1992-1995 Mitsubishi Fuso FE FG Series Truck Service Manual – PDF DOWNLOAD
DESCRIPTION:
1992-1995 Mitsubishi Fuso FE FG Series Truck Service Manual – PDF DOWNLOAD
FOREWORD :
This Service Manual contains maintenance and repair methods for all those who are involved in the maintenance and repair of Mitsubishi Fuso Truck FE.FG Series. Read this manual carefully as an aid to providing correct, efficient and fast maintenance. Please note, however, that dueto continued vehicle improvements the specifications and numerical given for use ( ‘n maintenance may change without notice.
TABLE OF CONTENTS:
1992-1995 Mitsubishi Fuso FE FG Series Truck Service Manual – PDF DOWNLOAD
1992-1995 FE/FG Service Manual 1
Foreword 1
Group 00 – General 4
1995 Model Changes 5
Outline of the ’95 Model Change 7
Group 00 – General 8
(1) Change of Model 8
(2) Change of Engine Stamp Mark Position 8
Group 11 – Engine 8
(3) Tension of Air Conditioner Belt 8
(4) Change of Piston 8
(5) Change of Connecting Rod 9
(6) Change of Front Oil Seal 9
(7) Change of Camshaft 10
(8) Change of Camshaft Bushing 10
(9) Change of Timing Gear Case Sealer 10
(10) Change of Tappet 11
Group 12 – Lubrication 11
(11) Change of Oil Pump 11
(12) Change of Oil Filter 11
Group 13 – Fuel and Engine Control 12
(13) Change of Injection Pump 12
(14) Addition of Inspection Procedure Using the Pre-Stroke Type Injection Pump System MUT 12
Group 15 – Intake and Exhaust 13
(15) Employment of Catalyst Converter 13
(16) Change of Exhaust Manifold 13
(17) Change of Front Pipe 14
Group 16 – Engine Electrical 14
(18) Change of Alternator 14
(19) Change of Vacuum Pump 15
Group 22 – Manual Transmission 15
(20) Change of Special Tool for Main Shaft Removal and Installation 15
(21) Change of Shift Fork and Jaw Set 16
(22) Change of Speed Meter Gear 16
Group 23 – Automatic Transmission 17
(23) Change of Manual Lever Attaching Nut 17
(24) Change of Oil Cooler Piping 17
(25) Change of Oil Temperature 18
Group 35 – Brake 18
(26) Modification of Exhaust Brake Circuit Diagram 18
Group 36 – Parking Brake 18
(27) Change of Parking Brake Lever 18
Group 37 – Steering 18
(28) Change of Power Steering Oil Pump Gear Attaching Nut 18
(29) Change of Power Steering Oil Pump 19
Group 42 – Cab and Body 19
(30) Change of Outside Mirror Stay 19
Group 55 – Heater and Air Conditioner 19
(31) Change of Air Conditioner Compressor 19
1994 Minor Change 77
Table of Contents 78
1 Differences of 1994 Model From 1993 Model 79
2 Change Due to Running Change Made on 1993 Model 80
1993 Minor Change 81
1 Differences of 1993 Model From 1992 Model 83
2 Electrical Wiring Diagram 100
Group 00 – General 102
Table of Contents 103
1 External Views 104
2 Major Specifications 106
3 Power Train Table 111
4 Equipment Model Notation 111
5 Performance Curves 112
51 Operation Performance Curves 112
52 Engine Performance Curves 114
6 Servicing Precautions 115
7 Standard Bolts and Nuts Tightening Torque Table 121
8 Towing Precautions 122
9 Chassis and Engine Numbers 122
10 Vehicle Identification Number 123
Group 01 – Maintenance Schedule 124
Table of Contents 125
1 How To Read the Maintenance Schedule Tables 126
2 Maintenance Schedule Tables 127
3 Maintenance Operations 129
31 Replacement of the Engine Oil Filter Element 129
32 Replacement of the Fuel Filter Element 129
33 Water Separator Condensation Drain 130
34 Cleaning the Fuel Feed Pump Gauze Filter 130
35 Bleeding Air From the Fuel Line 130
36 Adjusting V-Belt Tension 131
37 Cleaning and Replacement of the Air Cleaner Element 132
38 Inspecting the Clutch Pedal 133
39 The Tires 133
391 Air Pressure 133
392 Removing Tires 133
393 Putting Tires On 135
394 Checking the Wheel Nuts for Looseness 136
395 Tire Rotation 136
310 Adjusting the Clearance of the Wheel Brake Shoe (FG Model Only) 137
311 Checking for Wear in the Disk Brake Pads (FE Model Only) 138
312 Adjusting the Clearance of the Parking Brake Shoe 138
313 The Battery 139
3131 Cleaning the Battery Terminals 139
3132 Inspecting the Battery 139
314 Fuses 140
4 Lubrication 142
41 Engine Oil 143
42 Gear Oil for Manual Transmissions 144
43 Transmission Fluid for Automatic Transmissions 144
44 Front Axle <FG Model Only> and Rear Axle Gear Oil 146
45 Transfer Gear Oil <FG Model Only> 146
46 Power Steering Fluid 147
47 Brake Fluid 149
48 Greasing the Various Areas of the Chassis 152
Group 11 – Engine 154
Table of Contents 155
1 Troubleshooting 156
2 Engine Removal and Installation (Manual Transmission Vehicles) 163
21 Service Standards 163
211 Tightening Torque Table 163
212 Lubricant Table 163
22 Engine and Transmission Removal 164
221 Preparations Before Removal 164
222 Harness Removal 166
223 Vacuum Hose Removal 170
224 Removal of Parts Around Engine 171
225 Removal of Each Engine Parts 173
226 Removal of Each Transmission Parts 177
227 Removing the Engine From the Vehicle 179
228 Separating the Engine From the Transmission 181
23 Installation of the Engine and Transmission 182
231 Engine and Transmission Installation 182
232 Installation the Engine and Transmission in the Vehicle 183
233 Installation of Each Transmission Part 186
234 Installation of Each Engine Part 189
