DOOR
Inside the right door (L.H.D. model)
 When installing the weather strip, use soap water.
CB-45
DOOR
Outside the right door (L.H.D. model)
Disassembly sequence (Assembly sequence is in the reverse order of disassembly.)

10 Glass runner 11 Inside handle escutcheon 12 Inside handle
13 Inside handle bracket 14 Waterproof film 15 Door glass
16 Glass runner lower 17 Power window motor assembly 18 Door lock assembly
19 Protector 20 Grommet 21 Outside handle
22 Outside handle bracket 23 Key cylinder assembly 24 Door sash (lower)
25 Lower cover 26 Side turn signal light assembly 27 Harness (for ash tray)
28 Harness assembly 29 Door striker assembly 30 Door hinge assembly
31 Check link .32 Door panel assembly
CB-46
DOOR

<Removing the power window motor (regulator assembly)
(right door and left door)>
1. Remove the cap.
2. Remove the handle escutcheon by using 2 pieces of flat-blade
screwdrivers.
 By inserting a flat-blade screwdriver into the back of the inside
handle lever, pull the escutcheon backward to disengage the
pawl. By using another flat-blade screwdriver, pry off the han-
dle escutcheon toward outside to remove it.
NOTE
 Carefully conduct this removal work as the hooking pawl
(made of plastic) protrudes on the front part of the han-
dle escutcheon.
3. Inserting a flat-blade screwdriver into the front of the power

window switch (switch finisher), pull upward while pressing the
clip from the clearance and take it out by pulling backward.
NOTE
 Carefully conduct this removal work as the pawl (made of
plastic) protrudes on the rear part of the switch assem-
bly.
4. Remove the glass protector.

5. Remove the door finisher by using a flat-blade screwdriver.
NOTE
 When removing the trim clip, never apply excessive force
so that the door panel and door finisher is not damaged.
Be sure to insert the flat-blade screwdriver into the notch
to remove the trim clip.
CB-47
DOOR
6. Remove while pulling the door finisher upward.

7. Remove the film while cutting the butyl tape (waterproof film)
by using a knife.
8. Adjust height of the glass so that the window glass mounting
bolt aligns with the working hole.
9. Removing the glass holder bolt from the regulator motor
assembly, separate the window glass.
10. Removing 4 bolts which lock the regulator motor assembly to

the door and 4 bolts which lock the slide rail, remove the regu-
lator motor assembly from the working hole.
CB-48
CAB MIRROR
CAB MIRROR
CB-49
CAB MIRROR
Parts name
1 Arm assembly 2 Mirror assembly (back) 3 Ball bushing
4 Holder 5 Screw 6 Cover
7 Base cover 8 Screw (with washer) 9 Arm base (lower)
10 Base packing (lower) 11 Base packing (upper) 12 Arm base (upper)
13 Mirror arm cap 14 Nut (N-lock) 15 Plane washer
16 Washer
NOTE
 The locked type mirror is not retractable. When retracting
by your hand, never apply excessive force.

Removal of left/right base cover
Pull out toward the front of the vehicle while holding the upper/lower
portions with your fingers.
Removal of the right/left mirror assemblt (back)

1. In order to remove the right/left mirror assembly (back), tilt the
mirror main bodies downward from their standard position.
CB-50
CAB MIRROR
2. As clearance is created in the cover notch section A, insert

your finger into the clearance to pull it in the direction shown
by the arrow. and release a pawl of cover.
3. After disengaging both pawls, pull the cover to remove it.
CB-51
CAB MIRROR
4. Remove 4 screws. When 4 screws and the holder are

removed, the main body can be removed.
Key point of installation

Installation of the right/left main mirrors and the right/left
side under mirror
1. Install the ball joint to the arm-pin section.
CB-52
CAB MIRROR
2. Setting the main body on the ball joint, at first tighten the
holder with screws from the side with a convex. Next tighten
the opposite side using screws
Tightening torque [N•m {kgf•m}]: 4.3 - 6.37 {0.4 - 0.65}
NOTE
 Adjust positions of the right/left mirrors in accordance
with the matching marks.
CB-53
CAB MIRROR
3. On completion of correct positioning, install the cover by align-

ing with the arm notch section.
4. After installation is completed, align both matching mark of

