2005 Mitsubishi Fuso (FE/FG/FK/FM) OEM Service & Repair Manual

SERVICE MANUAL 2005 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 cor- rect, efficient maintenance. Please note that the information and specifications contained within this manual may change without notice. This is due to product modifications and continued vehicle improvements that are made throughout the model years. Should you encounter any discrepancy in the information provid- ed, please do not hesitate to contact your nearest Mi- tsubishi Fuso Dealer or Mitsubishi Fuso Truck of America, Inc. May 2004 GROUP INDEX GENERAL .............................................. 00 MAINTENANCE SCHEDULE ................. 01 ENGINE................................................... 11 LUBRICATION ........................................ 12 FUEL AND ENGINE CONTROL ............. 13A ELECTRONICALLY CONTROLLED FUEL SYSTEM ....................................... 13E COOLING................................................ 14 INTAKE AND EXHAUST ........................ 15 EMISSION CONTROL ............................ 17 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 DOOR...................................................... 43 EXTERIOR .............................................. 51 INTERIOR ............................................... 52 ELECTRICAL .......................................... 54 AIR-CONDITIONER ................................ 55A HEATER .................................................. 55B

00-1 INDEX EQUIPMENT TYPE CODES LIST ...................................................... 00-2 POWER TRAIN LIST ......................................................................... 00-3 HOW TO READ THIS MANUAL ........................................................ 00-4 CHASSIS NUMBER, ENGINE NUMBER, POWER TRAIN LABEL ................................................................... 00-10 VEHICLE IDENTIFICATION NUMBER ........................................... 00-11 PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-12 JACKING UP THE VEHICLE .......................................................... 00-24 DIAGNOSIS CODES 1. Connecting Multi-Use Tester ..................................................... 00-26 2. Accessing / Erasing Diagnosis Codes <Common Rail, Exhaust Gas Recirculation, Pre-heater> ........... 00-30 3. Accessing / Erasing Diagnosis Codes <Automatic Transmission> ................................................... 00-32 4. Accessing / Erasing Diagnosis Codes <Anti-lock Brake System> ................................................... 00-34 TABLE OF STANDARD TIGHTENING TORQUES.......................... 00-36

00-2 Component Name plate marking Code description Engine 4M50-T 4 M 5 0 T Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4) Clutch C5W33 C 5 W 33 Disc OD Facing material (W: Woven) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the clutch Transmission M036S5W M 036 S 5 W Variation (W: With directly-mounted transfer) Forward speeds Type of mesh (S: Synchromesh) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the transmission Propeller shaft P3 P 3 Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the propeller shaft Front axle F200T F 200 T Vehicle type (T: Truck) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the front axle Rear axle R033T R 03 3 T Vehicle type (T: Truck) Order of development within same series Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the rear axle Reduction and differential D033H D 03 3 H Tooth profile (H: Hypoid gear) Order of development within same series Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the reduction & differential EQUIPMENT TYPE CODES LIST

00 00-3 Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Reduction & differential FE83DDZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE83DEZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE83DGZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE83DDZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE83DEZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE83DGZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE84DDZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE84DEZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE84DGZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE84DHZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H FE84DDZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE84DEZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE84DGZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE84DHZSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE84DHWSLSUB 4M50-T8 Torque converter M036A6 P3 R033T D033H FE85DDZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H FE85DEZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H FE85DGZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H FE85DHZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H FE85DJZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H FE85DDZSLSUB 4M50-T8 Torque converter M036A6 P3 R035T D035H FE85DEZSLSUB 4M50-T8 Torque converter M036A6 P3 R035T D035H FE85DGZSLSUB 4M50-T8 Torque converter M036A6 P3 R035T D035H FE85DHZSLSUB 4M50-T8 Torque converter M036A6 P3 R035T D035H FE85DJZSLSUB 4M50-T8 Torque converter M036A6 P3 R035T D035H FG84DC6SLSUA 4M50-T7 C5W33 M036S5W Front: P2 Rear: P3 R033T Front: D1H Rear: D033H FG84DE6SLSUA 4M50-T7 C5W33 M036S5W Front: P2 Rear: P3 R033T Front: D1H Rear: D033H POWER TRAIN TABLE