235 Installation of Parts Around the Engine 193
236 Vacuum Hose Installation 195
237 Harness Installation 196
24 Adjustment After Installation 200
241 Operations After Installation 200
242 Adjustment 202
3 Engine Removal and Installation (Automatic Transmission Vehicles) 203
31 Service Standards 203
311 Tightening Torque Table 203
32 Engine and Transmission Removal 203
321 Preparations Before Removal 203
322 Harness Removal 204
323 Vacuum Hose Removal 206
324 Removal of Parts Around Engine 206
325 Removal of Each Engine Part 206
326 Removal of Each Transmission Part 207
327 Removing the Engine From the Vehicle 209
328 Separating the Engine and Transmission 211
33 Installation of the Engine and Transmission 212
331 Transmission Installation 212
332 Installing the Engine and Transmission in the Vehicle 213
333 Installation of Each Transmission Part 215
334 Installation of Each Engine Part 217
335 Installation of Parts Around the Engine 217
336 Vacuum Hose Installation 217
337 Harness Installation 217
34 Adjustment After Installation 220
341 Operations After Installation 220
342 Adjustment 222
4 Engine Assembly 223
41 Specifications 223
42 Service Standards 223
421 Service Standards Table 223
422 Tightening Torque Table 224
423 Special Tools Table 224
43 Valve Clearance Inspection and Adjustment 225
44 Compression Pressure Measurement 226
45 Oil Pressure Inspection 228
46 Fuel Injection Timing Inspection and Adjustment 229
47 Bleeding the Fuel System 232
48 Inspection and Adjustment of V-Belt Tension 233
481 V-Belt Tension Inspection 233
482 V-Belt Tension Adjustment 233
49 Turbocharger Boost Pressure Measurement 234
5 Cylinder Head and Valve Mechanism 236
51 Service Standards 236
511 Service Standards Table 236
512 Tightening Torque Table 236
513 Special Tools Table 237
52 General Description 238
521 Cylinder Head 238
522 Valve Mechanism 239
53 Removal 239
54 Disassembly 242
541 Rocker and Bracket Assembly 242
542 Cylinder Head Assembly 243
55 Inspection 245
56 Reassembly 253
561 Cylinder Head Assembly 253
562 Rocker and Bracket Assembly 255
57 Installation 257
6 Flywheel and Rear Plate (Manual Transmission Vehicles) 260
61 Service Standards 260
611 Service Standards Table 260
612 Tightening Torque Table 260
613 Special Tools Table 260
614 Lubricant Table 260
62 General Description 261
63 Disassembly 262
64 Inspection 263
65 Reassembly 264
7 Flywheel and Flywheel Housing (Automatic Transmission Vehicles) 268
71 Service Standards 268
711 Tightening Torque Table 268
712 Special Tools Table 268
713 Lubricant Table 268
72 General Description 269
73 Disassembly 270
74 Inspection 271
75 Reassembly 272
8 Timing Gear and Camshaft 275
81 Service Standards 275
811 Service Standards Table 275
812 Tightening Torque Table 275
813 Lubricant Table 275
814 Special Tools Table 275
82 General Description 277
83 Disassembly 277
84 Inspection 280
85 Reassembly 284
9 Crankcase and Main Moving Parts 287
91 Service Standards 287
911 Service Standards Table 287
912 Tightening Torque Table 288
913 Sealant Table 288
914 Special Tools Table 288
92 General Description 290
921 Crankshaft 290
922 Connecting Rod 290
923 Piston 290
93 Disassembly 291
94 Inspection 295
95 Reassembly 306
Group 12 – Lubrication 313
Table of Contents 314
1 Troubleshooting 315
2 Lubrication System 316
21 Specifications 316
22 General Description 317
221 System Outline 317
222 Lubrication of Main Moving Parts 318
223 Camshaft Lubrication 318
224 Valve Mechanism Lubrication 318
225 Timing Gear Lubrication 319
226 Turbocharger Lubrication 319
227 Injection Pump Assembly Lubrication 319
228 Vacuum Pump Lubrication 320
23 Oil Pressure Check 320
3 Oil Pan and Oil Strainer 321
31 Service Standards 321
311 Tightening Torque Table 321
312 Sealant Table 321
32 General Description 321
33 Removal 321
34 Installation 322
35 Post-Installation Inspection 323
4 Oil Pump 324
41 Service Standards 324
411 Service Standards Table 324
42 General Description 324
43 Removal 324
44 Disassembly and Inspection 325
45 Reassembly 327
46 Installation 328
5 Oil Cooler and Oil Filter 329
51 Service Standards 329
511 Service Standards Table 329
512 Tightening Torque Table 329
513 Special Tools Table 329
52 General Description 330
53 Removal 331
54 Disassembly and Inspection 332
55 Reassembly 333
56 Installation 334
Group 13 – Fuel and Engine Control 335
Table of Contents 336
1 Troubleshooting 337
2 Fuel System 343
3 Pre-Stroke Control Injection Pump System 344
31 Specifications 344
32 Service Standards 345
321 Service Standards Table 345
322 Tightening Torque Table 346
323 Special Tools Table 346
33 General Description 347
331 Pre-Stroke Control Injection Pump System 347
332 Control Unit 350
333 Sensors 351
334 Injection Pump Unit 352
335 Governor 354
336 Feed Pump 359
34 Service Procedure 360
341 System Inspection 363
342 Removing Injection Pump Assembly 387
343 Installing Injection Pump Assembly 389
344 Bleeding Air From the Fuel System 391
345 Fuel Injection Timing Adjustment 391
346 Minimum Unloaded Idling Speed and Maximum Speed Adjustment 391
347 Idle Up Adjustment <Manual Transmission Equipped Vehicles> 392
348 Engine Stop Cable Operational Check 392
4 Injection Nozzles 393
