1992-1995 Mitsubishi FUSO FH100 Truck Service Manual PDF Download

fhcover
Format: PDF
Pages: 1,536
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1992, 1993, 1994, 1995 Mitsubishi FUSO FH Series Truck (U.S. model) Service & Repair

  • FH100 with 6D31-T2 engine

Manual Part Number: TWME9106 plus model year changes

Topics List:

Group 00 – General
Group 00 – General (Supplement)
Group 00 – General (’95 Minor Change)
Group 00 – General (’94 Minor Change)
Group 00 – General (’93 Minor Change)
Group 00 – General
Table of Contents
1. External Views
2. Major Specifications
3. Power Train Table
4. Equipment Model Notation
5. Performance Curves
5.1 Operation Performance Curves
5.2 Engine Performance Curves
6. Servicing Precautions
7. Standard Bolts and Nuts Tightening Torque Table
8. Towing Precautions
9. Chassis and Engine Numbers
10. Vehicle Identification Number
Group 01 – Maintenance Schedule
Table of Contents
1. How to Read the Maintenance Schedule Tables
2. Maintenance Schedule Tables
3. Maintenance Operations
3.1 Replacement of the Engine Oil Filter Element
3.2 Replacement of the Fuel Filter Element
3.3 Inspection of Air Dryer
3.4 Cleaning of the Fuel Feed Pump Gauze Filter
3.5 Bleeding Air from the Fuel Line
3.6 Water Separator Condensation Drain
3.7 Adjusting V-Belt Tension
3.8 Cleaning and Replacement of the Air Cleaner Element
3.9 Inspecting the Clutch Pedal <Vehicles with Manual Transmission>
3.10 The Tires
3.10.1 Air Pressure
3.10.2 Removing Tires
3.10.3 Tire Mounting
3.10.4 Checking the Wheel Nuts for Looseness
3.10.5 Tire Rotation
3.11 Adjusting the Clearance of the Wheel Brake Shoe
3.12 Adjusting the Clearance of the Parking Brake Shoe
3.13 The Battery
3.14 Fuses
4. Lubrication
4.1 Engine Oil
4.2 Gear Oil for Manual Transmission
4.3 Automatic Transmission Fluid and Oil Filters for Automatic Transmission
4.4 Rear Axle Gear Oil
4.5 Power Steering Fluid
4.6 Brake Fluid
4.6.1 Brake Fluid Tank
4.6.2 Clutch Fluid Tank
4.7 Greasing the Various Areas of the Chassis
Group 11 – Engine
Table of Contents
1. Troubleshooting
2. Engine Removal and Installation (Manual Transmission Vehicles)
2.1 Service Standards
2.1.1 Tightening Torque Table
2.2 Removal of Engine and Transmission
2.2.1 Preparation for Removal
2.2.2 Removal of Harness
2.2.3 Removal of Air Compressor Hoses, Actuator and Tube Assembly
2.2.4 Removal of Parts Around the Engine
2.2.5 Removal of Engine Parts
2.2.6 Removal of Transmission Parts
2.2.7 Removal of Transmission
2.2.8 Removing the Engine from the Vehicle
2.3 Installation of the Engine and Transmission
2.3.1 Installation of Engine
2.3.2 Installation of Transmission
2.3.3 Installation of Transmission Parts
2.3.4 Installation of Engine Parts
2.3.5 Installation of Parts Around the Engine
2.3.6 Installation of Air Compressor Hoses, Actuator and Tube Assembly
2.3.7 Installation of Harness
2.4 Adjustment After Installation
2.4.1 Preparation for Adjustment
2.4.2 Adjustment
3. Engine Removal and Installation (Automatic Transmission Vehicles)
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 Removal of Engine and Transmission
3.2.1 Preparation for Removal
3.2.2 Removal of Harness
3.2.3 Removal of Air Compressor Hose
3.2.4 Removal of Parts Around the Engine
3.2.5 Removal of Engine Parts
3.2.6 Removal of Transmission Parts
3.2.7 Removal of Transmission
3.2.8 Removing the Engine from the Vehicle
3.3 Installation of the Engine and Transmission
3.3.1 Installation of the Engine
3.3.2 Installation of Transmission
3.3.3 Installation of Transmission Parts
3.3.4 Installation of Engine Parts
3.3.5 Installation of Parts Around the Engine
3.3.6 Installation of Air Compressor Hose
3.3.7 Installation of Harnesses
3.4 Adjustment After Installation
3.4.1 Preparation for Adjustment
3.4.2 Adjustment
4. Engine Assembly
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Special Tools Table
4.3 Inspection and Adjustment of Valve Clearance
4.4 Measurement of Compression Pressure
4.5 Inspection of Oil Pressure
4.6 Inspection and Adjustment of Fuel Injection Start Timing
4.7 Bleeding the Fuel System
4.8 Inspection and Adjustment of V-Belt Tension
4.9 Measurement of Turbocharger Boost Pressure
5. Cylinder Head and Valve Mechanism
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 General Description
