1992 1993 1994 1995 Mitsubishi Fuso Truck FK FM Series Service Manual – PDF DOWNLOAD
DESCRIPTION:
1992 1993 1994 1995 Mitsubishi Fuso Truck FK FM Series Service Manual – PDF DOWNLOAD
Group 00 Supplement
1995 Model Changes
1994 Minor Change
1993 Minor Change
1992 Group 00 – General
FOREWORD:
This service manual contains the instructions for the servicing of the Mitsubishi Fuso FK, FM series trucks. Please make the most of this service manual to perform correct servicing and wasteless operations. Note that some of the contents of this service manual are subject to change owing to improvements, etc. that may be introduced after publication of the service manual.
TABLE OF CONTENTS:
1992 1993 1994 1995 Mitsubishi Fuso Truck FK FM Series Service Manual – PDF DOWNLOAD
92-95 FK/FM Service Manual 1
Compilation of This Manual 2
Group 00 – General 5
Group 00 – General [Supplement] 6
Table of Contents 7
Summary of Modifications 8
Group 01 – Maintenance Schedule 10
Group 35A – Brake (Air Over Hydraulic Brake) 13
Group 35B – Brake (Full Air Brake) 25
’95 Model Changes 35
’94 Minor Change 67
Table of Contents 68
1 Differences of 1994 Model from 1993 Model 69
2 Details of Change Due to Running Change Made on 1993 Model 70
’93 Minor Change 74
Table of Contents 75
1 FK457 (Vehicles with M6S6) 76
11 Major Specifications 76
12 Power Train Table 80
13 Operation Performance Curves 81
2 Differences of 1993 Model from 1992 Model 83
Group 00 – General 85
Table of Contents 86
1 Exterior Views 87
2 Major Specifications 89
3 Power Train Table 96
4 Equipment Model Notation 97
5 Peformance Curves 98
51 Operation Performance Curves 98
52 Engine Performance Curve 108
6 Servicing Precautions 108
7 Standard Bolts and Nuts Tightening Torque Table 114
8 Towing Precautions 115
9 Chassis and Engine Numbers 115
10 Vehicle Identification Number 116
Group 01 – Maintenance Schedule 117
Table of Contents 118
1 Using the Maintenance Schedule Table 119
2 Maintenance Schedule 120
21 Replacement of Oil Filter Element 126
22 Replacement of Fuel Filter Element 126
23 Cleaning of Fuel Feed Pump Gauze Filter 127
24 Bleeding of Fuel System 127
25 Adjustment of V-Belt Tension 127
26 Cleaning and Replacement of Air Cleaner Element 128
27 Inspection of Clutch Pedal 129
271 Inspection of Pedal Play 129
272 Clearance to Floorboard When Released 129
273 Clutch Operation 129
28 Servicing of Tires 130
281 Tire Inflation Pressures 130
282 Removal of Tire 130
283 Installation of Tire 131
284 Retightening of Wheel Nuts 131
285 Tire Rotation 132
29 Servicing of Air Drier 132
210 Adjustment of Wheel Brake Shoe Clearance 133
2101 Air Over Hydraulic Brake <FK Series> 133
2102 Full Air Brake <FM Series> 133
211 Adjustment of Parking Brake Shoe Clearance <FK Series> 135
212 Servicing of Battery 135
2121 Cleaning of Battery Terminals 136
2122 Inspection of Fluid Level 136
2123 Specific Gravity 136
213 Replacement of Fuses 137
3 Lubrication 139
31 Engine 140
311 Engine Oil Level and Contamination 140
312 Replacement of Engine Oil 141
32 Clutch 142
321 Inspection of Fluid Level of the Clutch Reservoir Tank 142
322 Replacement of Brake Fluid 142
323 Bleeding of Clutch System 143
33 Transmission 143
331 Inspection of Transmission Gear Oil Level 143
332 Replacement of Transmission Gear Oil 144
34 Rear Axle 144
341 Inspection of Rear Axle Gear Oil Level 144
342 Replacement of Rear Axle Gear Oil 144
35 Brake <FK Series> 144
351 Inspection of Fluid Level of the Brake Reservoir Tank 144
352 Replacement of Brake Fluid 144
353 Bleeding of Brake System 145
36 Power Steering 146
361 Inspection of Power Steering Fluid Level 146
362 Replacement of Power Steering Fluid 146
363 Bleeding of Power Steering System 147
37 Chassis Parts 147
Group 11 – Engine 149
Table of Contents 150
1 Troubleshooting 151
2 Specifications 153
3 Service Standards 154
31 Service Standards Table 154
32 Tightening Torque Table 157
4 Special Tools 158
5 General 163
6 Service Procedure 166
61 Removal and Installation of Engine and Transmission 166
62 Engine Proper 171
621 Measurement of Compression Pressure 171
622 Cylinder Head and Valve Mechanism 172
623 Flywheel, Timing Gear and Camshaft 184
624 Crankcase and Main Moving Parts 196
625 Adjustment 212
Group 12 – Lubrication 213
Table of Contents 214
1 Troubleshooting 215
2 Specifications 215
3 Service Standards 216
31 Service Standards Table 216
32 Tightening Torque Table 216
4 Special Tools 217
5 General 217
6 Service Procedure 223
61 Oil Pump 223
611 Removal and Installation 223
612 Disassembly and Inspection 225
613 Reassembly 227
62 Oil Cooler 227
621 Removal and Installation 227
622 Disassembly and Inspection 228
63 Oil Filter 229
Group 13 – Fuel and Engine Control 230
Group 13 – Fuel and Engine Control 231
Table of Contents 232
1 Troubleshooting 233
2 Specifications 237
3 Service Standards 238
31 Service Standards Table 238
32 Tightening Torque Table 238
4 Special Tools 239
5 General 240
51 Fuel System 240
52 Engine Control 245
6 Service Procedure 246
61 Injection Pump Assembly 246
611 Removal and Installation 246
612 Inspection and Adjustment of Fuel Injection Timing 249
613 Cleaning of Fuel Feed Pump Gauze Filter 250
62 Injection Nozzle 250
621 Removal and Installation 250
622 Disassembly 250
623 Cleaning and Inspection 251
624 Reassembly 252
625 Test and Adjustment 252
63 Fuel Filter 253
64 Water Separator 254
65 Bleeding the Fuel System 254
66 Engine Control 255
661 Removal and Installation 255
662 Inspection and Adjustment 255
67 Fuel Tank and Fuel Gauge Unit 257
Group 13A – Fuel and Engine Control <for 1995 Model> 258
Table of Contents 259
1 Troubleshooting 260
2 Specifications 263
3 Service Standards 264
31 Service Standards Table 264
32 Tightening Torque Table 265
4 Special Tools 266
5 General 267
51 Fuel System 267
52 Prestroke Control Type Injection Pump System 272
53 Engine Control 279
6 Service Procedure 280
61 Injection Pump Assembly 280
611 Removal and Installation 280
612 Inspection and Adjustment of Fuel Injection Timing 284
613 Cleaning of Fuel Feed Pump Gauze Filter 284
614 Adjustment of No-Load Minimum and Maximum Speeds 285
62 Inspection of Prestroke Control Type Injection Pump System 286
621 Troubleshooting Procedures 286
622 Inspection Items by Multi-Use Tester (MUT) 290
623 Inspection on the Basis of DIAG Code 291
624 Other Inspections 305
625 Inspection of Transient Malfunctions 309
63 Injection Nozzle 310
631 Removal and Installation 310
632 Disassembly 310
633 Cleaning and Inspection 310
634 Reassembly 311
635 Test and Adjustment 312
64 Fuel Filter 313
65 Water Separator 313
66 Bleeding the Fuel System 314
67 Engine Control 315
671 Removal and Installation 315
672 Inspection and Adjustment 317
68 Fuel Tank and Fuel Gauge Unit 318
Group 14 – Cooling 319
Table of Contents 320
1 Troubleshooting 321
2 Specifications 322
3 Service Standards 322
31 Service Standards Table 322
32 Tightening Torque Table 323
4 Special Tool 323
5 General 324
6 Service Procedure 328
61 Removal and Installation of Cooling System 328
62 Water Pump 331
621 Disassembly and Inspection 331
622 Reassembly 333
63 Inspection of Thermostat 334
64 Inspection of Auto-Cool Fan Coupling 335
65 Inspection of Radiator 335
66 Inspection and Adjustment of V-Belt Tension 336
67 Cleaning of Cooling System 336
