Vehicle Segment:
Light Commercial Vehicle / Utility Vehicle / Compact Pickup Truck
Key Competitors Era:
Ford Ranger, Nissan D21 (Hardbody), Mitsubishi L200/Triton, Isuzu KB/D-Max.
Value Proposition:
Robust, reliable, and simple to maintain, popular for its durability and capability in various conditions, especially with the diesel engine.
Manual Advantage:
Provides detailed, factory-level information crucial for effective DIY maintenance and repair, directly applicable due to the shared platform with the Toyota Hilux.
Primary Coverage:
Engine, Transmission (Manual), Drivetrain, Suspension, Steering, Brakes, Fuel System, Electrical System, Cooling System, Exhaust System, Body, Interior
Estimated Page Count:
Approximately 800-1200 pages (typical for comprehensive workshop manuals of this era for this platform)
Manual Type:
Workshop Service Repair Manual
Format:
Digital (likely PDF, potentially scanned)
Engine Management:
Engine mechanical (assembly, disassembly, overhaul), fuel injection system (components, testing, adjustment), lubrication system, cooling system, intake and exhaust systems.
Drivetrain And Transmission:
Manual transmission (disassembly, inspection, assembly, fluid specifications), clutch system, driveshafts, differentials, rear axle assembly.
Suspension And Steering:
Front suspension (independent), rear suspension (leaf springs), steering system (power steering components if equipped), wheel alignment specifications.
Brakes And Wheels:
Front disc brakes, rear drum brakes, parking brake system, brake fluid specifications, hydraulic system troubleshooting.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting system, ignition system (if applicable for diesel glow plugs), wiring diagrams, fuse and relay information, diagnostic procedures for electrical faults.
Body And Interior:
Body panel removal/installation, door mechanisms, seat adjustments, HVAC system (heating, ventilation, and air conditioning - basic information), interior trim components.
Maintenance Procedures:
Routine checks (fluid levels, tire pressure), oil and filter changes, fuel filter replacement, air filter replacement, coolant flush and fill, belt inspection and replacement.
Repair Procedures:
Engine component repair (pistons, rings, bearings, cylinder head), fuel injector testing and replacement, water pump replacement, alternator and starter motor repair, brake pad and shoe replacement, clutch replacement, suspension component replacement.
Troubleshooting Guides:
System-specific diagnostic charts for common problems (e.g., poor starting, lack of power, brake issues, electrical faults).
Torque Specifications:
Detailed torque values for all critical fasteners across various systems.
Depth Of Information:
Comprehensive rebuild procedures for major components, detailed diagnostic trees, and specifications for a wide range of repairs and adjustments.
Engine Type:
Naturally Aspirated Inline-4 Cylinder Diesel
Displacement:
2.4 Liters (2446 cc)
Bore X Stroke:
92.0 mm x 92.0 mm (approximate, based on Toyota 2L-T specifications)
Compression Ratio:
22.0:1 (typical for 2L engine)
Horsepower Output:
Approx. 76-83 HP @ 4000 RPM (depending on specific tuning and market)
Torque Output:
Approx. 109-116 lb-ft @ 2200 RPM (depending on specific tuning and market)
Injection System:
Indirect Injection with Bosch inline injection pump (typical)
Glow Plug System:
Essential for cold starts, detailed operation and testing procedures in manual.
Transmission Type:
5-speed Manual Transmission
Optional Transmission:
4-speed Automatic Transmission (Less common for this engine/era, but possible)
Drivetrain:
Rear-Wheel Drive (RWD) or Four-Wheel Drive (4WD) options available.
Gear Ratios:
Specific gear ratios detailed within the manual for optimal performance and fuel economy.
Crash Safety Era:
Minimal electronic safety features; emphasis on passive safety (seat belts, structural integrity). No official crash test ratings as per modern standards.
Active Safety Systems:
None typical for the era (e.g., ABS, traction control not standard)
Passive Safety Features:
Seat belts, reinforced cabin structure.
Infotainment System:
Basic AM/FM radio, optional cassette player. No advanced infotainment or touchscreens.
Driver Assistance Features:
None typical for the era.
Connectivity Options:
No modern connectivity features (Bluetooth, USB, etc.).
Oil Change Interval:
Every 5,000 - 7,500 km or 6 months (whichever comes first), consult manual for specifics.
Fuel Filter Interval:
Every 20,000 - 30,000 km (highly dependent on diesel quality, manual provides guidance).
Air Filter Interval:
Every 20,000 - 30,000 km or as needed based on operating conditions.
Engine Oil Type:
API CD or higher, SAE 10W-30 or 15W-40 (depending on ambient temperature), Capacity approx. 5.5 - 6.0 Liters.
Coolant Type:
Ethylene Glycol based coolant, typically 50/50 mix with distilled water. Check manual for specific VW/Toyota recommendation.
Transmission Fluid Type:
GL-4 SAE 75W-90 or 80W-90 gear oil.
Brake Fluid Type:
DOT 3 or DOT 4.
Common Diesel Issues:
Glow plug failure, injector pump wear, injector nozzle clogging, potential for head gasket issues if overheated, valve seat wear.
Chassis And Body Issues:
Rust and corrosion, particularly on chassis, wheel arches, and cab corners. Suspension wear (bushings, ball joints).
