Archive for the ‘FUSO Manuals’ Category

1986-1987 Mitsubishi FUSO Fighter FM FK Truck Service Manual PDF Download

cover
Format: PDF
Pages: 751
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1986-1987 Mitsubishi FUSO Fighter FM, FK Series Truck (US/Canada) Service & Repair

  • FK415
  • FK455
  • FM555 (including 10-speed transmission)

Topics List:

Foreword
1. Group Classification
2. Definition of Terms and Unit Used
3. Notes On Illustrations
Group 00 – General
1. Exterior 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. Vehicle Identification Number
8. Standard Bolts and Nuts Tightening Torque Table
Group 01 – Maintenance Schedule
1. Using the Maintenance Schedule Table
2. Maintenance Schedule Table
2.1 Replacement of Oil Filter Element
2.2 Replacement of the Fuel Filter Element
2.3 Cleaning of the Fuel Feed Pump Gauze Filter
2.4 Bleeding of the Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.6.1 Dry Dust Buildup
2.6.2 Oil Smoke, Soot, and Oil Black Deposits
2.6.3 Inspection After Drying
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressure
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Adjusting Gear Type [FK415, FK455]
2.10.2 Adjusting Cam Type [FM555]
2.11 Adjustment of Parking Brake Shoe Clearance
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brakes
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of the Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Oil Level
3.6.2 Replacement of Power Steering Oil
3.6.3 Bleeding of the Power Steering System
3.7 Lubrication
Group 11 – Engine
1. General
1.1 Engine Proper
1.2 Air Compressor
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Engine Proper
4.1.1 Measurement of Compression Pressure
4.1.2 Removal
4.1.3 Disassembly
4.1.4 Inspection and Correction
4.1.5 Reassembly
4.1.6 Installation
4.1.7 Adjustment
4.2 Air Compressor
4.2.1 Removal
4.2.2 Disassembly
4.2.3 Inspection and Correction
4.2.4 Reassembly
4.2.5 Installation
5. Special Tool
6. Troubleshooting
6.1 Engine
6.2 Valve Mechanism
Group 12 – Lubrication
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Oil Pump
4.1.1 Removal
4.1.2 Disassembly and Inspection
4.1.3 Reassembly
4.1.4 Installation
4.2 Oil Filter, Oil Cooler
4.2.1 Disassembly and Inspection
4.3 Regulator Valve, Check Valve [6D14T]
4.3.1 Regulator Valve
4.3.2 Check Valve [6D14T]
5. Special Tool
6. Troubleshooting
Group 13 – Fuel
1. General
1.1 Fuel System
1.2 Engine Control
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Injection Pump
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection and Correction
4.1.4 Reassembly
4.1.5 Test and Adjustment
4.2 Governor
4.2.1 Removal and Disassembly
4.2.2 Inspection and Reassembly
4.2.3 Adjustment
4.3 Auto Timer
4.3.1 Disassembly and Inspection
4.3.2 Reassembly
4.3.3 Adjustment
4.4 Feed Pump
4.4.1 Disassembly and Reassembly
4.4.2 Test
4.5 Injection Nozzle
4.5.1 Removal
4.5.2 Disassembly
4.5.3 Cleaning and Inspection
4.5.4 Reassembly
4.5.5 Test and Adjustment
4.5.6 Installation
4.6 Fuel Filter
4.6.1 Disassembly and Reassembly
4.7 Water Separator
4.7.1 Disassembly and Reassembly
4.8 Bleeding the Fuel System
4.9 Engine Control
4.9.1 Removal and Installation
4.9.2 Adjustment
5. Special Tool
6. Troubleshooting
Group 14 – Cooling
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Auto Cool Fan Coupling
4.1.1 Removal and Disassembly
4.1.2 Inspection and Correction
4.1.3 Reassembly and Installation
4.2 Water Pump
4.2.1 Removal
4.2.2 Disassembly and Inspection
4.2.3 Reassembly
4.3 Thermostat
4.3.1 Removal and Disassembly
4.3.2 Inspection
4.4 Radiator
4.4.1 Removal and Disassembly
4.4.2 Inspection
4.4.3 Installation
4.4.4 Gas Leak Test
4.5 Reservoir Tank
4.5.1 Removal and Inspection
4.6 Cleaning of Cooling System
5. Special Tool
6. Troubleshooting
Group 15 – Intake and Exhaust
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Turbocharger [6D14T]
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection and Correction
4.1.4 Reassembly
4.1.5 Installation
4.1.6 Adjustment
4.2 Air Cleaner
4.2.1 Disassembly and Reassembly
4.2.2 Inspection and Cleaning
4.3 Inlet Manifold
4.4 Exhaust Manifold
4.5 P.C.V. (Positive Crankcase Ventilation) Valve [6D14T]
5. Special Tool
6. Troubleshooting
Group 16 – Engine Electrical
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Starter
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection
4.1.4 Reassembly
4.2 Alternator
4.2.1 Removal
4.2.2 Disassembly
4.2.3 Inspection
4.2.4 Reassembly
4.2.5 Tests
4.2.6 Installation
4.3 Glow Plug System
4.3.1 Removal and Installation
4.3.2 Inspection
5. Troubleshooting
Group 21 – Clutch [C5W33]
1. General
1.1 Clutch Control
1.2 Clutch Proper
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal
4.1.1 Removal From Vehicle
4.2 Clutch Proper
4.2.1 Disassembly and Inspection
4.2.2 Reassembly and Adjustment
4.3 Clutch Pedal
4.3.1 Diassembly and Inspection
4.3.2 Reassembly and Adjustment
4.4 Clutch Master Cylinder
4.4.1 Disassembly and Inspection
4.4.2 Reassembly and Adjustment
4.5 Clutch Power Cylinder
4.5.1 Disassembly and Inspection
4.5.2 Reassembly
4.6 Replacement of Clutch System Fluid
4.7 Bleeding Clutch System
4.8 Adjustment of Clutch Control
5. Special Tool
6. Troubleshooting
Group 21 – Clutch [C6W35]
1. General
1.1 Clutch Control
1.2 Clutch Proper
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal
4.1.1 Removal from Vehicle
4.2 Clutch Proper
4.2.1 Disassembly and Inspection
4.2.2 Reassembly and Adjustment
4.3 Clutch Pedal
4.3.1 Disassembly and Inspection
4.3.2 Reassembly and Adjustment
4.4 Clutch Master Cylinder
4.4.1 Disassembly and Inspection
4.4.2 Reassembly and Adjustment
4.5 Clutch Booster
4.5.1 Disassembly and Inspection
4.5.2 Reassembly and Adjustment
4.6 Inspection of Clutch Disc Wear
4.7 Replacement of Clutch System Fluid
4.8 Bleeding Clutch System
4.9 Adjustment of Clutch Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M5S5]
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Rear Cover
4.4.10 Speedometer Gears
4.4.11 Transmission Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M6S5]
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Rear Cover
4.4.10 Speedometer Gears
4.4.11 Transmission Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M8S2x5]
1. General
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Splitter, Upper
4.4.10 Rear Cover
4.4.11 Speedometer Gears
4.4.12 Splitter Case and Gears
4.4.13 Power Shift
4.4.14 Splitter Control
4.4.15 Transmission Control
5. Special Tool
6. Troubleshooting
Group 25 – Propeller Shaft
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
4.4 Propeller Shaft Dynamic Balance Adjustment Procedures
5. Special Tool
6. Troubleshooting
Group 26 – Front Axle
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Wheel Hub and Brake Drum
4.2.1 Disassembly, Inspection and Correction
4.2.2 Reassembly
4.2.3 Adjustment of Bearing Starting Torque
4.3 Front Axle, Knuckle and Kingpin
4.3.1 Disassembly, Inspection and Correction
4.3.2 Measurement of Front Axle Bends
4.3.3 Measurement of Kingpin Inclination
4.3.4 Reassembly
4.4 Adjustment After Installation (Wheel Alignment)
5. Special Tool
6. Troubleshooting
Group 27 – Rear Axle
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Wheel Hub and Brake Drum
4.2.1 Disassembly, Inspection and Correction
4.2.2 Reassembly
4.2.3 Adjustment of Bearing Starting Torque
4.3 Reduction and Differential
4.3.1 Disassembly, Inspection and Correction
4.3.2 Reassembly
4.3.3 Adjustment of Starting Torque of Reduction Pinion Bearing
4.3.4 Selection of Reduction Pinion Mounting Adjusting Shim
4.3.5 Adjustment of Differential Case Side Bearing and Reduction Gear
4.3.6 Reduction Gear Tooth Contact
5. Special Tool
6. Troubleshooting
Group 31 – Wheel and Tire
1. Specifications
2. Service Procedure
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Troubleshooting
Group 33 – Front Suspension
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
5. Special Tool
6. Troubleshooting
Group 34 – Rear Suspension
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
5. Special Tool
6. Troubleshooting
Group 35 – Brake
1. General
1.1 Service Brake
1.2 Parking Brake
1.3 Exhaust Brake
2. Specifications
2.1 Service Brake
2.2 Parking Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standard Table
3.1.1 Service Brake
3.1.2 Parking Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Parking Brake
3.2.3 Exhaust Brake
4. Service Procedure of Service Brake
4.1 Brake System Diagram
4.2 Brake Pedal and Air Brake Valve
4.2.1 Removal and Installation
4.2.2 Brake Pedal
4.2.3 Air Brake Valve
4.2.4 Inspection and Adjustment After Reassembly
4.3 Brake Booster
4.3.1 Brake Booster for FK Series
4.3.2 Brake Booster for FM Series
4.3.3 Function Check After Reassembly
4.4 Air Pressure Governor
4.4.1 Function Check
4.4.2 Disassembly, Inspection and Correction
4.4.3 Reassembly
4.4.4 Inspection and Adjustment After Reassembly
4.5 Check Valve
4.5.1 Disassembly, Inspection and Correction
4.5.2 Reassembly and Inspection
4.6 Safety Valve
4.7 Low Air Pressure Switch
4.8 Stop Lamp Switch
4.9 Supply Valve
4.9.1 Disassembly, Inspection and Correction
4.9.2 Reassembly and Adjustment
4.10 Air Drier
4.10.1 Maintenance and Inspection
4.10.2 Disassembly, Inspection and Correction
4.10.3 Reassembly
4.10.4 Inspection After Installation in Vehicle
4.10.5 Troubleshooting
4.11 Wheel Brake
4.11.1 Removal and Installation
4.11.2 Disassembly, Inspection and Correction
4.11.3 Reassembly
4.11.4 Replacement of Brake Lining and Correction of Brake Drum
4.12 Inspection and Adjustment After Installation
4.12.1 Replacement of Brake Fluid and Bleeding of Brake (Oil) System
4.12.2 Brake Shoe Clearance Adjustment
5. Service Procedure of Parking Brake
5.1 Parking Brake Drum Assembly
5.1.1 Key Points for Removal
5.2 Parking Brake Proper
5.3 Parking Brake Control
5.4 Adjustment After Installation
6. Service Procedure of Exhaust Brake
6.1 Exhaust Brake Valve
6.1.1 Disassembly and Inspection
6.1.2 Reassembly and Adjustment
6.2 Control Cylinder
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Exhaust Brake Microswitch
7. Special Tool
7.1 Service Brake
7.2 Parking Brake
8. Troubleshooting
Group 37 – Steering
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation of Steering System
4.1.1 Removal of Starter Switch Wires and Cables
4.1.2 Removal of Upper and Lower Shaft Assembly
4.1.3 Removal of Starter Switch
4.1.4 Installation of Starter Switch
4.2 Disassembly and Reassembly of Steering Wheel
4.3 Steering Shaft
4.3.1 Disassembly, Inspection and Correction
4.3.2 Reassembly
4.4 Details of Link and Bracket Section
4.5 Drag Link
4.6 Tie Rod
4.7 Integral Power Steering Booster
4.7.1 Disassembly, Inspection and Correction
4.7.2 Reassembly and Adjustment
4.8 Power Steering Oil Pump
4.8.1 Disassembly, Inspection and Correction
4.8.2 Reassembly
4.8.3 Adjustment
4.9 Power Steering Oil Tank
4.9.1 Disassembly
4.9.2 Reassembly
4.10 Adjustment After Installation
4.10.1 Bleeding
4.10.2 Performance Verification Tests
4.10.3 Steering Wheel Play
4.10.4 Adjustment of Steering Angle
5. Special Tool
6. Troubleshooting
Group 41 – Frame
1. General
2. Specifications
3. Service Procedure
3.1 Frame
3.2 Rivets
3.3 Shape of Frame
4. Troubleshooting
Group 42 – Cab
1. General
2. Specifications
3. Service Standards
3.1 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Cab Removal and Installation
4.1.1 Removal
4.1.2 Installation
4.2 Doors
4.2.1 Removal of Doors
4.2.2 Door Installation Adjustment
4.2.3 Door Trim
4.2.4 Door Locking System
4.2.5 Parts Related to Glass
4.3 Seats
4.3.1 Seats
4.3.2 Seat Belts
4.4 Floor Mat
4.5 Overhead Console
4.6 Trims
4.7 Instrument Panel
4.8 Windshield Glass and Rear Window Glass
4.8.1 Removal
4.8.2 Installation
4.9 Rearview Mirrors
4.10 Removal of Front Panel and Related Parts
5. Troubleshooting
Group 54 – Chassis Electrical
1. General
2. Specifications
2.1 Electrical
2.2 Meter and Gauge
2.3 Lighting
2.4 Exhaust Brake
2.5 Wiper and Washer
2.6 Accessory
3. Service Procedure
3.1 Aiming of Headlamps
3.2 Warning and Indicator Lamps
4. Troubleshooting
Group 55 – Heater
1. General
2. Specifications
3. Service Procedure
3.1 Removal and Installation
3.2 Cleaning of Air Filter
3.3 Heater Control Adjustment Procedures
4. Troubleshooting
Wiring Diagram
Alphabetical Index

1990-1991 Mitsubishi FUSO FE FG Truck Service Manual PDF Download

cover
Format: PDF
Pages: 1,734
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1990-1991 Mitsubishi FUSO FE, FG Series Truck (US/Canada) Service & Repair

  • FE434
  • FE444
  • FG434

Manual Part Number: TWSE8911

Topics List:

Foreword
1. Group Classification
2. Definition of Terms and Unit Used
3. Notes On Illustrations
Group 00 – General
1. Exterior 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. Vehicle Identification Number
8. Standard Bolts and Nuts Tightening Torque Table
Group 01 – Maintenance Schedule
1. Using the Maintenance Schedule Table
2. Maintenance Schedule Table
2.1 Replacement of Oil Filter Element
2.2 Replacement of the Fuel Filter Element
2.3 Cleaning of the Fuel Feed Pump Gauze Filter
2.4 Bleeding of the Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.6.1 Dry Dust Buildup
2.6.2 Oil Smoke, Soot, and Oil Black Deposits
2.6.3 Inspection After Drying
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressure
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Adjusting Gear Type [FK415, FK455]
2.10.2 Adjusting Cam Type [FM555]
2.11 Adjustment of Parking Brake Shoe Clearance
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brakes
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of the Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Oil Level
3.6.2 Replacement of Power Steering Oil
3.6.3 Bleeding of the Power Steering System
3.7 Lubrication
Group 11 – Engine
1. General
1.1 Engine Proper
1.2 Air Compressor
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Engine Proper
4.1.1 Measurement of Compression Pressure
4.1.2 Removal
4.1.3 Disassembly
4.1.4 Inspection and Correction
4.1.5 Reassembly
4.1.6 Installation
4.1.7 Adjustment
4.2 Air Compressor
4.2.1 Removal
4.2.2 Disassembly
4.2.3 Inspection and Correction
4.2.4 Reassembly
4.2.5 Installation
5. Special Tool
6. Troubleshooting
6.1 Engine
6.2 Valve Mechanism
Group 12 – Lubrication
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Oil Pump
4.1.1 Removal
4.1.2 Disassembly and Inspection
4.1.3 Reassembly
4.1.4 Installation
4.2 Oil Filter, Oil Cooler
4.2.1 Disassembly and Inspection
4.3 Regulator Valve, Check Valve [6D14T]
4.3.1 Regulator Valve
4.3.2 Check Valve [6D14T]
5. Special Tool
6. Troubleshooting
Group 13 – Fuel
1. General
1.1 Fuel System
1.2 Engine Control
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Injection Pump
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection and Correction
4.1.4 Reassembly
4.1.5 Test and Adjustment
4.2 Governor
4.2.1 Removal and Disassembly
4.2.2 Inspection and Reassembly
4.2.3 Adjustment
4.3 Auto Timer
4.3.1 Disassembly and Inspection
4.3.2 Reassembly
4.3.3 Adjustment
4.4 Feed Pump
4.4.1 Disassembly and Reassembly
4.4.2 Test
4.5 Injection Nozzle
4.5.1 Removal
4.5.2 Disassembly
4.5.3 Cleaning and Inspection
4.5.4 Reassembly
4.5.5 Test and Adjustment
4.5.6 Installation
4.6 Fuel Filter
4.6.1 Disassembly and Reassembly
4.7 Water Separator
4.7.1 Disassembly and Reassembly
4.8 Bleeding the Fuel System
4.9 Engine Control
4.9.1 Removal and Installation
4.9.2 Adjustment
5. Special Tool
6. Troubleshooting
Group 14 – Cooling
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Auto Cool Fan Coupling
4.1.1 Removal and Disassembly
4.1.2 Inspection and Correction
4.1.3 Reassembly and Installation
4.2 Water Pump
4.2.1 Removal
4.2.2 Disassembly and Inspection
4.2.3 Reassembly
4.3 Thermostat
4.3.1 Removal and Disassembly
4.3.2 Inspection
4.4 Radiator
4.4.1 Removal and Disassembly
4.4.2 Inspection
4.4.3 Installation
4.4.4 Gas Leak Test
4.5 Reservoir Tank
4.5.1 Removal and Inspection
4.6 Cleaning of Cooling System
5. Special Tool
6. Troubleshooting
Group 15 – Intake and Exhaust
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Turbocharger [6D14T]
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection and Correction
4.1.4 Reassembly
4.1.5 Installation
4.1.6 Adjustment
4.2 Air Cleaner
4.2.1 Disassembly and Reassembly
4.2.2 Inspection and Cleaning
4.3 Inlet Manifold
4.4 Exhaust Manifold
4.5 P.C.V. (Positive Crankcase Ventilation) Valve [6D14T]
5. Special Tool
6. Troubleshooting
Group 16 – Engine Electrical
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Starter
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection
4.1.4 Reassembly
4.2 Alternator
4.2.1 Removal
4.2.2 Disassembly
4.2.3 Inspection
4.2.4 Reassembly
4.2.5 Tests
4.2.6 Installation
4.3 Glow Plug System
4.3.1 Removal and Installation
4.3.2 Inspection
5. Troubleshooting
Group 21 – Clutch [C5W33]
1. General
1.1 Clutch Control
1.2 Clutch Proper
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal
4.1.1 Removal From Vehicle
4.2 Clutch Proper
4.2.1 Disassembly and Inspection
4.2.2 Reassembly and Adjustment
4.3 Clutch Pedal
4.3.1 Diassembly and Inspection
4.3.2 Reassembly and Adjustment
4.4 Clutch Master Cylinder
4.4.1 Disassembly and Inspection
4.4.2 Reassembly and Adjustment
4.5 Clutch Power Cylinder
4.5.1 Disassembly and Inspection
4.5.2 Reassembly
4.6 Replacement of Clutch System Fluid
4.7 Bleeding Clutch System
4.8 Adjustment of Clutch Control
5. Special Tool
6. Troubleshooting
Group 21 – Clutch [C6W35]
1. General
1.1 Clutch Control
1.2 Clutch Proper
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal
4.1.1 Removal from Vehicle
4.2 Clutch Proper
4.2.1 Disassembly and Inspection
4.2.2 Reassembly and Adjustment
4.3 Clutch Pedal
4.3.1 Disassembly and Inspection
4.3.2 Reassembly and Adjustment
4.4 Clutch Master Cylinder
4.4.1 Disassembly and Inspection
4.4.2 Reassembly and Adjustment
4.5 Clutch Booster
4.5.1 Disassembly and Inspection
4.5.2 Reassembly and Adjustment
4.6 Inspection of Clutch Disc Wear
4.7 Replacement of Clutch System Fluid
4.8 Bleeding Clutch System
4.9 Adjustment of Clutch Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M5S5]
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Rear Cover
4.4.10 Speedometer Gears
4.4.11 Transmission Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M6S5]
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Rear Cover
4.4.10 Speedometer Gears
4.4.11 Transmission Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M8S2x5]
1. General
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Splitter, Upper
4.4.10 Rear Cover
4.4.11 Speedometer Gears
4.4.12 Splitter Case and Gears
4.4.13 Power Shift
4.4.14 Splitter Control
4.4.15 Transmission Control
5. Special Tool
6. Troubleshooting
Group 25 – Propeller Shaft
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
4.4 Propeller Shaft Dynamic Balance Adjustment Procedures
5. Special Tool
6. Troubleshooting
Group 26 – Front Axle
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Wheel Hub and Brake Drum
4.2.1 Disassembly, Inspection and Correction
4.2.2 Reassembly
4.2.3 Adjustment of Bearing Starting Torque
4.3 Front Axle, Knuckle and Kingpin
4.3.1 Disassembly, Inspection and Correction
4.3.2 Measurement of Front Axle Bends
4.3.3 Measurement of Kingpin Inclination
4.3.4 Reassembly
4.4 Adjustment After Installation (Wheel Alignment)
5. Special Tool
6. Troubleshooting
Group 27 – Rear Axle
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Wheel Hub and Brake Drum
4.2.1 Disassembly, Inspection and Correction
4.2.2 Reassembly
4.2.3 Adjustment of Bearing Starting Torque
4.3 Reduction and Differential
4.3.1 Disassembly, Inspection and Correction
4.3.2 Reassembly
4.3.3 Adjustment of Starting Torque of Reduction Pinion Bearing
4.3.4 Selection of Reduction Pinion Mounting Adjusting Shim
4.3.5 Adjustment of Differential Case Side Bearing and Reduction Gear
4.3.6 Reduction Gear Tooth Contact
5. Special Tool
6. Troubleshooting
Group 31 – Wheel and Tire
1. Specifications
2. Service Procedure
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Troubleshooting
Group 33 – Front Suspension
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
5. Special Tool
6. Troubleshooting
Group 34 – Rear Suspension
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
5. Special Tool
6. Troubleshooting
Group 35 – Brake
1. General
1.1 Service Brake
1.2 Parking Brake
1.3 Exhaust Brake
2. Specifications
2.1 Service Brake
2.2 Parking Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standard Table
3.1.1 Service Brake
3.1.2 Parking Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Parking Brake
3.2.3 Exhaust Brake
4. Service Procedure of Service Brake
4.1 Brake System Diagram
4.2 Brake Pedal and Air Brake Valve
4.2.1 Removal and Installation
4.2.2 Brake Pedal
4.2.3 Air Brake Valve
4.2.4 Inspection and Adjustment After Reassembly
4.3 Brake Booster
4.3.1 Brake Booster for FK Series
4.3.2 Brake Booster for FM Series
4.3.3 Function Check After Reassembly
4.4 Air Pressure Governor
4.4.1 Function Check
4.4.2 Disassembly, Inspection and Correction
4.4.3 Reassembly
4.4.4 Inspection and Adjustment After Reassembly
4.5 Check Valve
4.5.1 Disassembly, Inspection and Correction
4.5.2 Reassembly and Inspection
4.6 Safety Valve
4.7 Low Air Pressure Switch
4.8 Stop Lamp Switch
4.9 Supply Valve
4.9.1 Disassembly, Inspection and Correction
4.9.2 Reassembly and Adjustment
4.10 Air Drier
4.10.1 Maintenance and Inspection
4.10.2 Disassembly, Inspection and Correction
4.10.3 Reassembly
4.10.4 Inspection After Installation in Vehicle
4.10.5 Troubleshooting
4.11 Wheel Brake
4.11.1 Removal and Installation
4.11.2 Disassembly, Inspection and Correction
4.11.3 Reassembly
4.11.4 Replacement of Brake Lining and Correction of Brake Drum
4.12 Inspection and Adjustment After Installation
4.12.1 Replacement of Brake Fluid and Bleeding of Brake (Oil) System
4.12.2 Brake Shoe Clearance Adjustment
5. Service Procedure of Parking Brake
5.1 Parking Brake Drum Assembly
5.1.1 Key Points for Removal
5.2 Parking Brake Proper
5.3 Parking Brake Control
5.4 Adjustment After Installation
6. Service Procedure of Exhaust Brake
6.1 Exhaust Brake Valve
6.1.1 Disassembly and Inspection
6.1.2 Reassembly and Adjustment
6.2 Control Cylinder
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Exhaust Brake Microswitch
7. Special Tool
7.1 Service Brake
7.2 Parking Brake
8. Troubleshooting
Group 37 – Steering
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation of Steering System
4.1.1 Removal of Starter Switch Wires and Cables
4.1.2 Removal of Upper and Lower Shaft Assembly
4.1.3 Removal of Starter Switch
4.1.4 Installation of Starter Switch
4.2 Disassembly and Reassembly of Steering Wheel
4.3 Steering Shaft
4.3.1 Disassembly, Inspection and Correction
4.3.2 Reassembly
4.4 Details of Link and Bracket Section
4.5 Drag Link
4.6 Tie Rod
4.7 Integral Power Steering Booster
4.7.1 Disassembly, Inspection and Correction
4.7.2 Reassembly and Adjustment
4.8 Power Steering Oil Pump
4.8.1 Disassembly, Inspection and Correction
4.8.2 Reassembly
4.8.3 Adjustment
4.9 Power Steering Oil Tank
4.9.1 Disassembly
4.9.2 Reassembly
4.10 Adjustment After Installation
4.10.1 Bleeding
4.10.2 Performance Verification Tests
4.10.3 Steering Wheel Play
4.10.4 Adjustment of Steering Angle
5. Special Tool
6. Troubleshooting
Group 41 – Frame
1. General
2. Specifications
3. Service Procedure
3.1 Frame
3.2 Rivets
3.3 Shape of Frame
4. Troubleshooting
Group 42 – Cab
1. General
2. Specifications
3. Service Standards
3.1 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Cab Removal and Installation
4.1.1 Removal
4.1.2 Installation
4.2 Doors
4.2.1 Removal of Doors
4.2.2 Door Installation Adjustment
4.2.3 Door Trim
4.2.4 Door Locking System
4.2.5 Parts Related to Glass
4.3 Seats
4.3.1 Seats
4.3.2 Seat Belts
4.4 Floor Mat
4.5 Overhead Console
4.6 Trims
4.7 Instrument Panel
4.8 Windshield Glass and Rear Window Glass
4.8.1 Removal
4.8.2 Installation
4.9 Rearview Mirrors
4.10 Removal of Front Panel and Related Parts
5. Troubleshooting
Group 54 – Chassis Electrical
1. General
2. Specifications
2.1 Electrical
2.2 Meter and Gauge
2.3 Lighting
2.4 Exhaust Brake
2.5 Wiper and Washer
2.6 Accessory
3. Service Procedure
3.1 Aiming of Headlamps
3.2 Warning and Indicator Lamps
4. Troubleshooting
Group 55 – Heater
1. General
2. Specifications
3. Service Procedure
3.1 Removal and Installation
3.2 Cleaning of Air Filter
3.3 Heater Control Adjustment Procedures
4. Troubleshooting
Wiring Diagram
Alphabetical Index