68 Gas Leak Test 339
69 Bleeding Cooling System 339
Group 15 – Intake and Exhaust 340
Table of Contents 341
1 Troubleshooting 342
2 Specifications 343
3 Service Standards 343
31 Service Standards Table 343
32 Tightening Torque Table 344
4 Special Tools 344
5 General 345
6 Service Procedure 350
61 Removal, Installation and Inspection of Intake System 350
62 Air Cleaner 351
621 Disassembly and Reassembly 351
622 Inspection and Cleaning 351
63 Removal, Installation and Inspection of Exhaust System 353
64 Turbocharger 354
641 Removal and Installation 354
642 Disassembly 355
643 Cleaning and Inspection 358
644 Reassembly 361
645 Measurement of Turbocharger Boost Pressure 367
65 Intercooler 369
651 Removal and Installation 369
652 Inspection 369
Group 16 – Engine Electrical 370
Table of Contents 371
1 Troubleshooting 372
2 Specifications 373
3 Service Standards 374
31 Service Standards Table 374
32 Tightening Torque Table 375
4 General 376
41 Starter 377
42 Alternator 382
43 Glow System 385
5 Service Procedure 388
51 Starter 388
511 Removal and Installation 388
512 Disassembly 388
513 Inspection 391
514 Reassembly 398
515 Inspection and Adjustment After Reassembly 400
52 Alternator 401
521 Removal and Installation 401
522 Disassembly 402
523 Inspection 404
524 Reassembly 408
525 Inspection and Adjustment After Installation 409
53 Glow System 412
531 Removal and Installation 412
532 Inspection 412
Group 21 – Clutch 416
Table of Contents 417
1 Troubleshooting 418
2 Specifications 421
3 Service Standards 422
31 Service Standards Table 422
32 Tightening Torque Table 424
4 Special Tools 425
5 General 427
51 Clutch Proper 427
52 Clutch Control 428
521 Clutch Master Cylinder 429
522 Clutch Booster 430
6 Service Procedure 432
61 Clutch 432
611 Removal and Installation 432
612 Disassembly and Inspection 434
613 Reassembly and Adjustment 438
62 Clutch Pedal 440
621 Removal and Installation 440
622 Disassembly and Inspection 441
623 Reassembly and Adjustment 444
63 Clutch Master Cylinder 446
631 Disassembly and Inspection 446
632 Reassembly 448
64 Power Cylinder 448
641 Removal and Installation 448
642 Disassembly and Inspection 449
643 Reassembly 449
65 Clutch Booster (Vehicles with M8S2x5) 450
651 Removal and Installation 450
652 Disassembly and Inspection 450
653 Reassembly 453
654 Performance Test 455
655 On-the-Vehicle Functional Check 455
66 Clutch Housing 457
661 Disassembly 457
662 Reassembly 458
67 Replacement of Brake Fluid in Clutch System 460
68 Bleeding the Clutch System 460
69 Adjustment of Clutch Pedal 462
610 Lubrication of Drive Pinion Splines 463
Group 22 – Manual Transmission 464
Group 22A – Manual Transmission (M5S5, M6S5) 465
Table of Contents 466
1 Troubleshooting 467
2 Specifications 468
3 Service Standards 469
31 Service Standards Table 469
32 Tightening Torque Table 471
4 Special Tools 472
5 General 475
6 Service Procedure 477
61 Removal and Installation of Transmission 477
611 Key Points for Removal 477
612 Key Points for Installation 479
613 Inspection and Adjustment After Installation 479
62 Transmission Assembly 480
621 Disassembly 480
622 Reassembly 481
63 Transmission 482
631 Inspection Before Disassembly 482
632 Disassembly and Inspection 483
633 Reassembly 486
64 Main Shaft 490
641 Disassembly and Inspection 490
642 Reassembly 494
65 Counter Shaft 496
651 Disassembly 496
652 Reassembly 497
66 Lower Gear Shifter 498
661 Disassembly and Inspection 498
662 Reassembly 500
67 Upper Gear Shifter 501
671 Disassembly and Inspection 501
672 Reassembly 502
68 Rear Cover 504
681 Disassembly and Inspection 504
682 Reassembly 506
69 Transmission Control 508
