Mitsubishi Fuso FE FG FK FM Series 1996-2001 Workshop Repair Service Manual PDF - MMTBSFUSOEM9601OPEK.zip
A full factory-style service and repair guide, complete with Electrical Wiring Diagrams, covering the Mitsubishi Fuso FE.FG.FK.FM Series from 1996-2001 — packed with every technical detail needed to service, troubleshoot, fix, and overhaul these trucks the way professional technicians do.
Inside the Mitsubishi Fuso FE.FG.FK.FM Series 1996-2001 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 FE.FG.FK.FM Series 1996-2001 Service Manual (TWME9502&TWME9503&TWSE9501).pdf
PRODUCT DETAILS:
Total Pages: 5,067 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
1996-2001 Service Manual...1
96-01 FE/FG Service Manual...2
Group 00 - General...3
2001 Model Year Changes...4
Foreword/Group Index...5
2001 Model Changes...6
Group 00 - General...18
Power Train Table...19
Vehicle Identification Number...20
Engine Number...20
Precautions for Maintenance Operation...21
Group 01 - Maintenance Schedule...22
How to Read the Maintenance Schedule Tables...23
Maintenance Schedule Tables...24
Maintenance Operations...25
Lubrication...35
Group 11 - Engine '4D34T3'...37
Flywheel...38
Flywheel Power Take-Off...42
Group 23 - Automatic Transmission...45
Structure and Operation...46
Troubleshooting...50
Group 24 - Transfer 'FG'...57
Structure and Operation...58
Removal and Installation of Transfer Assembly...60
Front Drive...64
Idler Gear and Rear Drive...70
Group 54 - Electrical...76
101 Battery...78
104 Fuse...81
110 Power Circuit...82
125 Battery Charging Circuit...84
130 Ground...86
Specifications '4M5'...87
Structure and Operation '4M5'...88
201 Starter '4M5'...89
210 Engine Starting Circuit '4M5 Automatic Transmission'...102
225 Engine Warming Up Circuit '4M5'...106
410 Tachometer Circuit '4M5'...108
604 Relay and Control Unit...110
629 Mirror Heater Circuit...112
710 Exhaust Brake Circuit '4M5 Automatic Transmission'...114
801 Engine Electrics '4M5'...116
810 Four-Wheel Drive Circuit 'FG'...120
910 Multipurpose Timing Control Unit Circuit '4M5'...122
2000 Model Year Changes...123
Foreword/Group Index...124
2000 Model Changes...125
Group 00 - General...133
Power Train Table...134
Vehicle Identification Number...134
Group 26B - Front Axle 'FG'...135
Structure and Operation...136
On-Vehicle Inspection and Adjustment...138
Wheel Hub and Brake Drum...142
Group 42 - Cab...149
Structure and Operation...150
Troubleshooting...152
Door...154
Group 54 - Electrical...159
Specifications...161
Structure and Operation...161
104 Fuse...162
106 Alternator...164
110 Power Circuit...170
210 Engine Starting Circuit...172
313 Daytime Running Light Circuit...176
401 Meter Cluster...180
622 Power Window and Auto Door Lock Circuit...182
710 Exhaust Brake Circuit...186
1999 Model Year Changes...190
Foreword/Group Index...191
1999 Model Changes...192
Group 00 - General...200
Power Train Table...201
Vehicle Identification Number...201
Connector Configuration Chart...202
Group 37 - Steering...203
Steering System...204
Group 54 - Electrical...210
125 Battery Charging Circuit...212
210 Engine Starting Circuit...214
225 Engine Warming Up Circuit...218
340 Backup Lamp Circuit 'Automatic Transmission'...220
604 Relay and Control Unit...222
710 Exhaust Brake Circuit...224
1998 Model Year Changes...232
Foreword...233
1998 Model Changes...234
Power Train Table...242
Vehicle Identification Number...242
Structure and Operation...244
Multiplate Limited Slip Differential Assembly 'D033H'...246
1997 Model Year Changes...252
Foreword...253
1997 Model Changes...254
212 Sub-Starter Circuit...255
Group 00 - General...259
Table of Contents...260
Model Coding System...261
Power Train Table...262
Chassis Number and Engine Number...262
Power Train Label...263
Vehicle Identification Number...263
Precautions for Maintenance Operation...265
Table of Standard Tightening Torques...277
Connector Configuration Chart...281
Group 01 - Maintenance Schedule...302
Group 01 - '98 Minor Change - Maintenance Schedule...303
Table of Contents...304
How To Read the Maintenance Schedule Tables...305
Maintenance Schedule Tables...306