1990-1991 Mitsubishi FUSO FK FM Truck Service Manual PDF Download

cover
Format: PDF
Pages: 904
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1990-1991 Mitsubishi FUSO FK FM Series Trucks (U.S. models) Service & Repair

  • See full model list at bottom of page
  • FK415 w/ 6D14T2 engine
  • FK455 w/ 6D14T engine
  • FM555 w/ 6D14T engine
  • FM557 w/ 6D16T2 engine

Manual Part Number: TWME8910

Topics List:

Foreword
Compilation of this Manual
1. Group Classification
2. Definitions of Terms and Units Used
3. Notes On Illustrations
Group 00 – General
Table of Contents
1. Exterior 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. Using Maintenance Schedule Table
2. Maintenance Schedule
2.1 Replacement of Oil Filter Element
2.2 Replacement of Fuel Filter Element
2.3 Cleaning of Fuel Feed Pump Gauze Filter
2.4 Bleeding of Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.6.1 Dry Dust Buildup
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressures
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Air Over Hydraulic Brake <FK415, FK455>
2.10.2 Full Air Brake <FM Series>
2.11 Adjustment of Parking Brake Shoe Clearance <FK415, FK455>
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brake <FK415, FK455>
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Fluid Level
3.6.2 Replacement of Power Steering Fluid
3.6.3 Bleeding of Power Steering System
3.7 Chassis Parts
Group 11 – Engine
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Engine and Transmission
6.2 Engine Proper
6.2.1 Measurement of Compression Pressure
6.2.2 Cylinder Head and Valve Mechanism
6.2.3 Flywheel, Timing Gear, and Camshaft
6.2.4 Crankcase and Main Moving Parts
6.2.5 Adjustment
Group 12 – Lubrication
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Oil Pump
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Oil Filter and Oil Cooler
6.2.1 Removal and Installation
6.2.2 Disassembly, Inspection, and Reassembly of Oil Filter
6.2.3 Disassembly, Inspection, and Reassembly of Oil Cooler
6.3 Regulator Valve
6.4 Check Valve
Group 13 – Fuel and Engine Control
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Fuel System
5.2 Engine Control
6. Service Procedure
6.1 Injection Pump Assembly
6.1.1 Removal and Installation
6.1.2 Inspection and Adjustment of Fuel Injection Timing
6.2 Feed Pump
6.2.1 Disassembly, Inspection, and Reassembly
6.2.2 Test
6.3 Injection Nozzle
6.3.1 Removal and Installation
6.3.2 Disassembly
6.3.3 Cleaning and Inspection
6.3.4 Reassembly
6.3.5 Test and Adjustment
6.4 Fuel Filter
6.5 Water Separator
6.6 Bleeding the Fuel System
6.7 Engine Control
6.7.1 Removal and Installation
6.7.2 Adjustment
6.8 Fuel Tank and Fuel Gauge Unit
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Cooling System
6.2 Water Pump
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Inspection of Thermostat
6.4 Inspection of Auto Cool Fan Coupling
6.5 Inspection of Radiator
6.6 Inspection and Adjustment of V-Belt Tension
6.7 Cleaning of Cooling System
6.8 Gas Leak Test
6.9 Bleeding Cooling System
Group 15 – Intake and Exhaust
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal, Installation, and Inspection of Intake System
6.2 Air Cleaner
6.2.1 Disassembly and Reassembly
6.2.2 Inspection and Cleaning
6.3 Removal, Installation, and Inspection of Exhaust System
6.4 Turbocharger
6.4.1 Removal and Installation
6.4.2 Disassembly
6.4.3 Cleaning and Inspection
6.4.4 Reassembly
6.4.5 Measurement of Turbocharger Boost Pressure
6.5 Intercooler <6D16T2>
6.5.1 Removal and Installation
6.5.2 Inspection
Group 16 – Engine Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Starter
5.2 Alternator
5.3 Glow System
6. Service Procedure
6.1 Starter
6.1.1 Removal and Installation
6.1.2 Disassembly
6.1.3 Inspection
6.1.4 Reassembly
6.1.5 Inspection and Adjustment After Reassembly
6.2 Alternator
6.2.1 Removal and Installation
6.2.2 Disassembly
6.2.3 Inspection
6.2.4 Reassembly
6.2.5 Inspection and Adjustment After Installation
6.3 Glow System
6.3.1 Removal and Installation of Glow Plug
6.3.2 Inspection
Group 21 – Clutch
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Clutch Proper
5.2 Clutch Control
5.2.1 Clutch Master Cylinder
5.2.2 Clutch Booster
6. Service Procedure
6.1 Clutch
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Clutch Pedal
6.2.1 Removal and Installation
6.2.2 Disassembly and Inspection
6.2.3 Reassembly and Adjustment
6.3 Clutch Master Cylinder
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Power Cylinder
6.4.1 Removal and Installation
6.4.2 Disassembly and Inspection
6.4.3 Reassembly
6.5 Clutch Booster (Vehicles With M8S2x5)
6.5.1 Removal and Installation
6.5.2 Disassembly and Inspection
6.5.3 Reassembly
6.5.4 Performance Test
6.5.5 On-the-Vehicle Functional Check
6.6 Clutch Housing
6.6.1 Disassembly
6.6.2 Reassembly
6.7 Replacement of Brake Fluid in Clutch System
6.8 Bleeding the Clutch System
6.9 Adjustment of Clutch Pedal
6.10 Lubrication of Drive Pinion Splines
Group 22A – Manual Transmission (M5S5, M6S5)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Rear Cover
6.8.1 Disassembly and Inspection
6.8.2 Reassembly
6.9 Transmission Control
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.9.3 Adjustment After Installation
Group 22B – Manual Transmission (M8S5, M8S2x5)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Upper Splitter <M8S2x5 Only>
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Rear Cover
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.10 Splitter Case and Gear <M8S2x5 Only>
6.10.1 Inspection Before Disassembly
6.10.2 Disassembly and Inspection
6.10.3 Reassembly
6.11 Power Shift
6.11.1 Disassembly and Inspection
6.11.2 Reassembly
6.12 Splitter Control <M8S2x5 Only>
6.12.1 Splitter Air Piping
6.12.2 Power Cylinder
6.13 Transmission Control
6.13.1 Disassembly and Inspection
6.13.2 Reassembly
6.13.3 Adjustment After Installation
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Specification
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Automatic Transmission Control
5.2 Oil Cooler
6. Service Procedure
6.1 Removal and Installation of Automatic Transmission
6.1.1 Removal
6.1.2 Installation
6.2 Oil Seal and Speedometer Worm
6.2.1 Removal and Installation
6.2.2 Replacement of Front Oil Seal
6.2.3 Replacement of Rear Oil Seal
6.2.4 Replacement of Speedometer Worm
6.3 Automatic Transmission Control System
6.3.1 Removal and Installation
6.3.2 Inspection After Installation
6.4 Oil Cooler
6.4.1 Removal and Installation
6.5 Oil Filter
6.5.1 Removal and Installation
6.6 Replacement of Oil and Oil Filter
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Front Propeller Shaft
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Rear Propeller Shaft
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Adjustment After Reassembly
Group 26 – Front Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection, and Corrections
6.2.2 Reassembly
6.3 Front Axle, Knuckle, and Kingpin
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Inspection and Adjustment After Installation
Group 27 – Rear Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection, and Corrections
6.2.2 Reassembly
6.3 Reduction and Differential
6.3.1 Removal
6.3.2 Inspection Before Disassembly
6.3.3 Disassembly and Inspection
6.3.4 Reassembly
Group 31 – Wheel and Tire
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
5. Service Procedure
5.1 Removal
5.2 Disassembly and Reassembly
5.2.1 Tire With Tube
5.2.2 Tubeless Tire
5.3 Inspection and Correction
5.4 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection, and Correction
6.3 Installation
Group 34 – Rear Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection, and Correction
6.3 Installation
Group 35A – Brake (Air Over Hydraulic Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Drier
5.4 Dual Brake Valve
5.5 Brake Booster (Airmaster)
5.6 Air Pressure Governor
5.7 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Drier
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Brake Booster (Airmaster)
6.2.5 Air Pressure Governor
6.2.6 Check Valve
6.2.7 Supply Valve
6.2.8 Safety Valve
6.2.9 Low Air Pressure Switch
6.2.10 Stop Lamp Switch
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Wheel Cylinder
6.3.3 Rear Wheel Brake
6.3.4 Rear Wheel Cylinder
6.4 Inspection and Adjustment After Installation
6.4.1 Shoe Clearance Adjustment
6.4.2 Replacement of Brake Fluid and Bleeding of Brake System
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control
6.5.4 Adjustment and Inspection After Installation
Group 35B – Brake (Full Air Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Drier
5.4 Dual Brake Valve
5.5 Air Pressure Governor
5.6 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Drier
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Air Pressure Governor
6.2.5 Check Valve
6.2.6 Supply Valve
6.2.7 Safety Valve
6.2.8 Low Air Pressure Switch
6.2.9 Stop Lamp Switch
6.2.10 Relay Valve
6.2.11 Quick Release Valve
6.2.12 Double Check Valve
6.2.13 Air Check Valve
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Brake Chamber
6.3.3 Rear Wheel Brake
6.3.4 Rear Brake Chamber
6.4 Inspection and Adjustment After Installation
6.4.1 Adjustment of Brake Shoe Clearance
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control
6.5.4 Adjustment and Inspection After Installation
Group 36A – Parking Brake (Center Parking Brake)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Parking Brake
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Parking Brake Control
6.2.1 Removal and Installation
6.2.2 Parking Brake Lever
6.3 Adjustment
Group 36B – Parking Brake (Wheel Parking Brake)
Table of Contents
1. Troubleshooting
2. Service Standards
2.1 Service Standards Table
2.2 Tightening Torque Table
3. General
3.1 Parking Brake System
3.2 Parking Brake Control Valve
3.3 Spring Brake Valve
4. Service Procedure
4.1 Parking Brake Control Valve
4.1.1 Disassembly
4.1.2 Reassembly
4.1.3 Inspection After Reassembly
4.2 Spring Brake Valve
4.2.1 Disassembly
4.2.2 Reassembly
4.2.3 Inspection After Reassembly
Group 37 – Steering
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Steering Shaft
6.2.1 Removal
6.2.2 Installation
6.2.3 Disassembly, Inspection, and Correction
6.2.4 Reassembly
6.3 Link and Bracket Section
6.3.1 Disassembly
6.3.2 Reassembly
6.4 Drag Link
6.5 Tie Rod
6.6 Integral Power Steering Booster
6.6.1 Disassembly, Inspection, and Correction
6.6.2 Reassembly and Adjustment
6.7 Power Steering Oil Pump
6.7.1 Removal
6.7.2 Installation
6.7.3 Disassembly, Inspection, and Correction
6.7.4 Reassembly
6.7.5 Adjustment
6.8 Power Steering Oil Tank
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Adjustment After Installation
6.9.1 Bleeding
6.9.2 Performance Verification Tests
6.9.3 Steering Wheel Play
6.9.4 Adjustment of Steering Angle
Group 41 – Frame
Table of Contents
1. General
2. Service Procedure
2.1 Inspection and Repair
2.1.1 Frame
2.1.2 Rivets
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Procedures
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
4.1 Cab Proper
4.2 Cab Mounting
4.2.1 Front Cab Mounting
4.2.2 Rear Cab Mounting
4.3 Cab Tilt System
5. Service Procedure
5.1 Removal
5.1.1 Key Points for Removal
5.1.2 Key Points for Installation
5.1.3 Inspection and Adjustment After Installation
5.2 Cab Mounting
5.2.1 Front Cab Mounting
5.2.2 Cab Stay
5.2.3 Rear Cab Mounting
5.2.4 Cab Tilt Link
5.3 Doors
5.3.1 Removal of Doors
5.3.2 Door Installation Adjustment
5.3.3 Front Door Assembly
5.4 Interior Parts
5.4.1 Seats and Center Console
5.4.2 Seat Belts
5.4.3 Floor Mat
5.4.4 Overhead Console
5.4.5 Trim and Headlining
5.4.6 Instrument Panel
5.5 Window Glass
5.5.1 Removal
5.5.2 Installation
5.6 Exterior Parts
5.6.1 Front Panel, Fender, and Allied Parts
5.6.2 Rear View Mirrors
Group 54 – Chassis Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
4. General
5. Service Procedure
5.1 Battery
5.1.1 General Description
5.1.2 Inspection
5.2 Fuses
5.2.1 General Description
5.2.2 Inspection
5.3 Fusible Link
5.3.1 General Description
5.3.2 Inspection
5.4 Starter Switch and Cold Starter Switch
5.4.1 General Description
5.4.2 Inspection
5.5 Sub-Starter System
5.5.1 General Description
5.5.2 Inspection
5.6 Combination Switch
5.6.1 General Description
5.6.2 Inspection
5.7 Lighting System
5.7.1 General Description
5.7.2 Inspection
5.7.3 Inspection and Adjustment After Installation
5.8 Meter System
5.8.1 General Description
5.8.2 Inspection
5.9 Indicators and Warning Lamps
5.9.1 General Description
5.9.2 Inspection
5.10 Wiper and Washer System
5.10.1 General Description
5.10.2 Inspection
5.10.3 Inspection and Adjustment After Installation
5.11 Horn
5.11.1 General Description
5.11.2 Inspection
5.12 Back-Up Buzzer
5.12.1 General Description
5.12.2 Inspection
5.13 Radio and Cassette Stereo
5.13.1 Mounting Position
5.13.2 AM/FM Radio
5.13.3 AM/FM Radio and Cassette Stereo
5.13.4 Troubleshooting
5.14 Cigarette Lighter
5.14.1 General Description
5.14.2 Inspection
Wiring Diagram – FK <Manual Transmission>
Wiring Diagram – FK <Automatic Transmission>
Wiring Diagram – FM
Group 55A – 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 A/C Switch
3.10 Thermo Sensor
3.11 Power Relay
3.12 Dual Pressure Switch
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 Dual 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 Leak Test
6.2.1 Test Point
6.2.2 Test Procedure
6.3 Evacuation
6.4 Gas Charge
6.5 Checking the Refrigerant Level
6.6 Performance Test
6.6.1 Preparation
6.6.2 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. Specifications
3. General
3.1 Ventilation System
3.2 Heater
4. Service Procedure
4.1 Removal and Installation
4.2 Cleaning of Air Filter
4.3 Heater Control Adjustment Procedure

Full model list:

  • FK415HSLSU
  • FK415HSLSUB
  • FK415JSLSU
  • FK415JSLSUB
  • FK415KSLSU
  • FK415KSLSUB
  • FK415LSLSU
  • FK415LSLSUB
  • FK455HSLSU
  • FK455JSLSU
  • FK455KSLSU
  • FK455LSLSU
  • FK455MSLSU
  • FM555FSLSU
  • FM555FSLSUA
  • FM555HSLSU
  • FM555HSLSUA
  • FM555JSLSU
  • FM555JSLSUA
  • FM555LSLSU
  • FM555LSLSUA
  • FM555MSLSU
  • FM555MSLSUA
  • FM557FSLSU
  • FM557FSLSUA
  • FM557HSLSU
  • FM557HSLSUA
  • FM557JSLSU
  • FM557JSLSUA
  • FM557LSLSU
  • FM557LSLSUA
  • FM557MSLSU
  • FM557MSLSUA

1992-1995 Mitsubishi FUSO FE FG Truck Service Manual PDF Download

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Format: PDF
Pages: 1,801
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1992, 1993, 1994, 1995 Mitsubishi FUSO FE FG Series Truck (U.S. models) Service & Repair

  • FE439 w/ 4D34-T3
  • FE449 w/ 4D34-T3
  • FG439 w/ 4D34-T3

Manual Part Number: TWSE9105 plus model year changes

Topics List:

Foreword
Group 00 – General
(1) Change of Model
(2) Change of Engine Stamp Mark Position
Group 11 – Engine
(3) Tension of Air Conditioner Belt
(4) Change of Piston
(5) Change of Connecting Rod
(6) Change of Front Oil Seal
(7) Change of Camshaft
(8) Change of Camshaft Bushing
(9) Change of Timing Gear Case Sealer
(10) Change of Tappet
Group 12 – Lubrication
(11) Change of Oil Pump
(12) Change of Oil Filter
Group 13 – Fuel and Engine Control
(13) Change of Injection Pump
(14) Addition of Inspection Procedure Using the Pre-Stroke Type Injection Pump System MUT
Group 15 – Intake and Exhaust
(15) Employment of Catalyst Converter
(16) Change of Exhaust Manifold
(17) Change of Front Pipe
Group 16 – Engine Electrical
(18) Change of Alternator
(19) Change of Vacuum Pump
Group 22 – Manual Transmission
(20) Change of Special Tool for Main Shaft Removal and Installation
(21) Change of Shift Fork and Jaw Set
(22) Change of Speed Meter Gear
Group 23 – Automatic Transmission
(23) Change of Manual Lever Attaching Nut
(24) Change of Oil Cooler Piping
(25) Change of Oil Temperature
Group 35 – Brake
(26) Modification of Exhaust Brake Circuit Diagram
Group 36 – Parking Brake
(27) Change of Parking Brake Lever
Group 37 – Steering
(28) Change of Power Steering Oil Pump Gear Attaching Nut
(29) Change of Power Steering Oil Pump
Group 42 – Cab and Body
(30) Change of Outside Mirror Stay
Group 55 – Heater and Air Conditioner
(31) Change of Air Conditioner Compressor
1994 Minor Change
Table of Contents
1. Differences of 1994 Model From 1993 Model
2. Change Due to Running Change Made on 1993 Model
1993 Minor Change
1. Differences of 1993 Model From 1992 Model
2. Electrical Wiring Diagram
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 Water Separator Condensation Drain
3.4 Cleaning the Fuel Feed Pump Gauze Filter
3.5 Bleeding Air From the Fuel Line
3.6 Adjusting V-Belt Tension
3.7 Cleaning and Replacement of the Air Cleaner Element
3.8 Inspecting the Clutch Pedal
3.9 The Tires
3.9.1 Air Pressure
3.9.2 Removing Tires
3.9.3 Putting Tires On
3.9.4 Checking the Wheel Nuts for Looseness
3.9.5 Tire Rotation
3.10 Adjusting the Clearance of the Wheel Brake Shoe (FG Model Only)
3.11 Checking for Wear in the Disk Brake Pads (FE Model Only)
3.12 Adjusting the Clearance of the Parking Brake Shoe
3.13 The Battery
3.13.1 Cleaning the Battery Terminals
3.13.2 Inspecting the Battery
3.14 Fuses
4. Lubrication
4.1 Engine Oil
4.2 Gear Oil for Manual Transmissions
4.3 Transmission Fluid for Automatic Transmissions
4.4 Front Axle <FG Model Only> and Rear Axle Gear Oil
4.5 Transfer Gear Oil <FG Model Only>
4.6 Power Steering Fluid
4.7 Brake Fluid
4.8 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
2.1.2 Lubricant Table
2.2 Engine and Transmission Removal
2.2.1 Preparations Before Removal
2.2.2 Harness Removal
2.2.3 Vacuum Hose Removal
2.2.4 Removal of Parts Around Engine
2.2.5 Removal of Each Engine Parts
2.2.6 Removal of Each Transmission Parts
2.2.7 Removing the Engine From the Vehicle
2.2.8 Separating the Engine From the Transmission
2.3 Installation of the Engine and Transmission
2.3.1 Engine and Transmission Installation
2.3.2 Installation the Engine and Transmission in the Vehicle
2.3.3 Installation of Each Transmission Part
2.3.4 Installation of Each Engine Part
2.3.5 Installation of Parts Around the Engine
2.3.6 Vacuum Hose Installation
2.3.7 Harness Installation
2.4 Adjustment After Installation
2.4.1 Operations After Installation
2.4.2 Adjustment
3. Engine Removal and Installation (Automatic Transmission Vehicles)
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 Engine and Transmission Removal
3.2.1 Preparations Before Removal
3.2.2 Harness Removal
3.2.3 Vacuum Hose Removal
3.2.4 Removal of Parts Around Engine
3.2.5 Removal of Each Engine Part
3.2.6 Removal of Each Transmission Part
3.2.7 Removing the Engine From the Vehicle
3.2.8 Separating the Engine and Transmission
3.3 Installation of the Engine and Transmission
3.3.1 Transmission Installation
3.3.2 Installing the Engine and Transmission in the Vehicle
3.3.3 Installation of Each Transmission Part
3.3.4 Installation of Each Engine Part
3.3.5 Installation of Parts Around the Engine
3.3.6 Vacuum Hose Installation
3.3.7 Harness Installation
3.4 Adjustment After Installation
3.4.1 Operations After Installation
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 Valve Clearance Inspection and Adjustment
4.4 Compression Pressure Measurement
4.5 Oil Pressure Inspection
4.6 Fuel Injection Timing Inspection and Adjustment
4.7 Bleeding the Fuel System
4.8 Inspection and Adjustment of V-Belt Tension
4.8.1 V-Belt Tension Inspection
4.8.2 V-Belt Tension Adjustment
4.9 Turbocharger Boost Pressure Measurement
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 Rear Plate (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 Lubricant 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 Lubricant 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 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 Vacuum Pump 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
3. Pre-Stroke Control 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 Pre-Stroke Control Injection Pump System
3.3.2 Control Unit
3.3.3 Sensors
3.3.4 Injection Pump Unit
3.3.5 Governor
3.3.6 Feed Pump
3.4 Service Procedure
3.4.1 System Inspection
3.4.2 Removing Injection Pump Assembly
3.4.3 Installing Injection Pump Assembly
3.4.4 Bleeding Air From the Fuel System
3.4.5 Fuel Injection Timing Adjustment
3.4.6 Minimum Unloaded Idling Speed and Maximum Speed Adjustment
3.4.7 Idle Up Adjustment <Manual Transmission Equipped Vehicles>
3.4.8 Engine Stop Cable Operational Check
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 Testing 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 From the Engine Side
8.4.2 Removing the Throttle Cable and Accelerator Pedal
8.4.3 Disconnecting the Accelerator Control Cable and Accelerator Lever
8.4.4 Removing the Engine Stop Cable
8.5 Inspection
8.6 Installation
8.6.1 Installing the Engine Stop Cable
8.6.2 Installing the Throttle Cable, Accelerator Lever Assembly and Accelerator Pedal
8.6.3 Securing the Accelerator Control Cable
8.6.4 Installing the Accelerator Control Cable and the Engine Stop Cable to Engine Side
8.7 Post-Installation Adjustment
8.7.1 Accelerator Pedal Stopper Adjustment
8.7.2 Engine Stop Cable Operation Check
8.7.3 Accelerator Switch (Exhaust Brake Microswitch) Adjustment
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Cooling System
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Removal
2.4.1 Radiator Removal
2.4.2 Cooling Fan and Auto-Cool Fan Coupling Removal
2.4.3 Water Pump Removal
2.4.4 Thermostat Removal
2.5 Installation
2.5.1 Thermostat Installation
2.5.2 Water Pump Installation
2.5.3 Cooling Fan and Auto-Cool Fan Coupling Installation
2.5.4 Radiator 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 Removal
3.3 Inspection
3.4 Installation
4. Water Pump
4.1 General Description
5. Thermostat
5.1 Service Standards
5.2 General Description
5.3 Inspection
6. Radiator
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.2 General Description
6.2.1 Radiator
6.2.2 Pressure Cap
6.2.3 Radiator Shroud
6.2.4 Condenser Tank
6.3 Inspection and Cleaning
6.3.1 Radiator Cleaning
6.3.2 Radiator Inspection
6.3.3 Pressure Cap Inspection
6.3.4 Radiator (Cooling System) Cleaning
6.3.5 Cooling System Air Bleeding
6.3.6 Gas Leak Test
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 Disassembly
2.5.1 Air Cleaner Disassembly
2.5.2 Removing the Intake Shutter
2.6 Inspection and Cleaning
2.7 Reassembly
2.7.1 Actuator Installation
2.7.2 Air Cleaner Reassembly
2.8 Installation
2.9 Post-Installation Adjustment
3. Exhaust System
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 General Description
3.3 Removal
3.4 Installation
4. Turbocharger
4.1 Sepcifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Lubricants Table
4.3 General Description
4.4 Removal
4.5 Disassembly
4.6 Inspection and Cleaning
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 Standard
5.2.1 Service Standards Table
5.2.2 Tightening Torque Table
5.3 Outline
5.4 Removal
5.5 Inspection and Cleaning
5.6 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 Lubrication Table
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 Lubrication 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. Vacuum Pump
5.1 Service Standards
5.2 General Description
5.3 Removal
5.4 Disassembly
5.5 Inspection
5.6 Reassembly
5.7 Testing
6. Glow Plug System
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Special Tools Table
6.1.3 Tightening Torque Table
6.2 General Description
6.3 Removal
6.4 Inspection
6.4.1 Glow Plug Inspection
6.4.2 Glow Controller Inspection
6.4.3 Water Temperature Gauge Unit Inspection
6.5 Installation
7. Idle Up System and Warning System
7.1 Service Standards
7.1.1 Service Standards Table
7.1.2 Tightening Torque Table
7.1.3 Lubrication Table
7.2 General Description
7.3 Removal
7.4 Inspection
7.5 Installation
7.6 Adjustment
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 Before Removal
2.4.2 Removal
2.5 Inspection and Adjustment
2.5.1 Inspection
2.5.2 Adjustment
2.6 Installation
2.7 Post-Installation Adjustment
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 Special Tools Table
3.3 General Description
3.4 Clutch Hose and Clutch Tube
3.4.1 Removal
3.4.2 Inspection
3.4.3 Installation
3.5 Clutch Pedal
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 Disassembly
3.6.2 Inspection
3.6.3 Reassembly
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
3.8 Clutch Housing Assembly
3.8.1 Removal
3.8.2 Disassembly
3.8.3 Reassembly
3.8.4 Installation
3.9 Fluid Change of Clutch System
3.10 Bleeding the Clutch System
3.11 Post-Installation Adjustment
3.12 Clutch Adjustment
Group 22 – Manual Transmission
Table of Contents
1. Troubleshooting
2. Removing the Transmission
2.1 Service Standards
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
3.3 General Description
3.4 Removal
3.4.1 Clutch Housing Assembly
3.4.2 Gear Shift, Upper and Lower
3.4.3 Rear Cover
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 Special Tools Table
4.2 Preliminary Inspection
4.3 Disassembly
4.4 Inspection
4.5 Reassembly
5. Gear Shift, Lower
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.2 Disassembly
5.3 Inspection
5.4 Reassembly
6. Gear Shift, Upper
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.2 Disassembly
6.3 Inspection
6.4 Reassembly
7. Rear Cover
7.1 Service Standards
7.1.1 Service Standards Table
7.1.2 Tightening Torque Table
7.1.3 Special Tools Table
7.2 Disassembly
7.3 Inspection
7.4 Reassembly
8. Transmission Control
8.1 Service Standards
8.2 General Description
8.3 Preliminary Operations
8.4 Removal
8.5 Inspection, Repair and Replacement
8.6 Installation
8.7 Cross-Shaft Assembly
8.7.1 Disassembly
8.7.2 Inspection
8.7.3 Reassembly
8.8 Select Lever Assembly
8.8.1 Disassembly
8.8.2 Inspection and Replacement
8.8.3 Reassembly
8.9 Shift Lever Assembly
8.9.1 Disassembly
8.9.2 Inspection and Replacement
8.9.3 Reassembly
8.10 NO.1 Cross Lever Assembly
8.10.1 Disassembly
8.10.2 Inspection
8.10.3 Reassembly
8.11 Lever Complete
8.11.1 Disassembly
8.11.2 Inspection
8.11.3 Reassembly
8.12 Change Lever Complete
8.12.1 Disassembly
8.12.2 Inspection
8.12.3 Reassembly
8.13 Post-Installation Adjustment
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. Specifications
5.1 Control Mechanisms
5.1.1 Line Pressure Control
5.1.2 Gear Shift Control
5.1.3 Lockup Control
5.1.4 Overrun Clutch Control
5.1.5 Shift Pattern Selector Control
5.1.6 Self Diagnosis Function
5.1.7 Fail Safe Functions
5.2 Electronic Control Devices
5.2.1 Control Unit
5.2.2 Accelerator Sensor
5.2.3 Idle Switch (Accelerator Switch)
5.2.4 Vehicle Speed Sensor 2
5.2.5 Vehicle Speed Sensor 1
5.2.6 Fluid Temperature Sensor
5.2.7 Shift Solenoids A and B
5.2.8 Line Pressure Solenoid and Lock Up Solenoid
5.2.9 Overrun Clutch Solenoid
5.2.10 Engine Speed Sensor
5.2.11 Dropping Register
5.2.12 Power Mode Switch
5.3 Hydraulic Pressure Control Device
5.4 Gear Shift Mechanism
5.4.1 Reverse Clutch (Multi-Plate Clutch)
5.4.2 HIGH Clutch (Multi-Plate Clutch)
5.4.3 Brake Band
5.4.4 Forward Clutch (Multi-Plate Clutch) Overrun Clutch (Multi-Plate Clutch)
5.4.5 Low and Reverse Brake (Multi-Plate Clutch)
5.4.6 Planetary Gear
5.4.7 Forward One Way Clutch
5.4.8 Low One Way Clutch
5.4.9 Torque Transmission Path
5.5 Torque Converter (With Lock Up)
5.6 Oil Pump (Variable Capacity Vane Pump)
6. Service Standards
6.1 Maintenance and Inspection
6.1.1 ATF Inspection
6.1.2 ATF Replacement
6.2 Transmission Removal and Installation
6.2.1 Tasks Prior To Removal
6.2.2 Removal
6.2.3 Installation
6.2.4 Inspection and Adjustment After Installation
6.3 Removal and Installation of Transmission PTO
6.4 Oil Seal Replacement
6.5 Inhibitor Switch
6.5.1 Removal and Installation
6.5.2 Inspection and Adjustment
6.6 Accelerator Sensor Inspection
6.7 Automatic Transmission Control System Inspection
6.7.1 Inspection Preparation Tasks
6.7.2 Sensor Switch and Harness Inspection
6.7.3 Automatic Transmission Control Unit Inspection
6.7.4 Post Inspection Tasks
6.8 Causes of Failure and Prevention
6.8.1 Causes of Automatic Transmission Failure
6.8.2 Self Diagnosis Function
6.8.3 Load Test
6.8.4 Line Pressure Test
6.8.5 Stall Test
6.8.6 Fluid Leakage
6.9 Oil Cooler
6.9.1 Service Standards
6.9.2 General Description
6.9.3 Oil Cooler Fan System
6.9.4 Removal and Installation
6.9.5 Inspection