5.2.1 Cylinder Head
5.2.2 Valve Mechanism
5.3 Removal
5.4 Disassembly
5.4.1 Rocker and Bracket Assembly
5.4.2 Cylinder Head Assembly
5.5 Inspection
5.6 Reassembly
5.6.1 Cylinder Head Assembly
5.6.2 Rocker and Bracket Assembly
5.7 Installation
6. Flywheel and Flywheel Housing (Manual Transmission Vehicles)
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.1.3 Special Tools Table
6.1.4 Sealant Table
6.2 General Description
6.3 Disassembly
6.4 Inspection
6.5 Reassembly
7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles)
7.1 Service Standards
7.1.1 Tightening Torque Table
7.1.2 Special Tools Table
7.1.3 Sealant Table
7.2 General Description
7.3 Disassembly
7.4 Inspection
7.5 Reassembly
8. Timing Gear and Camshaft
8.1 Service Standards
8.1.1 Service Standards Table
8.1.2 Tightening Torque Table
8.1.3 Lubricant Table
8.1.4 Sealant Table
8.1.5 Special Tools Table
8.2 General Description
8.3 Disassembly
8.4 Inspection
8.5 Reassembly
9. Crankcase and Main Moving Parts
9.1 Service Standards
9.1.1 Service Standards Table
9.1.2 Tightening Torque Table
9.1.3 Sealant Table
9.1.4 Special Tools Table
9.2 General Description
9.2.1 Crankshaft
9.2.2 Connecting Rod
9.2.3 Piston
9.3 Disassembly
9.4 Inspection
9.5 Reassembly
Group 12 – Lubrication
Table of Contents
1. Troubleshooting
2. Lubrication System
2.1 Specifications
2.2 General Description
2.2.1 System Outline
2.2.2 Lubrication of Main Moving Parts
2.2.3 Camshaft Lubrication
2.2.4 Valve Mechanism Lubrication
2.2.5 Timing Gear Lubrication
2.2.6 Turbocharger Lubrication
2.2.7 Injection Pump Assembly Lubrication
2.2.8 Air Compressor Lubrication
2.3 Oil Pressure Check
3. Oil Pan and Oil Strainer
3.1 Service Standards
3.1.1 Tightening Torque Table
3.1.2 Sealant Table
3.2 General Description
3.3 Removal
3.4 Installation
3.5 Post-Installation Inspection
4. Oil Pump
4.1 Service Standards
4.1.1 Service Standards Table
4.2 General Description
4.3 Removal
4.4 Disassembly and Inspection
4.5 Reassembly
4.6 Installation
5. Oil Cooler and Oil Filter
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 General Description
5.3 Removal
5.4 Disassembly and Inspection
5.5 Reassembly
5.6 Installation
Group 13 – Fuel and Engine Control
Table of Contents
1. Troubleshooting
2. Fuel System
2.1 General Description
2.2 Removal and Installation of the Fuel Hoses
3. Prestroke Control Type Injection Pump System
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.3.1 Prestroke Control Type Injection Pump System
3.3.2 Control Unit
3.3.3 Sensors
3.3.4 Injection Pump Proper
3.3.5 Governor
3.3.6 Feed Pump
3.3.7 Coupling
3.4 Service Procedure
3.4.1 Inspection of System
3.4.2 Removal of Injection Pump Assembly
3.4.3 Installation of Injection Pump Assembly
3.4.4 Adjustments After Installation of Injection Pump
3.4.5 Bleeding Air from the Fuel System
3.4.6 Adjustment of Fuel Injection Timing
3.4.7 Adjustment of No-Load Minimum and Maximum Speeds
3.4.8 Operation Check of the Engine Stop Cable
4. Injection Nozzles
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.3 General Description
4.4 Removal
4.5 Disassembly
4.6 Inspection and Cleaning
4.7 Reassembly
4.8 Test and Adjustment
4.9 Installation
5. Fuel Filter
5.1 Specifications
5.2 Service Standards
5.2.1 Tightening Torque Table
5.2.2 Special Tools Table
5.3 General Description
5.4 Removal and Inspection
5.5 Installation
6. Water Separator
6.1 Specifications
6.2 Service Standards
6.3 General Description
6.4 Removal
6.5 Disassembly and Inspection
6.6 Reassembly
6.7 Installation
6.8 Draining Water
7. Fuel Tank
7.1 Specifications
7.2 Service Standards
7.3 General Description
7.4 Removal
7.5 Inspection
7.6 Installation
8. Engine Control System
8.1 Specifications
8.2 Service Standards
8.3 General Description
8.4 Removal
8.4.1 Disconnecting the Accelerator Control Cable and Engine Stop Cable
8.4.2 Removal of the Throttle Cable
8.4.3 Removal of the Accelerator Pedal and Accelerator Lever Assembly
8.5 Inspection
8.6 Installation
8.6.1 Installation of Accelerator Lever Assembly and Accelerator Pedal
8.6.2 Installation of Throttle Cable
8.6.3 Installation of Accelerator Control Cable and Engine Stop Cable
8.7 Adjustment After Installation
8.7.1 Adjustment of the Accelerator Pedal Stopper
8.7.2 Operation Check of the Engine Stop Cable
8.7.3 Adjustment of the Accelerator Switch (Exhaust Brake Microswitch)
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Cooling System
2.1 Specifications
2.2 General Description
2.3 Removal
2.3.1 Preparation for Removal
2.3.2 Radiator and Reservoir Tank Removal
2.3.3 Cooling Fan and Auto-Cool Fan Coupling Removal
2.3.4 Water Pump Removal
2.3.5 Thermostat Removal
2.4 Installation
2.4.1 Thermostat Installation
2.4.2 Water Pump Installation
2.4.3 Cooling Fan and Auto-Cool Fan Coupling Installation
2.4.4 Radiator and Reservoir Tank Installation
2.4.5 Operations After Installation
3. Cooling Fan and Auto-Cool Fan Coupling
3.1 General Description
3.1.1 Cooling Fan
3.1.2 Auto-Cool Fan Coupling
3.2 Auto-Cool Fan Coupling Inspection
4. Thermostat
4.1 Service Standards
4.1.1 Service Standards Table
4.2 General Description
4.3 Inspection
5. Radiator
5.1 Service Standards
5.2 General Description
5.2.1 Radiator
5.2.2 Pressure Cap
5.2.3 Radiator Shroud
5.2.4 Reservoir Tank
5.3 Inspection and Cleaning
5.3.1 Radiator Cleaning
5.3.2 Radiator Inspection
5.3.3 Pressure Cap Inspection
5.3.4 Radiator (Cooling System) Cleaning
5.3.5 Gas Leak Test
5.3.6 Cooling System Air Bleeding
Group 15 – Intake and Exhaust
Table of Contents
1. Troubleshooting
2. Intake System
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.5 Air Cleaner Disassembly, Cleaning and Reassembly
2.5.1 Disassembly
2.5.2 Cleaning
2.5.3 Reassembly
2.6 Installation
2.7 Intake System Inspection
3. Exhaust System
3.1 Service Standards
3.2 General Description
3.3 Removal
3.4 Inspection
3.5 Installation
3.6 Exhaust System Inspection
4. Turbocharger
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Lubricant Table
4.3 General Description
4.4 Removal
4.5 Disassembly
4.6 Cleaning and Inspection
4.6.1 Cleaning
4.6.2 Inspection
4.7 Reassembly
4.8 Installation
4.9 Post-Installation Inspection
5. Intercooler
5.1 Specifications
5.2 Service Standards
5.3 Outline
5.4 Removal
5.5 Cleaning and Inspection
5.6 Installation
6. Intake Shutter Valve System <Vehicles with Manual Transmission>
6.1 Specifications
6.2 Service Standards
6.2.1 Service Standards Table
6.2.2 Tightening Torque Table
6.3 General Description
6.4 Removal
6.5 Inspection
6.6 Installation
Group 16 – Engine Electrical
Table of Contents
1. Troubleshooting
2. Electrical System
2.1 Specifications
2.2 General Description
2.2.1 Starting System
2.2.2 Charging System
3. Starter
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Lubricant
3.2 General Description
3.3 Removal
3.4 Disassembly
3.5 Inspection
3.6 Reassembly
3.7 Testing
3.8 Installation
4. Alternator
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Lubricant Table
4.2 General Description
4.3 Removal
4.4 Disassembly
4.5 Inspection
4.6 Reassembly
4.7 Testing
4.7.1 Handling Precautions
4.7.2 Performance Testing
4.7.3 Regulator Inspection
4.8 Installation
5. Glow System
5.1 Service Standards
5.1.1 Service Standards
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 General Description
5.3 Removal
5.4 Inspection
5.4.1 Glow Plug Inspection
5.4.2 Glow Relay Inspection
5.4.3 Glow Controller Inspection
5.5 Installation
Group 21 – Clutch
Table of Contents
1. Troubleshooting
2. Clutch Proper
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.2.3 Special Tools Table
2.3 General Description
2.4 Removal
2.4.1 Operation Before Removal
2.4.2 Removal of Clutch Proper
2.5 Disassembly
2.6 Inspection
2.7 Reassembly
2.8 Installation
2.9 Post-Installation Adjustment
2.10 Lubrication of Drive Pinion Splines
3. Clutch Control
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Sealant Table
3.2.4 Special Tools Table
3.3 General Description
3.4 Clutch Hose and Piping
3.4.1 Removal
3.4.2 Inspection
3.4.3 Installation
3.4.4 Post-Installation Work
3.5 Clutch Pedal Assembly
3.5.1 Removal
3.5.2 Disassembly
3.5.3 Inspection
3.5.4 Reassembly
3.5.5 Installation
3.5.6 Post-Installation Adjustment
3.6 Clutch Master Cylinder
3.6.1 Removal
3.6.2 Disassembly
3.6.3 Inspection
3.6.4 Reassembly
3.6.5 Installation
3.6.6 Post-Installation Adjustment
3.7 Clutch Power Cylinder
3.7.1 Removal
3.7.2 Disassembly
3.7.3 Inspection
3.7.4 Reassembly
3.7.5 Installation
3.7.6 Post-Installation Adjustment
3.8 Clutch Housing Assembly
3.8.1 Removal
3.8.2 Disassembly
3.8.3 Reassembly
3.8.4 Installation
3.8.5 Post-Installation Adjustment
3.9 Fluid Change in the Clutch System
3.10 Bleeding the Clutch System
3.11 Clutch Pedal Inspection and Adjustment
3.12 Clutch Adjustment
Group 22 – Manual Transmission
Table of Contents
1. Troubleshooting
2. Removing and Installing
2.1 Service Standards
2.1.1 Tightening Torque Table
2.2 Preliminary Operations
2.3 Removal
2.4 Installation
3. Transmission Assembly
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.2.4 Sealant Table
3.3 General Description
3.4 Removal
3.4.1 Clutch Housing Assembly
3.4.2 Gear Shift, Upper and Lower
3.4.3 Rear Cover and Parking Brake
3.4.4 Transmission
3.5 Installation
3.5.1 Transmission
3.5.2 Rear Cover
3.5.3 Gear Shift, Upper and Lower
3.5.4 Clutch Housing Assembly
4. Main Shaft Assembly
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 Preliminary Inspection
4.3 Disassembly
4.4 Inspection
4.5 Reassembly
5. Counter Shaft Assembly
5.1 Service Standards
5.1.1 Sealant Table
5.2 Special Tools Table
5.3 Disassembly
5.4 Reassembly
6. Reverse Gear
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.1.3 Special Tools Table
6.2 Disassembly and Inspection
6.3 Reassembly
7. Gear Shift, Lower
7.1 Service Standards
7.1.1 Service Standards Table
7.1.2 Tightening Torque Table
7.1.3 Sealant Table
7.2 General Description
7.3 Disassembly
7.4 Inspection
7.5 Reassembly
8. Gear Shift, Upper
8.1 Service Standards
8.1.1 Service Standards Table
8.1.2 Tightening Torque Table
8.1.3 Sealant Table
8.2 Disassembly
8.3 Inspection
8.4 Reassembly
9. Rear Cover
9.1 Service Standards
9.1.1 Service Standards Table
9.1.2 Tightening Torque Table
9.1.3 Special Tools Table
9.1.4 Sealant Table
9.2 Disassembly
9.3 Inspection
9.4 Reassembly
10. Transmission Control
10.1 Specifications
10.2 Service Standards
10.2.1 Service Standards Table
10.2.2 Tightening Torque Table
10.3 General Description
10.4 Preliminary Operations
10.5 Removal
10.6 Inspection, Repair and Replacement
10.7 Installation
10.8 Control Cable
10.8.1 Shift Cable
10.8.2 Select Cable
10.8.3 Inspection
10.9 Set Board Assembly
10.9.1 Disassembly and Reassembly
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Removing and Installing
2.1 Specifications
2.2 Service Standards
2.2.1 Tightening Torque Table
2.2.2 Special Tools Table
2.3 Removal
2.4 Installation
3. Oil Seal and Speedometer Worm
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Tightening Torque Table
3.1.3 Special Tools Table
3.2 Removal and Installation
3.3 Replacement of Front Oil Seal
3.4 Replacement of Rear Oil Seal
3.5 Replacement of Speedometer Worm
4. Automatic Transmission Control System
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Sealant Table
4.2 General Description
4.3 Removal and Installation
4.4 Inspection After Installation
4.5 Oil Cooler
4.6 Fluid Pipe and Oil Temperature Sensor
4.7 Replacement of Fluid and Oil Filter
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Propeller Shaft
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.2.3 Special Tools Table
2.3 General Description
2.4 Removal
2.5 Disassembly
2.6 Inspection
2.7 Reassembly
2.8 Installation
Group 26 – Front Axle
Table of Contents
1. Troubleshooting
2. Front Axle Assembly
2.1 Specifications
2.2 Service Standards
2.2.1 Tightening Torque Table
2.3 General Description
2.4 Removal
2.5 Installation
2.6 Post-Installation Adjustment
3. Wheel Hub and Brake Drum
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Tightening Torque Table
3.1.3 Sealant Table
3.1.4 Special Tools Table
3.2 Disassembly
3.3 Inspection
3.4 Reassembly
4. Front Axle and Knuckle
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 Removal
4.3 Disassembly
4.4 Inspection
4.5 Reassembly
4.6 Installation
Group 27 – Rear Axle
Table of Contents
1. Troubleshooting
2. Rear Axle Assembly
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.2.3 Special Tools Table
2.3 General Description
2.4 Removal
2.5 Inspection
2.6 Installation
3. Wheel Hub and Brake Drums
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Tightening Torque Table
3.1.3 Special Tools Table
3.2 Disassembly
3.3 Inspection
3.4 Reassembly
4. Reduction and Differential
