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2002-2004 Mitsubishi Fuso Canter Fe Gf 4m5 4d3 Full Service Repair Manual – PDF Download
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2002-2004 Mitsubishi Fuso Canter Fe Gf 4m5 4d3 Full Service Repair Manual
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Description
2002-2004 Mitsubishi Fuso Canter Fe Gf 4m5 4d3 Full Service Repair Manual
FILE DETAILS:
2002-2004 Mitsubishi Fuso Canter Fe Gf 4m5 4d3 Full Service Repair Manual
LANGUAGE:ENGLISH
PAGES:1599
DOWNLOADABLE:YES
FILE TYPE:PDF
2002-2004 MITSUBISHI FUSO CANTER FE GF 4M5 4D3 FULL SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
2002-2004 Mitsubishi Fuso Canter Fe Gf 4m5 4d3 Full Service Repair Manual
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.
TABLE OF CONTENTS:
2002-2004 Mitsubishi Fuso Canter Fe Gf 4m5 4d3 Full Service Repair Manual
'02-'04 S/M................................................................................ 0 FE-FG...................................................................................... 0 Forward................................................................................ 1 How to Read this Manual................................................................ 2 Index.............................................................................. 3 How This Manual Is Structured...................................................... 4 Terms.............................................................................. 17 Group 00 - General..................................................................... 18 Index.............................................................................. 19 Model Coding System................................................................ 20 Power Train Table.................................................................. 21 Chassis No. & Engine No./Power Train Label......................................... 22 Vehicle Identification No.......................................................... 23 Precautions for Maintenance Operation.............................................. 24 Table of Standard Tightening Torques............................................... 36 Connector Configuration Chart...................................................... 40 Group 01 - Maintenance Schedule........................................................ 82 Index.............................................................................. 83 How To Read the Maintenance Schedule Tables........................................ 84 Maintenance Schedule Tables........................................................ 86 Maintenance Operations............................................................. 88 Lubrication Tables................................................................. 110 Lubrication........................................................................ 112 Group 11A - Engine <4M5>............................................................... 130 Index.............................................................................. 131 Specifications..................................................................... 132 Structure & Operation.............................................................. 134 Troubleshooting.................................................................... 144 On-Vehicle Inspection & Adjustment................................................. 146 Removal & Installation of Engine................................................... 150 Rocker Cover, Rocker Assemblies & Camshafts........................................ 154 Cylinder Head & Valve Mechanism.................................................... 168 Front Case......................................................................... 182 Timing Gears & Balance Shafts...................................................... 186 Pistons, Connecting Rods & Cylinder Liners......................................... 194 Flywheel........................................................................... 206 Crankshaft & Crankcase............................................................. 210 Balance Shaft Bushings............................................................. 0 Group 11B - Engine <4D3>............................................................... 223 Index.............................................................................. 224 Specifications..................................................................... 225 Structure & Operation.............................................................. 226 Troubleshooting.................................................................... 229 Inspection & Adjustment Mounted in Vehicle......................................... 230 Removal & Installation of Engine................................................... 235 Cylinder Head & Valve Mechanism.................................................... 239 Timing Gear........................................................................ 253 Camshaft........................................................................... 257 Piston, Connecting Rods & Cylinder Sleeve.......................................... 263 Flywheel <Without Flywheel Power Take-Off>......................................... 277 Flywheel <With Flywheel Power Take-Off>............................................ 281 Crankshaft & Crankcase............................................................. 289 Group 12A - Lubrication <4M5>.......................................................... 296 Index.............................................................................. 297 Specifications..................................................................... 298 Structure & Operation.............................................................. 300 Troubleshooting.................................................................... 309 On-Vehicle Inspection & Adjustment................................................. 310 Oil Pan, Oil Strainer & Oil Jet.................................................... 314 Oil Pump........................................................................... 316 Oil Filter......................................................................... 320 Oil Cooler......................................................................... 322 Group 12B - Lubrication <4D3>.......................................................... 325 Index.............................................................................. 326 Specifications..................................................................... 327 Structure & Operation.............................................................. 328 Troubleshooting.................................................................... 335 Inspection & Adjustment Mounted in Vehicle......................................... 