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

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