Mitsubishi Fuso FE.FG Series Workshop Repair Manual 1990-1991 incl. TWSE8911 - MMTBSFUSOEG9001OPEK.zip
A full factory-style repair manual featuring Electrical Wiring Diagrams for the Mitsubishi Fuso FE.FG Series 1990-1991, packed with every technical detail needed to service, troubleshoot, fix, and rebuild your truck the way professional technicians do.
The Mitsubishi Fuso FE.FG Series 1990-2001 workshop service repair manual covers:
* 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 FE.FG Series 1990-1991 Service Manual (TWSE8911).pdf
Mitsubishi Fuso FE.FG Series 1992-1995 Service Manual (TWSE9105).pdf
Mitsubishi Fuso FE.FG Series 1995-2001 Service Manual (TWSE9501).pdf
PRODUCT DETAILS:
Total Pages: 5,802 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
FE.FG Series 1990-1991 Fuso Service Manual (TWSE8911 - 1,734 pages).....1
1990-1991 FE/FG Service Manual.....1
Foreword.....2
Manual Layout.....3
Group 00 - 1991 Minor Changes.....5
Group 00 - General.....13
Table of Contents.....14
1. External Views.....15
2. Major Specifications.....17
3. Power Train Table.....22
4. Equipment Model Notation.....22
5. Performance Curves.....23
5.1 Operation Performance Curves.....23
5.2 Engine Performance Curves.....27
6. Servicing Precautions.....28
7. Standard Bolts and Nuts Tightening Torque Table.....32
8. Towing Precautions.....33
9. Vehicle Identification Number.....34
Group 01 - Maintenance Schedule.....35
Table of Contents.....36
1. How to Read the Maintenance Schedule Tables.....37
2. Maintenance Schedule Tables.....38
3. Maintenance Operations.....40
3.1 Replacement of the Oil Filter Element.....40
3.2 Replacement of the Fuel Filter Element.....40
3.3 The Water Separator.....40
3.4 Cleaning the Fuel Feed Pump Gauze Filter.....41
3.5 Bleeding Air from the Fuel Line.....41
3.6 Adjusting V-Belt Tension.....42
3.7 Cleaning and Replacement of the Air Cleaner Element.....43
3.8 Inspecting the Clutch Pedal.....44
3.9 The Tires.....44
3.9.1 Air Pressure.....44
3.9.2 Removing Tires.....44
3.9.3 Putting Tires On.....46
3.9.4 Checking the Wheel Nuts for Looseness.....47
3.9.5 Tire Rotation.....47
3.10 Adjusting the Clearance of the Wheel Brake Shoe (Drum Brake).....48
3.11 Checking for Wear in the Disk Brake Pads.....49
3.12 Adjusting the Clearance of the Parking Brake Shoe.....49
3.13 The Battery.....50
3.13.1 Cleaning the Battery Terminals.....50
3.13.2 Inspecting the Battery.....50
3.14 Fuses.....51
4. Lubrication.....53
4.1 Engine Oil.....54
4.2 Gear Oil for Manual Transmissions.....55
4.3 Transmission Fluid for Automatic Transmissions.....55
4.4 Front Axle and Rear Axle Gear Oil.....58
4.5 Transfer Gear Oil .....59
4.6 Power Steering Fluid.....59
4.7 Brake Fluid.....62
4.8 Greasing the Various Areas of the Chassis.....65
Group 11 - Engine.....67
Table of Contents.....68
1. Troubleshooting.....69
2. Engine Removal and Installation (Manual Transmission Vehicles).....76
2.1 Service Standards.....76
2.1.1 Tightening Torque Table.....76
2.1.2 Lubricant Table.....76
2.2 Engine and Transmission Removal.....77
2.2.1 Preparations Before Removal.....77
2.2.2 Harness Removal.....79
2.2.3 Vacuum Hose Removal.....83
2.2.4 Removal of Parts Around Engine.....85
2.2.5 Removal of Each Engine Part.....86
2.2.6 Removal of Each Transmission Part.....90
2.2.7 Removing the Engine From the Vehicle.....92
2.2.8 Separating the Engine From the Transmission.....94
2.3 Installation of the Engine and Transmission.....95
2.3.1 Engine and Transmission Installation.....95
2.3.2 Installation the Engine and Transmission in the Vehicle.....96
