1996-2001 Mitsubishi FUSO FE FG Truck (USA) Service Manual – PDF DOWNLOAD
FILE DETAILS:
1996-2001 Mitsubishi FUSO FE FG Truck (USA) Service Manual – PDF DOWNLOAD
Language : English
Pages : 1710
Downloadable : Yes
File Type : PDF
Size: 55.7 MB
TABLE OF CONTENTS:
1996-2001 Mitsubishi FUSO FE FG Truck (USA) Service Manual – PDF DOWNLOAD
REMOVAL AND INSTALLATION OF ENGINE
• Charge and Discharge of Engine Coolant,
Removal and Installation of Hoses 10- 2
• Removal and Installation of Transmission Related Parts 10- 4
• Removal and Installation of Engine Related Parts 10- 6
• Removal and Installation of Engine
< FE > 10- 8
< FG > 10-10
REMOVAL AND INSTALLATION OF ENGINE
• Charge and Discharge of Engine Coolant,
Removal and Installation of Hoses 2
• Removal and Installation of Transmission Related Parts 4
• Removal and Installation of Engine Related Parts 6
• Removal and Installation of Engine 8
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 6
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Inspection of Engine Compression 7
• Inspection and Adjustment of Valve Clearance 9
CYLINDER HEAD AND VALVE MECHANISM 12
TIMING GEAR 26
CAMSHAFT 30
PISTON, CONNECTING ROD AND CYLINDER SLEEVE 36
FLYWHEEL 50
CRANKSHAFT AND CRANKCASE 54
SPECIFICATIONS 11A- 2
STRUCTURE AND OPERATION 11A- 4
TROUBLESHOOTING 11A-14
ON-VEHICLE INSPECTION AND ADJUSTMENT 11A-16
ROCKER COVER, ROCKER ASSEMBLIES AND CAMSHAFTS 11A-20
CYLINDER HEAD AND VALVE MECHANISM 11A-34
FRONT CASE 11A-48
TIMING GEARS AND BALANCE SHAFTS 11A-52
PISTONS, CONNECTING RODS AND CYLINDER LINERS 11A-60
FLYWHEEL 11A-72
CRANKSHAFT AND CRANKCASE 11A-76
BALANCE SHAFT BUSHINGS 11A-84
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 12
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Replacement of Oil Filter 13
• Replacement of Engine Oil 14
• Measurement of Oil Pressure 15
OIL PAN, OIL STRAINER AND OIL JET 16
OIL PUMP 18
OIL COOLER AND OIL FILTER 22
SPECIFICATIONS 12A- 2
STRUCTURE AND OPERATION 12A- 4
TROUBLESHOOTING 12A-14
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Oil Filter Replacement 12A-16
• Engine Oil Replacement 12A-17
• Oil Pressure Measurement 12A-18
OIL PAN, OIL STRAINER AND OIL JET 12A-20
OIL PUMP 12A-22
OIL FILTER 12A-26
OIL COOLER 12A-28
SPECIFICATIONS 13 – 2
STRUCTURE AND OPERATION 13 – 4
TROUBLESHOOTING13 -32
READING AND ERASING DIAGNOSIS CODES13 -36
SERVICE PROCEDURES USING MUT-II 13 -42
INSPECTION BASED ON DIAGNOSIS CODE 13 -44
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Checking and Adjusting Injection Timing 13 -48
• Bleeding Air from Fuel System 13 -51
• Cleaning Gauze Filter 13 -51
• Replacing Fuel Filter 13 -52
ENGINE CONTROL13 -53
FUEL TANK 13 -58
FUEL FILTER13 -59
WATER SEPARATOR 13 -60
INJECTION PUMP13 -62
INJECTION NOZZLE13 -66
INSPECTION OF OTHER DEVICES 13 -70
ELECTRIC CIRCUIT AND PART INSTALLATION LOCATIONS 13 -82
SPECIFICATIONS 2
STRUCTURE AND OPERATION 4
TROUBLESHOOTING 24
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Inspection and Adjustment of Fuel Injection Timing 28
• Inspection and Adjustment of No-Load Minimum and
Maximum Revolution 31
• Inspection and Adjustment of Idling Actuator < with Cab Cooler > 32
PRE-STROKE CONTROL INJECTION PUMP SYSTEM
• Troubleshooting Procedure 34
• Electric Circuit and Position of Parts Installation 40
• Inspection by Individual Diagnosis Code 42
• Inspection of Temporary Faults 60
ENGINE CONTROL 62
FUEL TANK 67
WATER SEPARATOR 68
FUEL FILTER 70
INJECTION PUMP 72
INJECTION NOZZLE 76
SPECIFICATIONS 13A- 2
STRUCTURE AND OPERATION 13A- 3
1 Fuel System (Fuel flow) 13A- 3
2 Engine Control 13A- 4
3 Fuel Filter 13A- 5
ON-VEHICLE INSPECTION AND ADJUSTMENT 13A- 6
1 Checking Minimum and Maximum
No-Load Speeds 13A- 6
2 Bleeding Air from Fuel System 13A- 7
3 Replacing Fuel Filter 13A- 7
ENGINE CONTROL 13A-10
FUEL TANK 13A-13
FUEL FILTER 13A-14
INJECTION PUMP 13A-16
INJECTION NOZZLE 13A-20
SPECIFICATIONS 13E- 2
STRUCTURE AND OPERATION
1 General 13E- 3
2 Electronic Control System 13E- 5
3 Pin Configuration of Engine Control Unit 13E- 9
TROUBLESHOOTING
1 Inspection Procedures 13E-14
2 Connection of Multi-Use Tester II 13E-16
3 Reading and Erasing Diagnostic Trouble Codes 13E-17
4 Diagnostic Trouble Codes and Check Items 13E-19
5 Service Data of Multi-Use Tester II 13E-28
6 Actuator Test by Mutil-Use Tester II 13E-30
7 Checks at Connector of Control Unit 13E-32
8 Checks on Intermittent Troubles 13E-35
INSPECTION OF ELECTRICAL EQUIPMENT 13E-36
LOCATIONS OF PARTS 13E-44
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 5
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Measurement of Turbo Boost Pressure 6
AIR DUCT AND AIR CLEANER 8
TURBOCHARGER 12
INTERCOOLER 18
INTAKE MANIFOLD 20
EXHAUST MANIFOLD 22
EXHAUST PIPE AND MUFFLER 24
SPECIFICATIONS / STRUCTURE AND OPERATION 15A- 2
1 Air Cleaner 15A- 2
2 Turbocharger Assembly 15A- 3
TROUBLESHOOTING 15A- 4
ON-VEHICLE INSPECTION AND ADJUSTMENT 15A- 5
1 Measurement of Turbocharger Boost Pressure 15A- 5
AIR DUCT AND AIR CLEANER 15A- 8
TURBOCHARGER 15A-11
INTERCOOLER 15A-16
INTAKE MANIFOLD 15A-18
EXHAUST MANIFOLD 15A-20
EXHAUST PIPE AND MUFFLER 15A-21
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 5
WORK BEFORE REMOVAL AND INSTALLATION OF
TRANSMISSION ASSEMBLY 7
REMOVAL AND INSTALLATION OF TRANSMISSION
ASSEMBLY 8
GEAR SHIFTER UPPER 10
REAR COVER AND REVERSE IDLER GEAR 16
TRANSMISSION BODY 20
DRIVE PINION ASSEMBLY 28
MAINSHAFT ASSEMBLY 30
COUNTERSHAFT ASSEMBLY
< NON-BACKLASH MECHANISM > 36
TRANSMISSION CONTROL 40
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING PROCEDURE 50
ELECTRIC CIRCUIT AND PARTS INSTALLATION POSITION 62
INSPECTION BY INDIVIDUAL DIAGNOSIS CODE 65
INSPECTION BY SYMPTOM 92
INSPECTION OF TEMPORARY FAULT 107
INSPECTION USING THE CHECK BOX (HARNESS CHECKER) 108
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Stall Test 112
• Line Pressure Test 113
• Road Test 115
• Inspection of Automatic Transmission Fluid 117
• Replacement of Automatic Transmission Fluid 118
WORK BEFORE REMOVAL AND INSTALLATION OF AUTOMATIC
TRANSMISSION ASSEMBLY 120
REMOVAL AND INSTALLATION OF AUTOMATIC
TRANSMISSION ASSEMBLY 121
OIL COOLER 126
AUTOMATIC TRANSMISSION CONTROL 130
REPLACEMENT OF RELATIVE PARTS OF AUTOMATIC
TRANSMISSION BODY 142
SPECIFICATIONS 24- 2
STRUCTURE AND OPERATION 24- 2
TROUBLESHOOTING 24- 4
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY 24- 6
FRONT DRIVE 24- 10
IDLER GEAR AND REAR DRIVE 24- 16
TRANSFER CONTROL 24- 22
GROUP 25 PROPELLER SHAFT
< P2: FG (FRONT AXLE TO TRANSFER) >
SPECIFICATIONS 25- 2
STRUCTURE AND OPERATION 25- 2
TROUBLESHOOTING 25- 3
REMOVAL AND INSTALLATION OF PROPELLER SHAFT 25- 4
REAR PROPELLER SHAFT 25- 6
BALANCING PROPELLER SHAFT 25-10
GROUP 25 PROPELLER SHAFT
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 3
REMOVAL AND INSTALLATION OF PROPELLER SHAFT 4
REAR PROPELLER SHAFT 6
FRONT PROPELLER SHAFT 10
BALANCING PROPELLER SHAFT 14
GROUP 26 FRONT AXLE
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Adjustment of Wheel Alignment 4
• Adjustment of Steering Angle 7
• Measurement of Side Slip 7
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT AXLE 8
WHEEL HUB AND ROTOR 10
FRONT AXLE, KNUCKLE AND KINGPIN 16
GROUP 27 REAR AXLE
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 5
WORK BEFORE REMOVAL AND INSTALLATION OF REAR AXLE 7
WHEEL HUB AND BRAKE DRUM < FE639 > 8
WHEEL HUB AND ROTOR < FE649 > 16
AXLE HOUSING 24
REDUCTION AND DIFFERENTIAL 28
GROUP 33 FRONT SUSPENSION
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 3
WORK BEFORE REMOVAL AND INSTALLATION OF FRONT
SUSPENSION 4
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY 6
LEAF SPRING ASSEMBLY 8
SHOCK ABSORBER 10
STABILIZER 12
GROUP 34 REAR SUSPENSION
STRUCTURE AND OPERATION 34- 2
TROUBLESHOOTING 34- 3
WORK BEFORE REMOVAL AND INSTALLATION
OF REAR SUSPENSION 34- 4
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY
< FE > 34- 6
< FG > 34- 10
LEAF SPRING ASSEMBLY 34- 14
SHOCK ABSORBER 34- 17
STABILIZER < FE > 34- 18
GROUP 34 REAR SUSPENSION
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 3
WORK BEFORE REMOVAL AND INSTALLATION
OF REAR SUSPENSION 4
REMOVAL AND INSTALLATION OF LEAF SPRING ASSEMBLY 6
LEAF SPRING ASSEMBLY 10
SHOCK ABSORBER 13
STABILIZER 14
SPECIFICATIONS 35- 2
STRUCTURE AND OPERATION 35- 3
TROUBLESHOOTING 35- 32
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Replacement of Brake Fluid 35- 38
• Air Bleeding of Brake System 35- 40
• Inspection and Adjustment of Brake Pedal Free Play 35- 42
• Inspection and Adjustment of Clearance between
Brake Pedal and Floor Panel 35- 42
• Inspection and Replacement of Disc Brake Pad 35- 43
• Drum Brake Lining Thickness Inspection and Replacement 35- 46
• Inspection of Brake Shoe Clearance 35- 46
• Inspection of Brake Booster (Master Vac) 35- 47
• Inspection of Bypass Valve 35- 52
BRAKE MASTER CYLINDER 35- 54
BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC) 35- 56
FRONT WHEEL BRAKE
< FE639 : DISC BRAKE > 35- 58
< FE649 : DISC BRAKE > 35- 62
< FG639 : DRUM BRAKE > 35- 66
REAR WHEEL BRAKE
< FE639, FG639 : DRUM BRAKE > 35- 72
< FE649 : DISC BRAKE > 35- 80
VACUUM PUMP 35- 84
LOAD SENSING VALVE 35- 85
EXHAUST BRAKE SYSTEM 35- 86
GROUP 35 BRAKE
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 26
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Replacement of Brake Fluid 32
• Air Bleeding of Brake System 34
• Inspection and Adjustment of Brake Pedal Free Play 36
• Inspection and Adjustment of Clearance between
Brake Pedal and Floor Panel 36
• Inspection and Replacement of Disc Brake Pad 37
• Drum Brake Lining Thickness Inspection and Replacement 40
• Inspection of Brake Shoe Clearance 40
• Inspection of Brake Booster (Master Vac) 41
• Inspection of Bypass Valve 46
BRAKE MASTER CYLINDER 48
BRAKE PEDAL AND BRAKE BOOSTER (MASTER VAC) 50
FRONT WHEEL BRAKE
< FE639 : DISC BRAKE > 52
< FE649 : DISC BRAKE > 56
REAR WHEEL BRAKE
< FE639 : DRUM BRAKE > 60
< FE649 : DISC BRAKE > 68
VACUUM PUMP 72
LOAD SENSING VALVE 74
EXHAUST BRAKE SYSTEM 76
GROUP 36 PARKING BRAKE
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 4
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Adjustment of Parking Brake Shoe Clearance
and Ratchet Bar Pulling Stroke 5
PARKING BRAKE CONTROL 6
PARKING BRAKE ASSEMBLY 8
BACKING PLATE AND SHOE ASSEMBLY 10
GROUP 37 STEERING
SPECIFICATIONS 37- 2
STRUCTURE AND OPERATION 37- 3
TROUBLESHOOTING 37- 8
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Change of Power Steering Fluid 37- 11
• Bleeding of Power Steering System 37- 12
• Steering Wheel Play 37- 12
• Performance Verification Test of Power Steering System 37- 13
STEERING SYSTEM 37- 14
STEERING COLUMN SUBASSEMBLY 37- 20
POWER STEERING BOOSTER
< FE > 37- 24
< FG > 37- 30
POWER STEERING OIL PUMP 37- 36
POWER STEERING OIL TANK 37- 40
POWER STEERING FLUID LINE 37- 41
DRAG LINK 37- 42
TIE ROD ASSEMBLY 37- 44
GROUP 37 STEERING
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 8
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Change of Power Steering Fluid 11
• Bleeding of Power Steering System 12
• Steering Wheel Play 12
• Performance Verification Test of Power Steering System 13
STEERING SYSTEM 14
STEERING COLUMN SUBASSEMBLY 18
POWER STEERING BOOSTER 22
POWER STEERING OIL PUMP 28
POWER STEERING OIL TANK 32
POWER STEERING FLUID LINE 33
DRAG LINK 34
TIE ROD ASSEMBLY 36
GROUP 41 FRAME
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
INSPECTION AND REPAIR OF FRAMES 2
GROUP 42 CAB
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 13
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Adjustment of Cab Tilt 17
• Adjustment of Door Fitting 18
REMOVAL AND INSTALLATION OF CAB 20
FRONT CAB MOUNTING 28
REAR CAB MOUNTING 30
CAB TILT LINK 32
DOOR 35
CAB EXTERIOR FITTING 40
MIRROR 44
WIPER AND WASHER 46
CAB INTERIOR FITTING 49
INSTRUMENT PANEL 51
WINDOW GLASS 54
SPECIFICATIONS < ALTERNATOR > 54 -2
STRUCTURE AND OPERATION < ALTERNATOR > 54- 3
TROUBLESHOOTING 54- 5
100 ON-VEHICLE INSPECTION AND ADJUSTMENT 54- 6
106 ALTERNATOR 54- 8
401 METER CLUSTER 54- 16
810 FOUR-WHEEL DRIVE CIRCUIT 54- 18
GROUP 55B HEATER
SPECIFICATIONS 2
STRUCTURE AND OPERATION 3
TROUBLESHOOTING 9
HEATER HOSE 10
HEATER CONTROL 12
AIR DUCT 15
HEATER UNIT AND BLOWER ASSEMBLY 16
GROUP 14 COOLING
SPECIFICATIONS 2
STRUCTURE AND OPERATION 2
TROUBLESHOOTING 6
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Replacing Coolant and Cleaning Cooling System 8
• Air Bleeding of Cooling System 10
• Gas Leakage Test 10
RADIATOR 12
COOLING FAN AND V-BELT 14
WATER PUMP 18
THERMOSTAT 20
GROUP 14A COOLING
SPECIFICATIONS 14A- 2
STRUCTURE AND OPERATION 14A- 2
TROUBLESHOOTING 14A- 4
ON-VEHICLE INSPECTION AND ADJUSTMENT 14A- 6
• Replacing Coolant and Cleaning Cooling System 14A- 6
• Air Bleeding of Cooling System 14A- 8
• Gas Leak Testing 14A- 8
RADIATOR 14A-10
COOLING FAN, V-RIBBED BELT AND WATER PUMP 14A-18
WATER HOSE & PIPE 14A-24
THERMOSTAT 14A-26
GROUP 23 AUTOMATIC TRANSMISSION
SPECIFICATIONS 23- 2
STRUCTURE AND OPERATION 23- 4
TROUBLESHOOTING PROCEDURES 23-40
TROUBLESHOOTING 23-42
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Stall Test 23-52
• Time Lag Test 23-53
• Line Pressure Test 23-54
• Road Test 23-56
• Inspection of Automatic Transmission Fluid 23-58
• Changing Automatic Transmission Fluid 23-59
REMOVAL AND INSTALLATION OF AUTOMATIC
TRANSMISSION ASSEMBLY 23-60
OIL COOLER 23-65
AUTOMATIC TRANSMISSION CONTROL 23-68
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS 23-78
INSPECTION AND ADJUSTMENT OF OTHER DEVICES 23-84
GROUP 31 WHEEL AND TIRE
SPECIFICATIONS 2
TROUBLESHOOTING 2
WHEEL AND TIRE 3
GROUP 35A ANTI-LOCK BRAKE SYSTEM (ABS)
SPECIFICATIONS 35A- 2
STRUCTURE AND OPERATION 35A- 2
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Periodic Inspection Procedures 35A- 9
• Inspection of Wheel Speed Sensor Signal Waveform
Using Oscilloscope 35A-10
• Hydraulic Unit Operation Check35A-11
TROUBLESHOOTING
• Troubleshooting Procedures 35A-13
• Diagnosis Code Indication 35A-14
• Diagnosis Code Chart 35A-17
• Actuator Drive Chart 35A-17
• Service Data 35A-18
WHEEL SPEED SENSOR AND ROTOR
< FRONT AXLE : DISC BRAKE > 35A-20
< FRONT AXLE : DRUM BRAKE > 35A-24
< REAR AXLE : DISC BRAKE > 35A-30
< REAR AXLE : DRUM BRAKE > 35A-36
ELECTRIC CIRCUIT AND PART INSTALLATION
LOCATIONS 35A-42
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