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Lubricant Table
4.1.4 Special Tools Table
4.2 Removal
4.3 Pre-Disassembly Inspection
4.4 Disassembly
4.5 Inspection
4.6 Reassembly
4.7 Installation
Group 31 – Wheels and Tires
Table of Contents
1. Troubleshooting
2. Wheel and Tire
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.4.1 Preparation for Removal
2.4.2 Removing Front Tires
2.4.3 Removing Rear Tires
2.5 Removal of Tire
2.6 Inspection
2.7 Installation of Tire
2.8 Inspection and Adjustment After Installation
2.9 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Front Suspension Assembly
2.1 Service Standards
2.1.1 Service Standards Table
2.1.2 Tightening Torque Table
2.1.3 Special Tools Table
2.2 General Description
2.3 Removal
2.4 Inspection
2.5 Installation
3. Leaf Springs
3.1 Specifications
3.2 Service Standards
3.3 General Description
3.4 Pre-Disassembly Inspection
3.5 Disassembly
3.6 Inspection
3.7 Reassembly
4. Shock Absorbers
4.1 Specifications
4.2 General Description
4.3 Disassembly
4.4 Inspection
5. Stabilizer
5.1 General Description
5.2 Pre-Disassembly Inspection
5.3 Disassembly
5.4 Inspection
5.5 Reassembly
Group 34 – Rear Suspension
Table of Contents
1. Troubleshooting
2. Rear Suspension Assembly
2.1 Service Standards
2.1.1 Service Standards Table
2.1.2 Tightening Torque Table
2.1.3 Special Tools Table
2.2 General Description
2.3 Removal
2.4 Inspection
2.5 Installation
3. Leaf Springs
3.1 Specifications
3.2 General Description
3.3 Pre-Disassembly Inspection
3.4 Disassembly
3.5 Inspection
3.6 Reassembly
4. Shock Absorbers
4.1 Specifications
4.2 General Description
4.3 Disassembly
4.4 Inspection
5. Stabilizer
5.1 General Description
5.2 Pre-Disassembly Inspection
5.3 Disassembly
5.4 Inspection
5.5 Reassembly
Group 35 – Brake
Table of Contents
1. Troubleshooting
2. Brake System
2.1 Specifications
2.2 Service Standards
2.2.1 Tightening Torque Table
2.2.2 Special Tools Table
2.3 General Description
2.4 Bleeding the Brake Fluid Lines
2.5 Changing the Brake Fluid
3. Brake Piping and Brake Fluid Tank
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 General Description
3.3 Inspection Before Removal
3.4 Removing the Brake Fluid
3.5 Removal
3.6 Disassembly
3.7 Inspection
3.8 Reassembly
3.9 Installation
4. Air Tank
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Sealant Table
4.3 General Description
4.4 Drain Cock
4.4.1 Air Leak Test
4.4.2 Functional Inspection
4.4.3 Removal
4.4.4 Installation
4.5 Safety Valve
4.5.1 Air Leak Test
4.5.2 Functional Inspection
4.5.3 Removal
4.5.4 Installation
4.6 Air Tank
4.6.1 Air Leak Test
4.6.2 Removal
4.6.3 Installation
5. Air Compressor
5.1 Specifications
5.2 Service Standards
5.2.1 Service Standards Table
5.2.2 Tightening Torque Table
5.2.3 Special Tools Table
5.3 General Description
5.4 Removal
5.5 Disassembly
5.6 Inspection
5.7 Reassembly
5.8 Installation
6. Brake Pedal Assembly
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.2 Removal
6.3 Disassembly
6.4 Inspection
6.5 Reassembly
6.6 Installation
6.7 Adjusting the Pedal Height
7. Dual Brake Valve
7.1 Specifications
7.2 Service Standards
7.2.1 Service Standards Table
7.2.2 Tightening Torque Table
7.2.3 Sealant Table
7.3 General Description
7.4 Removal
7.5 Disassembly
7.6 Inspection
7.7 Reassembly
7.8 Installation
8. Brake Booster (Air-Master)
8.1 Specifications
8.2 Service Standards
8.2.1 Service Standards Table
8.2.2 Tightening Torque Table
8.2.3 Sealant Table
8.3 General Description
8.4 Removal
8.5 Disassembly
8.6 Inspection
8.7 Reassembly
8.8 Installation
8.9 Inspection After Installation
9. Air Dryer
9.1 Specifications
9.2 Service Standards
9.2.1 Service Standards Table
9.2.2 Tightening Torque Table
9.2.3 Sealant Table
9.3 General Description
9.4 Maintenance and Inspection
9.4.1 Maintenance and Inspection
9.4.2 Inspection and Replacement of Desiccant
9.4.3 Inspection After Replacement
9.5 Removal
9.6 Disassembly
9.7 Reassembly
9.8 Inspection After Reassembly
9.9 Installation
9.10 Inspection After Installation
10. Air Pressure Governor
10.1 Specifications
10.2 Service Standards
10.2.1 Service Standards Table
10.2.2 Tightening Torque Table
10.2.3 Sealant Table
10.3 General Description
10.4 Functional Inspection
10.5 Adjustment
10.6 Removal
10.7 Disassembly
10.8 Reassembly