Group 24 – Transfer
Table of Contents
1. Troubleshooting
2. Removing the Transfer
2.1 Service Standards
2.1.1 Tightening Torque Table
2.1.2 Special Tool Table
2.2 Removal
2.3 Installation
3. Transfer Main Body
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 Disassembly
3.5 Inspection and Replacement
3.6 Reassembly
4. Transfer Control
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 Installation
4.6 Adjustment After Installation
4.7 Disassembly
4.8 Inspection
4.9 Reassembly
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Rear 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
3. Front, Rear Propeller Shaft <Two Joints>
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
3.5 Disassembly
3.6 Inspection
3.7 Reassembly
3.8 Installation
4. Double Cardin Propeller Shaft
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 General Description
4.4 Removal
4.5 Disassembly
4.6 Inspection
4.7 Reassembly
4.8 Installation
Group 26 – Front Axle
Group 26A – Front Axle <FE>
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 Rotor
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. Front Axle Center 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 26B – Front Axle <FG>
Table of Contents
1. Troubleshooting
2. Front Axle Assembly
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 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 Special Tools Table
3.2 Disassembly
3.3 Inspection
3.4 Reassembly
4. Axle, Knuckle and Drive Shaft
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 Disassembly
4.3 Inspection and Adjustment
4.4 Reassembly
5. Reduction and Differential
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 Removal
5.3 Preliminary Inspection
5.4 Disassembly
5.5 Inspection
5.6 Reassembly
5.7 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
2.3 General Description
2.4 Removal
2.5 Disassembly
2.6 Inspection
2.7 Reassembly
2.8 Installation
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 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 Special Tools Table
4.2 Removal
4.3 Preliminary Inspection
4.4 Disassembly
4.5 Inspection
4.6 Reassembly
4.7 Installation
Group 31 – Wheels and Tires
Table of Contents
1. Troubleshooting
2. Wheels and Tires
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 Removal
2.4.3 Front Tires
2.4.4 Rear Tires
2.4.5 Inspection of Wheel Bolt and Nut
2.5 Disassembly and Inspection
2.6 Reassembly
2.7 Post-Assembly Inspection and Adjustment
2.8 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Front Suspension Assembly
2.1 Service Standards
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 <FE Series Only>
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 Standard 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 <FE Series Only>
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
2.3 General Description
2.4 Bleeding of Air From the Brake System
2.4.1 Front Brake System
2.4.2 Rear Brake System
2.4.3 Bypass Valve System
2.5 Replacing of Brake Fluid
2.5.1 Draining the Brake Fluid
2.5.2 Changing Front Brake System Brake Fluid
2.5.3 Changing Rear Brake System Brake Fluid
2.5.4 Changing the Brake Fluid of the Bypass Valve System
2.5.5 Bleeding of Brake System
3. Brake Piping
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 Inspection Before Removal
3.3 Draining Out Brake Fluid
3.4 Removal
3.5 Inspection
3.6 Installation
4. Vacuum Tank
4.1 Service Standards
4.1.1 Service Standards Table
4.2 Vacuum Switch
4.2.1 Inspection
4.2.2 Removal
4.2.3 Installation
4.3 Vacuum Tank
4.3.1 Removal
4.3.2 Inspection
4.3.3 Installation
5. Brake Pedal
5.1 Service Standard
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.2 Brake Fluid Tank
5.2.1 Inspection Before Removal
5.2.2 Removal
5.2.3 Inspection
5.2.4 Installation
5.3 Brake Pedal
5.3.1 Removal
5.3.2 Disassembly
5.3.3 Inspection
5.3.4 Assembly
5.3.5 Installation
5.3.6 Positioning Brake Pedal
5.3.7 Brake Pedal Play
5.3.8 Distance Between Brake Pedal and Floor Board
5.3.9 Adjustment of Stop Lamp Switch
6. Brake Booster (Master Vac)
6.1 Specifications
6.2 Service Standards
6.2.1 Tightening Torque Table
6.2.2 Special Tools Table
6.3 General Description
6.4 Removal
6.5 Disassembly
6.6 Inspection
6.7 Reassembly
6.8 Installation
6.9 Adjustments After Installation
6.10 Inspection After Installation
7. Brake Master Cylinder
7.1 Specifications
7.2 Service Standards
7.2.1 Service Standards Table
7.2.2 Tightening Torque Table
7.3 General Description
7.4 Removal
7.5 Disassembly
7.6 Inspection
7.7 Reassembly
7.8 Installation
8. Proportioning Valve
8.1 Specifications
8.2 Service Standards
8.2.1 Service Standards Table
8.2.2 Tightening Torque Table
8.3 General Description
8.3.1 Valve Unit
8.3.2 Sensor
8.4 Removal
8.5 Disassembly
8.6 Inspection
8.7 Reassembly
8.8 Installation
8.9 Adjustment After Installation and Functional Test
9. Bypass Valve
9.1 General Description
9.2 Functional Inspection
9.3 Removal
9.4 Installation
10. Front Disc Brake <FE Series>
10.1 Specifications
10.2 Service Standards
10.2.1 Service Standards Table
10.2.2 Tightening Torque Table
10.2.3 Special Tools
10.3 General Description
10.4 Replacing the Pads
10.5 Removal
10.6 Disassembly
10.7 Inspection
10.8 Reassembly
10.9 Installation
10.10 Measure Dragging Torque (Tangential Force)
11. Front Drum Brake <FG Series>
11.1 Specifications
11.2 Service Standards
11.2.1 Service Standards Table
11.2.2 Tightening Torque Table
11.3 Outline
11.4 Removal
11.5 Disassembly
11.6 Inspection
11.7 Reassembly
11.8 Wheel Cylinder
11.8.1 Disassembly
11.8.2 Inspection
11.8.3 Reassembly
11.9 Installation
11.10 Shoe Clearance Adjustment
12. Rear Drum Brake
12.1 Specifications
12.2 Service Standards
12.2.1 Service Standards Table
12.2.2 Tightening Torque Table
12.3 General Description
12.4 Removal
12.5 Disassembly
12.6 Inspection
12.7 Reassembly
12.8 Wheel Cylinder <FE Series>
12.8.1 Disassembly
12.8.2 Inspection
12.8.3 Reassembly
12.9 Wheel Cylinder <FG Series>
12.9.1 Disassembly
12.9.2 Inspection
12.9.3 Reassembly
12.10 Installation
12.11 Adjusting Shoe Clearance
13. Exhaust Brake System
13.1 Specifications
13.2 Service Standards
13.2.1 Service Standards Table
13.2.2 Tightening Torque Table
13.3 General Description
13.4 Removal
13.5 Disassembly
13.6 Inspection
13.7 Reassembly
13.8 Installation
13.9 Inspection After Installation
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 Operations
2.4.2 Parking Brake Lever Assembly
2.4.3 Parking Brake Cable
2.4.4 Inspection
2.5 Disassembly and Inspection
2.5.1 Disassembly
2.5.2 Inspection
2.6 Assembly and Repair
2.7 Installation
2.7.1 Parking Brake Lever Assembly
2.7.2 Parking Brake Cable
2.8 Post-Installation Adjustments
3. Parking Brake Drum and Brake Shoe
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 Operations
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. Steering System
2.1 Service Standards
2.1.1 Service Standards Table
2.1.2 Tightening Torque Table
2.2 General Description
2.2.1 Steering System
2.2.2 Power Steering System
2.3 Power Steering Oil Change
2.4 Performance Verification Tests
2.5 Overall Power Steering Inspection
3. Steering Wheel and Shaft
3.1 Specifications
3.2 Service Standards
3.2.1 Tightening Torque Table
3.3 General Description
3.4 Removal
3.5 Disassembly
3.6 Assembly
3.7 Installation
3.8 Post-Installation Inspection
4. Steering Linkage
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.2 General Description
4.3 Drag Link
4.3.1 Removal
4.3.2 Installation
4.3.3 Greasing
4.4 Tie Rod
4.4.1 Removal
4.4.2 Disassembly
4.4.3 Inspection
4.4.4 Assembly
4.4.5 Installation
4.4.6 Greasing
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 Special Tools Table
5.3 General Description
5.3.1 Structure
5.3.2 Operation
5.4 Removal
5.5 Pre-Disassembly Work and Inspection
5.6 Disassembly
5.7 Inspection
5.8 Assembly
5.9 Post-Assembly Work and Inspection
5.10 Installation
5.11 Post-Installation Inspection
6. Power Steering Oil Pump
6.1 Specifications
6.2 Service Standards
6.2.1 Service Standards Table
6.2.2 Tightening Torque Table
6.3 General Description
6.4 Removal
6.5 Disassembly
6.6 Inspection
6.7 Assembly
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
1.3.3 Nuts and Bolts
1.4 Frame Shape
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Cab
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Cab Tilting Method
2.5 Removal
2.5.1 Operations Before Removal
2.5.2 Operations Inside the Cab
2.5.3 Operations In Front of the Cab
2.5.4 Cab Tilting Operations
2.5.5 Lifting the Cab
2.6 Installing the Cab
2.6.1 Lifting the Cab
2.6.2 Operations for Tilting the Cab
2.6.3 Operations In Front of the Cab
2.6.4 Operations Inside the Cab
2.6.5 Operations After Installation
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 Removal
3.4.1 Operations Before Removal
3.4.2 Removing the Cab Tilt Link
3.4.3 Removing the Rear Cab Mounting
3.4.4 Removing the Cab Hinge
3.5 Installation
3.5.1 Cab Hinge Installation
3.5.2 Rear Cab Mounting Installation
3.5.3 Cab Tilt Link Installation
3.5.4 Operations After Installation
4. Front Windshield Glass and Rear Window Glass
4.1 Specifications
4.2 Service Standards
4.3 Removal
4.3.1 Operations Before Removal
4.3.2 Removal Operations
4.4 Installation
4.4.1 Installation Operations
4.4.2 Operations After Installation
5. Door Assembly
5.1 Specifications
5.2 Service Standards
5.3 General Description
5.4 Removal
5.4.1 Operations Before Removal
5.4.2 Removing the Door Trim
5.4.3 Removing the Front Door Window Glass
5.4.4 Removing the Front Door Window Regulator
5.4.5 Removing the Front Door Locking System
5.4.6 Removing the Outside Mirror Stay Assembly
5.4.7 Removing the Front Door Panel
5.5 Installation
5.5.1 Front Door Panel Installation
5.5.2 Outside Mirror Stay Assembly Installation
5.5.3 Front Door Locking System Installation
5.5.4 Inspection and Adjustment After Installing the Front Door Locking System
5.5.5 Front Door Window Regulator Installation
5.5.6 Front Door Window Glass Installation
5.5.7 Door Trim Installation
6. Seat and Seat Belts
6.1 Specifications
6.2 Service Standards
6.3 Removal
6.3.1 Removing the Driver’s Seat
6.3.2 Removing the Passenger Seat
6.3.3 Removing the Seat Belts
6.4 Inspection
6.4.1 Seat Belt Installation
6.4.2 Driver’s Seat Installation
6.4.3 Passenger Seat Installation
7. Trim
7.1 Service Standards
7.2 Removal
7.3 Installation
8. Floor Mats
8.1 Removal
8.2 Installation
9. Instrument Panel
9.1 Service Standards
9.2 Removal
9.3 Installation
10. Cab and Associated Parts
10.1 Service Standards
10.2 Removal
10.3 Installation
11. Silencer
11.1 Service Standards
11.2 Removal
11.3 Installation
Group 54 – Chassis Electrical
Table of Contents
1. Troubleshooting
2. Chassis Electrical System
2.1 Specifications
2.2 General Description
2.3 Wiring Harness
2.4 Central Ground Connections
3. Battery
3.1 Specifications
3.2 General Description
3.3 Inspection
4. Fuses and Relays
4.1 Specifications
4.2 Service Standards
4.3 General Description
4.4 Installation Locations
4.5 Inspection
5. Fusible Link
5.1 Specifications
5.2 General Description
5.3 Installation Locations
5.4 Inspection
6. Starting System
6.1 Specifications
6.2 General Description
6.3 Installation Locations
6.4 Inspection
7. Column Switches
7.1 Specifications
7.2 General Description
7.3 Installation Locations
7.4 Inspection
8. Lighting System
8.1 Specifications
8.2 Wiring Diagram
8.3 General Description
8.4 Installation Locations
8.5 Inspection
9. Meters and Gauges
9.1 Specifications
9.2 Service Standards
9.3 Wiring Diagram
9.4 General Description
9.5 Installation Locations
9.6 Inspection
10. Indicators and Warning Lamps
10.1 Specifications
10.2 Service Standards
10.3 Wiring Diagram
10.4 General Description
10.5 Installation Locations
10.6 Inspection
11. Exhaust Brake System
11.1 Specifications
11.2 Wiring Diagram
11.3 General Description
11.4 Installation Locations
11.5 Inspection
12. Wipers and Washer
12.1 Specifications
12.2 Wiring Diagram
12.3 Installation Locations
12.4 Inspection
13. Sub-Starting System
13.1 Specifications
13.2 Wiring Diagram
13.3 General Description
13.4 Installation Locations
13.5 Inspection
14. Horn
14.1 Specifications
14.2 Wiring Diagram
14.3 Installation Locations
14.4 Inspection
15. Radio (Option), Cassette Stereo (Option), Speakers and Antenna
15.1 Specifications
15.2 General Description
15.3 Installation Locations
15.4 Inspection
16. Cigarette Lighter
16.1 Specifications
16.2 Wiring Diagram
16.3 General Description
16.4 Installation Locations
16.5 Inspection
Group 55A – Air Conditioner
Group 55A (9401) – Air Conditioner
Foreword/Table of Contents
1. Specifications
2. Outlines of Refrigeration System
3. Construction
4. Troubleshooting
5. Removal and Installation
6. Treatment After Installation
7. Cooling Unit
8. Maintenance
9. Compressor
Group 55A (9105) – Air Conditioner
Table of Contents
1. Specifications
2. Outlines of Refrigeration System
3. Construction
4. Troubleshooting
5. Removal and Installation
6. Treatment After Installation
7. Cooling Unit
8. Maintenance
9. Compressor
Group 55B – Heater
Table of Contents
1. Troubleshooting
2. Heater
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Wiring Diagram
2.5 Pre-Removal Inspection
2.5.1 Heater Switch Inspection
2.5.2 Mode Selector 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 Disassembly
2.8 Reassembly
2.9 Installation
2.10 Post-Installation Adjustments
2.11 Water Hoses
2.11.1 Inspection
2.11.2 Removal
2.11.3 Connection
3. Ventilation
3.1 Service Standards
3.2 Removal
3.3 Installation
3.4 Post-Installation Adjustments