mirror arm and mirror base. Adjust and confirm the back view.
CB-54
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Item Standard cab
Overall width of cab (mm) 2,490
Cab tilting system Electro-hydraulic system
Tilt angle 65 degrees
Cab mounting type Full floating type, air suspension
Cab tilt stopper Auto-lock with warning buzzer
Wiper type Triple wiper
SERVICE DATA
CB-55
SERVICE DATA
Unit: mm
Section Item Maintenance standard Service limit
Clearance between door and cab (a) 11.6 - 17.6 –
Clearance between door and cab (b) 4.5 - 6.5 –
Step between door and cab (c) –1 - 1 –
Clearance between upper side of door and cab (d) 6.5 - 8.5 –
Clearance between door and cab (e) 11.6 - 17.6 –
Step between door and cab (f) 1-3 –
Clearance between door and cab (g) 11.6 - 17.6 –
Clearance between door and cab (h) 4.5 - 6.5 –
Step between door and cab (i) 1-3 –
Cab and door Clearance between door and cab (j) 13.6 - 17.6 –
Clearance between door and cab (k) 4.4 - 6.4 –
Step between door and cab (l) –1 - 1 –
Clearance between door and cab (m) 13.6 - 17.6 –
Clearance between upper side of door and cab (n) 7.8 - 9.8 –
Clearance between door and cab (o) 13.5 - 17.5 –
Clearance between door and cab (p) 4.5 - 6.5 –
Step between door and cab (q) –1 - 0 –
Clearance between door and cab (r) 4.5 - 6.5 –
Step between door and cab (s) –1 - 0 –
CB-56
SERVICE DATA
TIGHTENING TORQUE
Tightening torque
Item Remarks
N•m kgf•m
Steering lock bolt 51 - 61 5.2 - 6.2
Bolts are broken at
Cab SMJ (Supper multi junction) connector bolt 3-5 0.3 - 0.5 the time of excessive
body tightening
Wiper link mounting nut 14 - 20 1.4 - 2.0
Wiper arm mounting nut 19.6 - 23.5 2.0 - 2.4
Door striker assembly mounting bolt 12.7 - 20.6 1.3 - 2.1
Door Door lock assembly mounting bolt 5.1 - 6.5 0.5 - 0.7
Door hinge bolt 17.5 - 23.7 1.8 - 2.4
Mirror arm mounting nut 26.0 - 34.0 2.7 - 3.5
Mirror arm base (upper/lower)
7.2 - 10.8 0.7 - 1.1
RH mounting bolt (door side)
Rear view mirror mounting bolt 4.3 - 6.37 0.4 - 0.65
Mirror arm holder mounting bolt 4.3 - 6.37 0.4 - 0.65
R.H.D. Mirror arm mounting nut (upper) 80 - 100 8.2 - 10.2
model Mirror arm mounting nut (lower) 35.0 - 45.0 3.6 - 4.6
Sub-arm mounting bolt (cab side) 7.2 - 10.8 0.7 - 1.1
LH Mirror mounting bolt (rear/under/side-
4.3 - 6.37 0.4 - 0.65
under)
Sub-arm mounting bolt (arm mount-
10.8 - 15.7 1.1 - 1.6
ing)
Cab
mirror Mirror arm mounting nut 26.0 - 34.0 2.7 - 3.5
7.2 - 10.8 0.7 - 1.1
LH mounting bolt
Mirror assembly (main/wide angle)
4.3 - 6.37 0.4 - 0.65
mounting bolt
Mirror arm mounting nut 26.0 - 34.0 2.7 - 3.5
L.H.D.
model 7.2 - 10.8 0.7 - 1.1
mounting bolt
Mirror assembly (main/wide angle/
RH 4.3 - 6.37 0.4 - 0.65
side close) mounting bolt
Front under mirror mounting bolt 4.3 - 6.37 0.4 - 0.65
Sub-arm mounting bolt (cab side) 7.2 - 10.8 0.7 - 1.1
Sub-arm mounting nut 26.0 - 34.0 2.7 - 3.5
CB-57

Cab Body

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PRECAUTIONS FOR OPERATION

Precautions for washing a vehicle with high-pressure

Precautions for wiping dirt

Cab lifter (for standard cab)

3. Completely discharge air, refrigerant, and clutch fluid. As for

5. Disconnect air hoses, clutch hoses, and car cooler hoses.

<Work after tilting up cab>

2. Disconnect the chassis harness and the cab harness.

5. Disengage the transmission linkage.

7. Hold the cab in the tilt-up position by using a crane.

<Lowering the cab in specified position>

<Work after returning cab to specified position>

2. After disconnecting a SMJ (Supper Multi Junction) connector,

<Lifting and moving cab>

<When removing without tilting up first step>

Key point of removal work of the lid grille

Key point of removal work of the lower grille

Key point of removal work of the bumper end cap

Key point of removal work of the assist grip

2. After the pawl located on the lower side is disengaged, turn

Key point of removal work of the wiper motor

Key point of removal work of the washer tube joint

Key point of removal/installation work of the interior trim

Key point of installation

3. When installing cables/wires/hoses, arrange so that they do

MODIFICATION AND REPLACEMENT

1. Remove the bolts while loosening them attached to the male

3. Place, on the surface plate, the male connector to which bolts

4. When jointing the male/female connectors, be sure to tighten

5. After installing the SMJ connector, securely install the box

Procedure for assembling the wiper link

1. Install the joint seal to the retainer at the link end.

2. Scooping grease inside the retainer by using a clean stick

5. Confirming that the joint seal is properly installed to the

Procedure for setting the wiper arm

Procedure for setting the injection point of washer

INSTRUMENT PANEL AND

Disassembling sequence (Reassembly sequence is in the reverse order of disassembly.)

Key point of disassembly

2. Removing the finisher console front.

3. Removing the instrument lower panel (passenger’s side).

4. Removing the console center front (with the console center).

5. Removing the console center rear (with the console center).

6. Removing the escutcheon RH.

7. Removing the cluster lid C.

8. Removing the instrument lower panel (center).

9. Removing the instrument lower panel (driver’s side LH).

10. Removing the instrument lower panel (driver’s side RH).

12. Removing the finisher console center.

13. Removing the console side.

14. Removing the console driver.

15. Removing the finisher end (driver’s side).

17. Removing the fuse lid.

18. Removing the instrument panels (driver’s/passenger’s sides).

19. Removing the ventilator (passenger’s side).

20. Removing finisher console upper.

Key point of reassembly

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Key point of disassembly

2. Removing the finisher console front.

3. Removing the instrument lower panel (passenger’s side).

4. Removing the console center rear (with console center).