41 Specifications 393
42 Service Standards 393
421 Service Standards Table 393
422 Tightening Torque Table 393
43 General Description 394
44 Removal 394
45 Disassembly 394
46 Inspection and Cleaning 396
47 Reassembly 397
48 Testing and Adjustment 399
49 Installation 400
5 Fuel Filter 401
51 Specifications 401
52 Service Standards 401
521 Tightening Torque Table 401
522 Special Tools Table 401
53 General Description 402
54 Removal and Inspection 402
55 Installation 402
6 Water Separator 404
61 Specifications 404
62 Service Standards 404
63 General Description 404
64 Removal 404
65 Disassembly and Inspection 405
66 Reassembly 405
67 Installation 406
68 Draining Water 406
7 Fuel Tank 407
71 Specifications 407
72 Service Standards 407
73 General Description 407
74 Removal 408
75 Inspection 409
76 Installation 410
8 Engine Control System 412
81 Specifications 412
82 Service Standards 413
83 General Description 413
84 Removal 414
841 Disconnecting the Accelerator Control Cable and Engine Stop Cable From the Engine Side 415
842 Removing the Throttle Cable and Accelerator Pedal 415
843 Disconnecting the Accelerator Control Cable and Accelerator Lever 417
844 Removing the Engine Stop Cable 418
85 Inspection 420
86 Installation 421
861 Installing the Engine Stop Cable 422
862 Installing the Throttle Cable, Accelerator Lever Assembly and Accelerator Pedal 423
863 Securing the Accelerator Control Cable 426
864 Installing the Accelerator Control Cable and the Engine Stop Cable to Engine Side 426
87 Post-Installation Adjustment 428
871 Accelerator Pedal Stopper Adjustment 428
872 Engine Stop Cable Operation Check 429
873 Accelerator Switch (Exhaust Brake Microswitch) Adjustment 429
Group 14 – Cooling 431
Table of Contents 432
1 Troubleshooting 433
2 Cooling System 435
21 Specifications 435
22 Service Standards 435
23 General Description 436
24 Removal 436
241 Radiator Removal 436
242 Cooling Fan and Auto-Cool Fan Coupling Removal 438
243 Water Pump Removal 439
244 Thermostat Removal 440
25 Installation 441
251 Thermostat Installation 441
252 Water Pump Installation 442
253 Cooling Fan and Auto-Cool Fan Coupling Installation 443
254 Radiator Installation 444
3 Cooling Fan and Auto-Cool Fan Coupling 446
31 General Description 446
311 Cooling Fan 446
312 Auto-Cool Fan Coupling 446
32 Removal 447
33 Inspection 447
34 Installation 448
4 Water Pump 449
41 General Description 449
5 Thermostat 450
51 Service Standards 450
52 General Description 450
53 Inspection 451
6 Radiator 452
61 Service Standards 452
611 Service Standards Table 452
612 Tightening Torque Table 452
62 General Description 452
621 Radiator 452
622 Pressure Cap 453
623 Radiator Shroud 453
624 Condenser Tank 454
63 Inspection and Cleaning 454
631 Radiator Cleaning 454
632 Radiator Inspection 454
633 Pressure Cap Inspection 455
634 Radiator (Cooling System) Cleaning 455
635 Cooling System Air Bleeding 458
636 Gas Leak Test 458
Group 15 – Intake and Exhaust 459
Table of Contents 460
1 Troubleshooting 461
2 Intake System 463
21 Specifications 463
22 Service Standards 463
221 Service Standards Table 463
222 Tightening Torque Table 463
23 General Description 464
24 Removal 465
25 Disassembly 467
251 Air Cleaner Disassembly 467
252 Removing the Intake Shutter 467
26 Inspection and Cleaning 468
27 Reassembly 469
271 Actuator Installation 469
272 Air Cleaner Reassembly 469
28 Installation 469
29 Post-Installation Adjustment 471
3 Exhaust System 472
31 Service Standards 472
311 Tightening Torque Table 472
32 General Description 472
33 Removal 473
34 Installation 478
4 Turbocharger 484
41 Sepcifications 484
42 Service Standards 484
421 Service Standards Table 484
422 Tightening Torque Table 484
423 Lubricants Table 485
43 General Description 485
44 Removal 486
45 Disassembly 490
46 Inspection and Cleaning 494
461 Cleaning 494
462 Inspection 495
47 Reassembly 497
48 Installation 504
49 Post-Installation Inspection 506
5 Intercooler 507
51 Specifications 507
52 Service Standard 507
521 Service Standards Table 507
522 Tightening Torque Table 507
53 Outline 508
54 Removal 508
55 Inspection and Cleaning 509
56 Installation 510
Group 16 – Engine Electrical 511
Table of Contents 512
1 Troubleshooting 513
2 Electrical System 518
21 Specifications 518
22 General Description 519
221 Starting System 521
222 Charging System 525
3 Starter 526
31 Service Standards 526
311 Service Standards Table 526
312 Lubrication Table 526
32 General Description 527
33 Removal 528
34 Disassembly 530
35 Inspection 534
36 Reassembly 542
37 Testing 547
38 Installation 549
4 Alternator 550
41 Service Standards 550
411 Service Standards Table 550
412 Tightening Torque Table 550
413 Lubrication Table 550
42 General Description 551
43 Removal 554
44 Disassembly 555
45 Inspection 557
46 Reassembly 562
47 Testing 565
471 Handling Precautions 565
472 Performance Testing 566
473 Regulator Inspection 567
48 Installation 568
5 Vacuum Pump 570
51 Service Standards 570
52 General Description 570
53 Removal 571
54 Disassembly 571
55 Inspection 572
56 Reassembly 573
57 Testing 574
6 Glow Plug System 575
61 Service Standards 575
611 Service Standards Table 575