10.9 Installation
11. Check Valve
11.1 Service Standards
11.1.1 Service Standards Table
11.1.2 Tightening Torque Table
11.1.3 Sealant Table
11.2 General Description
11.3 Removal
11.4 Disassembly
11.5 Inspection
11.6 Reassembly
11.7 Installation
12. Switch
12.1 Specifications
12.2 Service Standards
12.2.1 Tightening Torque Table
12.2.2 Sealant Table
12.3 Stop Lamp Switch
12.3.1 Removal
12.3.2 Inspection
12.3.3 Installation
12.4 Low Air Pressure Switch
12.4.1 Removal
12.4.2 Inspection
12.4.3 Installation
13. Front Drum Brake
13.1 Specifications
13.2 Service Standards
13.2.1 Service Standards Table
13.2.2 Tightening Torque Table
13.2.3 Special Tools Table
13.3 General Description
13.4 Removal
13.5 Disassembly
13.6 Inspection
13.7 Reassembly
13.8 Wheel Cylinder
13.8.1 Disassembly
13.8.2 Inspection
13.8.3 Reassembly
13.9 Installation
13.10 Adjusting Holder Pin
13.11 Adjusting Shoe Clearance
14. Rear Drum Brake
14.1 Specifications
14.2 Service Standards
14.2.1 Service Standards Table
14.2.2 Tightening Torque Table
14.2.3 Special Tools Table
14.3 General Description
14.4 Removal
14.5 Disassembly
14.6 Inspection
14.7 Reassembly
14.8 Wheel Cylinder
14.8.1 Disassembly
14.8.2 Inspection
14.8.3 Reassembly
14.9 Installation
14.10 Adjusting Holder Pin
14.11 Adjusting Shoe Clearance
15. Exhaust Brake System
15.1 Specifications
15.2 Service Standards
15.2.1 Service Standards Table
15.2.2 Tightening Torque Table
15.2.3 Sealant Table
15.3 General Description
15.4 Removal
15.5 Disassembly
15.5.1 Exhaust Brake Unit
15.6 Inspection
15.7 Reassembly
15.8 Installation
15.9 Operation Test After Installing
15.10 Control Cylinder
15.10.1 Disassembly
15.10.2 Inspection
15.10.3 Reassembly
15.10.4 Inspection After Assembly
15.11 Supply Valve
15.11.1 Disassembly
15.11.2 Reassembly
15.11.3 Airtightness Test After Reassembling
15.11.4 Operation Test After Reassembling
Group 36 – Parking Brake
Table of Contents
1. Troubleshooting
2. Parking Brake Control
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.4.1 Preliminary Operation
2.4.2 Parking Brake Cable
2.4.3 Parking Brake Lever Assembly
2.5 Disassembly and Inspection
2.5.1 Disassembly
2.5.2 Inspection
2.6 Reassembly
2.7 Installation
2.7.1 Parking Brake Lever Assembly
2.7.2 Parking Brake Cable
2.8 Post-Installation Adjustment
3. Parking Brake Drum and Shoes
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.4 Removal
3.4.1 Preliminary Operation
3.4.2 Removal
3.5 Disassembly and Inspection
3.5.1 Disassembly
3.5.2 Inspection
3.6 Reassembly
3.7 Installation
Group 37 – Steering
Table of Contents
1. Troubleshooting
2. Power Steering System
2.1 Service Standards
2.1.1 Service Standards Table
2.1.2 Tightening Torque Table
2.2 General Description
2.3 Replacement of Power Steering Fluid
2.4 Performance Verification Tests
2.5 Overall Checks on Power Steering
3. Steering Wheel and Shaft
3.1 Specifications
3.2 Service Standards
3.2.1 Tightening Torque Table
3.3 General
3.4 Removal
3.5 Disassembly
3.6 Reassembly
3.7 Installation
3.8 Inspection After Installation
4. Steering Linkage
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 General Description
4.3 Drag Link
4.3.1 Removal
4.3.2 Disassembly
4.3.3 Inspection and Reassembly
4.3.4 Installation
4.4 Tie Rod
4.4.1 Removal
4.4.2 Disassembly
4.4.3 Inspection and Reassembly
4.4.4 Installation
4.5 Post-Installation Inspection and Adjustment
5. Power Steering Booster
5.1 Specifications
5.2 Service Standards
5.2.1 Service Standards Table
5.2.2 Tightening Torque Table
5.2.3 Sealant Table
5.2.4 Special Tools Table
5.3 General Description
5.3.1 Construction
5.3.2 Operation
5.4 Removal
5.5 Disassembly
5.6 Inspection
5.7 Reassembly
5.8 Installation
5.9 Post-Installation Work
6. Power Steering Oil Pump
6.1 Specifications
6.2 Service Standards
6.2.1 Service Standards Table
6.2.2 Tightening Torque Table
6.2.3 Special Tools Table
6.3 General Description
6.4 Removal
6.5 Disassembly
6.6 Inspection
6.7 Reassembly
6.8 Installation
6.9 Post-Installation Inspection and Adjustment
Group 41 – Frame
Table of Contents
1. Frame Assembly
1.1 Specifications
1.2 General Description
1.3 Inspection and Repair
1.3.1 Frame
1.3.2 Rivets
1.4 Frame Shape
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Cab Proper
