2002-2004 Mitsubishi Fuso Truck FE FG FH FK FM Series Service Repair Factory Manual INSTANT (2002 2003 2004)

SERVICE MANUAL 2002 Model FOREWORD This Service Manual contains maintenance and repair methods for the Mitsubishi Fuso Truck FE, FG Series. Read this manual carefully as an aid in providing correct, efficient maintenance. Please note that the information and specifications contained within this manual may change without notice. This is due to product modifications and contined vehicle improvements that are made throughout the model years. Should you encounter any discrepancy in the information provided, please do not hesitate to contact your nearest Mitsubishi Fuso Dealer or Mitsubishi Fuso Truck of America, Inc. April 2001 GROUP INDEX HOW TO READ THIS MANUAL GENERAL ............................................. 00 MAINTENANCE SCHEDULE ............... 01 ENGINE < 4M5 > ................................................... 11A < 4D3 > .................................................... 11B LUBRICATION < 4M5 > ................................................... 12A < 4D3 > .................................................... 12B FUEL AND ENGINE CONTROL < 4M5 > ................................................... 13A < 4D3 > .................................................... 13B ELECTRONICALLY CONTROLLED FUEL SYSTEM < 4M5 > ................................................... 13EA < 4D3 > .................................................... 13EB COOLING < 4M5 > ................................................... 14A < 4D3 > .................................................... 14B INTAKE AND EXHAUST < 4M5 > ................................................... 15A < 4D3 > .................................................... 15B CLUTCH ............................................... 21 MANUAL TRANSMISSION .................. 22 AUTOMATIC TRANSMISSION ............ 23 TRANSFER ........................................... 24 PROPELLER SHAFT ........................... 25 FRONT AXLE < FE > ...................................................... 26A < FG > ..................................................... 26B REAR AXLE ......................................... 27 WHEEL AND TIRE ............................... 31 FRONT SUSPENSION ......................... 33 REAR SUSPENSION ........................... 34 BRAKE ................................................. 35A ANTI-LOCK BRAKE SYSTEM ............. 35E PARKING BRAKE ................................ 36 STEERING ............................................ 37 FRAME ................................................. 41 CAB ...................................................... 42 ELECTRICAL ....................................... 54 AIR-CONDITIONER .............................. 55A HEATER ............................................... 55B

How to Read this Manual Pub No. TWSE0101-H

INDEX HOW THIS MANUAL IS STRUCTURED ................................................. 2 TERMS ................................................................................................... 15

2 23915 23929 I'm here to explain how to use this manual. To get the most out of your manual, follow along carefully and read all the notes given by my assistant. This manual is divided into groups, with one group for each main area of the vehicle. By way of example, let's look at Group 21, which covers the clutch. We're here to help you. Group 21 Group 27 Group 31 Each group is divided into five parts, as shown below. Specifications Specifications, oil quantities, and other information pertaining to system components. Structure and Operation Information on the structure and operation of the overall system and its components. Troubleshooting An item-by-item guide to fault symptoms and their probable causes. On-Vehicle Inspection and Adjustment Instructions for on-vehicle inspection and adjustment operations. Service Instructions (See the next and subsequent pages.) The service instructions are the most important parts of this manual. Starting on the next page, you'll learn more about them. INDEX SPECIFICATIONS .......................................................... STRUCTURE AND OPERATION ................................... TROUBLESHOOTING ................................................... ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Clutch Fluid Replacement and Air Bleeding ................... 2. Inspection of Clutch Booster Functionality ..................... 3. Clutch Pedal Play ............................................................... CLUTCH PEDAL ............................................................ CLUTCH MASTER CYLINDER ...................................... CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER ...................................................................... CLUTCH POWER CYLINDER ........................................ CLUTCH-PROPER ........................................................ CLUTCH HOUSING ....................................................... CLUTCH DISC WEAR INDICATOR SWITCH ................. 23916 23917 HOW THIS MANUAL IS STRUCTURED

3 Now, let's take a detailed look at the service instructions. Please follow along carefully. 23918 26310 20244 INDEX SPECIFICATIONS ................................................. ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Clutch Fluid Replacement and Air Bleeding ........ 2. Inspection of Clutch Booster Functionality ......... 3. Clutch Pedal Play ................................................... CLUTCH PEDAL ................................................... CLUTCH MASTER CYLINDER ............................. CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER ............................................................. CLUTCH POWER CYLINDER .............................. CLUTCH-PROPER ................................................ CLUTCH HOUSING .............................................. The service instructions consist of the parts shown below. Starting on page 7, these parts are described in detail in order of the circled numbers. Name of system or assembly Key numbers List of part names Group number This appears on each right-hand page. Exploded view This shows the system or assembly in its dis- assembled form. Service standards Tightening torques Lubricants, fluids and/or sealants This table shows the required brands and quantities of oils, greases and/or sealants. Special tools Service procedure Service procedures 1 2 HOW THIS MANUAL IS STRUCTURED

4 23922 26312 20245 23921 26311 Look at the exploded view first; it gives an overview of the system or assembly. All other information is given in parts to . I see... First I look at the exploded view, then I look at parts to . Basically, you should find the information you need from parts to as you perform the service procedure. But how should I find the information I need? I'll show you on the next page. HOW THIS MANUAL IS STRUCTURED 3 4 5

5 5.9 {4.3, 0.6} 26314 20252 45204 Find the information you need using the key numbers. For example, let's assume you're assembling the clutch and need the tightening torque for the bolt . To find the tightening torque, just look up key number 1 in the “Tightening torques” table. I see... The key numbers for the exploded view match the key numbers on other parts of the page. To help you find information quickly: Tightening torques are marked with Ê . Lubricants, fluids and sealants are marked with - . And every key number that appears in the service procedure is enclosed with a square. 6 HOW THIS MANUAL IS STRUCTURED

6 1 1 Ê Explanatory notes for the exploded view are given below. Explanatory notes for the parts list are given on the facing page. CLUTCH-PROPER <C5> Pressure Plate-and-Lever Assembly ● Pre-disassembly operations Õ P21 - 44 • Disassembly sequence 1 Bolt 2 Lock plate 3 Support nut 4 Pressure spring 5 Pressure spring cap 6 Return spring 7 Release lever plate 8 Clutch cover 9 Release lever pin 10 Support lever pin 11 Support lever 12 Release lever 13 Bushing 14 Pressure plate P Positioning pin Ù : Non-reusable part NOTE Do not remove the bushing 13 unless it is defective. ● Assembly sequence Reverse the order of disassembly. Repair kit : Clutch release Lever kit ● Post-assembly Inspection and adjustment Õ P21 - 44 This mark indicates a part that cannot be reused. Pressure Plate-and-Lever Assembly This mark indicates that lubricant or sealant must be applied to the part. The key number enclosed with a square indicates that the part is men- tioned in the service procedure. This mark indicates that a tightening torque is specified for the part. So parts without Ê marks don't have specified tightening torques ? No, they don't. But every bolt and nut must be tightened to a standard torque. A Ê mark shows either that the part must be tightened to a torque other than the standard torque or that the standard torque cannot be determined from the part's shape or markings. Standard tightening torques are explained at the bottom of the next page. 2 3 - - 12 7 - 8 6 11 5 - Ù HOW THIS MANUAL IS STRUCTURED Exploded view 1 Ê 2 3 - - 12 7 - 8 6 11 5 - Ù 23925 23927 23928 1 8 23926 : Indicates positioning pin. P P P

7 PRECAUTIONS FOR MAINTENANCE OPERATIONS ....................................... TABLE OF STANDARD TIGHTENING TORQUES ...................... ● Pre-disassembly operations Õ P21 - 44 ● Disassembly sequence 1 Bolt 2 Lock plate 3 Support nut 4 Pressure spring 5 Pressure spring cap 6 Return spring 7 Release lever plate 8 Clutch cover 9 Release lever pin 10 Support lever pin 11 Support lever 12 Release lever 13 Bushing 14 Pressure plate Ù : Non-reusable part NOTE Do not remove bushing 13 unless it is faulty. ● Assembly sequence Follow the disassembly sequence in reverse. Repair kit : Clutch Release Lever kit ● Post-assembly inspection and adjustment Õ P21 - 44 The key numbers are given here. This shows that certain operations must be performed before disassembly. The key numbers show the disassembly sequence. Links to reference information are given as follows: • Õ P21 - 44 Refer to the indicated page of the same group. • ^ Gr 42 Refer to the indicated group in another manual. The name of the specified repair kit (if any) is given here. The assembly sequence is given here. Assembly is usually performed in the opposite order to disassembly. If the assembly sequence is otherwise specified, it is given in terms of key numbers like this: ● Assembly sequence 14→12→10→13→11..... Now let's look at standard tightening torques. Normally, bolts and nuts have numbers or markings to show their material strength. Tightening torques for bolts and nuts with such numbers and markings are shown in the Table of Standard Tightening Torques that appears in group 00. INDEX ENGINE NUMBER AND NUMBER PLATE ................................................... + + + The names of parts are given here. 2 23930 This shows that certain operations must be performed after assembly. HOW THIS MANUAL IS STRUCTURED

2002-2004 Mitsubishi Fuso Truck FE FG FH FK FM Series Service Repair Factory Manual INSTANT (2002 2003 2004)

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