00-4 This manual consists of the following parts: • Specifications • Structure and Operation • Troubleshooting • On-vehicle Inspection and Adjustment • Service procedures On-vehicle Inspection and Adjustment • Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are described including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedure • Procedures for servicing components and parts off the vehicle are described centering on key points in their re- moval, installation, disassembly, reassembly, inspection, etc. Inspection • Check items subject to acceptance or otherwise on the basis of service standards are all given. • Some routine visual checks and cleaning of some reused parts are not described but must be always included in actual service work. Caution • This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: Terms and Units Front and rear The forward running direction of the vehicle is the front and the reversing direction is the rear. Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. DANGER Precautions that should be taken in handing potentially dangerous substances such as battery fluid and coolant additives. WARNING Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION Precautionary instructions, which, if not observed, could result in damage to or de- struction of equipment or parts. NOTE Suggestions or supplementary information for more efficient use of equipment or a better understandings. HOW TO READ THIS MANUAL

00 00-5 Tightening torque • Values are directly specified for out-of-standard tightening torques for bolts and nuts. • Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.) • When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry. Units Tightening torques and other parameters are given in SI* units with imperial unit and metric units added in brackets { }. *SI: Le Système International d’Unités Unit SI unit {imperial unit, metric unit} Conversion factor Force N {lbs, kgf} 9.80665 N {2.2046 lbs, 1 kgf} Moment of force N·m {ft.lbs, kgf·m} 9.80665 N·m {7.2329 ft.lbs, 1 kgf·m} Pressure Positive pressure kPa {psi, kgf/cm 2 } 98.0665 kPa {14.22 psi, 1 kgf/cm 2 } Vacuum pressure kPa {in.Hg, mmHg} 0.133322 kPa {0.03937 in.Hg, 1 mmHg} Volume J {BTU, kcal} 4186.05 J {3.96825BTU, 1 kcal} Heat quantity W {BTU/h, kcal/h} 1.16279W {3.96825BTU/h, 1 kcal/h} Unit SI unit {imperial unit} Conversion factor Length mm {in.} 1 mm {0.03937 in.} m {ft.} 1 m {3.2808 ft.} km {mile} 1 km {0.6214 mile} Mass kg {lb} 1 kg {2.2046 lb} g {oz} 1 g {0.035274 oz} Temperature (in degree Celsius) °C {° F} 1°C {(1°C × 1.8 + 32)° F} Velocity km/h {mph} 1 km/h {0.6214 mph} m/s {ft/s} 1 m/s {3.281 ft/s} Volume L {qts}, L {gal} 1 L {1.05336 qts}, 1 L {0.2642 gal} cm 3 {cu.in.} 1 cm 3 {0.061023 cu.in.} Area m 2 {in 2 }, m 2 {ft 2 } 1 m 2 {1.550 × 10 3 in 2 }, 1 m 2 {1.076 × 10 ft 2 } Example: 390 N·m {290 ft.lbs, 40 kgf·m} Metric unit SI unit Imperial unit Example: 30 mm {1.18 in.} SI unit Imperial unit

00-6 Symbol Denotation Application Remarks Tightening torque Parts not tightened to standard torques (standard torques specified where necessary for servicing) Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are specified. Locating pin Parts to be positioned for installation Non-reusable parts Parts not to be reused Lubricant and/or sealant Parts to be coated with lubricant or sealant for assembly or installation Necessary lubricant and/or sealant, quantity required, etc. are specified in table. Special tool Parts for which special tools are required for service operation Tool name/shape and part number are shown in table. *a Associated part Parts associated with those removed/disas- sembled for servicing HOW TO READ THIS MANUAL

00 00-7

2005 Mitsubishi Fuso (FE/FG/FK/FM) OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed