2008 Mitsubishi Fuso Truck FE FG FK FM Series Service Manual – PDF DOWNLOAD
DESCRIPTION:
2008 Mitsubishi Fuso Truck FE FG FK FM Series Service Manual – PDF DOWNLOAD
FOREWORD:
This Service Manual contains maintenance and repair methods for the Mitsubishi Fuso Truck FE. FG FK FM 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 continued vehicle improvements that are made throughout the model years.
TABLE OF CONTENTS:
2008 Mitsubishi Fuso Truck FE FG FK FM Series Service Manual – PDF DOWNLOAD
2008 Service Manual 1
2008 FE/FG Service Manual 2
Group 00 – General 3
Table of Contents 4
Equipment Type Codes List 5
Power Train Table 6
How To Read This Manual 7
Chassis Number, Engine Number, Power Train Label 11
Vehicle Identification Number 12
Precautions for Maintenance Operation 13
Jacking Up the Vehicle 25
Diagnosis Codes 27
1 Diagnosis Codes 27
2 Reading and Erasing the Diagnosis Code 28
Table of Standard Tightening Torques 33
Group 01 – Maintenance Schedule 36
Table of Contents 37
How to Read the Maintenance Schedule Tables 38
Maintenance Schedule Tables 40
Maintenance Operations 44
Lubrication Tables 50
Lubrication 52
Group 11 – Engine 56
Table of Contents 57
Specifications 58
Structure and Operation 59
1 Exploded View 59
2 Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame 60
3 Valve Mechanism 61
4 Connecting Rod 62
5 Piston 62
6 Timing Gears 63
7 Flywheel 63
8 Balance Shafts 64
9 Crankcase and Main Bearings 65
10 Oil Seals 67
Troubleshooting 68
On-Vehicle Inspection and Adjustment 70
1 Measuring Compression Pressure 70
2 Inspection and Adjustment of Valve Clearances 72
3 Removal and Installation of Injector <Crew Cab (Fixed Type)> 74
Engine Removal and Installation 76
<Tilt Cab> 76
<Fixed Cab> 84
Rocker Cover 86
Rockers and Camshafts 88
Cylinder Head and Valve Mechanism 102
Pistons, Connecting Rod and Cylinder Liners 118
Flywheel 132
Front Case 136
Timing Gears and Balance Shafts 140
Crankshaft and Crankcase 148
Balance Shaft Bushings 156
Group 12 – Lubrication 161
Table of Contents 162
Specifications 163
Structure and Operation 164
1 Lubrication System 164
2 Oil Pump 165
3 Oil Cooler 166
4 Oil Filter 167
5 Lubrication of Engine Components 168
Troubleshooting 171
On-Vehicle Inspection and Adjustment 173
1 Oil Filter Replacement 173
2 Engine Oil Replacement 177
3 Engine Oil Level Inspection 179
4 Oil Pressure Measurement 180
Oil Pan, Oil Strainer and Oil Jets 181
Oil Pump 183
Oil Filter 187
Oil Cooler 191
Group 13A – Fuel and Engine Control 193
Table of Contents 194
Specifications 195
Structure and Operation 196
1 Fuel System (Flow of Fuel) 196
2 Engine Control 197
3 Fuel Filter 198
Troubleshooting 199
On-Vehicle Inspection and Adjustment 201
1 Inspecting and Adjusting No-Load Minimum and Maximum Speeds 201
2 Air-Bleeding of Fuel System 202
3 Fuel Filter Replacement 203
Fuel Tank 205
<Outside Frame Type> 205
<Inside Frame Type> 207
Fuel Filter 209
Engine Control 213
Common Rail 217
Supply Pump 221
Injector 225
Group 13EA – Common Rail System 228
Table of Contents 229
Specifications 230
Structure and Operation 231
1 Overview 231
2 Electronic Control System 240
3 Electronic Control Unit Connection Diagram 248
Troubleshooting 250
1 Diagnosis Procedure 250
2 Diagnostic Precautions 250
3 Inspection Based on Fault Codes 251
4 Multi-Use Tester Service Data1192
5 Mode 06 Data1196
6 Actuator Tests Performed Using Multi-Use Tester1198
Registration and Alteration of Data In Engine Electronic Control Unit1202
1 Operation at Electronic Control Unit Replacement1202
2 Resetting the Diesel Particulate Filter Related Information (Resetting Electronic Control Unit)1202
Inspection of Electrical Equipment1204
Installed Locations of Parts1214
Electric Circuit Diagram1220
Group 13EB – Auto Cruise and Vehicle Speed Limitation System1225
Table of Contents1226
Structure and Operation1227
1 General Description1227
2 Electronic Control System1227
3 Electronic Control Unit Connection Diagram1231
Troubleshooting1233
1 Diagnosis Procedure1233
2 Diagnostic Precautions1234
3 Inspection Based on Diagnosis Codes1235
4 Multi-Use Tester Service Data1239
5 Actuator Tests Performed Using Multi-Use Tester1240
6 Works Required When Replacing the Multifunction Vehicle Control Unit (MVCU)1240
7 Inspection Performed at Electronic Control Unit Connectors1241
Inspection of Electrical Equipment1242
Installed Locations of Parts1243
Electric Circuit Diagram1247
Group 14 – Cooling1249
Table of Contents1250
Specifications1251
Structure and Operation1253
1 Cooling System (Flow of Coolant)1253
2 Thermostat1254
3 Water Pump1254
Troubleshooting1255
On-Vehicle Inspection and Adjustment1257
1 Inspection and Adjustment of Belt Tension1257
2 Inspection of Cracks or Damage of the Belt1262
3 Coolant Replacement and Cleaning of Cooling System1263
4 Air Bleeding of Cooling System1265
5 Air/Gas Leakage Test1265
Disconnection and Connection of Hoses and Pipes1267
Radiator, Fan Shroud1271
Cooling fan, Belt and Water Pump1279
Tension Pulley1282
Thermostat1283
Pressure Cap and Water Outlet Case1285
Group 15 – Intake and Exhaust1287
Table of Contents1288
Specifications1289
Structure and Operation1289
1 Air Cleaner1289
2 Turbocharger1290
3 Turbocharger Control System1291
4 Diesel Particulate Filter Regeneration Control System1295
Troubleshooting1305
On-Vehicle Inspection and Adjustment1307
1 Measurement of Turbocharger Boost Pressure1307
2 Cleaning and Inspection of Air Cleaner Element1308
3 Diesel Particulate Filter Unit Inspection for Clogging and Cleaning the Diesel Particulate Filter Unit1309
4 Resetting the DPF-Related Information (Resetting Electronic Control Unit)1313
Air Duct and Air Cleaner1317
<Except Crew Cab>1317
<Crew Cab>1321
Turbocharger1325
Intercooler1331
Intake Manifold1335
Exhaust Manifold1337
Exhaust Pipe1339
Diesel Particulate Filter1341
Group 17 – Emission Control1347
Table of Contents1348
Structure and Operation1349
1 Exhaust Gas Recirculation System1349
2 Crankcase Emission Control System1354
Exhaust Gas Recirculation Valve, Pipe and Cooler1355
Crankcase Emission Control System1359
Group 21 – Clutch1362
Table of Contents1363
Specifications1364
Structure and Operation1365
1 Clutch Control1365
2 Clutch Master Cylinder1366
3 Clutch Proper and Clutch Direct Power Cylinder1368
Troubleshooting1370
On-Vehicle Inspection and Adjustment1372
1 Replacement of Brake Fluid (Clutch System)1372
2 Air Bleeding of Brake Fluid (Clutch System)1374
3 Inspection of Clutch Disc Wear Limit1376
Clutch Pedal1378
Clutch Master Cylinder1382
Clutch Proper1384
Clutch Control1388
Group 22 – Manual Transmission1393
Table of Contents1394
Specifications1395
Structure and Operation1397
1 Transmission1397
2 Synchromesh Mechanism1399
3 Interlock Mechanism1402
4 Speedometer Gear Bushing1402
Troubleshooting1403
On-Vehicle Inspection and Adjustment1405
1 Inspection of Transmission Oil Leak1405
2 Inspection of Looseness in Transmission Mounting Bolts1405
3 Inspection of Play In Companion Flange and Looseness in Lock Nut1406
4 Inspection and Replacement of Transmission Oil1406
Removal and Installation of Transmission1409
Gear Shifter Upper1413
Rear Cover <S5> and Parking Brake1419
Extension Housing <S6> and Parking Brake1423
Reverse Idler Gear1429
6th Gear <S6>1433
Transmission Body1439
Drive Pinion1455
Mainshaft1457
Countershaft1467
Transmission Control1469
Bearing Puller and Installer1473
Group 23 – Automatic Transmission1474
Table of Contents1475
Specifications1476
Structure and Operation1477
1 Overview1477
2 Electronic Control System1483
3 Electronic Control Unit Connection Diagram1488
Troubleshooting1490
1 Diagnosis Procedure1490
2 Diagnostic Precautions1490
3 Inspections Based on Diagnosis Codes1491
4 Multi-Use Tester Service Data1789
5 Possible Causes of Symptoms1792
On-Vehicle Inspection and Adjustment1796
1 Inspection of Automatic Transmission Oil Leakage1796
2 Check for Looseness in Automatic Transmission Mounting Bolts1796
3 Inspection of Play in Companion Flange and Looseness in Lock Nut1797
4 Inspection of Automatic Transmission Fluid1797
5 Replacement of Automatic Transmission Fluid1798
6 Stall Test1800
7 Time Lag Test1801
8 Line Pressure Test1802
9 Road Test1804
10 Dealer Adjust1805
Removal and Installation of Automatic Transmission1808
Parking Brake1814
Automatic Transmission Control1816
Oil Cooler1826
<Except Crew Cab>1826
<Crew Cab>1828
Replacement of Part of Automatic Transmission Main Body1830
Inspection of Electrical Equipment1834
Installed Locations of Parts1838
Electric Circuit Diagram1842
Group 24 – Transfer1846
Table of Contents1847
Specifications1848
Structure and Operation1849
1 Transfer1849
2 Speedometer Gear Bushing1850
Troubleshooting1851
On-Vehicle Inspection and Adjustment1852
1 Inspection of Looseness in Transmission and Transfer Mounting Bolts1852
2 Inspection of Play and Looseness in Companion Flange1852
3 Inspection and Replacement of Transfer Oil1853
Removal and Installation of Transmission (With Transfer)1854
Removal and Installation of Transfer1858
Front Drive1860
Rear Drive1866
Transfer1872
Transfer Control (High-Low Switching)1880
Group 25 – Propeller Shaft1884
Table of Contents1885
Specifications1886
Structure and Operation1886
1 Configuration of Propeller Shaft Connection1886
2 Propeller Shaft <Without Center Bearing>1887
3 Propeller Shaft <With Center Bearing>1888
Troubleshooting1889
Removal and Installation of Propeller Shaft1890
<Between T/M (or T/F) and Rear Axle>1890
<Between Front Axle and T/F>1892
Propeller Shaft1894
<P2>1894
<P3>1900
Group 26A – Front Axle <FE>1911
Table of Contents1912
Specifications1913
Structure and Operation1914
1 Wheel Hub and Rotor1914
2 Knuckle and Kingpin, Front Axle1915
Troubleshooting1916
On-Vehicle Inspection and Adjustment1917
1 Inspection and Adjustment of Wheel Alignment1917
2 Inspection and Adjustment of Steering Angle1921
3 Inspection of Side Slip1922
4 Inspection of Tie Rod End Ball Joint1922
Wheel Hub and Rotor1923
Knuckle and Kingpin, Front Axle1933
Tie Rod1941
Group 26B – Front Axle <FG>1943
Table of Contents1944
Specifications1945
Structure and Operation1945
1 Wheel Hub and Brake Drum1945
2 Free Wheel Hub1946
3 Drive Shaft and Steering Knuckle, Axle Housing1947
4 Reduction and Differential1948
Troubleshooting1949
On-Vehicle Inspection and Adjustment1953
1 Inspection and Adjustment of Wheel Alignment1953
2 Inspection and Adjustment of Steering Angle1957
3 Inspection of Side Slip1957
4 Inspection of Tie Rod End Ball Joint1958
5 Inspection and Replacement of Axle Oil1958
Wheel Hub and Brake Drum1961
Drive Shaft and Steering Knuckle1973
Tie Rod1979
Axle Housing1981
Reduction and Differential1983
Group 27 – Rear Axle1998
Table of Contents1999
Specifications2000
Structure and Operation2001
1 Wheel Hub and Rotor2001
2 Wheel Hub and Brake Drum2002
3 Reduction and Differential2003
4 Limited Slip Differential2004
Troubleshooting2006
On-Vehicle Inspection and Adjustment2008
1 Inspection and Replacement of Axle Oil2008
Wheel Hub and Rotor2010
Wheel Hub and Brake Drum2020
Axle Housing2032
Reduction and Differential2036
Group 31 – Wheel and Tire2063
Table of Contents2064
Specifications2065
Troubleshooting2066
Wheel and Tire2067
Group 33 – Front Suspension2072
Table of Contents2073
Structure and Operation2074
1 Front Suspension Elements2074
Troubleshooting2075
Stabilizer2076
Shock Absorber2078
<FE>2078
<FG>2080
Leaf Spring2082
<FE>2082
<FG>2086
Group 34 – Rear Suspension2090
Table of Contents2091
Structure and Operation2092
1 Rear Suspension Elements2092
Troubleshooting2093
Shock Absorber2094
Leaf Spring2096
Stabilizer2112
Group 35A – Brake2115
Table of Contents2116
Specifications2117
Structure and Operation2119
1 Brake System2119
2 Vacuum Pump2122
3 Vacuum Booster and Brake Master Cylinder <Except FE85>2123
4 Hydraulic Booster and Brake Master Cylinder <FE85>2129
5 Flow Priority Valve <FE85>2135
6 Front Disc Brake <FE>2136
7 Front Drum Brake <FG>2137
8 Rear Disc Brake <FE>2140
9 Rear Drum Brake <FG>2141
10 Exhaust Brake System <FE>2142
Troubleshooting2145
On-Vehicle Inspection and Adjustment2149
1 Replacement of Brake Fluid2149
2 Air Bleeding of Brake System2151
3 Inspection and Adjustment of Brake Pedal Free Play2155
4 Inspection and Adjustment of Brake Pedal Pressed Height from Floor2155
5 Inspection of Brake Pedal Full Stroke and Adjustment of Installed Height of Brake Pedal2156
6 Inspection and Replacement of Disc Brake Pad <FE>2157
7 Measurement of Disc Brake Drag Torque <FE>2160
8 Inspection of Drum Brake Lining Thickness <FG>2160
9 Initial Setting of Clearance Between Brake Drum and Shoe <FG>2161
10 Inspection of Check Valve in Vacuum Line Hose2162
11 Inspection of Vacuum Pump2162
12 Inspection of Vacuum Booster <Except FE85>2163
13 Inspection of Hydraulic Booster <FE85>2168
Vacuum Pump2170
Brake Master Cylinder2171
<With Vacuum Booster>2171
<With Hydraulic Booster>2175
Brake Pedal & Vacuum Booster, Hydraulic Booster2177
Front Disc Brake2179
<235 mm {925 in} Disc>2179
<252 mm {992 in} Disc>2183
Front Drum Brake2187
Rear Disc Brake2193
<235 mm {925 in} Disc>2193
<252 mm {992 in} Disc>2195
Rear Drum Brake2197
Exhaust Brake System2203
Group 35E – Anti-Lock Brake System (ABS)2205
Table of Contents2206
Specifications2207
Structure and Operation2209
1 Overview2209
2 Electronic Control System2219
3 Electronic Control Unit Schematic Diagram2223
Troubleshooting2225
1 Diagnosis Procedure2225
2 Diagnostic Precautions2225
3 Diagnosis Based on Diagnosis Codes2226
4 Multi-Use Tester Service Data2232
5 Actuator Test Using Multi-Use Tester2234
6 Inspection at Hydraulic Unit (Electronic Control Unit) Connector2235
On-Vehicle Inspection and Adjustment2237
1 Functional Check2237
2 Inspection of Hydraulic Unit (Electronic Control Unit) Operation2238
3 Inspection After Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)2239
4 Oscilloscopic Inspection Through Wheel Speed Sensor Signal Waveform2240
Hydraulic Unit Connector Coupling and Uncoupling2241
Inspection of Electrical Components2243
Components Location2245
Electrical Wiring Diagram2247
Group 36 – Parking Brake2249
Table of Contents2250
Specifications2251
Structure and Operation2252
1 Components and Parts2252
2 Parking Brake Lever2252
3 Parking Brake2253
Troubleshooting2254
On-Vehicle Inspection and Adjustment2255
1 Adjustment of Parking Brake Shoe Clearance2255
2 Inspection and Adjustment of Parking Brake Lever2256
Parking Brake Control2259
Parking Brake2263
<FE (Manual Transmission)>2263
<FE (Automatic Transmission)>2265
<FG>2267
Group 37 – Steering2269
Table of Contents2270
Specifications2271
Structure and Operation2273
1 Steering System2273
2 Oil Flow2273
3 Power Steering Gear (Backlash Compensation Mechanism)2274
4 Power Steering Oil Pump <KYB Product>2275
5 Power Steering Oil Pump <Unisia JKC Steering Systems Product>2277
Troubleshooting2279
On-Vehicle Inspection and Adjustment2281
1 Change of Power Steering Fluid2281
2 Bleeding of Power Steering System2282
3 Performance Verification Test of Power Steering System2283
4 Steering Wheel Play2284
5 Steering Column Looseness2284
6 Inspection of Drag Link Ball Joint2284
Steering Column2285
Power Steering Gear Assembly and Drag Link2295
Power Steering Oil Pump2313
<KYB Product>2313
<Unisia JKC Steering Systems Product>2317
Power Steering Oil Tank2321
Group 41 – Bumper and Frame2323
Table of Contents2324
Specifications2325
Structure and Operation2326
Front Bumper2327
Frame2329
Group 42 – Cab2334
Table of Contents2335
Specifications2336
Structure and Operation2337
1 Front Cab Mounting2337
2 Rear Cab Mounting <Except Crew Cab>2338
3 Center and Rear Cab Mountings <Crew Cab>2338
4 Cab Tilt Link <Except Crew Cab>2339
Troubleshooting2340
On-Vehicle Inspection and Adjustment2342
1 Adjustment of Cab Tilt System <Except Crew Cab>2342
Removal and Installation of Cab2344
<Except Crew Cab>2344
<Crew Cab>2348
Front Cab Mounting2352
<Except Crew Cab>2352
<Crew Cab>2354
Rear Cab Mounting <Except Crew Cab>2356
Center and Rear Cab Mountings <Crew Cab>2357
Cab Tilt Link <Except Crew Cab>2358
Cab Stay <Except Crew Cab>2360
Group 43 – Door2361
Table of Contents2362
Specifications2363
Structure and Operations2364
1 Front Door Lock System2364
2 Rear Door Lock System <Crew Cab>2364
3 Front Door Glass Opening and Closing Mechanism2365
4 Rear Door Glass Opening and Closing Mechanism <Crew Cab>2367
Troubleshooting2369
On-Vehicle Inspection and Adjustment2371
1 Adjustment of Front Door Alignment2371
2 Adjustment of Rear Door Alignment <Crew Cab>2374
Front Door2377
Rear Door <Crew Cab>2385
Group 51 – Exterior2392
Table of Contents2393
Structure and Operation2394
1 Wiper and Washer System2394
Troubleshooting2395
Mirror2396
Wiper and Washer2398
Front Cover2400
Front Grille, Front Corner Panel and Headlamp2402
Fender2406
Step2408
Garnish <Crew Cab>2410
Wheel House2411
Window Glass2412
Group 52 – Interior2415
Table of Contents2416
Seat2417
<Driver>2417
<Passenger>2419
<Rear>2421
Seat Belt2423
Instrument Panel2429
Trim and Scuff Plate2443
<Except Crew Cab>2443
<Crew Cab>2447
Head Lining2449
<Except Crew Cab>2449
<Crew Cab>2451
Group 54 – Electrical2453
Table of Contents2454
How to Read This Group2457
54-00A – General2461
Precautions for Maintenance Operation2462
54-00B – Specifications2472
Specifications2473
54-00C – Structure and Operation2476
1 Starter2477
2 Alternator2478
3 Headlamps2481
4 Meter Cluster2482
5 Daytime Running Light System2491
6 Wiper Control2493
7 Starter Continuous Energizing Preventing Function and Preheating Function2495
54-00D – Troubleshooting2498
Troubleshooting2499
54-01 – Power, Charge and Ground Circuit2507
High-Current Fuse Box2508
Fuse Box2510
110 – Power Circuit2512
115 – Reserve Power Circuit2525
125 – Battery Charging Circuit2526
130 – Ground2528
54-02 – Starting, Stopping and Preheating Circuit2546
210 – Engine Starting Circuit2547
215 – Engine Stopping Circuit 228
220 – Engine Preheating Circuit2549
54-03 – Lighting Circuit2551
310 – Headlamp Circuit2552
313 – Daytime Running Light Circuit2554
320 – Tail, Clearance and License Plate Lamps Circuit2556
325 – Stop Lamp Circuit2558
330 – Turn Signal and Hazard Lamp Circuit2560
340 – Backup Lamp Circuit2562
345 – Cab Lamp Circuit2564
348 – Illumination Lamp Circuit2566
349 – Identification Lamp and Side Marker Lamp Circuit2567
352 – Van Body Dome Light Circuit2568
54-04 – Meter Circuit2569
401 – Meter Cluster Internal Circuit2570
410 – Tachometer Circuit2572
412 – Speedometer Circuit2573
420 – Fuel Gauge Circuit2574
425 – Water Temperature Gauge Circuit2575
54-05 – Indicator and Warning Lamp Circuit2576
510 – Parking Brake Indicator Circuit2577
515 – Brake Warning Circuit2579
535 – Engine Oil Level Warning Circuit2581
536 – Engine Oil Pressure Warning Circuit2582
537 – Overheating Warning Circuit2583
540 – Brake Pad Warning Circuit2584
550 – Cab Tilt Warning Circuit2585
566 – Fuel Filter Warning Circuit2586
54-06 – Cab Side Electrical Circuit2587
610 – Cigarette Lighter Circuit2588
612 – Audio Circuit2589
614 – Wiper and Washer Circuit2590
616 – Horn Circuit2591
620 – Air-Conditioner Circuit2592
622 – Power Window and Central Door Lock Circuit2594
629 – Mirror Heater Circuit2595
54-07 – Chassis Side Electrical Circuit2596
710 – Exhaust Brake Circuit2597
54-08 – Engine and Transmission Electrical Circuit2599
810 – Four-Wheel Drive Circuit <FG>2600
850 – Transmission Power Take-Off Circuit2601
54-09 – Other Circuit2602
905 – Joint Connector (J/C)2603
907 – Diagnosis Switch and Memory Clear Switch2607
Electronically Controlled Fuel System Electric Circuit Diagram 228
Auto Cruise System Electric Circuit Diagram1225
Automatic Transmission System Electric Circuit Diagram1474
Anit-Lock Brake System Electric Circuit Diagram2205
54-10 – Electrical Equipment Installation Positions2608
A – Switch2609
B – Relay and Electronic Control Unit2613
C – Fuse, Meter, Sensor, Buzzer, Motor and Actuator2615
D – Air-Conditioner2616
E – Door2617
F – Roof2618
J – Joints of Main Harness Connectors2619
R – Engine2621
S – Transmission2623
T – Switch and Sensor2626
U – Fuse, Relay and Connectors2627
V – Magnetic Valve and Motor2630
W – Buzzer and Connectors2630
54-11 – Inspection of Electrical Equipment2631
#001 to #179 – Switch2632
#180 to #249 – Relay2638
#250 to #349 – Sensor2639
#350 to #409 – Control Unit2640
#410 to #509 – Motor2641
#510 to #539 – Actuator2643
#560 to #609 – Magnetic Valve2643
#610 to #649 – Buzzer, Horn2644
#650 to #699 – Lamp2646
#750 to #859 – Other2647
#860 – Battery2649
#890 – Meter2652
54-12 – Starter and Alternator2653
#930 – Starter2654
#940 – Alternator2668
54-13 – On-Vehicle Inspection and Adjustment2676
#950 – Inspection of Alternator2677
#951 – Inspection of Regulator2678
#955 – Inspection of Preheating System2679
#960 – Headlamp Aiming2681
54-14 – Connector Configuration Chart2683
Connector Configuration Chart2684
Group 55 – Heater, Air-Conditioner and Ventilation2766
Table of Contents2767
Specifications2768
Structure and Operation2770
1 Heater2770
2 Air Conditioner2771
3 Air Duct2772
4 Heater Control2773
Troubleshooting2776
On-Vehicle Inspection and Adjustment2778
1 Recovery of Refrigerant2778
2 Recharging the System With Refrigerant2779
3 Checking Refrigerant Charge Level2781
4 Adding Refrigerant2782
Connecting Air Conditioner Piping2783
Compressor2784
Condenser, Receiver2786
Heater Control2788
Air Duct2792
Heater and Cooling Unit, Blower2794
2008 FK/FM Service Manual2797
Group 00 – General2798
Table of Contents2799
Equipment Type Codes List2800
Power Trains Table2802
How To Read This Manual2804
Chassis Number, Engine Number, Power Train Label2808
Vehicle Identification Number2809
Precautions for Maintenance Operation2810
Jacking Up the Vehicle2822
Diagnosis Codes2824
1 Diagnosis Codes2824
2 Reading and Erasing the Diagnosis Code2825
Table of Standard Tightening Torques2832
Group 01 – Maintenance Schedule2835
Table of Contents2836
How To Read the Maintenance Schedule Tables2837
Maintenance Schedule Tables2839
Maintenance Operations2847
Lubrication Tables2853
Lubrication2855
Group 11 – Engine2859
Table of Contents2860
Specifications2861
Structure and Operation2862
1 Engine Proper2862
2 Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket2863
3 Valve Mechanism2864
4 Connecting Rod2864
5 Piston2865
6 Timing Gears2865
7 Flywheel2867
Troubleshooting2868
On-Vehicle Inspection and Adjustment2869
1 Measuring Compression Pressure2869
2 Inspection and Adjustment of Valve Clearances2873
Engine Removal and Installation2877
Rocker Cover, Rocker and Bracket, Camshaft2879
Cylinder Head and Valve Mechanism2889
Piston and Connecting Rod, Cylinder Liner2909
Flywheel2923
<Manual Transmission>2923
<Automatic Transmission>2931
Timing Gears2935
Crankshaft and Crankcase2941
Group 12 – Lubrication2951
Table of Contents2952
Specifications2953
Structure and Operation2954
1 Lubrication System2954
2 Oil Pump2955
3 Oil Cooler2956
4 Oil Filter2957
5 Lubrication of Engine Components2958
Troubleshooting2962
On-Vehicle Inspection and Adjustment2963
1 Oil Filter Replacement2963
2 Engine Oil Replacement2965
3 Engine Oil Level Inspection2966
4 Oil Pressure Measurement2967
Oil Pan, Oil Jets and Oil Level Sensor2968
Oil Pump, Oil Strainer2971
Oil Filter2974
Oil Cooler2975
Regulator Valve2977
Group 13A – Fuel and Engine Control2978
Table of Contents2979
Specifications2980
Structure and Operation2981
1 Fuel System (Flow of Fuel)2981
2 Engine Control2982
3 Fuel Filter2983
Troubleshooting2984
On-Vehicle Inspection and Adjustment2986
1 Inspecting No-Load and Maximum Speeds2986
2 Air-Bleeding of Fuel System2987
3 Fuel Filter Replacement2988
Fuel Tank2990
Fuel Filter2991
Engine Control2994
Common Rail3000
Supply Pump3002
Injector3004
Group 13EA – Common Rail System3007
Table of Contents3008
Specifications3009
Structure and Operation3011
1 Overview3011
2 Electronic Control System3019
3 Electronic Control Unit Connection Diagram3029
Troubleshooting3031
1 Diagnosis Procedure3031
2 Diagnostic Precautions3031
3 Inspections Based on Fault Codes3032
4 Multi-Use Tester Service Data3751
5 Actuator Tests Performed Using Multi-Use Tester3756
6 Registration and Alteration of Data in Engine Electronic Control Unit3759
7 Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit3760
Inspection of Electrical Equipment3761
Installed Locations of Parts3771
Electric Circuit Diagram3779
Group 13EB – Auto Cruise and Vehicle Speed Limitation System3788
Table of Contents3789
Structure and Operation3790
1 General Description3790
2 Electronic Control System3790
3 Electronic Control Unit Connection Diagram3794
Troubleshooting3796
1 Diagnostic Procedure3796
2 Diagnostic Precautions3796
3 Inspection Based on Diagnosis Codes3797
4 Multi-Use Tester Service Data3801
5 Actuator Tests Performed Using Mulit-Use Tester3802
6 Works Required When Replacing the Multifunction Vehicle Control Unit (MVCU)3802
7 Inspections Performed at Electronic Control Unit Connectors3803
Inspection of Electrical Equipment3804
Installed Locations of Parts3806
Electric Circuit Diagram3812
Group 14 – Cooling3816
Table of Contents3817
Specifications3818
Structure and Operation3819
1 Cooling System (Flow of Coolant)3819
2 Thermostat3820
3 Water Pump3820
Troubleshooting3821
On-Vehicle Inspection and Adjustment3822
1 Inspection and Adjustment of Belt Tension3822
2 Inspection of Cracks or Damage of the Belt3824
3 Coolant Replacement and Cleaning of Cooling System3825
4 Air Bleeding of Cooling System3827
5 Gas Leakage Test3827
Disconnection and Connection of Hoses and Pipes3828
Radiator and Fan Shroud3832
Cooling Fan, Belt and Water Pump3842
Thermostat3844
Group 15 – Intake and Exhaust3846
Table of Contents3847
Specifications3848
Structure and Operation3849
1 Air Cleaner3849
2 Turbocharger3850
3 Reducing Valve3852
4 Diesel Particulate Filter Regeneration Control System3853
Troubleshooting3862
On-Vehicle Inspection and Adjustment3864
1 Measurement of Turbocharger Boost Pressure3864
2 Cleaning and Inspection of Air Cleaner Element3866
3 Diesel Particulate Filter Unit Inspection for Clogging and Cleaning the Diesel Particulate Filter Unit3867
4 Resetting the DPF-Related Information (Resetting Electronic Control Unit)3871
Air Cleaner and Air Duct3874
Turbocharger3878
Intercooler3884
Intake Manifold3886
Exhaust Manifold3888
Exhaust Pipe3890
Diesel Particulate Filter3896
Group 17 – Emission Control3902
Table of Contents3903
Structure and Operation3904
1 Exhaust Gas Recirculation System3904
2 Blowby Gas Return System3909
On-Vehicle Inspection and Adjustment3910
1 Replacement of PCV Valve Element3910
EGR Valve, EGR Pipe and EGR Cooler3912
Blowby Gas Return System3914
Group 21 – Clutch3915
Table Of Contents3916
Specifications3917
Structure and Operation3918
1 Clutch Control3918
2 Clutch Master Cylinder3919
3 Clutch Proper3921
Troubleshooting3923
On-Vehicle Inspection and Adjustment3925
1 Replacement of Brake Fluid (Clutch System)3925
2 Air Bleeding of Brake Fluid (Clutch System)3927
3 Clutch Pedal Play3929
4 Clearance Between Clutch Pedal and Floor3930
5 Clutch Action3930
Clutch Pedal3931
Clutch Master Cylinder3935
Clutch Power Cylinder3937
Clutch Proper3939
Clutch Control3951
Group 22A – Manual Transmission <M060S6, M070S6>3953
Table of Contents3954
Specifications3955
Structure and Operation3956
1 Transmission3956
2 Synchromesh Mechanism3957
3 Power Shift3960
4 Interlock Mechanism3962
Troubleshooting3963
On-Vehicle Inspection and Adjustment3965
1 Inspection of Transmission Oil Leakage3965
2 Inspection of Looseness in Transmission Mounting Bolts3965
3 Inspection of Play and Looseness in Companion Flange3965
4 Inspection and Replacement of Transmission Oil3966
Removal and Installation of Transmission3967
Gear Shifter Upper and Interlock Plate3971
Power Shift3977
Extension Housing and Parking Brake3985
Reverse Idler Gear <M060>3991
6th Gear <M060>3993
Reverse Gear and Reverse Idler Gear <M070>3999
Transmission Body4003
Drive Pinion4021
Mainshaft4023
<M060>4023
<M070>4035
Countershaft4047
Transmission Control4051
Puller and Installer Kit4055
Group 23A – Automatic Transmission <M065A5 (Allison 1000RDS, 2200RDS)>4056
Table of Contents4057
Specifications4058
Structure and Operation4060
1 Outline4060
2 Electronic Control System4065
3 Electronic Control Unit Connection Diagram4068
Troubleshooting4070
1 Failure by Equipment4070
On-Vehicle Inspection and Adjustment4074
1 Inspection of Automatic Transmission Oil Leakage4074
2 Check for Looseness in Automatic Transmission Mounting Bolts and Nuts4074
3 Inspection of Play and Looseness in Companion Flange4075
4 Inspection of Automatic Transmission Cooling System4075
5 Inspection of Automatic Transmission Fluid4076
6 Replacement of Automatic Transmission Fluid4078
7 Replacement of Oil Filter4079
8 Stall Test4080
9 Line Pressure Test4082
10 Road Test4083
Removal and Installation of Automatic Transmission4084
Parking Brake <FK61>4088
Automatic Transmission Control4090
Oil Cooler4096
Parts Replacement of Automatic Transmission Proper4098
Inspection of Electrical Equipment4100
Installed Locations of Parts4104
Electrical Circuit Diagram4110
Group 23B – Automatic Transmission <M100A6 (Allison 3000RDS)>4114
Table of Contents4115
Specifications4116
Structure and Operation4118
1 Automatic Transmission4118
2 Automatic Transmission Control System4119
3 Oil Cooler System4120
4 Electronic Control Unit Connection Diagram4122
Troubleshooting4124
1 Reading/Clearing of Diagnosis Codes4124
2 List of Diagnosis Codes4125
On-Vehicle Inspection and Adjustment4128
1 Inspection of Automatic Transmission Oil Leakage4128
2 Check for Looseness in Automatic Transmission Mounting Bolts4128
3 Inspection of Play and Looseness in Companion Flange4129
4 Inspection of Automatic Transmission Cooling System4129
5 Inspection of Automatic Transmission Fluid4130
6 Replacement of Automatic Transmission Fluid4132
7 Level Check of Automatic Transmission Fluid4134
8 Replacement of Oil Filter4135
9 Stall Test4136
10 Line Pressure Test4137
11 Road Test4140
Oil Cooler4142
Inspection of Electrical Equipment4146
Installed Locations of Parts4148
Electrical Circuit Diagram4154
Group 25 – Propeller Shaft4158
Table of Contents4159
Specifications4160
Structure and Operation4160
1 Configuration of Propeller Shaft Connection4160
2 Propeller Shaft <Without Center Bearing>4161
3 Propeller Shaft <With Center Bearing>4161
Troubleshooting4162
Removal and Installation of Propeller Shaft4164
Propeller Shaft4166
<P8>4166
<P10>4180
Group 26A – Front Axle <FK61>4194
Table of Contents4195
Specifications4196
Structure and Operation4197
1 Wheel Hub and Brake Drum4197
2 Front Axle, Knuckle and Kingpin4197
Troubleshooting4198
On-Vehicle Inspection and Adjustment4200
1 Inspection and Adjustment of Wheel Alignment4200
2 Inspection and Adjustment of Steering Angle4204
3 Inspection of Side Slip4204
4 Inspection of Tie Rod End Ball Joint4205
5 Inspection of Wheel Bearing for Play4205
6 Inspection of Knuckle Joint for Play4205
Wheel Hub and Brake Drum4206
Front Axle, Knuckle and Kingpin4220
Tie Rod4228
Group 26B – Front Axle <FK62, FK65, FM>4231
Table of Contents4232
Specifications4233
Structure and Operation4234
1 Wheel Hub and Brake Drum4234
2 Front Axle, Knuckle and Kingpin4235
Troubleshooting4236
On-Vehicle Inspection and Adjustment4237
1 Inspection and Adjustment of Wheel Alignment4237
2 Inspection and Adjustment of Steering Angle4241
3 Inspection of Side Slip4241
4 Inspection of Tie Rod End Ball Joint4242
5 Inspection of Wheel Bearing for Play4242
6 Inspection of Knuckle Joint for Play4242
Wheel Hub and Brake Drum4243
Front Axle, Knuckle and Kingpin4259
<FK>4259
<FM>4267
Tie Rod4275
Group 27 – Rear Axle4278
Table of Contents4279
Specifications4280
Structure and Operation4281
1 Wheel Hub and Brake Drum4281
2 Reduction and Differential4283
Troubleshooting4284
On-Vehicle Inspection and Adjustment4286
1 Adjustment of Wheel Speed Sensor Gap4286
2 Inspection and Replacement of Differential Oil4288
3 Inspection of Wheel Bearing for Play4289
Wheel Hub and Brake Drum4290
Axle Housing4310
Reduction and Differential4314
Group 31 – Wheel and Tire4335
Table of Contents4336
Specifications4337
Troubleshooting4338
On-Vehicle Inspection and Adjustment4339
1 Inspection of Wheel Nut, Hub Bolt and Disc Wheel4339
Wheel and Tire4341
Group 33 – Front Suspension4349
Table of Contents4350
Structure and Operation4351
1 Front Suspension4351
Troubleshooting4352
Shock Absorber4353
Leaf Spring4355
Group 34A – Rear Suspension <LEAF>4362
Table of Contents4363
Structure and Operation4364
1 Rear Suspension4364
Troubleshooting4365
Shock Absorber4366
Leaf Spring4368
Group 34B – Rear Suspension <AIR>4377
Table of Contents4378
Specifications4379
Structure and Operation4379
1 Air Suspension4379
2 Air Suspension System4380
3 Leveling Valve4381
Troubleshooting4382
On-Vehicle Inspection and Adjustment4383
1 Adjustment of Air Spring Height4383
Leveling Valve4384
Air Spring4387
Shock Absorber4391
Leaf Spring4393
Lateral Rod4395
Supply Valve4398
Group 35A – Brake <AIR-OVER HYDRAULIC BRAKE>4398
Table of Contents4399
Specifications4400
Structure and Operation4402
1 Brake System4402
2 Air Compressor4404
3 Air Dryer4405
4 Dual Brake Valve4408
5 Brake Booster4414
6 Fluid Tank4416
7 Front Drum Brake4417
8 Rear Drum Brake4420
9 Supply Valve4421
10 Quick Release Valve4421
Troubleshooting4422
On-Vehicle Inspection and Adjustment4425
1 Exhaust Noise from Brake Valve4425
2 Air Pressure Build-Up4425
3 Replacement of Brake Fluid4426
4 Air Bleeding of Brake System4428
5 Inspection and Adjustment of Brake Pedal Free Play4431
6 Inspection of Drum Brake Lining Thickness4431
7 Initial Adjustment of Clearance Between Brake Drum and Shoe4432
8 Maintenance and Inspection of Air Dryer4434
9 Inspection and Adjustment of Air Dryer’s Air Pressure Governor4435
Handling of Nylon Tube for Air Line4438
<Compression Type>4438
<Tube Identification Colors>4440
Handling of Connector4441
Air Compressor4442
Air Dryer4446
Brake Pedal4450
Dual Brake Valve4452
Brake Booster4458
Fluid Tank4464
Front Wheel Brake4466
Rear Wheel Brake4474
Check Valve4482
Safety Valve4483
Supply Valve4484
Quick Release Valve4486
Group 35B – Brake <FULL AIR BRAKE>4488
Table of Contents4489
Specifications4490
Structure and Operation4492
1 Brake System4492
2 Air Compressor4398
3 Air Dryer4398
4 Dual Brake Valve4398
5 Front Drum Brake4496
6 Rear Drum Brake4500
7 Relay Valve4502
8 Quick Release Valve4398
9 Supply Valve4398
Troubleshooting4504
On-Vehicle Inspection and Adjustment4508
1 Exhaust Noise from Brake Valve4398
2 Air Pressure Build-Up4398
3 Inspection and Adjustment of Brake Pedal Free Play4398
4 Inspection of Brake Lining Thickness4508
5 Initial Adjustment of Clearance Between Brake Drum and Shoe4509
6 Maintenance and Inspection of Air Dryer4398
7 Inspection and Adjustment of Air Dryer’s Air Pressure Governor4398
Handling of Nylon Tube for Air Line4398
<Compression Type>4398
<Tube Identification Colors>4398
Handling of Connector4398
Air Compressor4398
Air Dryer4398
Brake Pedal4398
Dual Brake Valve4398
Front Wheel Brake4510
Rear Wheel Brake4520
Expander4532
Check Valve4398
Safety Valve4398
Relay Valve4540
Supply Valve4398
Quick Release Valve4398
Group 35E – Anti-Lock Brake System (ABS)4542
Table of Contents4543
Specifications4544
Structure and Operation4546
1 General Description4546
2 Electronic Control System4552
3 Electronic Control Unit Schematic Diagram4554
Troubleshooting4556
1 Diagnosis Procedure4556
2 Diagnostic Precautions4556
3 Inspections Based on Diagnosis Codes4557
4 Multi-Use Tester Service Data4574
5 Electronic Control Unit Information Display4574
6 Actuator Test Using Multi-Use Tester4575
7 Inspection at Electronic Control Unit Connector4578
On-Vehicle Inspection and Adjustment4580
1 Functional Check4580
2 Oscilloscopic Inspection through Wheel Speed Sensor Signal Waveform4584
Inspection of Electrical Components4586
Components Location4588
Electrical Wiring Diagram4592
Group 36A – Parking Brake <CENTER PARKING BRAKE>4595
Table of Contents4596
Specifications4597
Structure and Operation4598
1 Parking Brake System4598
2 Parking Brake Lever4599
3 Parking Brake4599
Troubleshooting4600
On-Vehicle Inspection and Adjustment4601
1 Adjustment of Parking Brake Shoe Clearance4601
2 Inspection and Adjustment of Parking Brake Lever4602
Parking Brake Control4603
Parking Brake4607
Group 36B – Parking Brake <WHEEL PARKING BRAKE>4609
Table of Contents4610
Structure and Operation4611
1 Parking Brake System4611
2 Parking Brake Control Valve4612
3 Spring Brake Valve4613
4 Relay Valve (With Double Check Valve)4616
Troubleshooting4617
On-Vehicle Inspection and Adjustment4619
1 Manual Release of Parking Brake4619
Parking Brake Control Valve4621
Spring Brake Valve4623
Double Check Valve4626
Relay Valve (With Double Check Valve)4627
Group 37 – Steering4629
Table of Contents4630
Specifications4631
Structure and Operation4633
1 Steering System4633
2 Fluid Flow4633
3 Power Steering Booster4634
4 Power Steering Oil Pump4636
Troubleshooting4639
On-Vehicle Inspection and Adjustment4643
1 Change of Power Steering Fluid4643
2 Bleeding of Power Steering System4644
3 Performance Verification Test of Power Steering System4645
4 Steering Wheel Play4646
5 Steering Column Looseness4646
6 Inspection of Drag Link Ball Joint4646
Steering Column4647
Power Steering Booster and Drag Link4653
Power Steering Oil Pump4677
<FK>4677
<FM>4681
Power Steering Oil Tank4687
Group 41 – Bumper and Frame4688
Table of Contents4689
Specifications4690
Structure and Operation4691
1 Frame4691
Front Bumper4692
Frame4694
Group 42 – Cab4699
Table of Contents4700
Specifications4701
Structure and Operation4703
1 Front Cab Mounting4703
2 Rear Cab Mounting4705
3 Cab Tilt Link4706
Troubleshooting4707
Removal and Installation of Cab4711
Front Cab Mounting4717
Rear Cab Mounting4721
Cab Tilt Link4723
Cab Stay4725
Group 43 – Door4726
Table of Contents4727
Specifications4728
Structure and Operation4730
1 Door Locking System4730
2 Door Glass Opening System4731
Troubleshooting4732
On-Vehicle Inspection and Adjustment4734
1 Adjustment of Door Alignment4734
Door4736
Group 51 – Exterior4746
Table of Contents4747
Structure and Operation4748
1 Wiper and Washer System4748
Troubleshooting4749
Mirror4750
Wiper and Washer4752
Front Panel4758
Front Grille4762
Corner Panel4764
Fender4766
Step4768
<No 1 Step>4768
<No 2 Step>4770
Wheel House4772
Window Glass4776
Group 52 – Interior4780
Table of Contents4781
Specifications4782
Structure and Operation4784
1 Air Suspension Seat4784
2 Emergency Locking Retractor Type Seat Belt4786
Troubleshooting4787
Driver Seat4788
Side Seat4792
Seat Belt4793
Instrument Panel4794
Floor Console4805
Scuff Plate, Trim4806
Head Lining4810
Group 54 – Electrical4813
Table of Contents4814
How To Read This Group4817
54-00A – General4821
Precautions for Maintenance Operation4822
54-00B – Specifications4832
Specifications4833
54-00C – Structure and Operation4836
1 Starter4837
2 Alternator4838
3 Headlamps4841
4 Meter Cluster4842
5 Daytime Running Light (DRL) System4853
6 MUTIC (Multipurpose Timing Control Unit)4855
7 Starter Continuous Energizing Preventing Function and Preheating Function4858
54-00D – Troubleshooting4862
Troubleshooting4863
54-01 – Power, Charge and Ground Circuit4871
High-Current Fuse Box4872
Relay and Fuse Box4874
104 – Relay and Fuse Box Circuit4876
110 – Power Circuit4877
115 – Reserve Power Circuit4889
125 – Battery Charging Circuit4890
130 – Ground4892
54-02 – Starting and Preheating Circuit4912
210 – Engine Starting Circuit4913
215 – Engine Stopping Circuit3007
220 – Engine Preheating Circuit4919
54-03 – Lighting Circuit4920
310 – Headlamp Circuit4921
313 – Daytime Running Light Circuit4923
320 – Tail, Clearance, and License Plate Lamps Circuit4925
325 – Stop Lamp Circuit4926
330 – Turn Signal and Hazard Lamp Circuit4927
340 – Backup Lamp Circuit4929
345 – Cab Lamp Circuit4932
348 – Illumination Lamp Circuit4933
349 – Identification and Side Marker Lamp Circuit4934
352 – Van Body Dome Light Circuit4935
54-04 – Meter Circuit4936
401 – Meter Cluster Internal Circuit4937
410 – Tachometer Circuit4939
412 – Speedometer Circuit4940
420 – Fuel Gauge Circuit4943
425 – Water Temperature Gauge Circuit4944
436 – Air Gauge Circuit4945
54-05 – Indicator and Warning Lamp Circuit4946
510 – Parking Brake Indicator Circuit4947
515 – Brake Warning Circuit4949
530 – Water Level and Overheating Warning Circuit4951
535 – Engine Oil Level Warning Circuit4952
536 – Engine Oil Pressure Warning Circuit4953
538 – Engine Oil Filter Warning Circuit4954
550 – Cab Tilt Warning Circuit4955
566 – Fuel Filter Warning Circuit4956
54-06 – Cab Side Electrical Circuit4957
610 – Cigarette Lighter Circuit4958
612 – Audio Circuit4959
614 – Wiper and Washer Circuit4960
616 – Horn Circuit4961
620 – Air-Conditioner Circuit4962
622 – Power Window and Central Door Lock Unit4964
629 – Mirror Heater Circuit4965
54-07 – Chassis Side Electrical Circuit4966
710 – Exhaust Brake Circuit4967
718 – Air Dryer Circuit4970
722 – Air Suspension Circuit4971
54-08 – Engine and Transmission Side Electrical Circuit4973
850 – Transmission Power Take-Off Circuit4974
54-09 – Other Circuit4975
905 – Joint Connector (J/C)4976
Common Rail System Electric Circuit Diagram3007
Cruise Control System Electric Circuit Diagram3788
Automatic Transmission System Electric Circuit Diagram4056
<(Allison 1000RDS, 2200RDS)>4056
<(Allison 3000RDS)>4114
Anti-Lock Brake System Electric Circuit Diagram4542
54-10 – Electrical Equipment Installation Positions4983
A – Switch4984
B – Relay and Electronic Control Unit4986
C – Meter, Sensor, Buzzer and Motor4990
D – Air-Conditioner4992
E – Door and Mirror4993
F – Roof4994
G – Cab4995
H – Cab Tilt4996
J – Joints of Main Harness Connectors4998
R – Engine5001
S – Transmission5002
T – Switch and Sensor5004
U – Fuse and Connectors5008
V – Magnetic Valve5010
W – Buzzer5010
X – Other5012
54-11 – Inspection of Electrical Equipment5015
#001 to #179 – Switch5016
#180 to #249 – Relay5023
#250 to #349 – Sensor5024
#350 to #409 – Control Unit5027
#410 to #509 – Motor5028
#510 to #539 – Actuator5029
#560 to #609 – Magnetic Valve5030
#610 to #649 – Buzzer, Horn5031
#650 to #699 – Lamp5031
#750 to #859 – Other5032
#860 – Battery5035
#890 – Meter5038
54-12 – Starter and Alternator5039
#930 – Starter5040
#940 – Alternator5054
54-13 – On-Vehicle Inspection and Adjustment5061
#950 – Inspection of Alternator5062
#951 – Inspection of Regulator5063
#955 – Inspection of Preheating System5064
#960 – Headlamp Aiming5066
#965 – Inspection of Brake Fluid Level Switch5068
54-14 – Connector Configuration Chart5069
Connector Configuration Chart5070
Group 55 – Heater, Air-Conditioner and Ventilation5152
Table of Contents5153
Specifications5154
Structure and Operation5156
1 Heater5156
2 Air-Conditioner5157
3 Air Duct5158
4 Air-Conditioner Control5159
Troubleshooting5161
On-Vehicle Inspection and Adjustment5162
1 Recovery of Refrigerant5162
2 Recharging the System with Refrigerant5163
3 Checking Refrigerant Charge Level5165
4 Adding Refrigerant5166
5 Cleaning and Replacement of Evaporator5167
6 Cleaning and Replacement of Heater Core5169
Connecting Air-Conditioner Piping5172
Compressor5173
Condenser5174
Air-Conditioner Control5176
Air Duct5178
Cooling and Heater Unit, Blower5180
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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