691 Disassembly and Inspection 508
692 Reassembly 509
693 Adjustment After Installation 510
610 Transmission PTO Control <Option> 511
6101 Transmission PTO Control Circuit 511
6102 Inspection 511
Group 22B – Manual Transmission (M8S5, M8S2x5) 513
Table of Contents 514
1 Troubleshooting 515
2 Specifications 516
21 Transmission Proper 516
22 Transmission Control 517
3 Service Standards 517
31 Service Standards Table 517
32 Tightening Torque Table 520
4 Special Tools 521
5 General 526
6 Service Procedure 528
61 Removal and Installation of Transmission 528
611 Key Points for Removal 528
612 Key Points for Installation 529
613 Inspection and Adjustment After Installation 530
62 Transmission Assembly 531
621 Disassembly 531
622 Reassembly 532
63 Transmission 533
631 Inspection Before Disassembly 533
632 Disassembly and Inspection 535
633 Reassembly 541
64 Main Shaft 547
641 Disassembly and Inspection 547
642 Reassembly 550
65 Counter Shaft 553
651 Disassembly 553
652 Reassembly 554
66 Lower Gear Shifter 555
661 Disassembly and Inspection 555
662 Reassembly 557
67 Upper Gear Shifter 558
671 Disassembly and Inspection 558
672 Reassembly 559
68 Upper Splitter <M8S2x5 Only> 561
681 Disassembly 561
682 Reassembly 561
69 Rear Cover <M8S2x5 Only> 562
691 Disassembly and Inspection 562
692 Reassembly 563
610 Extension Housing <M8S6 Only> 565
6101 Disassembly and Inspection 565
6102 Reassembly 566
611 Splitter Case and Gear <M8S2x5 Only> 567
6111 Inspection Before Disassembly 567
6112 Disassembly and Inspection 568
6113 Reassembly 570
612 Power Shift 572
6121 Disassembly and Inspection 572
6122 Reassembly 573
613 Splitter Control <M8S2x5 Only> 574
6131 Splitter Air Piping 574
6132 Power Cylinder 575
614 Transmission Control 576
6141 Disassembly and Inspection 576
6142 Reassembly 577
6143 Adjustment After Installation 578
615 Transmission PTO Control <Option> 579
6151 Transmission PTO Control Circuit 579
6152 Inspection 579
Group 22C – Manual Transmission (M6S6) 581
Table of Contents 582
1 Troubleshooting 583
2 Specifications 584
3 Service Standards 585
31 Service Standards Table 585
32 Tightening Torque Table 587
4 Special Tools 589
5 General 592
6 Service Procedure 594
61 Removal and Installation of Transmission 594
611 Key Points for Removal 594
612 Key Points for Installation 596
613 Inspection and Adjustment After Installation 596
62 Transmission Assembly 597
621 Disassembly 597
622 Reassembly 598
63 Transmission 599
631 Inspection Before Disassembly 599
632 Disassembly and Inspection 600
633 Reassembly 605
64 Main Shaft 611
641 Disassembly and Inspection 611
642 Reassembly 615
65 Counter Shaft 617
651 Disassembly 617
652 Reassembly 618
66 Lower Gear Shifter 619
661 Disassembly and Inspection 619
662 Reassembly 621
67 Upper Gear Shifter 622
671 Disassembly and Inspection 622
672 Reassembly 623
68 Extension Housing 625
681 Disassembly and Inspection 625
682 Reassembly 626
69 Transmission Control 628
691 Disassembly and Inspection 628
692 Reassembly 629
693 Adjustment After Installation 631
Group 23 – Automatic Transmission 632
Table of Contents 633
1 Troubleshooting 634
2 Specifications 636
3 Service Standards 636
31 Service Standards Table 636
32 Tightening Torque Table 637
4 Special Tools 638
5 General 639
51 Automatic Transmission Control 639
52 Oil Cooler 640
6 Service Procedure 641
61 Removal and Installation of Automatic Transmission 641
611 Removal 641
612 Installation 644
62 Oil Seal and Speedometer Worm 646
621 Removal and Installation 646
622 Replacement of Front Oil Seal 647
623 Replacement of Rear Oil Seal 647
624 Replacement of Speedometer Worm 647
63 Automatic Transmission Control System 649
631 Removal and Installation 649
632 Inspection After Installation 650
64 Oil Cooler 651
641 Removal and Installation 651
642 Inspection 652
65 Oil Filter 653
651 Removal and Installation 653
66 Replacement of Fluid and Oil Filter 654
Group 25 – Propeller Shaft 657
Table of Contents 658
1 Troubleshooting 659
2 Specifications 660
3 Service Standards 660
31 Service Standards Table 660
32 Tightening Torque Table 660
4 Special Tools 661
5 General 662
6 Service Procedure 663
61 Removal and Installation 663
62 Front Propeller Shaft 664
621 Disassembly and Inspection 664
622 Reassembly 668
63 Rear Propeller Shaft 671
631 Disassembly and Inspection 671
632 Reassembly 673
64 Adjustment After Reassembly 675
Group 26 – Front Axle 677
Table of Contents 678
1 Troubleshooting 679
2 Specifications 680
3 Service Standards 681
31 Service Standards Table 681
32 Tightening Torque Table 682
4 Special Tools 683
5 General 686
6 Service Procedure 687
61 Removal and Installation 687
62 Wheel Hub and Brake Drum 688
621 Disassembly, Inspection and Corrections 688
622 Reassembly 690
63 Front Axle, Knuckle and Kingpin 694
631 Disassembly and Inspection 694
632 Reassembly 697
64 Inspection and Adjustment After Installation 701
Group 27 – Rear Axle 705
Table of Contents 706
1 Troubleshooting 707
2 Specifications 708
3 Service Standards 709
31 Service Standards Table 709
32 Tightening Torque Table 710
4 Special Tools 711
5 General 717
6 Service Procedure 718
61 Removal and Installation 718
62 Wheel Hub and Brake Drum 719
621 Disassembly, Inspection and Corrections 719
622 Reassembly 721
63 Reduction and Differential 726
631 Removal 726
632 Inspection Before Disassembly 726
633 Disassembly and Inspection 728
634 Reassembly 732
Group 31 – Wheel and Tire 742
Table of Contents 743
1 Troubleshooting 744
2 Specifications 744
3 Service Standards 745
31 Service Standards Table 745
32 Tightening Torque Table 745
4 General 745
5 Service Procedure 746
51 Removal 746
52 Disassembly and Procedure 748
521 Tubeless Tire 748
53 Inspection and Correction 751
54 Installation 754
Group 33 – Front Suspension 756
Table of Contents 757
1 Troubleshooting 758
2 Specifications 758
3 Service Standards 759
31 Service Standards Table 759
32 Tightening Torque Table 759
4 Special Tools 760
5 General 760
6 Service Procedure 761
61 Removal and Installation 761
62 Disassembly, Inspection and Correction 762
63 Installation 766
Group 34 – Rear Suspension 768
Table of Contents 769
1 Troubleshooting 770
2 Specifications 770
3 Service Standards 771
31 Service Standards Table 771
32 Tightening Torque Table 771
4 Special Tools 772
5 General 773
6 Service Procedure 774
61 Removal and Installation 774
62 Disassembly, Inspection and Correction 776
63 Installation 779
Group 35 – Brake 781
Group 35A – Brake (Air Over Hydraulic Brake) 782
Table of Contents 783
1 Troubleshooting 784
2 Specifications 787
21 Service Brake 787
22 Wheel Brake 788
23 Exhaust Brake 788
3 Service Standards 788
31 Service Standards Table 788
311 Service Brake 788
312 Wheel Brake 791
313 Exhaust Brake 791
32 Tightening Torque Table 792
321 Service Brake 792
322 Wheel Brake 793
323 Exhaust Brake 793
4 Special Tools 794
5 General 795
51 Service Brake 795
52 Air Compressor 796
53 Air Dryer 797
54 Dual Brake Valve 799
55 Brake Booster (Airmaster) 805
56 Air Pressure Governor 808
57 Exhaust Brake System 809
6 Service Procedure 810
61 Brake System Diagram 810
62 Service Brake Equipment 811
621 Air Compressor 811
622 Air Dryer 818
623 Brake Pedal and Dual Brake Valve 821
624 Brake Booster (Airmaster) 829
625 Air Pressure Governor 837
626 Check Valve 840
627 Supply Valve 841
628 Safety Valve 842
629 Brake Fluid Tank 843
63 Wheel Brake 844
631 Front Wheel Brake 844
632 Front Wheel Cylinder 849
633 Rear Wheel Brake 850
634 Rear Wheel Cylinder 854
64 Inspection and Adjustment After Installation 855
641 Shoe Clearance Adjustment 855
642 Replacement of Brake Fluid and Bleeding of Brake System 856
65 Exhaust Brake 858
651 Exhaust Brake Unit 858
652 Control Cylinder 861
653 Exhaust Brake Control <Except A/T Vehicles> 862
654 Adjustment and Inspection After Installation <Except A/T Vehicles> 863
Group 35B – Brake (Full Air Brake) 864
Table of Contents 865
1 Troubleshooting 866
2 Specifications 868
21 Service Brake 868
22 Wheel Brake 869
23 Exhaust Brake 869
3 Service Standards 870
31 Service Standards Table 870
311 Service Brake 870
312 Wheel Brake 872
313 Exhaust Brake 873
32 Tightening Torque Table 873
321 Service Brake 873
322 Wheel Brake 875
323 Exhaust Brake 875
4 Special Tools 876
5 General 877
51 Service Brake 877
52 Air Compressor 878
53 Air Dryer 879
54 Dual Brake Valve 880
55 Air Pressure Governor 886
56 Exhaust Brake System 887
6 Service Procedure 889
61 Brake System Diagram 889
62 Service Brake Equipment 890
621 Air Compressor 890
622 Air Dryer 896
623 Brake Pedal and Dual Brake Valve 900
624 Air Pressure Governor 907
625 Check Valve 909
626 Supply Valve 910
627 Safety Valve 911
628 Relay Valve 912
629 Quick Release Valve 914
6210 Double Check Valve 915
6211 Air Check Valve 916
63 Wheel Brake 916
631 Front Wheel Brake 916
632 Front Brake Chamber 922
633 Rear Wheel Brake 923
634 Rear Brake Chamber 929
64 Inspection and Adjustment After Installation 931
641 Adjustment of Brake Shoe Clearance 931
65 Exhaust Brake 933
651 Exhaust Brake Unit 933
652 Control Cylinder 936
653 Exhaust Brake Control 937
654 Adjustment and Inspection After Installation 938
Group 36 – Parking Brake 939
Group 36A – Parking Brake (Center Parking Brake) 940
Table of Contents 941
1 Troubleshooting 942
2 Specifications 942
3 Service Standards 943
31 Service Standards Table 943
32 Tightening Torque Table 943
4 Special Tools 943
5 General 944
6 Service Procedure 945
61 Parking Brake 945
611 Removal and Installation 945
612 Disassembly and Inspection 945
613 Reassembly 946
62 Parking Brake Control 947
621 Removal and Installation 947
622 Parking Brake Lever 948
63 Adjustment 949
Group 36B – Parking Brake (Wheel Parking Brake) 950
Table of Contents 951
1 Troubleshooting 952
2 Service Standards 952
21 Service Standards Table 952
22 Tightening Torque Table 952
3 General 953
31 Parking Brake System 953
32 Parking Brake Control Valve 953
33 Spring Brake Valve 954
4 Service Procedure 956
41 Parking Brake Control Valve 956
411 Disassembly 956
412 Reassembly 957
413 Inspection After Reassembly 957
42 Spring Brake Valve 958
421 Disassembly 958
422 Reassembly 959
423 Inspection After Reassembly 959
Group 37 – Steering 961
Table of Contents 962
1 Troubleshooting 963
2 Specifications 967
3 Service Standards 968
31 Service Standards Table 968
32 Tightening Torque Table 969
4 Special Tools 970
5 General 974
6 Service Procedure 977
61 Removal and Installation 977
62 Steering Shaft 978
621 Removal 978
622 Installation 979
623 Disassembly, Inspection and Correction 980
624 Reassembly 981
63 Link and Bracket Section 982
631 Disassembly 982
632 Reassembly 983
64 Drag Link 984
65 Tie Rod 985
66 Integral Power Steering Booster 986
661 Disassembly, Inspection and Correction 986
662 Reassembly and Adjustment 990
67 Power Steering Oil Pump 996
671 Removal 996
672 Installation 997
673 Disassembly, Inspection and Correction 997
674 Reassembly 999
