1990-1991 Mitsubishi Fuso FE FG Series Truck Service Manual – PDF DOWNLOAD
DESCRIPTION:
1990-1991 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 due to continued vehicle improvements the specifications and numerical given for use in maintenance may change without notice.
TABLE OF CONTENTS:
1990-1991 Mitsubishi Fuso FE FG Series Truck Service Manual – PDF DOWNLOAD
1990-1991 FE/FG Service Manual 1
Foreword 2
Manual Layout 3
Group 00 – 1991 Minor Changes 5
Group 00 – General 13
Table of Contents 14
1 External Views 15
2 Major Specifications 17
3 Power Train Table 22
4 Equipment Model Notation 22
5 Performance Curves 23
51 Operation Performance Curves 23
52 Engine Performance Curves 27
6 Servicing Precautions 28
7 Standard Bolts and Nuts Tightening Torque Table 32
8 Towing Precautions 33
9 Vehicle Identification Number 34
Group 01 – Maintenance Schedule 35
Table of Contents 36
1 How to Read the Maintenance Schedule Tables 37
2 Maintenance Schedule Tables 38
3 Maintenance Operations 40
31 Replacement of the Oil Filter Element 40
32 Replacement of the Fuel Filter Element 40
33 The Water Separator 40
34 Cleaning the Fuel Feed Pump Gauze Filter 41
35 Bleeding Air from the Fuel Line 41
36 Adjusting V-Belt Tension 42
37 Cleaning and Replacement of the Air Cleaner Element 43
38 Inspecting the Clutch Pedal 44
39 The Tires 44
391 Air Pressure 44
392 Removing Tires 44
393 Putting Tires On 46
394 Checking the Wheel Nuts for Looseness 47
395 Tire Rotation 47
310 Adjusting the Clearance of the Wheel Brake Shoe (Drum Brake) 48
311 Checking for Wear in the Disk Brake Pads 49
312 Adjusting the Clearance of the Parking Brake Shoe 49
313 The Battery 50
3131 Cleaning the Battery Terminals 50
3132 Inspecting the Battery 50
314 Fuses 51
4 Lubrication 53
41 Engine Oil 54
42 Gear Oil for Manual Transmissions 55
43 Transmission Fluid for Automatic Transmissions 55
44 Front Axle <FG Models Only> and Rear Axle Gear Oil 58
45 Transfer Gear Oil <FG Models Only> 59
46 Power Steering Fluid 59
47 Brake Fluid 62
48 Greasing the Various Areas of the Chassis 65
Group 11 – Engine 67
Table of Contents 68
1 Troubleshooting 69
2 Engine Removal and Installation (Manual Transmission Vehicles) 76
21 Service Standards 76
211 Tightening Torque Table 76
212 Lubricant Table 76
22 Engine and Transmission Removal 77
221 Preparations Before Removal 77
222 Harness Removal 79
223 Vacuum Hose Removal 83
224 Removal of Parts Around Engine 85
225 Removal of Each Engine Part 86
226 Removal of Each Transmission Part 90
227 Removing the Engine From the Vehicle 92
228 Separating the Engine From the Transmission 94
23 Installation of the Engine and Transmission 95
231 Engine and Transmission Installation 95
232 Installation the Engine and Transmission in the Vehicle 96
233 Installation of Each Transmission Part 99
234 Installation of Each Engine Part 102
235 Installation of Parts Around the Engine 105
236 Vacuum Hose Installation 107
237 Harness Installation 109
24 Adjustment After Installation 113
241 Procedures After Installation 113
242 Adjustment 115
3 Engine Removal and Installation (Automatic Transmission Vehicles) 116
31 Service Standards 116
311 Tightening Torque Table 116
32 Engine and Transmission Removal 116
321 Preparations Before Removal 116
322 Harness Removal 117
323 Vacuum Hose Removal 119
324 Removal of Parts Around Engine 119
325 Removal of Each Engine Part 119
326 Removal of Each Transmission Part 120
327 Removing the Engine From the Vehicle 122
328 Separating the Engine and Transmission 124
33 Installation of the Engine and Transmission 125
331 Transmission Installation 125
332 Installing the Engine and Transmission in the Vehicle 126
333 Installation of Each Transmission Part 128
334 Installation of Each Engine Part 131
335 Installation of Parts Around the Engine 131
336 Vacuum Hose Installation 131
337 Harness Installation 131
34 Adjustment After Installation 134
341 Operations After Installation 134
342 Adjustment 136
4 Engine Assembly 137
41 Specifications 137
42 Service Standards 137
421 Service Standards Table 137
422 Tightening Torque Table 138
423 Special Tool Table 138
43 Valve Clearance Inspection and Adjustment 139
44 Compression Pressure Measurement 140
45 Oil Pressure Inspection 142
46 Fuel Injection Timing Inspection and Adjustment 142
47 Bleeding the Fuel System 146
48 Inspection and Adjustment of V-Belt Tension 146
481 V-Belt Tension Inspection 146
482 V-Belt Tension Adjustment 147
49 Turbocharger Boost Pressure Measurement 149
5 Cylinder Head and Valve Mechanism 151
51 Service Standards 151
511 Service Standard Table 151
512 Tightening Torque Table 151
513 Special Tool Table 152
52 General Description 153
521 Cylinder Head 153
522 Valve Mechanism 154
53 Removal 154
54 Disassembly 157
541 Rocker and Bracket Assembly 157
542 Cylinder Head Assembly 158
55 Inspection 160
56 Reassembly 168
561 Cylinder Head Assembly 168
562 Rocker and Bracket Assembly 170
57 Installation 172
6 Flywheel and Rear Plate (Manual Transmission Vehicles) 175
61 Service Standards 175
611 Maintenance Standards Table 175
612 Tightening Torque Table 175
613 Special Tool Table 175
614 Lubricant Table 175
62 General Description 176
63 Removal 177
64 Inspection 178
65 Installation 179
7 Flywheel and Flywheel Housing (Automatic Transmission Vehicles) 183
71 Service Standards 183
711 Tightening Torque Table 183
712 Special Tool Table 183
713 Lubricant Table 183
72 General Description 184
73 Removal 185
74 Inspection 186
75 Installation 187
8 Timing Gear and Camshaft 190
81 Service Standards 190
811 Service Standards Table 190
812 Tightening Torque Table 190
813 Lubricant Table 190
814 Special Tool Table 190
82 General Description 192
83 Removal 192
84 Inspection 195
85 Installation 199
9 Crankcase and Main Moving Parts 203
91 Service Standards 203
911 Service Standards Table 203
912 Tightening Torque Table 204
913 Sealant Table 204
914 Special Tool Table 204
92 General Description 206
921 Crankshaft 206
922 Connecting Rods 206
923 Piston 206
93 Disassembly 207
94 Inspection 211
95 Reassembly 222
Group 12 – Lubrication 228
Table of Contents 229
1 Troubleshooting 230
2 Lubrication System 231
21 Specifications 231
22 General Description 231
221 System Outline 231
222 Lubrication of Main Moving Parts 232
223 Camshaft Lubrication 233
224 Valve Mechanism Lubrication 233
225 Timing Gear Lubrication 233
226 Camshaft Skew Gear and Oil Pump Gear Lubrication 234
227 Turbocharger Lubrication 234
228 Injection Pump Assembly Lubrication 234
229 Vacuum Pump Lubrication 234
23 Oil Pressure Check 235
3 Oil Pump, Oil Filter 236
31 Service Standards 236
311 Service Standards Table 236
312 Tightening Torque Table 236
313 Special Tools Table 236
32 General Description 237
321 Oil Pump 237
322 Oil Filter 238
33 Removal 238
34 Disassembly and Inspection 239
35 Reassembly 242
36 Installation 244
4 Oil Cooler 246
41 Service Standards 246
411 Service Standards Table 246
412 Tightening Torque Table 246
42 General Description 246
43 Removal 247
44 Disassembly and Inspection 249
45 Reassembly 251
46 Installation 253
5 Oil Pan, Oil Strainer 255
51 Service Standards 255
511 Tightening Torque Table 255
512 Sealant Table 255
52 General Description 255
53 Removal 255
54 Installation 256
55 Post-Installation Inspection 257
Group 13 – Fuel and Engine Control 258
Table of Contents 259
1 Troubleshooting 260
2 Fuel System 266
3 Injection Pump Assembly 267
31 Specifications 267
32 Service Standards 267
321 Service Standards Table 267
322 Tightening Torque Table 268
323 Special Tools Table 269
33 General Description 270
331 Injection Pump 270
332 Governor 272
333 Feed Pump 277
334 Automatic Timer 278
34 Removal 279
35 Installation 282
36 Post-Installation Adjustment 284
361 Bleeding Air From the Fuel System 284
362 Fuel Injection Timing Adjustment 284
363 Minimum Unloaded Idling Speed and Maximum Speed Adjustment 285
364 Idle Up Adjustment <Manual Transmission Equipped Vehicles> 285
365 Engine Stop Cable Operational Check 286
4 Injection Nozzles 287
41 Specifications 287
42 Service Standards 287
421 Service Standards Table 287
422 Tightening Torque Table 287
43 General Description 288
44 Removal 288
45 Disassembly 288
46 Inspection and Cleaning 290
47 Reassembly 291
48 Testing and Adjustment 293
49 Installation 294
5 Fuel Filter 295
51 Specifications 295
52 Service Standards 295
521 Tightening Torque Table 295
522 Special Tools Table 295
53 General Description 296
54 Removal and Inspection 296
55 Installation 296
6 Water Separator 298
61 Specifications 298
62 Service Standards 298
63 General Description 298
64 Removal 298
65 Disassembly and Inspection 299
66 Reassembly 300
67 Installation 301
68 Draining Water 301
7 Fuel Tank 302
71 Specifications 302
72 Service Standards 302
73 General Description 302
74 Removal 303
75 Inspection 304
76 Installation 305
8 Engine Control System 307
81 Specifications 307
82 Service Standards 308
83 General Description 308
84 Removal 309
841 Disconnecting the Accelerator Control Cable and Engine Stop Cable from the Engine Side 310
842 Removing the Throttle Cable and Accelerator Pedal 310
843 Disconnecting the Accelerator Control Cable and Accelerator Lever 312
844 Removing the Engine Stop Cable 313
85 Inspection 315
86 Installation 316
861 Installating the Engine Stop Cable 317
862 Installing the Throttle Cable, Accelerator Lever Assembly, and Accelerator Pedal 318
863 Securing the Accelerator Control Cable 321
864 Installing the Accelerator Control Cable and the Engine Stop Cable to Engine Side 321
87 Post-Installation Adjustment 323
871 Accelerator Pedal Stopper Adjustment 323
872 Engine Stop Cable Operation Check 324
873 Accelerator Switch (Exhaust Brake Microswitch) Adjustment 325
Group 14 – Cooling 326
Table of Contents 327
1 Troubleshooting 328
2 Cooling System 330
21 Specifications 330
22 Service Standards 330
23 General Description 331
24 Removal 332
241 Radiator Removal 332
242 Cooling Fan and Auto Cool Fan Coupling Removal 334
243 Water Pump Removal 335
244 Thermostat Removal 336
25 Installation 337
251 Thermostat Installation 337
252 Water Pump Installation 338
253 Cooling Fan and Auto Cool Fan Coupling Removal 338
254 Radiator Installation 340
3 Cooling Fan and Auto Cool Fan Coupling 343
31 Service Standards 343
32 General Description 343
321 Cooling Fan 343
322 Auto Cool Fan Coupling 343
33 Inspection 344
4 Water Pump 345
41 Service Standards 345
411 Service Standards Table 345
412 Special Tools Table 345
42 General Description 345
43 Disassembly <4D31T> 345
44 Inspection <4D31T> 347
45 Reassembly <4D31T> 347
5 Thermostat 349
51 Service Standards 349
52 General Description 349
53 Inspection 350
6 Radiator 351
61 Service Standards 351
611 Service Standards Table 351
612 Tightening Torque Table 351
62 General Description 351
621 Radiator 351
622 Radiator Cap 352
623 Radiator Shroud 352
624 Condenser Tank 353
63 Inspection and Cleaning 353
631 Radiator Cleaning 353
632 Radiator Inspection 353
633 Radiator Cap Inspection 354
634 Radiator (Cooling System) Cleaning 354
635 Gas Leak Test 357
636 Cooling System Air Bleeding 357
Group 15 – Intake and Exhaust 358
Table of Contents 359
1 Troubleshooting 360
2 Intake System 362
21 Specifications 362
22 Service Standards 362
221 Service Standards Table 362
222 Tightening Torque Table 362
23 General Description 363
24 Removal 365
25 Disassembly 368
251 Air Cleaner Disassembly 368
252 Removing the Intake Shutter 370
26 Inspection and Cleaning 370
27 Reassembly 371
271 Actuator Installation 371
272 Air Cleaner Reassembly 372
28 Installation 374
29 Post-Installation Adjustment 376
3 Exhaust System 377
31 Service Standards 377
311 Tightening Torque Table 377
32 General Description 377
33 Removal 378
34 Installation 383
4 Turbocharger 389
41 Specifications 389
42 Service Standards 389
421 Service Standards Table 389
422 Tightening Torque Table 389
423 Lubricants Table 390
43 General Description 390
44 Removal 392
45 Disassembly 396
46 Inspection and Cleaning 400
461 Cleaning 400
462 Inspection 401
47 Reassembly 403
48 Installation 410
49 Post-Installation Inspection 412
5 Intercooler <4D31T2> 413
51 Specifications 413
52 Service Standards 413
53 Outline 413
54 Removal 413
55 Inspection and Cleaning 414
56 Installation 414
Group 16 – Engine Electrical 415
Table of Contents 416
1 Troubleshooting 417
2 Electrical System 422
21 Specifications 422
22 General Description 423
221 The Starting Device 426
222 Charger 433
3 Starter 434
31 Service Standards 434
311 Service Standards Table 434
312 Special Tools Table 434
313 Lubrication Table 434
32 General Description 435
33 Removal 436
34 Disassembly 438
35 Inspection 442
36 Reassembly 450
37 Testing 455
38 Installation 457
4 75A Alternator 458
41 Service Standards 458
411 Service Standards Table 458
412 Tightening Torque Table 458
413 Lubrication Table 458
42 General Description 459
43 Removal 462
44 Disassembly 463
45 Inspection 466
46 Reassembly 471
47 Testing 475
471 Handling Precautions 475
472 Performance Testing 476
473 Regulator Inspection 477
48 Installation 477
5 80A Alternator 479
51 Service Standards 479
511 Service Standards Table 479
512 Tightening Torque Table 479
513 Lubrication Table 479
52 General Description 480
53 Removal 483
54 Disassembly 484
55 Inspection 486
56 Reassembly 491
57 Testing 494
571 Handling Precautions 494
572 Performance Testing 495
573 Regulator Inspection 496
58 Installation 496
6 Vacuum Pump 498
61 Service Standards 498
62 General Description 498
63 Removal 499
64 Disassembly 499
65 Inspection 500
66 Reassembly 501
67 Testing 502
7 Glow System 503
71 Service Standards 503
711 Service Standards Table 503
712 Special Tools Table 503
713 Tightening Torque Table 503
72 General Description 504
73 Removal 506
74 Inspection 507
741 Glow Plug Inspection 507
742 Glow Control Inspection 507
743 Water Temperature Gauge Unit Inspection 508
75 Installation 508
8 Idle Up System 510
81 Service Standards 510
82 General Description 510
83 Removal 511
84 Inspection 511
85 Installation 512
86 Adjustment 512
Group 21 – Clutch 513
Table of Contents 514
1 Troubleshooting 515
2 Clutch Proper 524
21 Specifications 524
22 Service Standards 524
221 Service Standards Table 524
222 Tightening Torque Table 524
223 Special Tools Table 525
23 General Description 526
24 Removal 527
241 Before Removal 527
242 Removal 528
25 Inspection and Adjustment 529
251 Inspection 529
252 Adjustment 532
26 Installation 532
27 Post-Installation Adjustment 533
3 Clutch Control 534
31 Specifications 534
32 Service Standards 534
321 Service Standards Table 534
322 Tightening Torque Table 535
323 Special Tools Table 535
33 General Description 536
34 Clutch Hose and Clutch Tube 537
341 Removal 537
342 Inspection 538
343 Installation 539
35 Clutch Pedal 540
351 Removal 540
352 Disassembly 541
353 Inspection 542
354 Reassembly 544
355 Installation 545
356 Post-Installation Adjustment 546
36 Clutch Master Cylinder 547
361 Disassembly 547
362 Inspection 548
363 Reassembly 548
37 Clutch Power Cylinder 549
371 Removal 549
372 Disassembly 550
373 Inspection 551
374 Reassembly 552
375 Installation 553
38 Clutch Housing Assembly 553
381 Removal 553
382 Disassembly 554
383 Reassembly 556
384 Installation 557
39 Fluid Change of Clutch System 558
310 Bleeding the Clutch System 560
311 Post-Installation Adjustment 561
312 Clutch Adjustment 562
Group 22 – Manual Transmission 564
Table of Contents 565
1 Troubleshooting 566
2 Removing the Transmission 571
21 Service Standards 571
22 Preliminary Operations 571
23 Removal 572
24 Installation 575
3 Transmission Assembly 578
31 Specifications 578
32 Service Standards 578
321 Service Standards Table 578
322 Tightening Torque Table 578
323 Special Tools Table 579
33 General Description 581
34 Removal 583
341 Clutch Housing Assembly 583
342 Gear Shift, Upper and Lower 583
343 Rear Cover 583
344 Transmission 583
35 Installation 587
351 Transmission 587
352 Rear Cover 590
353 Gear Shift, Upper and Lower 590
354 Clutch Housing Assembly 591
4 Main Shaft Assembly 592
41 Service Standards 592
411 Service Standards Table 592
412 Special Tools Table 592
42 Preliminary Inspection 593
43 Disassembly 594
44 Inspection 598
45 Reassembly 599
5 Reverse Gear 604
51 Service Standards 604
52 Inspection and Replacement 604
6 Gear Shift, Lower 605
61 Service Standards 605
611 Service Standards Table 605
612 Tightening Torque Table 605
62 Disassembly 606
63 Inspection 608
64 Reassembly 609
7 Gear Shift, Upper 611
71 Service Standards 611
711 Service Standards Table 611
712 Tightening Torque Table 611
72 Disassembly 611
73 Inspection 612
74 Reassembly 613
8 Rear Cover 615
81 Service Standards 615
811 Service Standards Table 615
812 Tightening Torque Table 615
813 Special Tools Table 615
82 Disassembly 616
83 Inspection 618
84 Reassembly 618
9 Transmission Control 620
91 Service Standards 620
92 General Description 620
93 Preliminary Operations 621
94 Removal 621
95 Inspection, Repair, and Replacement 622
96 Installation 623
97 Cross-Shaft Assembly 625
971 Disassembly 625
972 Inspection 625
973 Reassembly 626
98 Control Rod Assembly 627
981 Disassembly 627
982 Inspection 627
983 Reassembly 628
99 Set Board Assembly 629
991 Disassembly 629
992 Inspection 630
993 Reassembly 631
910 Post-Installation Adjustment 632
Group 23A – Automatic Transmission <M2A3> 633
Table of Contents 634
1 Troubleshooting 635
2 Transmission Assembly 641
21 Specifications 641
22 Service Standards 641
23 General Description 642
24 Maintenance and Inspection 642
241 Preliminary Operations 642
242 Fluid Level Inspection 643
243 Fluid Replacement 643
244 Neutral Start and Backup Lamp Switch Inspection 645
25 Adjustment 645
251 Preliminary Operations 645
252 Kick-Down Band Adjustment 645
253 Low-Reverse Band Adjustment 646
26 Removing the Transmission 647
261 Preliminary Operations 647
262 Removal 648
263 Installation 652
27 Oil Seal Replacement 657
271 Front Oil Seal Replacement 657
272 Rear Oil Seal Replacement 658
28 Removing the Speedometer Pinion 659
3 Transmission Control 662
31 Service Standards 662
32 General Description 662
33 Range Selector 663
331 Preliminary Operations 663
332 Removal 663
333 Inspection 664
334 Installation 664
34 Selector Cable 665
341 Preliminary Operations 665
342 Removal 665
343 Inspection 666
344 Installation 666
345 Follow-Up Inspection 667
35 Throttle Cable 667
351 Removal 667
352 Inspection 668
353 Installation 668
354 Follow-Up Inspection 669
4 Oil Cooler 670
41 Service Standards 670
42 General Description 670
43 Removal, Inspection 671
Group 23B – Automatic Transmission (Body Unit) <M2A3> 672
Table of Contents 673
1 Specifications 674
2 Service Standards 675
3 General Description 676
31 Hydraulic Control System 677
32 Operating Instructions 677
4 Diagnosis and Test 679
41 Diagnosis – General 679
42 Hydraulic Pressure Tests 682
43 Converter Stall Test 683
44 Clutch and Servo Air Pressure Tests 684
45 Fluid Leakage – Transmission Converter Housing Area 685
46 Diagnosis Chart 690
5 Hydraulic Control Pressure Adjustments 691
51 Line Pressure 691
52 Throttle Pressure 691
6 Service In Vehicle 692
61 Neutral Start and Back-Up Lamp Switch 692
62 Governor and Parking Gear 692
63 Parking Lock Components 693
64 Valve Body and Accumulator Piston Removal 693
65 Valve Body Disassembly 694
66 Valve Body Reassembly 699
67 Valve Body and Accumulator Piston Installation 700
68 Aluminum Thread Repair 700
7 Service Out of Vehicle 701
71 Disassembly-Subassembly Removal 701
72 Recondition Subassemblies 703
721 Oil Pump and Reaction Shaft Support 703
722 Front Clutch 706
723 Rear Clutch 708
724 Planetary Gear Train 710
725 Overrunning Clutch 711
726 Kickdown Servo and Band 713
727 Low-Reverse Servo and Band 713
73 Assembly-Subassembly Installation 713
Group 23C – Automatic Transmission <M030A4> 717
Table of Contents 718
1 Troubleshooting 719
2 Specifications 723
3 Service Standards 724
31 Service Standards Table 724
32 Tightening Torque Table 725
4 Special Tools 726
5 Specifications 727
51 Control Mechanisms 730
511 Line Pressure Control 731
512 Gear Shift Control 732
513 Lockup Control 733
514 Overrun Clutch Control 734
515 Shift Pattern Selector Control 735
516 Self Diagnosis Function 736
517 Fail Safe Functions 737
52 Electronic Control Devices 739
521 Control Unit 739
522 Accelerator Sensor 739
523 Idle Switch (Accelerator Switch 740
524 Vehicle Speed Sensor 2 740
525 Vehicle Speed Sensor 1 740
526 Fluid Temperature Sensor 740
527 Shift Solenoids A and B 741
528 Line Pressure Solenoid and Lockup Solenoid 741
529 Overrun Clutch Solenoid 741
5210 Engine Speed Sensor 741
5211 Dropping Register 741
5212 Power Mode Switch 742
53 Hydraulic Pressure Control Device 743
54 Gear Shift Mechanism 745
541 Reverse Clutch (Multi-Plate Clutch) 747
542 High Clutch (Multi-Plate Clutch) 748
543 Brake Band 749
544 Forward Clutch (Multi-Plate Clutch) 750
545 Low and Reverse Brake (Multi-Plate Clutch) 751
546 Planetary Gear 752
547 Forward One Way Clutch 752
548 Low One Way Clutch 753
549 Torque Transmission Path 753
55 Torque Converter (With Lock up) 760
56 Oil Pump (Variable Capacity Vane Pump) 761
6 Service Standards 763
61 Maintenance and Inspection 763
611 ATF Inspection 763
612 ATF Replacement 764
62 Transmission Removal and Installation 765
621 Tasks Prior to Removal 765
622 Removal 765
623 Installation 767
624 Inspection and Adjustment After Installation 769
63 Oil Seal Replacement 770
64 Inhibitor Switch 771
641 Removal and Installation 771
642 Inspection and Adjustment 772
65 Accelerator Sensor Inspection 773
66 Automatic Transmission Control System Inspection 775
661 Inspection Preparation Tasks 775
662 Sensor Switch and Harness Inspection 776
663 Automatic Transmission Control Unit Inspection 777
664 Post-Inspection Tasks 777
67 Cause of Failure and Prevention 778
671 Causes of Automatic Transmission Failure 778
672 Self Diagnosis Function 778
673 Load Test 788
674 Line Pressure Test 788
675 Stall Test 790
676 Fluid Leakage 790
68 Removal and Installation of Oil Cooler 791
Group 24 – Transfer 792
Table of Contents 793
1 Troubleshooting 794
2 Removing the Transfer 796
21 Service Standards 796
211 Tightening Torque Table 796
212 Special Tool Chart 796
22 Removal 797
23 Installation 800
3 Transfer Main Body 804
31 Specifications 804
32 Service Standards 804
321 Service Standards Table 804
322 Tightening Torque Table 805
323 Special Tools 805
33 Specifications 807
34 Disassembly 808
35 Inspection 815
36 Reassembly 817
4 Transfer Control 826
41 Specifications 826
42 Service Standards 826
421 Service Standards Table 826
422 Tightening Torque Table 826
43 Specifications 827
44 Removal 827
45 Installation 829
46 Adjustment After Removal 830
47 Disassembly 831
48 Inspection 834
49 Reassembly 835
Group 25 – Propeller Shaft 839
Table of Contents 840
1 Troubleshooting 841
2 Front Propeller Shaft <Single Joint> 843
21 Specifications 843
22 Service Standards 843
221 Service Standards Table 843
222 Tightening Torque Table 843
223 Special Tools Table 844
23 General Description 844
24 Removal 845
25 Disassembly 847
26 Inspection 849
27 Reassembly 851
28 Installation 853
3 Rear Propeller Shaft <Two Joints> 855
31 Specifications 855
32 Service Standards 855
321 Service Standards Table 855
322 Tightening Torque Table 855
323 Special Tools Table 855
33 General Description 857
34 Removal 858
35 Disassembly 860
36 Inspection 863
37 Reassembly 865
38 Installation 869
4 Double Cardin Propeller Shaft 870
41 Specifications 870
42 Service Standards 870
421 Service Standards Table 870
422 Tightening Torque Table 870
423 Special Tools Table 871
43 General Description 871
44 Removal 872
45 Disassembly 874
46 Inspection 876
47 Reassembly 877
48 Installation 880
Group 26A – Front Axle <FE> 881
Table of Contents 882
1 Troubleshooting 883
2 Front Axle Assembly 886
21 Specifications 886
22 Service Standards 886
221 Tightening Torque Table 886
23 General Description 887
24 Removal 887
25 Installation 888
26 Post-Installation Adjusting 888
3 Wheel Hub and Rotor 892
31 Service Standards 892
311 Service Standards Table 892
312 Tightening Torque Table 892
313 Special Tools Table 893
32 Disassembly 894
33 Inspection 897
34 Reassembly 899
4 Front Axle Center and Knuckle 902
41 Service Standards 902
411 Service Standards Table 902
412 Tightening Torque Table 902
413 Special Tools Table 903
42 Removal 903
43 Disassembly 904
44 Inspection 907
45 Reassembly 909
46 Installation 911
Group 26B – Front Axle <FG> 912
Table of Contents 913
1 Troubleshooting 914
2 Front Axle Assembly 922
21 Specifications 922
22 Service Standards 922
221 Tightening Torque Table 922
222 Special Tools Table 922
23 General Description 923
24 Removal 925
25 Installation 926
26 Post-Installation Adjusting 926
3 Wheel Hub and Brake Drum 931
31 Service Standards 931
311 Service Standards Table 931
312 Tightening Torque Table 931
313 Special Tools Table 931
32 Disassembly 933
33 Inspection 938
34 Reassembly 940
4 Axle, Knuckle, and Drive Shaft 945
41 Service Standards 945
411 Service Standards Table 945
412 Tightening Torque Table 945
413 Special Tools Table 945
42 Disassembly 947
43 Inspection and Adjusting 950
44 Reassembly 951
5 Reduction and Differential 955
51 Service Standards 955
511 Service Standards Table 955
512 Tightening Torque Table 955
513 Special Tools Table 956
52 Removal 960
53 Preliminary Inspection 961
54 Disassembly 963
55 Inspection 966
56 Reassembly 968
57 Installation 973
Group 27 – Rear Axle 974
Table of Contents 975
1 Troubleshooting 976
2 Rear Axle Assembly 980
21 Specifications 980
22 Service Standards 980
221 Service Standards Table 980
222 Tightening Torque Table 980
23 General Description 981
24 Removal 982
25 Disassembly 983
26 Inspection 983
27 Reassembly 985
28 Installation 985
3 Wheel Hub and Brake Drum 987
31 Service Standards 987
311 Service Standards Table 987
312 Tightening Torque Table 987
313 Special Tools Table 988
32 Disassembly 990
33 Inspection 993
34 Reassembly 995
4 Reduction and Differential 999
41 Service Standards 999
411 Service Standards Table 999
412 Tightening Torque Table 999
413 Specials Tools Table1000
42 Removal1004
43 Preliminary Inspection1006
44 Disassembly1008
45 Inspection1012
46 Reassembly1014
47 Installation1020
Group 31 – Wheels and Tires1022
Table of Contents1023
1 Troubleshooting1024
2 Wheels and Tires1026
21 Specifications1026
22 Service Standards1026
221 Service Standards Table1026
222 Tightening Torque Table1026
23 General Description1026
24 Removal1027
241 Preliminary Operation1027
242 Removal1029
243 Front Tires1029
244 Rear Tires1030
245 Inspection of Wheel Bolt and Nut1031
25 Disassembly and Inspection1031
26 Reassembly1034
27 Post-Assembly Inspection and Adjustment1035
28 Installation1036
Group 33 – Front Suspension1038
Table of Contents1039
1 Troubleshooting1040
2 Front Suspension Assembly1042
21 Service Standards1042
22 General Description1042
23 Removal1043
24 Inspection1046
25 Installation1047
3 Leaf Springs1051
31 Specifications1051
32 Service Standards1051
33 General Description1051
34 Pre-Disassembly Inspection1051
35 Disassembly1052
36 Inspection1053
37 Reassembly1053
4 Shock Absorbers1055
41 Specifications1055
42 General Description1055
43 Disassembly1055
44 Inspection1056
5 Stabilizer <FE Series Only1057
51 General Description1057
52 Pre-Disassembly Inspection1057
53 Disassembly1057
54 Inspection1058
55 Reassembly1058
Group 34 – Rear Suspension1059
Table of Contents1060
1 Troubleshooting1061
2 Rear Suspension Assembly1063
21 Service Standards1063
211 Service Standards Table1063
212 Tightening Torque Table1063
213 Special Tools Table1064
22 General Description1065
23 Removal1065
24 Inspection1068
25 Installation1069
3 Leaf Springs1073
31 Specifications1073
32 Service Standards1073
33 General Description1073
34 Pre-Disassembly Inspection1074
35 Disassembly1074
36 Inspection1075
37 Reassembly1075
4 Shock Absorbers1076
41 Specifications1076
42 General Description1076
43 Disassembly1076
44 Inspection1076
5 Stabilizer <FE Series Only>1077
51 General Description1077
52 Pre-Disassembly Inspection1077
53 Disassembly1077
54 Inspection1078
55 Reassembly1078
Group 35 – Brake1079
Table of Contents1080
1 Troubleshooting1081
2 Brake System1092
21 Service Standards1092
211 Tightening Torque Table1092
22 General Description1092
23 Bleeding of Air From the Brake System1093
231 Front Brake System1094
232 Rear Brake System1097
233 Bypass Valve System1099
24 Replacing of Brake Fluid1102
241 Draining the Brake Fluid1102
242 Changing Front Brake System Brake Fluid1105
243 Changing Rear Brake System Brake Fluid1107
244 Changing the Brake Fluid of the Bypass Valve System1108
245 Bleeding of Brake System1109
3 Brake Piping1110
31 Service Standards1110
311 Tightening Torque Table1110
32 Inspection Before Removal1110
33 Draining Out Brake Fluid1111
34 Removal1112
35 Inspection1115
36 Installation1116
4 Vacuum Tank1122
41 Service Standards1122
411 Service Standards1122
42 Vacuum Switch1122
421 Inspection1122
422 Removal1122
423 Installation1123
43 Vacuum Tank1123
431 Removal1123
432 Inspection1124
433 Installation1124
5 Brake Pedal1126
51 Service Standards1126
511 Service Standards Table1126
512 Tightening Torque Table1126
52 Brake Fluid Tank1127
521 Inspection Before Removal1127
522 Removal1128
523 Inspection1132
524 Installation1133
53 Brake Pedal1137
531 Removal1138
532 Disassembly1147
533 Inspection1149
534 Assembly1150
535 Installation1151
536 Positioning Brake Pedal1160
537 Brake Pedal Play1160
538 Distance Between Brake Pedal and Floor Board1160
539 Adjustment of Stop Lamp Switch1161
6 Brake Booster (Master Vac)1162
61 Specifications1162
62 Service Standards1162
621 Tightening Torque Table1162
622 Special Tools Table1162
63 General Description1165
64 Removal1166
65 Disassembly1167
66 Inspection1172
67 Reassembly1174
68 Installation1181
69 Adjustment After Installation1181
610 Inspection and Installation1181
7 Brake Master Cylinder1184
71 Specifications1184
72 Service Standards1184
721 Service Standards Table1184
722 Tightening Torque Table1184
73 General Description1185
74 Removal1186
75 Disassembly1190
76 Inspection1192
77 Reassembly1193
78 Installation1197
8 Proportioning Valve1200
81 Specifications1200
82 Service Standards1200
821 Service Standards Table1200
822 Tightening Torque Table1200
823 Special Tools Table1201
83 General Description1202
831 Valve Unit1202
832 Sensor1203
84 Removal1203
85 Disassembly1205
86 Inspection1210
87 Reassembly1211
88 Installation1215
89 Adjustment After Installation and Functional Test1216
9 Bypass Valve1220
91 General Description1220
92 Functional Inspection1220
93 Removal1222
94 Installation1222
10 Front Disc Brake <FE Series>1224
101 Specifications1224
102 Service Standards1224
1021 Service Standards Table1224
1022 Tightening Torque Table1224
1023 Special Tools1225
103 General Description1225
104 Replacing the Pads1226
105 Removal1228
106 Disassembly1230
107 Inspection1231
108 Reassembly1233
109 Installation1235
1010 Measure Dragging Torque (Tangential Force)1236
11 Front Drum Brake <FG Series>1237
111 Specifications1237
112 Service Standards1237
1121 Service Standards Table1237
1122 Tightening Torque Table1237
113 Outline1238
114 Removal1238
115 Disassembly1240
116 Inspection1242
117 Reassembly1244
118 Wheel Cylinder1247
1181 Disassembly1247
1182 Inspection1248
1183 Reassembly1248
119 Installation1251
1110 Shoe Clearance Adjustment1252
12 Rear Drum Brake1254
121 Specifications1254
122 Service Standards1254
1221 Service Standards Table1254
1222 Tightening Torque Table1254
123 General Description1255
124 Removal1256
125 Disassembly1258
126 Inspection1260
127 Reassembly1262
128 Wheel Cylinder <FE Series>1265
1281 Disassembly1265
1282 Inspection1266
1283 Reassembly1266
129 Wheel Cylinder <FG Series>1270
1291 Disassembly1270
1292 Inspection1271
1293 Reassembly1272
1210 Installation1275
1211 Adjusting Shoe Clearance1275
13 Exhaust Brake System1278
131 Specifications1278
132 Service Standards1278
1321 Service Standards Table1278
1322 Tightening Torque Table1279
133 General Description1280
134 Removal1284
135 Disassembly1287
136 Inspection1288
137 Reassembly1290
138 Installation1292
139 Inspection After Installation1295
Group 36 – Parking Brake1296
Table of Contents1297
1 Troubleshooting1298
2 Parking Brake Control1300
21 Specifications1300
22 Service Standards1300
221 Service Standards Table1300
222 Tightening Torque Table1300
23 General Description1301
24 Removal1301
241 Preliminary Operations1301
242 Parking Brake Lever Assembly1302
243 Parking Brake Cable1303
244 Inspection1303
25 Disassembly and Inspection1304
251 Disassembly1304
252 Inspection1305
26 Assembly and Repair1306
27 Installation1307
271 Parking Brake Lever Assembly1307
272 Parking Brake Cable1308
28 Post-Installation Adjustments1309
3 Parking Brake Drum and Brake Shoe1311
31 Specifications1311
32 Service Standards1311
321 Service Standards Table1311
322 Tightening Torque Table1311
323 Special Tools Table1312
33 General Description1312
34 Removal1313
341 Preliminary Operations1313
342 Removal1313
35 Disassembly and Inspection1315
351 Disassembly1315
352 Inspection1316
36 Reassembly1318
37 Installation1319
Group 37 – Steering1321
Table of Contents1322
1 Troubleshooting1323
2 Steering System1336
21 Service Standards1336
211 Service Standards Table1336
212 Tightening Torque Table1336
22 General Description1337
221 Steering System1337
222 Power Steering System1337
23 Oil Pump V-Belt Inspection and Adjustment1338
24 Power Steering Oil Change1341
25 Performance Verification Tests1347
26 Overall Power Steering Inspection1351
3 Steering Wheel and Shaft1354
31 Specifications1354
32 Service Standards1354
321 Tightening Torque Table1354
33 General Description1355
34 Removal1355
35 Disassembly1361
36 Assembly1364
37 Installation1367
38 Post-Installation Inspection1372
4 Steering Linkage1373
41 Service Standards1373
411 Service Standards Table1373
412 Tightening Torque Table1373
42 General Description1374
43 Drag Link1375
431 Removal1375
432 Installation1377
433 Greasing1381
44 Tie Rods1381
441 Removal1381
442 Disassembly1383
443 Inspection1384
444 Assembly1384
445 Installation1386
446 Greasing1387
45 Post-Installation Inspection and Adjustment1387
5 Power Steering Booster1388
51 Specifications1388
52 Service Standards1388
521 Service Standards Table1388
522 Tightening Torque Table1389
523 Special Tools Table1389
53 General Description1391
531 Structure1391
532 Operation1392
54 Removal1395
55 Pre-Disassembly Work and Inspection1396
56 Disassembly1398
57 Inspection1404
58 Assembly1407
59 Post-Assembly Work and Inspection1414
510 Installation1415
511 Post-Installation Inspection1417
6 Power Steering Oil Pump1418
61 Specifications1418
62 Service Standards1418
621 Service Standards Table1418
622 Tightening Torque Table1419
623 Special Tools Table1419
63 General Description1420
64 Removal1423
65 Disassembly1425
66 Inspection1430
67 Assembly1434
68 Installation1438
69 Post-Installation Inspection and Adjustment1439
Group 41 – Frame1440
Table of Contents1441
1 Frame Assembly1442
11 Specifications1442
12 General Description1442
13 Inspection and Repair1443
131 Frame1443
132 Rivets1445
133 Nuts and Bolts1446
14 Frame Shape1446
Group 42 – Cab1449
Table of Contents1450
1 Troubleshooting1451
2 Cab1457
21 Specifications1457
22 Service Standards1457
23 General Description1458
24 Cab Tilting Method1458
25 Removal1460
251 Operations Before Removal1460
252 Operations Inside the Cab1462
253 Operations in Front of the Cab1464
254 Cab Tilting Operations1466
255 Lifting the Cab1469
26 Installing the Cab1470
261 Lifting the Cab1470
262 Operations for Tilting the Cab1471
263 Operations in Front of the Cab1474
264 Operations Inside the Cab1477
265 Operations After Installation1478
3 Cab Mounting1479
31 Specifications1479
32 Service Standards1479
33 General Description1480
331 Cab Mounting1480
332 Cab Hinge1480
333 Cab Stay1481
334 Cab Tilt Link1481
34 Removal1482
341 Operations Before Removal1482
342 Removing the Cab Tilt Link1482
343 Removing the Rear Cab Mounting1483
344 Removing the Cab Hinge1484
35 Installation1485
351 Cab Hinge Installation1485
352 Rear Cab Mounting Installation1487
353 Cab Tilt Link Installation1489
354 Operations After Installation1490
4 Front Windshield Glass and Rear Window Glass1491
41 Specifications1491
42 Service Standards1491
43 Removal1491
431 Operations Before Removal1491
432 Removal Operations1492
44 Installation1493
441 Installation Operations1493
442 Operations After Installation1494
5 Door Assembly1495
51 Specifications1495
52 Service Standards1495
53 General Description1496
54 Removal1497
541 Operations Before Removal1497
542 Removing the Door Trim1497
543 Removing the Front Door Window Glass1498
544 Removing the Front Door Window Regulator1500
545 Removing the Front Door Locking System1500
546 Removing the Outside Mirror Stay Assembly1501
547 Removing the Front Door Panel1502
55 Installation1502
551 Front Door Panel Installation1503
552 Outside Mirror Stay Assembly Installation1504
553 Front Door Locking System Installation1505
554 Inspection and Adjustment After Installing the Front Door Locking System1506
555 Front Door Window Regulator Installation1506
556 Front Door Window Glass Installation1507
557 Door Trim Installation1509
6 Seat and Seat Belts1511
61 Specifications1511
62 Service Standards1511
63 Removal1512
631 Removing the Driver’s Seat1512
632 Removing the Floor Console1512
633 Removing the Passenger Seat1513
634 Removing the Seat Belts1514
64 Installation1515
641 Seat Belt Installation1515
642 Driver’s Seat Installation1516
643 Passenger Seat Installation1516
644 Floor Console Installation1517
7 Trim1518
71 Full Trim <Vehicles Mounting the 4D31T2 Engine>1518
711 Removal1518
712 Installation1521
72 Semi Trim <Vehicles Mounting the 4D31T2 Engine>1524
721 Removal1524
722 Installation1525
8 Floor Mats1526
81 Removal1526
82 Installation1526
9 Instrument Panel1528
91 Service Standards1528
92 Removal1528
93 Installation1541
10 Front Panel and Fender1554
101 Service Standards1554
102 Removal1554
103 Installation1559
11 Silencer1565
111 Service Standards1565
112 Removal1565
113 Installation1566
Group 54 – Chassis Electrical1569
Table of Contents1570
1 Troubleshooting1571
2 Chassis Electrical System1586
21 Specifications1586
22 General Description1586
23 Wiring Harness1587
24 Central Ground Connections1591
3 Battery1592
31 Specifications1592
32 General Description1592
33 Inspection1593
4 Fuses and Relays1595
41 Specifications1595
42 General Description1597
43 Installation Locations1597
44 Inspection1597
5 Fusible Link1599
51 Specifications1599
52 General Description1599
53 Installation Locations1599
54 Inspection1599
6 Starting System1600
61 Specifications1600
62 General Description1600
63 Installation Locations1601
64 Inspection1601
7 Column Switches1603
71 Specifications1603
72 General Description1603
73 Installation Locations1604
74 Inspection1604
8 Lighting System1606
81 Specifications1606
82 Wiring Diagram1606
83 General Description1608
84 Installation Locations1611
85 Inspection1614
9 Meters and Gauges1616
91 Specifications1616
92 Wiring Diagram1617
93 General Description1618
94 Installation Locations1618
95 Inspection1620
10 Indicators and Warning Lamps1622
101 Specifications1622
102 Wiring Diagram1622
103 General Description1625
104 Installation Locations1627
105 Inspection1629
11 Exhaust Brake System1632
111 Specifications1632
112 Wiring Diagram1632
113 General Description1633
114 Installation Locations1634
115 Inspection1635
12 Wiper and Washer1636
121 Specifications1636
122 Wiring Diagram1637
123 Installation Locations1638
124 Inspection1638
13 Sub-Starting System1640
131 Specifications1640
132 Wiring Diagram1640
133 General Description1641
134 Installation Locations1642
135 Inspection1642
14 Horn1644
141 Specifications1644
142 Wiring Diagram1644
143 Installation Locations1644
144 Inspection1644
15 Radio, Speakers, and Antenna1645
151 Specifications1645
152 Wiring Diagram1645
153 Installation Locations1645
16 Cigarette Lighter1649
161 Specifications1649
162 Wiring Diagram1649
163 General Description1649
164 Installation Locations1649
165 Inspection1649
17 Heater and Air Conditioner1650
171 Specifications1650
172 General Description1650
173 Installation Locations1650
174 Inspection1651
Group 55A – Air Conditioner1652
Table of Contents1653
1 Specifications1654
2 Outlines of Refrigeration System1655
21 Air System1655
22 Refrigerating Cycle1655
23 Electrical System1656
3 Construction1657
31 Engine Compartment1657
32 Cab1657
33 Control System1658
34 Compressor and Magnetic Clutch1661
341 Compressor1661
342 Check Valve1662
343 Magnetic Clutch1662
35 Condenser1662
36 Receiver Drier1663
37 Cooling Unit1663
38 Expansion Valve1663
39 High Pressure Switch1664
310 Power Relay1664
311 A/C Switch1664
312 Thermo Sensor1664
4 Troubleshooting1665
41 General Precautions1665
42 Trouble, Cause, and Remedy1666
43 Inspection Procedures1668
431 A/C Switch1668
432 High Pressure Switch1668
433 Thermo Sensor1669
434 Magnetic Clutch1669
435 Refrigerant Charge1669
436 Receiver Drier Assembly1670
437 Belt Tension1670
438 Expansion Valve1653
439 Compressor1670
4310 Air Inclusion in Refrigerant Circuit1671
4311 Moisture Inclusion in Refrigerant Circuit1671
5 Removal and Installation1672
51 Precaution for Removal and Installation1672
52 Removal1672
521 Inside the Engine Compartment1672
522 Inside the Cab1673
53 Installation1676
6 Treatment After Installation1677
61 Check and Adjustment1677
62 Leak Test1677
621 Test Point1677
622 Test Procedure1677
63 Evacuation1678
64 Gas Charge1679
65 Checking the Refrigerant Level1679
66 Performance Test1680
661 Preparation1680
662 Stationary Performace Test1680
7 Cooling Unit1681
71 Components1681
72 Cautions in Disassembling1682
73 Disassembling1682
8 Maintenance1683
9 Compressor1684
91 Disassembling the Clutch1684
92 Reassembly the Clutch1685
93 Diassembling the Shaft Seal1686
94 Reassembly the Shaft Seal1687
95 Special Tool Figure1689
Group 55B – Heater1692
Table of Contents1693
1 Troubleshooting1694
2 Heater1698
21 Specifications1698
22 General Descriptions1698
23 Wiring Diagram1701
24 Pre-Removal Inspection1702
241 Heater Switch Inspection1702
242 Mode Selector Lever Inspection1702
243 Temperature Control Lever Inspection1705
244 Air Selector Lever Inspection1705
245 Side Ventilator Inspection1706
25 Removal1707
26 Disassembly1714
27 Reassembly1715
28 Installation1717
29 Post-Installation Adjustments1723
210 Water Hoses1723
2101 Inspection1723
2102 Removal1724
2103 Connection1725
3 Ventilation1727
31 Removal1727
32 Installation1730
33 Post-Installation Adjustment1733
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.V
