Mitsubishi Fuso FH Series 1992-2001 Workshop Repair Service Manual PDF Download - MMTBSFUSOFH9201.zip

A full service and repair guide featuring Electrical Wiring Diagrams for the Mitsubishi Fuso FH Series, covering model years 1992-2001. It contains every technical detail needed to service, troubleshoot, fix, and rebuild your vehicle the way professional technicians do.

Inside the Mitsubishi Fuso FH Series 1992-2001 workshop service repair manual, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Mitsubishi Fuso FH Series 1996-2001 Service Manual (TWME9502).pdf

Mitsubishi Fuso FH Series 1992-1995 Service Manual (TWME9106).pdf

PRODUCT DETAILS:

Total Pages: 3,188 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

FH Series 1992-1995 Fuso Service Manual (TWME9106)...1

92-95 FH Service Manual...1

Manual Layout...2

Group 00 - General...4

Group 00 - General (Supplement)...5

Group 00 - General ('95 Minor Change)...22

Group 00 - General ('94 Minor Change)...30

Group 00 - General ('93 Minor Change)...36

Group 00 - General...42

Table of Contents...43

1. External Views...44

2. Major Specifications...49

3. Power Train Table...52

4. Equipment Model Notation...52

5. Performance Curves...53

5.1 Operation Performance Curves...53

5.2 Engine Performance Curves...53

6. Servicing Precautions...53

7. Standard Bolts and Nuts Tightening Torque Table...60

8. Towing Precautions...61

9. Chassis and Engine Numbers...62

10. Vehicle Identification Number...62

Group 01 - Maintenance Schedule...64

Table of Contents...65

1. How to Read the Maintenance Schedule Tables...66

2. Maintenance Schedule Tables...67

3. Maintenance Operations...73

3.1 Replacement of the Engine Oil Filter Element...73

3.2 Replacement of the Fuel Filter Element...73

3.3 Inspection of Air Dryer...74

3.4 Cleaning of the Fuel Feed Pump Gauze Filter...74

3.5 Bleeding Air from the Fuel Line...74

3.6 Water Separator Condensation Drain...75

3.7 Adjusting V-Belt Tension...75

3.8 Cleaning and Replacement of the Air Cleaner Element...76

3.9 Inspecting the Clutch Pedal Vehicles with Manual Transmission>...77

3.10 The Tires...78

3.10.1 Air Pressure...78

3.10.2 Removing Tires...78

3.10.3 Tire Mounting...79

3.10.4 Checking the Wheel Nuts for Looseness...81

3.10.5 Tire Rotation...81

3.11 Adjusting the Clearance of the Wheel Brake Shoe...82

3.12 Adjusting the Clearance of the Parking Brake Shoe...83

3.13 The Battery...83

3.14 Fuses...85

4. Lubrication...89

4.1 Engine Oil...90

4.2 Gear Oil for Manual Transmission...91

4.3 Automatic Transmission Fluid and Oil Filters for Automatic Transmission...92

4.4 Rear Axle Gear Oil...95

4.5 Power Steering Fluid...96

4.6 Brake Fluid...100

4.6.1 Brake Fluid Tank...100

4.6.2 Clutch Fluid Tank...103

4.7 Greasing the Various Areas of the Chassis...106

Group 11 - Engine...107

Table of Contents...108

1. Troubleshooting...110

2. Engine Removal and Installation (Manual Transmission Vehicles)...113

2.1 Service Standards...113

2.1.1 Tightening Torque Table...113

2.2 Removal of Engine and Transmission...113

2.2.1 Preparation for Removal...113

2.2.2 Removal of Harness...114

2.2.3 Removal of Air Compressor Hoses, Actuator and Tube Assembly...116

2.2.4 Removal of Parts Around the Engine...116

2.2.5 Removal of Engine Parts...117

2.2.6 Removal of Transmission Parts...119

2.2.7 Removal of Transmission...121

2.2.8 Removing the Engine from the Vehicle...121

2.3 Installation of the Engine and Transmission...122

2.3.1 Installation of Engine...122

2.3.2 Installation of Transmission...123

2.3.3 Installation of Transmission Parts...123

2.3.4 Installation of Engine Parts...125

2.3.5 Installation of Parts Around the Engine...126

2.3.6 Installation of Air Compressor Hoses, Actuator and Tube Assembly...127

2.3.7 Installation of Harness...128

2.4 Adjustment After Installation...129

2.4.1 Preparation for Adjustment...129

2.4.2 Adjustment...131

3. Engine Removal and Installation (Automatic Transmission Vehicles)...132

3.1 Service Standards...132

3.1.1 Tightening Torque Table...132

3.2 Removal of Engine and Transmission...132

3.2.1 Preparation for Removal...132

3.2.2 Removal of Harness...133

3.2.3 Removal of Air Compressor Hose...134

3.2.4 Removal of Parts Around the Engine...135

3.2.5 Removal of Engine Parts...136

3.2.6 Removal of Transmission Parts...138

3.2.7 Removal of Transmission...140

3.2.8 Removing the Engine from the Vehicle...140

3.3 Installation of the Engine and Transmission...141

3.3.1 Installation of the Engine...141

3.3.2 Installation of Transmission...142

3.3.3 Installation of Transmission Parts...143

3.3.4 Installation of Engine Parts...144

3.3.5 Installation of Parts Around the Engine...145

3.3.6 Installation of Air Compressor Hose...146

3.3.7 Installation of Harnesses...146

3.4 Adjustment After Installation...148

3.4.1 Preparation for Adjustment...148

3.4.2 Adjustment...150

4. Engine Assembly...151

4.1 Specifications...151

4.2 Service Standards...151

4.2.1 Service Standards Table...151

4.2.2 Tightening Torque Table...152

4.2.3 Special Tools Table...152

4.3 Inspection and Adjustment of Valve Clearance...154

4.4 Measurement of Compression Pressure...155

4.5 Inspection of Oil Pressure...157

4.6 Inspection and Adjustment of Fuel Injection Start Timing...157

4.7 Bleeding the Fuel System...158

4.8 Inspection and Adjustment of V-Belt Tension...159

4.9 Measurement of Turbocharger Boost Pressure...160

5. Cylinder Head and Valve Mechanism...163

5.1 Service Standards...163

5.1.1 Service Standards Table...163

5.1.2 Tightening Torque Table...163

5.1.3 Special Tools Table...164

5.2 General Description...166

5.2.1 Cylinder Head...166

5.2.2 Valve Mechanism...166

5.3 Removal...167

5.4 Disassembly...169

5.4.1 Rocker and Bracket Assembly...169

5.4.2 Cylinder Head Assembly...169

5.5 Inspection...171

5.6 Reassembly...179

5.6.1 Cylinder Head Assembly...179

5.6.2 Rocker and Bracket Assembly...181

5.7 Installation...182

6. Flywheel and Flywheel Housing (Manual Transmission Vehicles)...185

6.1 Service Standards...185

6.1.1 Service Standards Table...185

6.1.2 Tightening Torque Table...185

6.1.3 Special Tools Table...185

6.1.4 Sealant Table...185

6.2 General Description...186

6.3 Disassembly...186

6.4 Inspection...187

6.5 Reassembly...189

7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles)...194

7.1 Service Standards...194

7.1.1 Tightening Torque Table...194

7.1.2 Special Tools Table...194

7.1.3 Sealant Table...194

7.2 General Description...195

7.3 Disassembly...195

7.4 Inspection...196

7.5 Reassembly...197

8. Timing Gear and Camshaft...201

8.1 Service Standards...201

8.1.1 Service Standards Table...201

8.1.2 Tightening Torque Table...201

8.1.3 Lubricant Table...201

8.1.4 Sealant Table...201

8.1.5 Special Tools Table...202

8.2 General Description...203

8.3 Disassembly...204

8.4 Inspection...207

8.5 Reassembly...211

9. Crankcase and Main Moving Parts...214

9.1 Service Standards...214

9.1.1 Service Standards Table...214

9.1.2 Tightening Torque Table...215