612 Special Tools Table 575
613 Tightening Torque Table 575
62 General Description 576
63 Removal 578
64 Inspection 579
641 Glow Plug Inspection 579
642 Glow Controller Inspection 579
643 Water Temperature Gauge Unit Inspection 580
65 Installation 580
7 Idle Up System and Warning System 582
71 Service Standards 582
711 Service Standards Table 582
712 Tightening Torque Table 582
713 Lubrication Table 582
72 General Description 583
73 Removal 584
74 Inspection 584
75 Installation 586
76 Adjustment 587
Group 21 – Clutch 588
Table of Contents 589
1 Troubleshooting 590
2 Clutch Proper 599
21 Specifications 599
22 Service Standards 599
221 Service Standards Table 599
222 Tightening Torque Table 599
223 Special Tools Table 600
23 General Description 601
24 Removal 602
241 Before Removal 602
242 Removal 603
25 Inspection and Adjustment 604
251 Inspection 604
252 Adjustment 607
26 Installation 607
27 Post-Installation Adjustment 608
3 Clutch Control 609
31 Specifications 609
32 Service Standards 609
321 Service Standards Table 609
322 Tightening Torque Table 610
323 Special Tools Table 610
33 General Description 611
34 Clutch Hose and Clutch Tube 612
341 Removal 612
342 Inspection 613
343 Installation 614
35 Clutch Pedal 615
351 Removal 615
352 Disassembly 616
353 Inspection 617
354 Reassembly 619
355 Installation 620
356 Post-Installation Adjustment 621
36 Clutch Master Cylinder 622
361 Disassembly 622
362 Inspection 623
363 Reassembly 623
37 Clutch Power Cylinder 624
371 Removal 624
372 Disassembly 625
373 Inspection 626
374 Reassembly 627
375 Installation 628
38 Clutch Housing Assembly 628
381 Removal 628
382 Disassembly 629
383 Reassembly 631
384 Installation 632
39 Fluid Change of Clutch System 633
310 Bleeding the Clutch System 635
311 Post-Installation Adjustment 636
312 Clutch Adjustment 637
Group 22 – Manual Transmission 639
Table of Contents 640
1 Troubleshooting 641
2 Removing the Transmission 646
21 Service Standards 646
22 Preliminary Operations 646
23 Removal 647
24 Installation 650
3 Transmission Assembly 653
31 Specifications 653
32 Service Standards 653
321 Service Standards Table 653
322 Tightening Torque Table 653
323 Special Tools Table 654
33 General Description 656
34 Removal 659
341 Clutch Housing Assembly 659
342 Gear Shift, Upper and Lower 659
343 Rear Cover 659
344 Transmission 659
35 Installation 663
351 Transmission 663
352 Rear Cover 666
353 Gear Shift, Upper and Lower 666
354 Clutch Housing Assembly 667
4 Main Shaft Assembly 668
41 Service Standards 668
411 Service Standards Table 668
412 Special Tools Table 668
42 Preliminary Inspection 669
43 Disassembly 670
44 Inspection 674
45 Reassembly 676
5 Gear Shift, Lower 681
51 Service Standards 681
511 Service Standards Table 681
512 Tightening Torque Table 681
52 Disassembly 682
53 Inspection 684
54 Reassembly 686
6 Gear Shift, Upper 688
61 Service Standards 688
611 Service Standards Table 688
612 Tightening Torque Table 688
62 Disassembly 688
63 Inspection 689
64 Reassembly 690
7 Rear Cover 693
71 Service Standards 693
711 Service Standards Table 693
712 Tightening Torque Table 693
713 Special Tools Table 693
72 Disassembly 694
73 Inspection 696
74 Reassembly 696
8 Transmission Control 699
81 Service Standards 699
82 General Description 700
83 Preliminary Operations 700
84 Removal 701
85 Inspection, Repair and Replacement 702
86 Installation 703
87 Cross-Shaft Assembly 707
871 Disassembly 707
872 Inspection 707
873 Reassembly 708
88 Select Lever Assembly 709
881 Disassembly 709
882 Inspection and Replacement 709
883 Reassembly 709
89 Shift Lever Assembly 710
891 Disassembly 710
892 Inspection and Replacement 710
893 Reassembly 711
810 NO1 Cross Lever Assembly 712
8101 Disassembly 712
8102 Inspection 713
8103 Reassembly 713
811 Lever Complete 715
8111 Disassembly 715
8112 Inspection 715
8113 Reassembly 716
812 Change Lever Complete 717
8121 Disassembly 717
8122 Inspection 718
8123 Reassembly 718
813 Post-Installation Adjustment 720
Group 23 – Automatic Transmission 721
Table of Contents 722
1 Troubleshooting 723
2 Specifications 727
3 Service Standards 728
31 Service Standards Table 728
32 Tightening Torque Table 729
4 Special Tools 730
5 Specifications 731
51 Control Mechanisms 734
511 Line Pressure Control 735
512 Gear Shift Control 736
513 Lockup Control 737
514 Overrun Clutch Control 738
515 Shift Pattern Selector Control 739
516 Self Diagnosis Function 740
517 Fail Safe Functions 741
52 Electronic Control Devices 743
521 Control Unit 743
522 Accelerator Sensor 743
523 Idle Switch (Accelerator Switch) 744
524 Vehicle Speed Sensor 2 744
525 Vehicle Speed Sensor 1 744
526 Fluid Temperature Sensor 744
527 Shift Solenoids A and B 745
528 Line Pressure Solenoid and Lock Up Solenoid 745
529 Overrun Clutch Solenoid 745
5210 Engine Speed Sensor 745
5211 Dropping Register 745
5212 Power Mode Switch 746
53 Hydraulic Pressure Control Device 747
54 Gear Shift Mechanism 749
541 Reverse Clutch (Multi-Plate Clutch) 751
542 HIGH Clutch (Multi-Plate Clutch) 752
543 Brake Band 753
544 Forward Clutch (Multi-Plate Clutch) Overrun Clutch (Multi-Plate Clutch) 754
545 Low and Reverse Brake (Multi-Plate Clutch) 755
546 Planetary Gear 756
547 Forward One Way Clutch 756
548 Low One Way Clutch 757
549 Torque Transmission Path 757
55 Torque Converter (With Lock Up) 764
56 Oil Pump (Variable Capacity Vane Pump) 765
6 Service Standards 767
61 Maintenance and Inspection 767
611 ATF Inspection 767
612 ATF Replacement 768
62 Transmission Removal and Installation 769
621 Tasks Prior To Removal 769
622 Removal 769
623 Installation 771
624 Inspection and Adjustment After Installation 773
63 Removal and Installation of Transmission PTO 774
64 Oil Seal Replacement 774
65 Inhibitor Switch 776
651 Removal and Installation 776
652 Inspection and Adjustment 777
66 Accelerator Sensor Inspection 778
67 Automatic Transmission Control System Inspection 780
671 Inspection Preparation Tasks 780
672 Sensor Switch and Harness Inspection 781
673 Automatic Transmission Control Unit Inspection 782
674 Post Inspection Tasks 782
68 Causes of Failure and Prevention 783
681 Causes of Automatic Transmission Failure 783
682 Self Diagnosis Function 783
683 Load Test 793
684 Line Pressure Test 793
685 Stall Test 795
686 Fluid Leakage 795
69 Oil Cooler 796
691 Service Standards 796
692 General Description 796
693 Oil Cooler Fan System 797
694 Removal and Installation 798
695 Inspection 799
Group 24 – Transfer 800
Table of Contents 801
1 Troubleshooting 802
2 Removing the Transfer 804
21 Service Standards 804
211 Tightening Torque Table 804
212 Special Tool Table 804
22 Removal 805
23 Installation 808
3 Transfer Main Body 812
31 Specifications 812
32 Service Standards 812
321 Service Standards Table 812
322 Tightening Torque Table 813
323 Special Tools Table 813
33 General Description 815
34 Disassembly 816
35 Inspection and Replacement 823
36 Reassembly 825
4 Transfer Control 835
41 Specifications 835
42 Service Standards 835
421 Service Standards Table 835
422 Tightening Torque Table 835
43 General Description 836
44 Removal 836
45 Installation 838
46 Adjustment After Installation 839
47 Disassembly 840
48 Inspection 843
49 Reassembly 844
Group 25 – Propeller Shaft 848
Table of Contents 849
1 Troubleshooting 850
2 Rear Propeller Shaft 852
21 Specifications 852
22 Service Standards 852
221 Service Standards Table 852
222 Tightening Torque Table 852
223 Special Tools Table 853
23 General Description 853
24 Removal 854
25 Disassembly 856
26 Inspection 858
27 Reassembly 860
28 Installation 862
3 Front, Rear Propeller Shaft <Two Joints> 864
31 Specifications 864
32 Service Standards 864
321 Service Standards Table 864
322 Tightening Torque Table 864
323 Special Tools Table 865
33 General Description 866
34 Removal 867
35 Disassembly 869
36 Inspection 872
37 Reassembly 874
38 Installation 878
4 Double Cardin Propeller Shaft 879
41 Specifications 879
42 Service Standards 879
421 Service Standards Table 879
422 Tightening Torque Table 879
423 Special Tools Table 880
43 General Description 880
44 Removal 881
45 Disassembly 883
46 Inspection 885
47 Reassembly 886
48 Installation 889
Group 26 – Front Axle 890
Group 26A – Front Axle <FE> 891
Table of Contents 892
1 Troubleshooting 893
2 Front Axle Assembly 896
21 Specifications 896
22 Service Standards 896
221 Tightening Torque Table 896
23 General Description 897
24 Removal 897
25 Installation 898
26 Post-Installation Adjustment 898
3 Wheel Hub and Rotor 902
31 Service Standards 902
311 Service Standards Table 902
312 Tightening Torque Table 902
313 Special Tools Table 903
32 Disassembly 904
33 Inspection 907
34 Reassembly 909
4 Front Axle Center and Knuckle 912
41 Service Standards 912
411 Service Standards Table 912
412 Tightening Torque Table 912
413 Special Tools Table 913
42 Removal 913
43 Disassembly 914
44 Inspection 917
45 Reassembly 919
46 Installation 921
Group 26B – Front Axle <FG> 922
Table of Contents 923
1 Troubleshooting 924
2 Front Axle Assembly 932
21 Specifications 932
22 Service Standards 932
221 Tightening Torque Table 932
222 Special Tools Table 932
23 General Description 933
24 Removal 935
25 Installation 936
26 Post-Installation Adjustment 936
3 Wheel Hub and Brake Drum 941
31 Service Standards 941
311 Service Standards Table 941
312 Tightening Torque Table 941
313 Special Tools Table 941
32 Disassembly 943
33 Inspection 948
34 Reassembly 950
4 Axle, Knuckle and Drive Shaft 955
41 Service Standards 955
411 Service Standards Table 955
412 Tightening Torque Table 955
413 Special Tools Table 955
42 Disassembly 957
43 Inspection and Adjustment 960
44 Reassembly 961
5 Reduction and Differential 965
51 Service Standards 965
511 Service Standards Table 965
512 Tightening Torque Table 965
513 Special Tools Table 966
52 Removal 970
53 Preliminary Inspection 971
54 Disassembly 973
55 Inspection 976
56 Reassembly 978
57 Installation 983
Group 27 – Rear Axle 984
Table of Contents 985
1 Troubleshooting 986
2 Rear Axle Assembly 990
21 Specifications 990
22 Service Standards 990
221 Service Standards Table 990
222 Tightening Torque Table 990
23 General Description 991
24 Removal 992
25 Disassembly 993
26 Inspection 993
27 Reassembly 995
28 Installation 995
3 Wheel Hub and Brake Drum 997
31 Service Standards 997
311 Service Standards Table 997
312 Tightening Torque Table 997