336 Oil Pan, Oil Strainer & Oil Jet.................................................... 339 Oil Pump........................................................................... 341 Oil Cooler & Oil Filter............................................................ 345 Group 13A - Fuel & Engine Control <4M5>................................................ 347 Index.............................................................................. 348 Specifications..................................................................... 349 Structure & Operation.............................................................. 350 On-Vehicle Inspection & Adjustment................................................. 353 Engine Control..................................................................... 357 Fuel Tank.......................................................................... 361 Fuel Filter........................................................................ 362 Injection Pump..................................................................... 363 Injection Nozzle................................................................... 367 Group 13B - Fuel & Engine Control <4D3>................................................ 376 Index.............................................................................. 377 Specifications..................................................................... 378 Structure & Operation.............................................................. 379 Troubleshooting.................................................................... 384 On-Vehicle Inspection & Adjustment................................................. 386 Engine Control..................................................................... 390 Fuel Tank.......................................................................... 396 Fuel Filter........................................................................ 397 Water Separator.................................................................... 398 Injection Pump..................................................................... 400 Injection Nozzle................................................................... 404 Group 13EA - Electronically Controlled Fuel System <4M5>............................... 408 Index.............................................................................. 409 Specifications..................................................................... 410 Structure & Operation.............................................................. 411 Troubleshooting.................................................................... 422 Inspection of Electrical Equipment................................................. 444 Locations of Parts................................................................. 452 Electrical Wiring Diagram.......................................................... 456 Group 13EB - Electronically Controlled Fuel System <4D3>............................... 457 Index.............................................................................. 458 Structure & Operation.............................................................. 459 Troubleshooting.................................................................... 477 Inspection of Electrical Equipment................................................. 488 Locations of Parts................................................................. 496 Electrical Wiring Diagram.......................................................... 497 Group 14A - Cooling <4M5>.............................................................. 498 Index.............................................................................. 499 Specifications/Structure & Operation............................................... 500 Troubleshooting.................................................................... 502 On-Vehicle Inspection & Adjustment................................................. 504 Radiator........................................................................... 508 Cooling Fan, V-Ribbed Belt, V-Belt & Water Pump.................................... 516 Water Hose & Pipe.................................................................. 520 Thermostat......................................................................... 522 Group 14B - Cooling <4D3>.............................................................. 524 Index.............................................................................. 525 Specifications/Structure & Operations.............................................. 526 Troubleshooting.................................................................... 528 Inspection & Adjustment Mounted In Vehicle......................................... 530 Radiator........................................................................... 534 Cooling Fan & V-Belt............................................................... 536 Water Pump......................................................................... 540 Thermostat......................................................................... 542 Group 15A - Intake & Exhaust <4M5>..................................................... 545 Index.............................................................................. 546 Specifications/Structure & Operation............................................... 547 Troubleshooting.................................................................... 549 On-Vehicle Inspection & Adjustment................................................. 550 Air Duct & Air Cleaner <Except Crew Cab>........................................... 553 Air Duct & Air Cleaner <Crew Cab>.................................................. 557 Turbocharger....................................................................... 560 Intercooler........................................................................ 565 Intake Manifold.................................................................... 567 Exhaust Manifold................................................................... 569 Exhaust Pipe & Muffler............................................................. 571 Group 15B - Intake & Exhaust <4D3>..................................................... 573 Index.............................................................................. 574 Specifications/Structure & Operation............................................... 575 Troubleshooting.................................................................... 578 Inspection & Adjustment Mounted In Vehicle......................................... 579 Air Duct & Air Cleaner............................................................. 581 Turbocharger....................................................................... 585 Intercooler........................................................................ 591 Intake Manifold.................................................................... 593 Exhaust Manifold................................................................... 595 Exhaust Pipe & Muffler............................................................. 597 Group 21 - Clutch...................................................................... 599 Index.............................................................................. 600 Specifications/Structure & Operation............................................... 601 Troubleshooting.................................................................... 604 Inspection & Adjustment Mounted In Vehicle......................................... 605 Clutch Pedal....................................................................... 609 Clutch Master Cylinder............................................................. 611 Clutch Power Cylinder.............................................................. 613 Work Before Removal & Installation of Clutch Body.................................. 615 Clutch Body........................................................................ 617 Clutch Control..................................................................... 621 Group 22 - Manual Transmission......................................................... 622 Index.............................................................................. 623 Specifications/Structure & Operations.............................................. 624 Troubleshooting.................................................................... 627 Work Before Removal & Installation of Transmission Assembly........................ 629 Removal & Installation of Transmission Assembly.................................... 630 Gear Shifter Upper................................................................. 632 Rear Cover & Reverse Idler Gear.................................................... 638 Transmission Body.................................................................. 642 Drive Pinion Assembly.............................................................. 650 Mainshaft Assembly................................................................. 652 Countershaft Assembly.............................................................. 658 Transmission Control............................................................... 662 Group 23 - Automatic Transmission...................................................... 675 Index.............................................................................. 676 Specifications..................................................................... 677 Structure & Operation.............................................................. 678 Troubleshooting Procedures......................................................... 715 On-Vehicle Inspection & Adjustment................................................. 727 Removal & Installation of Automatic Transmission Assembly.......................... 735 Oil Cooler......................................................................... 741 Automatic Transmission Control..................................................... 745 Replacement of Automatic Transmission Parts........................................ 755 Inspection & Adjustment of Other Devices........................................... 761 Location of Parts.................................................................. 763 Electrical Wiring Diagram.......................................................... 764 Group 24 - Transfer.................................................................... 766 Index.............................................................................. 767 Specifications/Structure & Operation............................................... 768 Troubleshooting.................................................................... 770 Removal & Installation of Transfer Assembly........................................ 772 Front Drive........................................................................ 776 Idler Gear & Rear Drive............................................................ 782 Transfer Control................................................................... 788 Group 25 - Propeller Shaft............................................................. 796 Index.............................................................................. 797 Specifications..................................................................... 798 Structure & Operation.............................................................. 799 Troubleshooting.................................................................... 800 Removal & Installation of Propeller Shaft <Transmission, Transfer To Rear Axle>.... 802 Removal & Installation of Propeller Shaft <Front Axle To Transfer>................. 803 Rear Propeller Shaft <P2 : FG639>.................................................. 804 Rear Propeller Shaft <P2 : FG649>.................................................. 808 Rear Propeller Shaft <P3>.......................................................... 812 Front Propeller Shaft.............................................................. 816 Balancing Propeller Shaft.......................................................... 820 Group 26A - Front Axle................................................................. 822 Index.............................................................................. 823 Specifications/Structure & Operation............................................... 824 Inspection & Adjustment Mounted In Vehicle......................................... 826 Work Before Removal & Installation of Front Axle................................... 830 Wheel Hub & Rotor.................................................................. 832 Front Axle, Knuckle & Kingpin...................................................... 841 Group 26B - Front Axle................................................................. 848 Index.............................................................................. 849 Specifications/Structure & Operation............................................... 850 Troubleshooting.................................................................... 854 On-Vehicle Inspection & Adjustment................................................. 856 Work Before Removal & Installation of Front Axle................................... 862 Wheel Hub & Brake Drum............................................................. 864 Knuckle & Drive Shaft.............................................................. 874 Axle Housing....................................................................... 880 Reduction & Differential........................................................... 882 Group 27 - Rear Axle................................................................... 895 Index.............................................................................. 896 Specifications..................................................................... 897 Structure & Operation.............................................................. 898 Troubleshooting.................................................................... 902 Work Before Removal & Installation of Rear Axle.................................... 904 Wheel Hub & Brake Drum <FE639, FG>................................................. 905 Wheel Hub & Rotor <FE640, FE649>................................................... 915 Axle Housing....................................................................... 925 Reduction & Differential........................................................... 929 Muliplate Limited Slip Differential Assembly....................................... 943 FEFG group 27 '04 minor changes.pdf................................................ 0 Group 27 - Rear Axle........................................................... 949 Index...................................................................... 950 Specifications............................................................. 951 Structure and Operation.................................................... 952 Troubleshooting............................................................ 956 Work Before Removal and Installation of Rear Axle.......................... 958 Wheel Hub and Brake Drum <FE639, FG>....................................... 959 Wheel Hub and Rotor <FE640, FE649>......................................... 969 Axle Housing............................................................... 979 Reduction and Differential................................................. 983 Multiplate Limited Slip Differential Assembly.............................. 997 Group 31 - Wheel & Tire................................................................1003 Index..............................................................................1004 Specifications/Troubleshooting.....................................................1005 Wheel & Tire.......................................................................1006 Group 33 - Front Suspension............................................................1010 Index..............................................................................1011 Structure & Operation..............................................................1012 Troubleshooting....................................................................1013 Work Before Removal & Installation of Front Suspension.............................1014 Removal & Installation of Leaf Spring Assembly <FE>................................1016 Removal & Installation of Leaf Spring Assembly <FG>................................1018 Leaf Spring Assembly <FE>..........................................................1022 Leaf Spring Assembly <FG>..........................................................1024 Shock Absorber <FE>................................................................1026 Shock Absorber <FG>................................................................1027 Stabilizer <FE>....................................................................1028 Group 34 - Rear Suspension.............................................................1030 Index..............................................................................1031 Structure & Operation..............................................................1032 Troubleshooting....................................................................1033 Work Before Removal & Installation of Rear Suspension..............................1034 Removal & Installation of Leaf Spring Assembly <FE>................................1036 Removal & Installation of Leaf Spring Assembly <FG>................................1040 Leaf Spring Assembly...............................................................1044 Shock Absorber.....................................................................1047 Stabilizer <FE>....................................................................1048 Group 35A - Brake......................................................................1050 Index..............................................................................1051 Specifications.....................................................................1052 Structure & Operation..............................................................1053 Troubleshooting....................................................................1074 On-Vehicle Inspection & Adjustment.................................................1080 Brake Master Cylinder..............................................................1096 Brake Pedal & Brake Booster (Master VAC)...........................................1098 Front Wheel Brake <FE639 (Except FE639 6 : Disc Brake>.............................1100 Front Wheel Brake <FE639 6, FE640 : Disc Brake>....................................1104 Front Wheel Brake <Drum Brake>.....................................................1108 Rear Wheel Brake <Drum Brake>......................................................1114 Rear Wheel Brake <Disc Brake>......................................................1122 Vacuum Pump........................................................................1126 Exhaust Brake System...............................................................1128 Group 35E - Anti-Lock Brake System (ABS)...............................................1132 Index..............................................................................1133 Specifications/Structure & Operation...............................................1134 On-Vehicle Inspection & Adjustment.................................................1147 Troubleshooting....................................................................1151 Electric Circuit & Part Installation Locations.....................................1157 Group 36 - Parking Brake...............................................................1159 Index..............................................................................1160 Specifications/Structure & Operation...............................................1161 Troubleshooting....................................................................1162 Inspection & Adjustment Mounted In Vehicle.........................................1163 Parking Brake Control..............................................................1165 Parking Brake Assembly.............................................................1167 Backing Plate & Shoe Assembly......................................................1169 Group 37 - Steering....................................................................1171 Index..............................................................................1172 Specifications.....................................................................1173 Structure & Operation..............................................................1174 Troubleshooting....................................................................1179 On-Vehicle Inspection & Adjustment.................................................1182 Steering System....................................................................1185 Steering Column Subassembly........................................................1191 Power Steering Booster <FE>........................................................1195 Power Steering Booster <FG>........................................................1201 Power Steering Oil Pump............................................................1207 Power Steering Oil Tank............................................................1211 Power Steering Fluid Line..........................................................1212 Drag Link..........................................................................1213 Tie Rod Assembly...................................................................1215 FEFG group 37 - '04 minor changes.pdf.............................................. 0 Group 37 - Steering............................................................1217 Index......................................................................1218 Specifications.............................................................1219 Structure and Operation....................................................1220 Troubleshooting............................................................1225 On-Vehicle Inspection and Adjustment.......................................1228 Steering System............................................................1231 Steering Column Subassembly................................................1237 Power Steering Booster.....................................................1241 Power Steering Oil Pump....................................................1247 Power Steering Oil Tank....................................................1251 Power Steering Fluid Line..................................................1252 Drag Link..................................................................1253 Tie Rod Assembly...........................................................1255 Group 41 - Frame.......................................................................1257 Index..............................................................................1258 Specifications/Structure & Operation/Inspection & Repair of Frames.................1259 Inspection & Repair of Frames......................................................1261 Group 42 - Cab.........................................................................1264 Index..............................................................................1265 Specifications.....................................................................1266 Structure & Operation..............................................................1267 Troubleshooting....................................................................1276 Inspection & Adjustment Mounted In Vehicle.........................................1281 Removal & Installation of Cab <Tilt Cab>...........................................1285 Removal & Installation of Cab <Fixed Cab>..........................................1292 Front Cab Mounting.................................................................1300 Rear Cab Mounting..................................................................1304 Cab Tilt Link......................................................................1306 Door...............................................................................1309 Front Door.........................................................................1310 Rear Door <Crew Cab>...............................................................1315 Cab Exterior Fitting...............................................................1318 Mirror.............................................................................1322 Wiper & Washer.....................................................................1324 Cab Interior Fitting...............................................................1328 Instrument Panel...................................................................1330 Window Glass.......................................................................1334 Group 54 - Electrical..................................................................1336 Index..............................................................................1337 How To Read This Group.............................................................1340 0-General..........................................................................1344 Specifications.................................................................1345 Structure & Operation..........................................................1349 Troubleshooting................................................................1369 1-Power, Charge & Ground Circuit...................................................1377 110-Power Circuit..............................................................1378 115-Reserve Power Circuit......................................................1387 125-Battery Charging Circuit...................................................1388 130-Ground.....................................................................1390 2-Starting & Preheating Circuit....................................................1396 210-Engine Starting Circuit....................................................1397 220-Engine Preheating Circuit..................................................1399 225-Engine Warm-Up Circuit.....................................................1400 3-Lighting Circuit.................................................................1402 310-Headlamp Circuit...........................................................1403 313-Daytime Running Light Circuit..............................................1405 320-Tail, Clearance & License Plate Lamp Circuit...............................1407 325-Stop Lamp Circuit..........................................................1408 330-Turn Signal & Hazard Lamp Circuit..........................................1409 340-Backup Lamp Circuit........................................................1410 345-Cab Lamp Circuit...........................................................1412 348-Illumination Lamp Circuit..................................................1413 349-Marker & Identification Lamp Circuit.......................................1414 352-Van Body Dome Light Circuit................................................1415 4-Meter Circuit....................................................................1416 401-Meter Cluster Internal Circuit.............................................1417 410-Tachometer Circuit.........................................................1419 412-Speed Sensor Circuit.......................................................1421 420-Fuel Gauge Circuit.........................................................1422 425-Water Temperature Gauge Circuit............................................1423 5-Indicator & Warning Lamp Circuit.................................................1424 510-Parking Brake Indicator