2.3.3 Installation of Each Transmission Part.....99
2.3.4 Installation of Each Engine Part.....102
2.3.5 Installation of Parts Around the Engine.....105
2.3.6 Vacuum Hose Installation.....107
2.3.7 Harness Installation.....109
2.4 Adjustment After Installation.....113
2.4.1 Procedures After Installation.....113
2.4.2 Adjustment.....115
3. Engine Removal and Installation (Automatic Transmission Vehicles).....116
3.1 Service Standards.....116
3.1.1 Tightening Torque Table.....116
3.2 Engine and Transmission Removal.....116
3.2.1 Preparations Before Removal.....116
3.2.2 Harness Removal.....117
3.2.3 Vacuum Hose Removal.....119
3.2.4 Removal of Parts Around Engine.....119
3.2.5 Removal of Each Engine Part.....119
3.2.6 Removal of Each Transmission Part.....120
3.2.7 Removing the Engine From the Vehicle.....122
3.2.8 Separating the Engine and Transmission.....124
3.3 Installation of the Engine and Transmission.....125
3.3.1 Transmission Installation.....125
3.3.2 Installing the Engine and Transmission in the Vehicle.....126
3.3.3 Installation of Each Transmission Part.....128
3.3.4 Installation of Each Engine Part.....131
3.3.5 Installation of Parts Around the Engine.....131
3.3.6 Vacuum Hose Installation.....131
3.3.7 Harness Installation.....131
3.4 Adjustment After Installation.....134
3.4.1 Operations After Installation.....134
3.4.2 Adjustment.....136
4. Engine Assembly.....137
4.1 Specifications.....137
4.2 Service Standards.....137
4.2.1 Service Standards Table.....137
4.2.2 Tightening Torque Table.....138
4.2.3 Special Tool Table.....138
4.3 Valve Clearance Inspection and Adjustment.....139
4.4 Compression Pressure Measurement.....140
4.5 Oil Pressure Inspection.....142
4.6 Fuel Injection Timing Inspection and Adjustment.....142
4.7 Bleeding the Fuel System.....146
4.8 Inspection and Adjustment of V-Belt Tension.....146
4.8.1 V-Belt Tension Inspection.....146
4.8.2 V-Belt Tension Adjustment.....147
4.9 Turbocharger Boost Pressure Measurement.....149
5. Cylinder Head and Valve Mechanism.....151
5.1 Service Standards.....151
5.1.1 Service Standard Table.....151
5.1.2 Tightening Torque Table.....151
5.1.3 Special Tool Table.....152
5.2 General Description.....153
5.2.1 Cylinder Head.....153
5.2.2 Valve Mechanism.....154
5.3 Removal.....154
5.4 Disassembly.....157
5.4.1 Rocker and Bracket Assembly.....157
5.4.2 Cylinder Head Assembly.....158
5.5 Inspection.....160
5.6 Reassembly.....168
5.6.1 Cylinder Head Assembly.....168
5.6.2 Rocker and Bracket Assembly.....170
5.7 Installation.....172
6. Flywheel and Rear Plate (Manual Transmission Vehicles).....175
6.1 Service Standards.....175
6.1.1 Maintenance Standards Table.....175
6.1.2 Tightening Torque Table.....175
6.1.3 Special Tool Table.....175
6.1.4 Lubricant Table.....175
6.2 General Description.....176
6.3 Removal.....177
6.4 Inspection.....178
6.5 Installation.....179
7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles).....183
7.1 Service Standards.....183
7.1.1 Tightening Torque Table.....183
7.1.2 Special Tool Table.....183
7.1.3 Lubricant Table.....183
7.2 General Description.....184
7.3 Removal.....185
7.4 Inspection.....186
7.5 Installation.....187
8. Timing Gear and Camshaft.....190
8.1 Service Standards.....190
8.1.1 Service Standards Table.....190
8.1.2 Tightening Torque Table.....190
8.1.3 Lubricant Table.....190
8.1.4 Special Tool Table.....190
8.2 General Description.....192
8.3 Removal.....192
8.4 Inspection.....195
8.5 Installation.....199
9. Crankcase and Main Moving Parts.....203
9.1 Service Standards.....203
9.1.1 Service Standards Table.....203
9.1.2 Tightening Torque Table.....204
9.1.3 Sealant Table.....204
9.1.4 Special Tool Table.....204
9.2 General Description.....206
9.2.1 Crankshaft.....206
9.2.2 Connecting Rods.....206
9.2.3 Piston.....206
9.3 Disassembly.....207
9.4 Inspection.....211
9.5 Reassembly.....222
Group 12 - Lubrication.....228
Table of Contents.....229
1. Troubleshooting.....230
2. Lubrication System.....231
2.1 Specifications.....231
2.2 General Description.....231
2.2.1 System Outline.....231
2.2.2 Lubrication of Main Moving Parts.....232
2.2.3 Camshaft Lubrication.....233
2.2.4 Valve Mechanism Lubrication.....233
2.2.5 Timing Gear Lubrication.....233
2.2.6 Camshaft Skew Gear and Oil Pump Gear Lubrication.....234
2.2.7 Turbocharger Lubrication.....234
2.2.8 Injection Pump Assembly Lubrication.....234
2.2.9 Vacuum Pump Lubrication.....234
2.3 Oil Pressure Check.....235
3. Oil Pump, Oil Filter.....236
3.1 Service Standards.....236
3.1.1 Service Standards Table.....236
3.1.2 Tightening Torque Table.....236
3.1.3 Special Tools Table.....236
3.2 General Description.....237
3.2.1 Oil Pump.....237
3.2.2 Oil Filter.....238
3.3 Removal.....238
3.4 Disassembly and Inspection.....239
3.5 Reassembly.....242
3.6 Installation.....244
4. Oil Cooler.....246
4.1 Service Standards.....246
4.1.1 Service Standards Table.....246
4.1.2 Tightening Torque Table.....246
4.2 General Description.....246
4.3 Removal.....247
4.4 Disassembly and Inspection.....249
4.5 Reassembly.....251
4.6 Installation.....253
5. Oil Pan, Oil Strainer.....255
5.1 Service Standards.....255
5.1.1 Tightening Torque Table.....255
5.1.2 Sealant Table.....255
5.2 General Description.....255
5.3 Removal.....255
5.4 Installation.....256
5.5 Post-Installation Inspection.....257
Group 13 - Fuel and Engine Control.....258
Table of Contents.....259
1. Troubleshooting.....260
2. Fuel System.....266
3. Injection Pump Assembly.....267
3.1 Specifications.....267
3.2 Service Standards.....267
3.2.1 Service Standards Table.....267
3.2.2 Tightening Torque Table.....268
3.2.3 Special Tools Table.....269
3.3 General Description.....270
3.3.1 Injection Pump.....270
3.3.2 Governor.....272
3.3.3 Feed Pump.....277
3.3.4 Automatic Timer.....278
3.4 Removal.....279
3.5 Installation.....282
3.6 Post-Installation Adjustment.....284
3.6.1 Bleeding Air From the Fuel System.....284
3.6.2 Fuel Injection Timing Adjustment.....284
3.6.3 Minimum Unloaded Idling Speed and Maximum Speed Adjustment.....285
3.6.4 Idle Up Adjustment .....285
3.6.5 Engine Stop Cable Operational Check.....286
4. Injection Nozzles.....287
4.1 Specifications.....287
4.2 Service Standards.....287
4.2.1 Service Standards Table.....287
4.2.2 Tightening Torque Table.....287
4.3 General Description.....288
4.4 Removal.....288
4.5 Disassembly.....288
4.6 Inspection and Cleaning.....290
4.7 Reassembly.....291
4.8 Testing and Adjustment.....293
4.9 Installation.....294
5. Fuel Filter.....295
5.1 Specifications.....295
5.2 Service Standards.....295
5.2.1 Tightening Torque Table.....295
5.2.2 Special Tools Table.....295
5.3 General Description.....296
5.4 Removal and Inspection.....296
5.5 Installation.....296
6. Water Separator.....298
6.1 Specifications.....298
6.2 Service Standards.....298
6.3 General Description.....298
6.4 Removal.....298
6.5 Disassembly and Inspection.....299
6.6 Reassembly.....300
6.7 Installation.....301
6.8 Draining Water.....301
7. Fuel Tank.....302
7.1 Specifications.....302
7.2 Service Standards.....302
7.3 General Description.....302
7.4 Removal.....303
7.5 Inspection.....304
7.6 Installation.....305
8. Engine Control System.....307