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Tilting the Cab
2.5 Removal
2.5.1 Operation Before Removal
2.5.2 Operation in the Cab
2.5.3 Operation at the Cab Front
2.5.4 Operation with the Cab Tilted
2.5.5 Hoisting the Cab
2.6 Installation
2.6.1 Installing the Cab
2.6.2 Operation with the Cab Tilted
2.6.3 Operation from Front of the Cab
2.6.4 Operation in the Cab
2.6.5 Post-Installation Operation
3. Cab Mounting
3.1 Specifications
3.2 Service Standards
3.3 General Description
3.3.1 Cab Mounting
3.3.2 Cab Hinge
3.3.3 Cab Stay
3.3.4 Cab Tilt Link
3.4 Cab Tilt Link
3.4.1 Removal
3.4.2 Installation
3.4.3 Inspection and Adjustment After Installation
3.5 Rear Cab Mounting
3.5.1 Removal
3.5.2 Installation
3.5.3 Post-Installation Inspection and Adjustment
3.6 Cab Hinge
3.6.1 Removal
3.6.2 Installation
3.6.3 Post-Installation Operation
4. Front Windshield Glass and Rear Window Glass
4.1 Specifications
4.2 Service Standards
4.3 Removal
4.3.1 Operation Before Removal
4.3.2 Removal
4.4 Installation
4.4.1 Installation Operation
4.4.2 Post-Installation Operation
5. Door Assembly
5.1 Specifications
5.2 Service Standards
5.3 General Description
5.4 Removal
5.4.1 Removing the Door Trim
5.4.2 Removing the Front Door Window Regulator
5.4.3 Removing the Front Door Locking System
5.4.4 Removing the Outside Mirror Stay Assembly
5.4.5 Removing the Front Door Panel Assembly
5.5 Installation
5.5.1 Installing the Front Door Panel Assembly
5.5.2 Installing the Outside Mirror Stay Assembly
5.5.3 Installing the Front Door Locking System
5.5.4 Inspection and Adjustment After Installation of the Front Door Locking System
5.5.5 Installing the Front Door Window Regulator
5.5.6 Installing the Door Trims
6. Seats, Seat Belts and Floor Mat
6.1 Specifications
6.2 Service Standards
6.3 Removal
6.3.1 Removing the Seats
6.3.2 Removing the Seat Belts
6.3.3 Removing the Floor Mats
6.4 Installation
6.4.1 Installing the Floor Mats
6.4.2 Installing the Seat Belts
6.4.3 Installing the Seats
7. Trim
7.1 Specifications
7.2 Removal
7.3 Installation
8. Instrument Panel
8.1 Service Standards
8.2 Removal
8.3 Installation
8.4 Post-Installation Operation
9. Wiper and Washer
9.1 Service Standards
9.2 Removal
9.3 Installation
9.4 Post-Installation Inspection
10. Cab and Associated Parts
10.1 Service Standards
10.2 Removal
10.3 Installation
10.4 Post-Installation Inspection
11. Silencer and Enclosure
11.1 Removal
11.2 Installation
Group 54 – Chassis Electrical
Table of Contents
1. Troubleshooting
2. Chassis Electrical
2.1 Specifications
2.2 General Description
2.3 Wiring Harness
2.4 Centralized Ground Connections
3. Battery
3.1 Specifications
3.2 Service Standards
3.3 General Description
3.4 Removal
3.5 Inspection
3.6 Installation
4. Fuses and Relays
4.1 Specifications
4.2 Service Standards
4.3 General Description
4.4 Removal and Installation
4.5 Inspection
4.5.1 Fuses
4.5.2 Relays
5. Fusible Link
5.1 Specifications
5.2 General Description
5.3 Removal and Inspection
5.4 Installation
6. Starter Switch and Cold Start Switch
6.1 Specifications
6.2 General Description
6.3 Removal and Installation
6.4 Inspection
7. Steering Column Switches
7.1 Specifications
7.2 General Description
7.3 Inspection
8. Lighting System
8.1 Specifications
8.2 Service Standards
8.3 General Description
8.3.1 Lamps and Switches
8.3.2 Circuit Description
8.4 Removal
8.5 Inspection
8.6 Installation
8.7 Inspection and Adjustment After Installation
9. Meters and Gauges
9.1 Specifications
9.2 Service Standards
9.3 General Description
9.4 Removal
9.5 Inspection
9.6 Installation
9.7 Inspection After Installation
10. Indicator and Warning Lamp System
10.1 Specifications
10.2 Service Standards
10.3 General Description
10.3.1 Function of Each Lamp
10.3.2 Operation of Each Lamp
10.4 Removal and Installation
10.5 Inspection
11. Exhaust Brake System (Vehicles with Manual Transmission)
11.1 Specifications
11.2 Service Standards
11.3 General Description
11.4 Removal and Installation
11.5 Inspection
11.6 Inspection After Installation
12. Wiper and Washer System
12.1 Specifications
12.2 Service Standards
12.3 General Description
12.3.1 Wiper System
12.3.2 Washer System
12.4 Removal and Installation
12.5 Inspection and Cleaning
12.6 Inspection and Adjustment After Installation
13. Substarter System
13.1 General Description
13.2 Removal and Installation
13.3 Inspection
14. Horn
14.1 Specifications
14.2 General Description
14.3 Removal and Installation
14.4 Inspection
14.5 Inspection After Installation
15. Radio (Option), Cassette Stereo (Option), Speakers, and Antenna
15.1 Specifications
15.2 General Description
15.3 Removal and Installation
15.4 Inspection and Adjustment
16. Cigarette Lighter
16.1 Specifications
16.2 Service Standards
16.3 General Description
16.4 Removal and Installation
16.5 Inspection
16.6 Inspection After Installation
Group 55A – Air Conditioner
Group 55A (9402) – Air Conditioner
Table of Contents
1. Specifications
2. Outlines of Refrigeration System
2.1 Air System
2.2 Refrigerating Cycle
2.3 Electrical System
3. Construction
3.1 Engine Compartment
3.2 Cab
3.3 Control System
3.4 Compressor and Magnetic Clutch
3.4.1 Compressor
3.4.2 Check Valve
3.4.3 Magnetic Clutch
3.5 Condenser
3.6 Receiver Drier
3.7 Cooling Unit
3.8 Expansion Valve
3.9 High Pressure Switch
3.10 Power Relay
3.11 A/C Switch
3.12 Thermo Sensor
4. Troubleshooting
4.1 General Precautions
4.2 Trouble, Cause and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 High Pressure Switch
4.3.3 Thermo Sensor
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Drier Assembly
4.3.7 Belt Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Refrigerant Circuit
4.3.11 Moisture Inclusion in Refrigerant Circuit
5. Removal and Installation
5.1 Precaution for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Compartment
5.2.2 Inside the Cab
5.3 Installation
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Refrigerant Charge
6.2.1 Installation of Charge Equipment
6.2.2 Refrigerant Charge and Leak Check
6.2.3 Removal of Charge Equipment
6.3 Gas Charge
6.4 Checking the Refrigerant Level
6.5 Performance Test
6.5.1 Preparation
6.5.2 Stationary Performance Test
7. Cooling Unit
7.1 Components
7.2 Cautions in Disassembling
7.3 Disassembling
8. Maintenance
9. Compressor
9.1 Disassembling the Clutch
9.2 Reassembly the Clutch
9.3 Disassembling the Shaft Seal
9.4 Reassembly the Shaft Seal
9.5 Special Tool Figure
Group 55A (9106) – Air Conditioner
Table of Contents
1. Specifications
2. Outlines of Refrigeration System
2.1 Air System
2.2 Refrigerating Cycle
2.3 Electrical System
3. Construction
3.1 Engine Compartment
3.2 Cab
3.3 Control System
3.4 Compressor and Magnetic Clutch
3.4.1 Compressor
3.4.2 Check Valve
3.4.3 Magnetic Clutch
3.5 Condenser
3.6 Receiver Drier
3.7 Cooling Unit
3.8 Expansion Valve
3.9 High Pressure Switch
3.10 Power Relay
3.11 A/C Switch
3.12 Thermo Sensor
4. Troubleshooting
4.1 General Precautions
4.2 Trouble, Cause and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 High Pressure Switch
4.3.3 Thermo Sensor
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Drier Assembly
4.3.7 Belt Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Refrigerant Circuit
4.3.11 Moisture Inclusion in Refrigerant Circuit
5. Removal and Installation
5.1 Precaution for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Compartment
5.2.2 Inside the Cab
5.3 Installation
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Refrigerant Charge and Leak Check
6.2.1 Installation of Charge Equipment
6.2.2 Refrigerant Charge and Leak Check
6.2.3 Removal of Charge Equipment
6.3 Gas Charge
6.4 Checking the Refrigerant Level
6.5 Performance Test
6.5.1 Preparation
6.5.2 Stationary Performance Test
7. Cooling Unit
7.1 Components
7.2 Cautions in Disassembling
7.3 Disassembling
8. Maintenance
9. Compressor
9.1 Disassembling the Clutch
9.2 Reassembly the Clutch
9.3 Disassembling the Shaft Seal
9.4 Reassembly the Shaft Seal
9.5 Special Tool Figure
Group 55B – Heater
Table of Contents
1. Troubleshooting
2. Heater and Ventilation
2.1 Specifications
2.2 Service Standards
2.3 General Descriptions
2.4 Wiring Diagram
2.5 Pre-Removal Inspection
2.5.1 Blower Switch Inspection
2.5.2 Mode Control Lever Inspection
2.5.3 Temperature Control Lever Inspection
2.5.4 Air Selector Lever Inspection
2.5.5 Side Ventilator Inspection
2.6 Removal
2.7 Installation
2.8 Post-Installation Adjustments
3. Heater Plumbing
3.1 Removal
3.2 Inspection
3.3 Installation

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