Circuit............................................1425 515-Brake Warning Circuit......................................................1426 535-Engine Oil Level & Oil Pressure Warning Circuit............................1427 537-Overheating Warning Circuit................................................1428 540-Brake PadWarning Circuit...................................................1429 550-Cab Tilt Warning Circuit...................................................1430 566-Fuel Filter Warning Circuit................................................1431 6-Cab Side Electrical Circuit......................................................1432 610-Cigarette Lighter Circuit..................................................1433 612-Audio Circuit..............................................................1434 614-Wiper & Washer Circuit.....................................................1435 616-Horn Circuit...............................................................1436 618-Heater Circuit.............................................................1437 622-Power Window & Auto Door Lock Circuit......................................1438 629-Mirror Heater Circuit......................................................1439 7-Chassis Side Electrical Circuit..................................................1440 710-Exhaust Brake Circuit......................................................1441 8-Engine & Transmission Side Electrical Circuit....................................1444 810-Four-Wheel Drive Circuit...................................................1445 850-Transmission Power Take-Off Circuit........................................1446 9-Others Circuit...................................................................1447 910-Multipurpose Timing Control Unit Circuit...................................1448 10-Parts Installation Position.....................................................1450 A-Switch.......................................................................1451 B-Relay & Electronic Control Unit..............................................1453 C-Fuse, Meter, Sensor & Motor..................................................1455 D-Heater & Air-Conditioner.....................................................1457 E-Door.........................................................................1459 F-Roof.........................................................................1460 J-Joint of Main Harness Connectors.............................................1461 R-Engine.......................................................................1463 S-Transmission.................................................................1465 T-Switch & Sensor..............................................................1466 U-Battery, Fuse & Connector....................................................1467 V-Magnetic Valve, Motor & Actuator.............................................1467 W-Buzzer & Lamp................................................................1467 11-Inspection of Parts.............................................................1468 001 to 179 Switch..............................................................1469 180 to 249 Switch..............................................................1475 250 to 349 Sensor..............................................................1478 350 to 409 Control Unit........................................................1480 410 to 509 Motor...............................................................1481 510 to 559 Actuator............................................................1483 560 to 609 Magnetic Valve......................................................1484 610 to 649 Buzzer & Horn.......................................................1485 650 to 699 Lamp................................................................1486 750 to 859 Other...............................................................1487 860 Battery....................................................................1489 870 to 889 Fuse................................................................1493 890 Meter Cluster..............................................................1497 12-Starter & Alternator............................................................1500 930 Starter <4D3>..............................................................1501 930 Starter <4M5>..............................................................1515 940 Alternator <4D3>...........................................................1529 940 Alternator <4M5>...........................................................1535 950 Inspection of Alternator...................................................1541 951 Inspection of Regulator....................................................1542 13-On-Vehicle Inspection & Adjustment..............................................1543 955 Inspection of Preheating System............................................1544 960 Headlamp Aiming............................................................1546 965 Inspection of Brake Fluid Level Switch.....................................1548 Group 55A - Air-conditioner............................................................1549 Forward & Table of Contents........................................................1550 Specifications.....................................................................1551 Outlines of Refrigeration System...................................................1552 Construction.......................................................................1554 Troubleshooting....................................................................1561 Removal & Installation.............................................................1568 Treatment After Installation.......................................................1571 Maintenance........................................................................1577 Cooling Unit Assembly..............................................................1578 Compressor & Clutch Assembly.......................................................1580 Group 55B - Heater.....................................................................1583 Index..............................................................................1584 Specifications.....................................................................1585 Structure & Operation..............................................................1586 Troubleshooting....................................................................1592 Heater Hose........................................................................1593 Heater Control.....................................................................1595 Air Duct...........................................................................1598 Heater Unit & Blower Assembly......................................................1599
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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