313 Special Tools Table 998
32 Disassembly1000
33 Inspection1003
34 Reassembly1005
4 Reduction and Differential1009
41 Service Standards1009
411 Service Standards Table1009
412 Tightening Torque Table1009
413 Special Tools Table1010
42 Removal1013
43 Preliminary Inspection1015
44 Disassembly1017
45 Inspection1021
46 Reassembly1026
47 Installation1034
Group 31 – Wheels and Tires1036
Table of Contents1037
1 Troubleshooting1038
2 Wheels and Tires1040
21 Specifications1040
22 Service Standards1040
221 Service Standards Table1040
222 Tightening Torque Table1040
23 General Description1040
24 Removal1041
241 Preliminary Operation1041
242 Removal1043
243 Front Tires1043
244 Rear Tires1044
245 Inspection of Wheel Bolt and Nut1045
25 Disassembly and Inspection1045
26 Reassembly1048
27 Post-Assembly Inspection and Adjustment1049
28 Installation1050
Group 33 – Front Suspension1053
Table of Contents1054
1 Troubleshooting1055
2 Front Suspension Assembly1057
21 Service Standards1057
22 General Description1057
23 Removal1058
24 Inspection1061
25 Installation1062
3 Leaf Springs1066
31 Specifications1066
32 Service Standards1066
33 General Description1066
34 Pre-Disassembly Inspection1066
35 Disassembly1067
36 Inspection1068
37 Reassembly1068
4 Shock Absorbers1070
41 Specifications1070
42 General Description1070
43 Disassembly1070
44 Inspection1071
5 Stabilizer <FE Series Only>1072
51 General Description1072
52 Pre-Disassembly Inspection1072
53 Disassembly1072
54 Inspection1073
55 Reassembly1073
Group 34 – Rear Suspension1074
Table of Contents1075
1 Troubleshooting1076
2 Rear Suspension Assembly1078
21 Service Standards1078
211 Service Standard Table1078
212 Tightening Torque Table1078
213 Special Tools Table1079
22 General Description1080
23 Removal1080
24 Inspection1083
25 Installation1084
3 Leaf Springs1088
31 Specifications1088
32 Service Standards1088
33 General Description1088
34 Pre-Disassembly Inspection1089
35 Disassembly1089
36 Inspection1090
37 Reassembly1090
4 Shock Absorbers1091
41 Specifications1091
42 General Description1091
43 Disassembly1091
44 Inspection1091
5 Stabilizer <FE Series Only>1092
51 General Description1092
52 Pre-Disassembly Inspection1092
53 Disassembly1092
54 Inspection1093
55 Reassembly1093
Group 35 – Brake1094
Table of Contents1095
1 Troubleshooting1096
2 Brake System1107
21 Specifications1107
22 Service Standards1107
221 Tightening Torque Table1107
23 General Description1107
24 Bleeding of Air From the Brake System1108
241 Front Brake System1109
242 Rear Brake System1112
243 Bypass Valve System1114
25 Replacing of Brake Fluid1117
251 Draining the Brake Fluid1117
252 Changing Front Brake System Brake Fluid1120
253 Changing Rear Brake System Brake Fluid1122
254 Changing the Brake Fluid of the Bypass Valve System1123
255 Bleeding of Brake System1124
3 Brake Piping1125
31 Service Standards1125
311 Tightening Torque Table1125
32 Inspection Before Removal1125
33 Draining Out Brake Fluid1126
34 Removal1127
35 Inspection1130
36 Installation1131
4 Vacuum Tank1137
41 Service Standards1137
411 Service Standards Table1137
42 Vacuum Switch1137
421 Inspection1137
422 Removal1137
423 Installation1138
43 Vacuum Tank1138
431 Removal1138
432 Inspection1139
433 Installation1139
5 Brake Pedal1141
51 Service Standard1141
511 Service Standards Table1141
512 Tightening Torque Table1141
52 Brake Fluid Tank1142
521 Inspection Before Removal1142
522 Removal1143
523 Inspection1147
524 Installation1148
53 Brake Pedal1152
531 Removal1153
532 Disassembly1162
533 Inspection1164
534 Assembly1165
535 Installation1166
536 Positioning Brake Pedal1175
537 Brake Pedal Play1175
538 Distance Between Brake Pedal and Floor Board1175
539 Adjustment of Stop Lamp Switch1176
6 Brake Booster (Master Vac)1177
61 Specifications1177
62 Service Standards1177
621 Tightening Torque Table1177
622 Special Tools Table1177
63 General Description1179
64 Removal1180
65 Disassembly1181
66 Inspection1187
67 Reassembly1189
68 Installation1196
69 Adjustments After Installation1196
610 Inspection After Installation1196
7 Brake Master Cylinder1199
71 Specifications1199
72 Service Standards1199
721 Service Standards Table1199
722 Tightening Torque Table1199
73 General Description1200
74 Removal1201
75 Disassembly1205
76 Inspection1207
77 Reassembly1208
78 Installation1212
8 Proportioning Valve1215
81 Specifications1215
82 Service Standards1215
821 Service Standards Table1215
822 Tightening Torque Table1215
83 General Description1216
831 Valve Unit1216
832 Sensor1217
84 Removal1217
85 Disassembly1219
86 Inspection1225
87 Reassembly1226
88 Installation1230
89 Adjustment After Installation and Functional Test1231
9 Bypass Valve1235
91 General Description1235
92 Functional Inspection1235
93 Removal1237
94 Installation1237
10 Front Disc Brake <FE Series>1239
101 Specifications1239
102 Service Standards1239
1021 Service Standards Table1239
1022 Tightening Torque Table1239
1023 Special Tools1240
103 General Description1240
104 Replacing the Pads1241
105 Removal1243
106 Disassembly1245
107 Inspection1246
108 Reassembly1248
109 Installation1250
1010 Measure Dragging Torque (Tangential Force)1251
11 Front Drum Brake <FG Series>1252
111 Specifications1252
112 Service Standards1252
1121 Service Standards Table1252
1122 Tightening Torque Table1252
113 Outline1253
114 Removal1253
115 Disassembly1255
116 Inspection1257
117 Reassembly1259
118 Wheel Cylinder1262
1181 Disassembly1262
1182 Inspection1263
1183 Reassembly1263
119 Installation1266
1110 Shoe Clearance Adjustment1267
12 Rear Drum Brake1269
121 Specifications1269
122 Service Standards1269
1221 Service Standards Table1269
1222 Tightening Torque Table1269
123 General Description1270
124 Removal1271
125 Disassembly1273
126 Inspection1275
127 Reassembly1277
128 Wheel Cylinder <FE Series>1280
1281 Disassembly1280
1282 Inspection1281
1283 Reassembly1281
129 Wheel Cylinder <FG Series>1285
1291 Disassembly1285
1292 Inspection1286
1293 Reassembly1287
1210 Installation1290
1211 Adjusting Shoe Clearance1290
13 Exhaust Brake System1293
131 Specifications1293
132 Service Standards1293
1321 Service Standards Table1293
1322 Tightening Torque Table1294
133 General Description1295
134 Removal1299
135 Disassembly1302
136 Inspection1303
137 Reassembly1305
138 Installation1307
139 Inspection After Installation1310
Group 36 – Parking Brake1311
Table of Contents1312
1 Troubleshooting1313
2 Parking Brake Control1315
21 Specifications1315
22 Service Standards1315
221 Service Standards Table1315
222 Tightening Torque Table1315
23 General Description1316
24 Removal1316
241 Preliminary Operations1316
242 Parking Brake Lever Assembly1317
243 Parking Brake Cable1318
244 Inspection1318
25 Disassembly and Inspection1319
251 Disassembly1319
252 Inspection1320
26 Assembly and Repair1321
27 Installation1322
271 Parking Brake Lever Assembly1322
272 Parking Brake Cable1323
28 Post-Installation Adjustments1324
3 Parking Brake Drum and Brake Shoe1326
31 Specifications1326
32 Service Standards1326
321 Service Standards Table1326
322 Tightening Torque Table1326
323 Special Tools Table1327
33 General Description1327
34 Removal1328
341 Preliminary Operations1328
342 Removal1328
35 Disassembly and Inspection1330
351 Disassembly1330
352 Inspection1331
36 Reassembly1333
37 Installation1334
Group 37 – Steering1336
Table of Contents1337
1 Troubleshooting1338
2 Steering System1351
21 Service Standards1351
211 Service Standards Table1351
212 Tightening Torque Table1351
22 General Description1352
221 Steering System1352
222 Power Steering System1352
23 Power Steering Oil Change1353
24 Performance Verification Tests1359
25 Overall Power Steering Inspection1363
3 Steering Wheel and Shaft1366
31 Specifications1366
32 Service Standards1366
321 Tightening Torque Table1366
33 General Description1367
34 Removal1367
35 Disassembly1373
36 Assembly1376
37 Installation1379
38 Post-Installation Inspection1384
4 Steering Linkage1385
41 Service Standards1385
411 Service Standards Table1385
412 Tightening Torque Table1385
42 General Description1386
43 Drag Link1387
431 Removal1387
432 Installation1389
433 Greasing1393
44 Tie Rod1393
441 Removal1393
442 Disassembly1395
443 Inspection1396
444 Assembly1396
445 Installation1398
446 Greasing1399
45 Post-Installation Inspection and Adjustment1399
5 Power Steering Booster1400
51 Specifications1400
52 Service Standards1400
521 Service Standards Table1400
522 Tightening Torque Table1401
523 Special Tools Table1401
53 General Description1403
531 Structure1403
532 Operation1404
54 Removal1407
55 Pre-Disassembly Work and Inspection1408
56 Disassembly1410
57 Inspection1416
58 Assembly1419
59 Post-Assembly Work and Inspection1426
510 Installation1427
511 Post-Installation Inspection1429
6 Power Steering Oil Pump1430
61 Specifications1430
62 Service Standards1430
621 Service Standards Table1430
622 Tightening Torque Table1431
63 General Description1431
64 Removal1435
65 Disassembly1436
66 Inspection1440
67 Assembly1445
68 Installation1450
69 Post-Installation Inspection and Adjustment1450
Group 41 – Frame1451
Table of Contents1452
1 Frame Assembly1453
11 Specifications1453
12 General Description1453
13 Inspection and Repair1454
131 Frame1454
132 Rivets1456
133 Nuts and Bolts1457
14 Frame Shape1457
Group 42 – Cab1460
Table of Contents1461
1 Troubleshooting1462
2 Cab1468
21 Specifications1468
22 Service Standards1468
23 General Description1469
24 Cab Tilting Method1469
25 Removal1471
251 Operations Before Removal1471
252 Operations Inside the Cab1473
253 Operations In Front of the Cab1475
254 Cab Tilting Operations1477
255 Lifting the Cab1480
26 Installing the Cab1481
261 Lifting the Cab1481
262 Operations for Tilting the Cab1482
263 Operations In Front of the Cab1486
264 Operations Inside the Cab1489
265 Operations After Installation1490
3 Cab Mounting1491
31 Specifications1491
32 Service Standards1491
33 General Description1492
331 Cab Mounting1492
332 Cab Hinge1492
333 Cab Stay1493
334 Cab Tilt Link1493
34 Removal1494
341 Operations Before Removal1494
342 Removing the Cab Tilt Link1494
343 Removing the Rear Cab Mounting1495
344 Removing the Cab Hinge1498
35 Installation1499
351 Cab Hinge Installation1499
352 Rear Cab Mounting Installation1500
353 Cab Tilt Link Installation1504
354 Operations After Installation1506
4 Front Windshield Glass and Rear Window Glass1507
41 Specifications1507
42 Service Standards1507
43 Removal1507
431 Operations Before Removal1507
432 Removal Operations1508
44 Installation1508
441 Installation Operations1508
442 Operations After Installation1509
5 Door Assembly1511
51 Specifications1511
52 Service Standards1511
53 General Description1512
54 Removal1513
541 Operations Before Removal1513
542 Removing the Door Trim1513
543 Removing the Front Door Window Glass1514
544 Removing the Front Door Window Regulator1516
545 Removing the Front Door Locking System1517
546 Removing the Outside Mirror Stay Assembly1518
547 Removing the Front Door Panel1518
55 Installation1518
551 Front Door Panel Installation1519
552 Outside Mirror Stay Assembly Installation1520
553 Front Door Locking System Installation1521
554 Inspection and Adjustment After Installing the Front Door Locking System1522
555 Front Door Window Regulator Installation1522
556 Front Door Window Glass Installation1523
557 Door Trim Installation1525
6 Seat and Seat Belts1527
61 Specifications1527
62 Service Standards1527
63 Removal1528
631 Removing the Driver’s Seat1528
632 Removing the Passenger Seat1529
633 Removing the Seat Belts1530
64 Inspection1532
641 Seat Belt Installation1532
642 Driver’s Seat Installation1533
643 Passenger Seat Installation1533
7 Trim1535
71 Service Standards1535
72 Removal1535
73 Installation1538
8 Floor Mats1541
81 Removal1541
82 Installation1541
9 Instrument Panel1543
91 Service Standards1543
92 Removal1543
93 Installation1555
10 Cab and Associated Parts1568
101 Service Standards1568
102 Removal1568
103 Installation1575
11 Silencer1582
111 Service Standards1582
112 Removal1582
113 Installation1584
Group 54 – Chassis Electrical1586
Table of Contents1587
1 Troubleshooting1588
2 Chassis Electrical System1605
21 Specifications1605
22 General Description1605
23 Wiring Harness1606
24 Central Ground Connections1610
3 Battery1611
31 Specifications1611
32 General Description1611
33 Inspection1612
4 Fuses and Relays1614
41 Specifications1614
42 Service Standards1615
43 General Description1615
44 Installation Locations1616
45 Inspection1618
5 Fusible Link1621
51 Specifications1621
52 General Description1621
53 Installation Locations1621
54 Inspection1621
6 Starting System1622
61 Specifications1622
62 General Description1622
63 Installation Locations1623
64 Inspection1623
7 Column Switches1625
71 Specifications1625
72 General Description1625
73 Installation Locations1626
74 Inspection1626
8 Lighting System1628
81 Specifications1628
82 Wiring Diagram1629
83 General Description1636
84 Installation Locations1639
85 Inspection1642
9 Meters and Gauges1645
91 Specifications1645
92 Service Standards1646
93 Wiring Diagram1647
94 General Description1648
95 Installation Locations1648
96 Inspection1652
10 Indicators and Warning Lamps1655
101 Specifications1655
102 Service Standards1655
103 Wiring Diagram1656
104 General Description1660
105 Installation Locations1663
106 Inspection1665
11 Exhaust Brake System1668
111 Specifications1668
112 Wiring Diagram1668
113 General Description1670
114 Installation Locations1670
115 Inspection1671
12 Wipers and Washer1672
121 Specifications1672
122 Wiring Diagram1673
123 Installation Locations1674
124 Inspection1674
13 Sub-Starting System1676
131 Specifications1676
132 Wiring Diagram1676
133 General Description1677
134 Installation Locations1677
135 Inspection1678
14 Horn1679
141 Specifications1679
142 Wiring Diagram1679
143 Installation Locations1679
144 Inspection1679
15 Radio (Option), Cassette Stereo (Option), Speakers and Antenna1680
151 Specifications1680
152 General Description1681
153 Installation Locations1682
154 Inspection1682
16 Cigarette Lighter1684
161 Specifications1684
162 Wiring Diagram1684
163 General Description1684
164 Installation Locations1684
165 Inspection1684
Group 55A – Air Conditioner1685
Group 55A (9401) – Air Conditioner1685
Foreword/Table of Contents1686
1 Specifications1687
2 Outlines of Refrigeration System1688
3 Construction1690
4 Troubleshooting1698
5 Removal and Installation1705
6 Treatment After Installation1710
7 Cooling Unit1716
8 Maintenance1718
9 Compressor1719
Group 55A (9105) – Air Conditioner1722
Table of Contents1723
1 Specifications1724
2 Outlines of Refrigeration System1725
3 Construction1727
4 Troubleshooting1735
5 Removal and Installation1742
6 Treatment After Installation1747
7 Cooling Unit1753
8 Maintenance1755
9 Compressor1756
Group 55B – Heater1759
Table of Contents1760
1 Troubleshooting1761
2 Heater1765
21 Specifications1765
22 Service Standards1765
23 General Description1765
24 Wiring Diagram1768
25 Pre-Removal Inspection1769
251 Heater Switch Inspection1769
252 Mode Selector Lever Inspection1769
253 Temperature Control Lever Inspection1772
254 Air Selector Lever Inspection1772
255 Side Ventilator Inspection1773
26 Removal1774
27 Disassembly1781
28 Reassembly1782
29 Installation1784
210 Post-Installation Adjustments1790
211 Water Hoses1790
2111 Inspection1790
2112 Removal1791
2113 Connection1792
3 Ventilation1794
31 Service Standards1794
32 Removal1794
33 Installation1797
34 Post-Installation Adjustments1800
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