9.1.3 Sealant Table...215

9.1.4 Special Tools Table...215

9.2 General Description...216

9.2.1 Crankshaft...216

9.2.2 Connecting Rod...217

9.2.3 Piston...217

9.3 Disassembly...218

9.4 Inspection...222

9.5 Reassembly...233

Group 12 - Lubrication...240

Table of Contents...241

1. Troubleshooting...242

2. Lubrication System...242

2.1 Specifications...242

2.2 General Description...243

2.2.1 System Outline...243

2.2.2 Lubrication of Main Moving Parts...244

2.2.3 Camshaft Lubrication...244

2.2.4 Valve Mechanism Lubrication...244

2.2.5 Timing Gear Lubrication...245

2.2.6 Turbocharger Lubrication...245

2.2.7 Injection Pump Assembly Lubrication...246

2.2.8 Air Compressor Lubrication...246

2.3 Oil Pressure Check...246

3. Oil Pan and Oil Strainer...247

3.1 Service Standards...247

3.1.1 Tightening Torque Table...247

3.1.2 Sealant Table...247

3.2 General Description...247

3.3 Removal...247

3.4 Installation...248

3.5 Post-Installation Inspection...250

4. Oil Pump...251

4.1 Service Standards...251

4.1.1 Service Standards Table...251

4.2 General Description...251

4.3 Removal...251

4.4 Disassembly and Inspection...252

4.5 Reassembly...255

4.6 Installation...256

5. Oil Cooler and Oil Filter...257

5.1 Service Standards...257

5.1.1 Service Standards Table...257

5.1.2 Tightening Torque Table...257

5.1.3 Special Tools Table...257

5.2 General Description...258

5.3 Removal...259

5.4 Disassembly and Inspection...260

5.5 Reassembly...261

5.6 Installation...262

Group 13 - Fuel and Engine Control...264

Table of Contents...265

1. Troubleshooting...266

2. Fuel System...268

2.1 General Description...268

2.2 Removal and Installation of the Fuel Hoses...269

3. Prestroke Control Type Injection Pump System...270

3.1 Specifications...270

3.2 Service Standards...270

3.2.1 Service Standards Table...270

3.2.2 Tightening Torque Table...271

3.2.3 Special Tools Table...271

3.3 General Description...272

3.3.1 Prestroke Control Type Injection Pump System...272

3.3.2 Control Unit...275

3.3.3 Sensors...276

3.3.4 Injection Pump Proper...277

3.3.5 Governor...279

3.3.6 Feed Pump...284

3.3.7 Coupling...285

3.4 Service Procedure...285

3.4.1 Inspection of System...288

3.4.2 Removal of Injection Pump Assembly...309

3.4.3 Installation of Injection Pump Assembly...311

3.4.4 Adjustments After Installation of Injection Pump...314

3.4.5 Bleeding Air from the Fuel System...314

3.4.6 Adjustment of Fuel Injection Timing...314

3.4.7 Adjustment of No-Load Minimum and Maximum Speeds...315

3.4.8 Operation Check of the Engine Stop Cable...315

4. Injection Nozzles...316

4.1 Specifications...316

4.2 Service Standards...316

4.2.1 Service Standards Table...316

4.2.2 Tightening Torque Table...316

4.3 General Description...317

4.4 Removal...317

4.5 Disassembly...317

4.6 Inspection and Cleaning...319

4.7 Reassembly...320

4.8 Test and Adjustment...322

4.9 Installation...323

5. Fuel Filter...324

5.1 Specifications...324

5.2 Service Standards...324

5.2.1 Tightening Torque Table...324

5.2.2 Special Tools Table...324

5.3 General Description...325

5.4 Removal and Inspection...325

5.5 Installation...325

6. Water Separator...327

6.1 Specifications...327

6.2 Service Standards...327

6.3 General Description...327

6.4 Removal...327

6.5 Disassembly and Inspection...328

6.6 Reassembly...328

6.7 Installation...329

6.8 Draining Water...329

7. Fuel Tank...330

7.1 Specifications...330

7.2 Service Standards...330

7.3 General Description...330

7.4 Removal...330

7.5 Inspection...332