675 Adjustment1001
68 Power Steering Oil Tank1001
681 Disassembly1001
682 Reassembly1001
69 Adjustment After Installlation1002
691 Bleeding1002
692 Performance Verification Tests1002
693 Steering Wheel Play1003
694 Adjustment of Steering Angle1003
Group 41 – Frame1004
Table of Contents1005
1 General1006
2 Service Procedure1006
21 Inspection and Repair1006
211 Frame1006
212 Rivets1009
213 Bolts and Nuts1009
Group 42 – Cab1010
Table of Contents1011
1 Troubleshooting1012
2 Specifications1014
3 Service Standards1014
31 Service Standards Table1014
32 Tightening Torque Table1014
4 General1015
41 Cab Proper1015
42 Cab Mounting1016
421 Front Cab Mounting1016
422 Rear Cab Mounting1016
43 Cab Tilt System1016
5 Service Procedure1017
51 Removal1017
511 Key Points for Removal1017
512 Key Points for Installation1019
513 Inspection and Adjustment After Installation1020
52 Cab Mounting1021
521 Front Cab Mounting1021
522 Cab Stay1023
523 Rear Cab Mounting1024
524 Cab Tilt Link1026
53 Doors1029
531 Removal of Doors1029
532 Doors Installation Adjustment1029
533 Front Door Assembly1031
54 Interior Parts1035
541 Seats and Center Console1035
542 Air Suspension1036
543 Seat Belts (3-Point Type Seat Belts with ELR)1038
544 Floor Mat1040
545 Overhead Console1041
546 Trim and Headlining1042
547 Instrument Panel1044
55 Window Glass1048
551 Removal1048
552 Installation1048
56 Exterior Parts1050
561 Front Panel, Fender and Allied Parts1050
562 Rear View Mirrors1052
Group 54 – Electrical1053
Table of Contents1054
1 Troubleshooting1055
2 Specifications1061
3 Service Standards1063
4 General1066
5 Service Procedure1069
51 Battery1069
511 General Description1069
512 Inspection1069
52 Fuses1071
521 General Description1071
522 Inspection1072
53 Fusible Link1074
531 General Description1074
532 Inspection1074
54 Starter Switch and Cold Start Switch1075
541 General Description1075
542 Inspection1076
55 Sub-Starter System1077
551 General Description1077
552 Inspection1077
56 Combination Switch1078
561 General Description1078
562 Inspection1079
57 Lighting System1080
571 General Description1080
572 Inspection1084
573 Inspection and Adjustment After Installation1088
58 Meter System1089
581 General Description1089
582 Inspection1090
59 Indicators and Warning Lamps1094
591 General Description1094
592 Inspection1097
510 Wiper and Washer System1101
5101 General Description1101
5102 Inspection1102
5103 Inspection and Adjustment After Installation1105
511 Horn1107
5111 General Description1107
5112 Inspection1107
512 Back Buzzer1108
5121 General Description1108
5122 Inspection1108
513 Radio and Cassette Stereo <Option>1108
5131 Mounting Position1108
5132 AM/FM Radio and AM/FM Radio With Cassette Stereo1109
5133 Troubleshooting1110
514 Cigarette Lighter1111
5141 General Description1111
5142 Inspection1111
Group 55A – Air Conditioner1113
Group 55A (9107) – Air Conditioner1114
Foreword/Table of Contents1115
1 Specifications1116
2 Outlines of Refrigeration System1117
21 Air System1117
22 Refrigerating Cycle1117
23 Electrical System1118
3 Construction1119
31 Engine Room1119
32 Cabin Room1119
33 Control System1120
34 Compressor and Magnetic Clutch1122
341 Compressor1122
342 Check Valve1123
343 Magnetic Clutch1123
35 Condenser1123
36 Receiver Drier1123
37 Cooling Unit1124
38 Expansion Valve1124
39 Dual Pressure Switch1125
310 Power Relay1125
311 A/C Switch1125
312 Fin Thermo1125
4 Troubleshooting1126
41 General1126
42 Trouble Cause and Remedy1127
43 Inspection Procedures1129
431 A/C Switch1129
432 Dual Pressure Switch1129
433 Fin Thermo1130
434 Magnetic Clutch1130
435 Refrigerant Charge1130
436 Receiver Drier Assembly1131