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

1992-1995 Mitsubishi FUSO Fighter FK FM Truck Service Manual PDF Download

fkfmcover
Format: PDF
Pages: 1,252
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1992, 1993, 1994, 1995 Mitsubishi FUSO FK FM Series Truck (US/Canada) Service & Repair

  • FK417
  • FK457
  • FM457
  • FM557

Manual Part Number: TWME9107 plus model year changes

Topics List:

Group 00 – General
Group 00 – General [Supplement]
Table of Contents
Summary of Modifications
Group 01 – Maintenance Schedule
Group 35A – Brake (Air Over Hydraulic Brake)
Group 35B – Brake (Full Air Brake)
’95 Model Changes
’94 Minor Change
Table of Contents
1. Differences of 1994 Model from 1993 Model
2. Details of Change Due to Running Change Made on 1993 Model
’93 Minor Change
Table of Contents
1. FK457 (Vehicles with M6S6)
1.1 Major Specifications
1.2 Power Train Table
1.3 Operation Performance Curves
2. Differences of 1993 Model from 1992 Model
Group 00 – General
Table of Contents
1. Exterior Views
2. Major Specifications
3. Power Train Table
4. Equipment Model Notation
5. Peformance Curves
5.1 Operation Performance Curves
5.2 Engine Performance Curve
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. Using the Maintenance Schedule Table
2. Maintenance Schedule
2.1 Replacement of Oil Filter Element
2.2 Replacement of Fuel Filter Element
2.3 Cleaning of Fuel Feed Pump Gauze Filter
2.4 Bleeding of Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressures
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Air Over Hydraulic Brake <FK Series>
2.10.2 Full Air Brake <FM Series>
2.11 Adjustment of Parking Brake Shoe Clearance <FK Series>
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brake <FK Series>
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Fluid Level
3.6.2 Replacement of Power Steering Fluid
3.6.3 Bleeding of Power Steering System
3.7 Chassis Parts
Group 11 – Engine
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Engine and Transmission
6.2 Engine Proper
6.2.1 Measurement of Compression Pressure
6.2.2 Cylinder Head and Valve Mechanism
6.2.3 Flywheel, Timing Gear and Camshaft
6.2.4 Crankcase and Main Moving Parts
6.2.5 Adjustment
Group 12 – Lubrication
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Oil Pump
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Oil Cooler
6.2.1 Removal and Installation
6.2.2 Disassembly and Inspection
6.3 Oil Filter
Group 13 – Fuel and Engine Control
Group 13 – Fuel and Engine Control
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Fuel System
5.2 Engine Control
6. Service Procedure
6.1 Injection Pump Assembly
6.1.1 Removal and Installation
6.1.2 Inspection and Adjustment of Fuel Injection Timing
6.1.3 Cleaning of Fuel Feed Pump Gauze Filter
6.2 Injection Nozzle
6.2.1 Removal and Installation
6.2.2 Disassembly
6.2.3 Cleaning and Inspection
6.2.4 Reassembly
6.2.5 Test and Adjustment
6.3 Fuel Filter
6.4 Water Separator
6.5 Bleeding the Fuel System
6.6 Engine Control
6.6.1 Removal and Installation
6.6.2 Inspection and Adjustment
6.7 Fuel Tank and Fuel Gauge Unit
Group 13A – Fuel and Engine Control <for 1995 Model>
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Fuel System
5.2 Prestroke Control Type Injection Pump System
5.3 Engine Control
6. Service Procedure
6.1 Injection Pump Assembly
6.1.1 Removal and Installation
6.1.2 Inspection and Adjustment of Fuel Injection Timing
6.1.3 Cleaning of Fuel Feed Pump Gauze Filter
6.1.4 Adjustment of No-Load Minimum and Maximum Speeds
6.2 Inspection of Prestroke Control Type Injection Pump System
6.2.1 Troubleshooting Procedures
6.2.2 Inspection Items by Multi-Use Tester (MUT)
6.2.3 Inspection on the Basis of DIAG Code
6.2.4 Other Inspections
6.2.5 Inspection of Transient Malfunctions
6.3 Injection Nozzle
6.3.1 Removal and Installation
6.3.2 Disassembly
6.3.3 Cleaning and Inspection
6.3.4 Reassembly
6.3.5 Test and Adjustment
6.4 Fuel Filter
6.5 Water Separator
6.6 Bleeding the Fuel System
6.7 Engine Control
6.7.1 Removal and Installation
6.7.2 Inspection and Adjustment
6.8 Fuel Tank and Fuel Gauge Unit
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tool
5. General
6. Service Procedure
6.1 Removal and Installation of Cooling System
6.2 Water Pump
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Inspection of Thermostat
6.4 Inspection of Auto-Cool Fan Coupling
6.5 Inspection of Radiator
6.6 Inspection and Adjustment of V-Belt Tension
6.7 Cleaning of Cooling System
6.8 Gas Leak Test
6.9 Bleeding Cooling System
Group 15 – Intake and Exhaust
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal, Installation and Inspection of Intake System
6.2 Air Cleaner
6.2.1 Disassembly and Reassembly
6.2.2 Inspection and Cleaning
6.3 Removal, Installation and Inspection of Exhaust System
6.4 Turbocharger
6.4.1 Removal and Installation
6.4.2 Disassembly
6.4.3 Cleaning and Inspection
6.4.4 Reassembly
6.4.5 Measurement of Turbocharger Boost Pressure
6.5 Intercooler
6.5.1 Removal and Installation
6.5.2 Inspection
Group 16 – Engine Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
4.1 Starter
4.2 Alternator
4.3 Glow System
5. Service Procedure
5.1 Starter
5.1.1 Removal and Installation
5.1.2 Disassembly
5.1.3 Inspection
5.1.4 Reassembly
5.1.5 Inspection and Adjustment After Reassembly
5.2 Alternator
5.2.1 Removal and Installation
5.2.2 Disassembly
5.2.3 Inspection
5.2.4 Reassembly
5.2.5 Inspection and Adjustment After Installation
5.3 Glow System
5.3.1 Removal and Installation
5.3.2 Inspection
Group 21 – Clutch
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Clutch Proper
5.2 Clutch Control
5.2.1 Clutch Master Cylinder
5.2.2 Clutch Booster
6. Service Procedure
6.1 Clutch
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly and Adjustment
6.2 Clutch Pedal
6.2.1 Removal and Installation
6.2.2 Disassembly and Inspection
6.2.3 Reassembly and Adjustment
6.3 Clutch Master Cylinder
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Power Cylinder
6.4.1 Removal and Installation
6.4.2 Disassembly and Inspection
6.4.3 Reassembly
6.5 Clutch Booster (Vehicles with M8S2x5)
6.5.1 Removal and Installation
6.5.2 Disassembly and Inspection
6.5.3 Reassembly
6.5.4 Performance Test
6.5.5 On-the-Vehicle Functional Check
6.6 Clutch Housing
6.6.1 Disassembly
6.6.2 Reassembly
6.7 Replacement of Brake Fluid in Clutch System
6.8 Bleeding the Clutch System
6.9 Adjustment of Clutch Pedal
6.10 Lubrication of Drive Pinion Splines
Group 22 – Manual Transmission
Group 22A – Manual Transmission (M5S5, M6S5)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Rear Cover
6.8.1 Disassembly and Inspection
6.8.2 Reassembly
6.9 Transmission Control
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.9.3 Adjustment After Installation
6.10 Transmission PTO Control <Option>
6.10.1 Transmission PTO Control Circuit
6.10.2 Inspection
Group 22B – Manual Transmission (M8S5, M8S2x5)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Upper Splitter <M8S2x5 Only>
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Rear Cover <M8S2x5 Only>
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.10 Extension Housing <M8S6 Only>
6.10.1 Disassembly and Inspection
6.10.2 Reassembly
6.11 Splitter Case and Gear <M8S2x5 Only>
6.11.1 Inspection Before Disassembly
6.11.2 Disassembly and Inspection
6.11.3 Reassembly
6.12 Power Shift
6.12.1 Disassembly and Inspection
6.12.2 Reassembly
6.13 Splitter Control <M8S2x5 Only>
6.13.1 Splitter Air Piping
6.13.2 Power Cylinder
6.14 Transmission Control
6.14.1 Disassembly and Inspection
6.14.2 Reassembly
6.14.3 Adjustment After Installation
6.15 Transmission PTO Control <Option>
6.15.1 Transmission PTO Control Circuit
6.15.2 Inspection
Group 22C – Manual Transmission (M6S6)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Extension Housing
6.8.1 Disassembly and Inspection
6.8.2 Reassembly
6.9 Transmission Control
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.9.3 Adjustment After Installation
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Automatic Transmission Control
5.2 Oil Cooler
6. Service Procedure
6.1 Removal and Installation of Automatic Transmission
6.1.1 Removal
6.1.2 Installation
6.2 Oil Seal and Speedometer Worm
6.2.1 Removal and Installation
6.2.2 Replacement of Front Oil Seal
6.2.3 Replacement of Rear Oil Seal
6.2.4 Replacement of Speedometer Worm
6.3 Automatic Transmission Control System
6.3.1 Removal and Installation
6.3.2 Inspection After Installation
6.4 Oil Cooler
6.4.1 Removal and Installation
6.4.2 Inspection
6.5 Oil Filter
6.5.1 Removal and Installation
6.6 Replacement of Fluid and Oil Filter
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Front Propeller Shaft
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Rear Propeller Shaft
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Adjustment After Reassembly
Group 26 – Front Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection and Corrections
6.2.2 Reassembly
6.3 Front Axle, Knuckle and Kingpin
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Inspection and Adjustment After Installation
Group 27 – Rear Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection and Corrections
6.2.2 Reassembly
6.3 Reduction and Differential
6.3.1 Removal
6.3.2 Inspection Before Disassembly
6.3.3 Disassembly and Inspection
6.3.4 Reassembly
Group 31 – Wheel and Tire
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
5. Service Procedure
5.1 Removal
5.2 Disassembly and Procedure
5.2.1 Tubeless Tire
5.3 Inspection and Correction
5.4 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection and Correction
6.3 Installation
Group 34 – Rear Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection and Correction
6.3 Installation
Group 35 – Brake
Group 35A – Brake (Air Over Hydraulic Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Dryer
5.4 Dual Brake Valve
5.5 Brake Booster (Airmaster)
5.6 Air Pressure Governor
5.7 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Dryer
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Brake Booster (Airmaster)
6.2.5 Air Pressure Governor
6.2.6 Check Valve
6.2.7 Supply Valve
6.2.8 Safety Valve
6.2.9 Brake Fluid Tank
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Wheel Cylinder
6.3.3 Rear Wheel Brake
6.3.4 Rear Wheel Cylinder
6.4 Inspection and Adjustment After Installation
6.4.1 Shoe Clearance Adjustment
6.4.2 Replacement of Brake Fluid and Bleeding of Brake System
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control <Except A/T Vehicles>
6.5.4 Adjustment and Inspection After Installation <Except A/T Vehicles>
Group 35B – Brake (Full Air Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Dryer
5.4 Dual Brake Valve
5.5 Air Pressure Governor
5.6 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Dryer
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Air Pressure Governor
6.2.5 Check Valve
6.2.6 Supply Valve
6.2.7 Safety Valve
6.2.8 Relay Valve
6.2.9 Quick Release Valve
6.2.10 Double Check Valve
6.2.11 Air Check Valve
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Brake Chamber
6.3.3 Rear Wheel Brake
6.3.4 Rear Brake Chamber
6.4 Inspection and Adjustment After Installation
6.4.1 Adjustment of Brake Shoe Clearance
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control
6.5.4 Adjustment and Inspection After Installation
Group 36 – Parking Brake
Group 36A – Parking Brake (Center Parking Brake)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Parking Brake
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Parking Brake Control
6.2.1 Removal and Installation
6.2.2 Parking Brake Lever
6.3 Adjustment
Group 36B – Parking Brake (Wheel Parking Brake)
Table of Contents
1. Troubleshooting
2. Service Standards
2.1 Service Standards Table
2.2 Tightening Torque Table
3. General
3.1 Parking Brake System
3.2 Parking Brake Control Valve
3.3 Spring Brake Valve
4. Service Procedure
4.1 Parking Brake Control Valve
4.1.1 Disassembly
4.1.2 Reassembly
4.1.3 Inspection After Reassembly
4.2 Spring Brake Valve
4.2.1 Disassembly
4.2.2 Reassembly
4.2.3 Inspection After Reassembly
Group 37 – Steering
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Steering Shaft
6.2.1 Removal
6.2.2 Installation
6.2.3 Disassembly, Inspection and Correction
6.2.4 Reassembly
6.3 Link and Bracket Section
6.3.1 Disassembly
6.3.2 Reassembly
6.4 Drag Link
6.5 Tie Rod
6.6 Integral Power Steering Booster
6.6.1 Disassembly, Inspection and Correction
6.6.2 Reassembly and Adjustment
6.7 Power Steering Oil Pump
6.7.1 Removal
6.7.2 Installation
6.7.3 Disassembly, Inspection and Correction
6.7.4 Reassembly
6.7.5 Adjustment
6.8 Power Steering Oil Tank
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Adjustment After Installlation
6.9.1 Bleeding
6.9.2 Performance Verification Tests
6.9.3 Steering Wheel Play
6.9.4 Adjustment of Steering Angle
Group 41 – Frame
Table of Contents
1. General
2. Service Procedure
2.1 Inspection and Repair
2.1.1 Frame
2.1.2 Rivets
2.1.3 Bolts and Nuts
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
4.1 Cab Proper
4.2 Cab Mounting
4.2.1 Front Cab Mounting
4.2.2 Rear Cab Mounting
4.3 Cab Tilt System
5. Service Procedure
5.1 Removal
5.1.1 Key Points for Removal
5.1.2 Key Points for Installation
5.1.3 Inspection and Adjustment After Installation
5.2 Cab Mounting
5.2.1 Front Cab Mounting
5.2.2 Cab Stay
5.2.3 Rear Cab Mounting
5.2.4 Cab Tilt Link
5.3 Doors
5.3.1 Removal of Doors
5.3.2 Doors Installation Adjustment
5.3.3 Front Door Assembly
5.4 Interior Parts
5.4.1 Seats and Center Console
5.4.2 Air Suspension
5.4.3 Seat Belts (3-Point Type Seat Belts with ELR)
5.4.4 Floor Mat
5.4.5 Overhead Console
5.4.6 Trim and Headlining
5.4.7 Instrument Panel
5.5 Window Glass
5.5.1 Removal
5.5.2 Installation
5.6 Exterior Parts
5.6.1 Front Panel, Fender and Allied Parts
5.6.2 Rear View Mirrors
Group 54 – Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
4. General
5. Service Procedure
5.1 Battery
5.1.1 General Description
5.1.2 Inspection
5.2 Fuses
5.2.1 General Description
5.2.2 Inspection
5.3 Fusible Link
5.3.1 General Description
5.3.2 Inspection
5.4 Starter Switch and Cold Start Switch
5.4.1 General Description
5.4.2 Inspection
5.5 Sub-Starter System
5.5.1 General Description
5.5.2 Inspection
5.6 Combination Switch
5.6.1 General Description
5.6.2 Inspection
5.7 Lighting System
5.7.1 General Description
5.7.2 Inspection
5.7.3 Inspection and Adjustment After Installation
5.8 Meter System
5.8.1 General Description
5.8.2 Inspection
5.9 Indicators and Warning Lamps
5.9.1 General Description
5.9.2 Inspection
5.10 Wiper and Washer System
5.10.1 General Description
5.10.2 Inspection
5.10.3 Inspection and Adjustment After Installation
5.11 Horn
5.11.1 General Description
5.11.2 Inspection
5.12 Back Buzzer
5.12.1 General Description
5.12.2 Inspection
5.13 Radio and Cassette Stereo <Option>
5.13.1 Mounting Position
5.13.2 AM/FM Radio and AM/FM Radio With Cassette Stereo
5.13.3 Troubleshooting
5.14 Cigarette Lighter
5.14.1 General Description
5.14.2 Inspection
Group 55A – Air Conditioner
Group 55A (9107) – Air Conditioner
Foreword/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 Room
3.2 Cabin Room
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 Dual Pressure Switch
3.10 Power Relay
3.11 A/C Switch
3.12 Fin Thermo
4. Troubleshooting
4.1 General
4.2 Trouble Cause and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 Dual Pressure Switch
4.3.3 Fin Thermo
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Drier Assembly
4.3.7 Belting Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Ref. Circuit
4.3.11 Moisture Inclusion in Ref. Circuit
5. Removal and Installation
5.1 Precautions for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Room
5.2.2 Cabin Room
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Leak Test
6.2.1 Test Points
6.2.2 Test Procedure
6.4 System Charging
6.4.1 Installation of Charge Equipment
6.4.2 Charging System
6.4.3 Charging With Small Cans
6.4.5 Correcting Low Refrigerant Level
6.4.6 Discharging System
6.5 Checking the Refrigerant Level
6.6 Performance Test
6.6.1 Preparation
6.6.2 Stationary Performance Test
7. Compressor
7.1 Compressor
7.2 Disassembly and Reassembly Precautions
7.2.1 Disassembly Precautions
7.2.2 Reassembly Precautions
7.2.3 Tools and Instruments
7.3 Precautions at Disassembly
7.4 Maintenance and Check
7.4.1 Inspection Standards
7.4.2 Consumable Parts
7.5 Assembly Procedure
7.5.1 Tightening Torque
7.5.2 Assembly Procedure
7.6 Special Tool Figure
8. Cooling Unit
8.1 Components
8.2 Cautions in Disassembling
8.3 Disassembling
9. Maintenance
Group 55A (9403) – 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 Room
3.2 Cabin Room
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 Assembly
3.7 Cooling Unit Assembly
3.8 Expansion Valve
3.9 Relief Valve
3.10 Dual Pressure Switch
3.11 Power Relay
3.12 A/C Switch
3.13 Fin Thermo
4. Troubleshooting
4.1 General Procedure
4.2 Trouble Cause and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 Dual Pressure Switch
4.3.3 Fin Thermo
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Assembly
4.3.7 Belting Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Ref. Circuit
4.3.11 Moisture Inclusion in Ref. Circuit
5. Removal and Installation
5.1 Precautions for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Room
5.2.2 Cabin Room
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Leak Test
6.2.1 Test Points
6.2.2 Test Procedure
6.3 System Charging
6.3.1 Evacuation
6.3.2 Evacuate the System
6.3.3 Removal of Charge Equipment
6.3.4 Discharging System
6.4 Checking the Refrigerant Level
6.5 Performance Test
6.5.1 Preparation
6.5.2 Stationary Performance Test
7. Compressor
7.1 Component of Compressor
7.2 Disassembly and Reassembly Precautions
7.2.1 Disassembly Precautions
7.2.2 Reassembly Precautions
7.2.3 Tools and Instruments
7.3 Precautions at Disassembly
7.4 Maintenance and Check
7.4.1 Inspection Standards
7.4.2 Consumable Parts
7.5 Assembly Procedure
7.5.1 Tightening Torque
7.5.2 Assembly Procedure
9.5 Special Tool Figure
8. Cooling Unit
8.1 Components
8.2 Cautions in Disassembling
8.3 Disassembling
9. Maintenance
Group 55B – Heater
Table of Contents
1. Troubleshooting
2. Specifications
3. General
3.1 Ventilation System
3.2 Heater
4. Service Procedure
4.1 Removal and Installation
4.2 Cleaning of Air Filter
4.3 Heater Control Adjustment Procedures

1997-2000 Mitsubishi FUSO Canter FE, FB (EUROPE) Truck Service Manual PDF Download

1997-2007 Mitsubishi FUSO Canter FE, FB (EUROPE) Truck Service Manual PDF Download
Format: PDF files (zipped)
Pages: 1,738
Compatible with: Windows/Mac computers

Covers: 1997, 1998, 1999, 2000 Mitsubishi FUSO FE, FB Series Truck (EUROPE) Service & Repair

  • FE531 w/ 4M40 engine
  • FE649 w/ 4D34T engine
  • FE659 w/ 4D34T engine
  • FB631 w/ 4M40 engine
  • FB641 w/ 4M40 engine

Manual Part Number: TWSE9601 plus supplements, engine shop manuals TWDE9602 & TWDE9603

Topics List:

  • GENERAL INFORMATION
  • SPECIFICATIONS
  • TORQUES
  • MAINTENANCE
  • REMOVAL AND INSTALLATION OF ENGINE
  • ENGINE REPAIR & OVERHAUL
  • FUEL SYSTEM
  • LUBRICATION SYSTEM
  • COOLING SYSTEM
  • INTAKE
  • EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE 
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB AND BODY
  • HEATER AND VENTILATION
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS

2001 Mitsubishi FUSO Canter FE, FB (EUROPE) Truck Service Manual PDF Download

1997-2007 Mitsubishi FUSO Canter FE, FB (EUROPE) Truck Service Manual PDF Download
Format: PDF files (zipped)
Pages: 1,380
Compatible with: Windows/Mac computers


Covers: 2001 Mitsubishi FUSO FE, FB Series Truck (EUROPE) Service & Repair

  • FB634 w/ 4M42T engine
  • FE534 w/ 4M42T engine
  • FE544 w/ 4M42T engine
  • FE649 w/ 4D34T engine
  • FE659 w/ 4D34T engine

Manual Part Number: TWSE0005 plus engine shop manuals TWDE0003 & TWDE0004

Topics List:

  • GENERAL INFORMATION
  • SPECIFICATIONS
  • TORQUES
  • MAINTENANCE
  • REMOVAL AND INSTALLATION OF ENGINE
  • ENGINE REPAIR & OVERHAUL
  • FUEL SYSTEM
  • LUBRICATION SYSTEM
  • COOLING SYSTEM
  • INTAKE
  • EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE 
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB AND BODY
  • HEATER AND VENTILATION
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS

1996-2001 Mitsubishi FUSO FE FG Truck (USA) Service Manual PDF Download

fefgcover
Format: PDF
Pages: 5,804
File size: 247mb
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1996, 1997, 1998, 1999, 2000, 2001 Mitsubishi FUSO Canter FE FG Series Truck (USA) Service & Repair

  • FE639 w/ 4D34-T3
  • FE640 w/ 4D34-T3
  • FE640 w/ 4M50T2
  • FE649 w/ 4D34-T3
  • FG639 w/ 4D34-T3

Manual Part Number: TWSE9501 plus model year changes

Topics List:

  • GENERAL INFORMATION
  • SPECIFICATIONS
  • TORQUES
  • MAINTENANCE SCHEDULE
  • MAINTENANCE OPERATIONS (OIL FILTER, FUEL FILTER, BELTS, INSPECTION, ETC.)
  • ENGINE REMOVAL & INSTALLATION
  • ENGINE
    • SPECIFICATIONS
    • STRUCTURE AND OPERATION
    • TROUBLESHOOTING
    • INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
      • Inspection of Engine Compression
      • Inspection and Adjustment of Valve Clearance
    • CYLINDER HEAD AND VALVE MECHANISM
    • ROCKER COVER, ROCKER ASSEMBLIES AND CAMSHAFTS
    • TIMING GEAR AND BALANCE SHAFTS
    • CAMSHAFT
    • PISTON, CONNECTING ROD AND CYLINDER SLEEVE
    • FLYWHEEL
    • CRANKSHAFT AND CRANKCASE
  • LUBRICATION (OIL SYSTEM)
  • FUEL SYSTEM AND ENGINE CONTROL
  • COOLING
  • INTAKE AND EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM
  • WIRING DIAGRAMS
  • AIR-CONDITIONER & HEATER

1996-2001 Mitsubishi FUSO Fighter FK FM Truck (USA) Service Manual PDF Download

fkfmcover
Format: PDF
Pages: 5,804
File size: 247mb
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1996, 1997, 1998, 1999, 2000, 2001 Mitsubishi FUSO Fighter FK FM Series Truck (USA models) Service & Repair

  • FK617
  • FM617
  • FM657

Manual Part Number: TWME9503 plus model year changes

Topics List:

  • GENERAL
  • MAINTENANCE SCHEDULE
  • ENGINE
  • LUBRICATION
  • FUEL AND ENGINE CONTROL
  • COOLING
  • INTAKE AND EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS
  • AIR-CONDITIONER & HEATER