437 Belting Tension1131
438 Expansion Valve1131
439 Compressor1132
4310 Air Inclusion in Ref Circuit1132
4311 Moisture Inclusion in Ref Circuit1132
5 Removal and Installation1133
51 Precautions for Removal and Installation1133
52 Removal1133
521 Inside the Engine Room1133
522 Cabin Room1134
6 Treatment After Installation1136
61 Check and Adjustment1136
62 Leak Test1136
621 Test Points1136
622 Test Procedure1136
64 System Charging1137
641 Installation of Charge Equipment1138
642 Charging System1138
643 Charging With Small Cans1139
645 Correcting Low Refrigerant Level1140
646 Discharging System1140
65 Checking the Refrigerant Level1140
66 Performance Test1141
661 Preparation1141
662 Stationary Performance Test1141
7 Compressor1142
71 Compressor1142
72 Disassembly and Reassembly Precautions1143
721 Disassembly Precautions1143
722 Reassembly Precautions1143
723 Tools and Instruments1143
73 Precautions at Disassembly1144
74 Maintenance and Check1152
741 Inspection Standards1152
742 Consumable Parts1153
75 Assembly Procedure1156
751 Tightening Torque1156
752 Assembly Procedure1157
76 Special Tool Figure1166
8 Cooling Unit1176
81 Components1176
82 Cautions in Disassembling1177
83 Disassembling1177
9 Maintenance1178
Group 55A (9403) – Air Conditioner1179
Table of Contents1180
1 Specifications1181
2 Outlines of Refrigeration System1182
21 Air System1182
22 Refrigerating Cycle1182
23 Electrical System1183
3 Construction1184
31 Engine Room1184
32 Cabin Room1184
33 Control System1185
34 Compressor and Magnetic Clutch1187
341 Compressor1187
342 Check Valve1188
343 Magnetic Clutch1188
35 Condenser1188
36 Receiver Assembly1188
37 Cooling Unit Assembly1189
38 Expansion Valve1189
39 Relief Valve1189
310 Dual Pressure Switch1190
311 Power Relay1190
312 A/C Switch1190
313 Fin Thermo1190
4 Troubleshooting1191
41 General Procedure1191
42 Trouble Cause and Remedy1192
43 Inspection Procedures1194
431 A/C Switch1194
432 Dual Pressure Switch1194
433 Fin Thermo1195
434 Magnetic Clutch1195
435 Refrigerant Charge1195
436 Receiver Assembly1196
437 Belting Tension1196
438 Expansion Valve1196
439 Compressor1197
4310 Air Inclusion in Ref Circuit1197
4311 Moisture Inclusion in Ref Circuit1197
5 Removal and Installation1198
51 Precautions for Removal and Installation1198
52 Removal1198
521 Inside the Engine Room1198
522 Cabin Room1199
6 Treatment After Installation1201
61 Check and Adjustment1201
62 Leak Test1201
621 Test Points1201
622 Test Procedure1201
63 System Charging1202
631 Evacuation1203
632 Evacuate the System1203
633 Removal of Charge Equipment1205
634 Discharging System1205
64 Checking the Refrigerant Level1205
65 Performance Test1206
651 Preparation1206
652 Stationary Performance Test1206
7 Compressor1207
71 Component of Compressor1207
72 Disassembly and Reassembly Precautions1208
721 Disassembly Precautions1208
722 Reassembly Precautions1208
723 Tools and Instruments1208
73 Precautions at Disassembly1209
74 Maintenance and Check1217
741 Inspection Standards1217
742 Consumable Parts1218
75 Assembly Procedure1221
751 Tightening Torque1221
752 Assembly Procedure1222
95 Special Tool Figure1231
8 Cooling Unit1241
81 Components1241
82 Cautions in Disassembling1242
83 Disassembling1242
9 Maintenance1243
Group 55B – Heater1244
Table of Contents1245
1 Troubleshooting1246
2 Specifications1247
3 General1247
31 Ventilation System1247
32 Heater1248
4 Service Procedure1249
41 Removal and Installation1249
42 Cleaning of Air Filter1250
43 Heater Control Adjustment Procedures1251
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealersinorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V