Maintenance Operations...308
Replacement of Oil Filter...308
Replacement of Fuel Filter...309
Draining of Water Separator Condensation...310
Cleaning of Fuel Feed Pump Gauze Filter...310
Bleeding of Air from Fuel Line...311
Adjustment of V-Belt Tension...312
Cleaning and Replacement of Air Cleaner Element...314
Inspection of Clutch Pedal Free Play...315
Tire...316
Inspection of Brake Lining Thickness 'Drum Brake Only'...321
Battery...321
Fuse...324
Lubrication...327
Engine Oil...329
Manual Transmission Gear Oil...331
Automatic Transmission Fluid...333
Transfer Gear Oil 'FG Model Only'...335
Front Axle Gear Oil 'FG Model Only' and Rear Axle Gear Oil...336
Power Steering Fluid...337
Brake Fluid...339
Greasing Various Areas of Chassis...343
Group 01 - Maintenance Schedule...345
Table of Contents...346
How To Read the Maintenance Schedule Tables...347
Maintenance Schedule Tables...348
Maintenance Operations...350
Replacement of Oil Filter...350
Replacement of Fuel Filter...351
Draining of Water Separator Condensation...352
Cleaning of Fuel Feed Pump Gauze Filter...352
Bleeding of Air from Fuel Line...353
Adjustment of V-Belt Tension...354
Cleaning and Replacement of Air Cleaner Element...356
Inspection of Clutch Pedal Free Play...357
Tire...358
Inspection of Brake Lining Thickness 'Rear Drum Brake'...363
Battery...363
Fuse...366
Lubrication...369
Engine Oil...370
Manual Transmission Gear Oil...372
Automatic Transmission Fluid...373
Rear Axle Gear Oil...375
Power Steering Fluid...376
Brake Fluid...378
Greasing Various Areas of Chassis...381
Group 10 - Removal and Installation of Engine...383
Group 10 - '98 Minor Change - Removal and Installation of Engine...384
Table of Contents...385
Removal and Installation of Engine...386
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses...386
Removal and Installation of Transmission Related Parts...388
Removal and Installation of Engine Related Parts...390
Removal and Installation of Engine...392
'FE'...392
'FG'...394
Group 10 - Removal and Installation of Engine...396
Table of Contents...397
Removal and Installation of Engine...398
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses...398
Removal and Installation of Transmission Related Parts...400
Removal and Installation of Engine Related Parts...402
Removal and Installation of Engine...404
Group 11 - Engine...406
Group 11A - '01 Minor Change - Engine '4M50T2'...407
Table of Contents...408
Specifications...409
Structure and Operation...411
Troubleshooting...421
On-Vehicle Inspection and Adjustment...423
Rocker Cover, Rocker Assemblies, and Camshafts...427
Cylinder Head and Valve Mechanism...441
Front Case...455
Timing Gears and Balance Shafts...459
Pistons, Connecting Rods and Cylinder Liners...467
Flywheel...479
Crankshaft and Crankcase...483
Balance Shaft Bushings...491
Group 11 - Engine...496
Table of Contents...497
Specifications...498
Structure and Operation...499
Troubleshooting...502
Inspection and Adjustment Mounted in Vehicle...503
Inspection of Engine Compression...503
Inspection and Adjustment of Valve Clearance...505
Cylinder Head and Valve Mechanism...508
Timing Gear...522
Camshaft...526
Piston, Connecting Rod and Cylinder Sleeve...532
Flywheel...546
Crankshaft and Crankcase...550
Group 12 - Lubrication...557
Group 12A - '01 Minor Change - Lubrication '4M50T2'...558
Table of Contents...559
Specifications...560
Structure and Operation...562
Troubleshooting...572
On-Vehicle Inspection and Adjustment...574
Oil Filter Replacement...574
Engine Oil Replacement...575
Oil Pressure Measurement...576
Oil Pan, Oil Strainer and Oil Jet...578
Oil Pump...580
Oil Filter...584
Oil Cooler...586
Group 12 - Lubrication...589
Table of Contents...590
Specifications...591
Structure and Operation...592
Troubleshooting...601
Inspection and Adjustment Mounted in Vehicle...602
Replacement of Oil Filter...602
Replacement of Engine Oil...603
Measurement of Oil Pressure...604
Oil Pan, Oil Strainer and Oil Jet...605
Oil Pump...607
Oil Cooler and Oil Filter...611
Group 13 - Fuel and Engine Control...613
Group 13A - '01 Minor Change - Fuel and Engine Control '4M50T2'...614
Table of Contents...615
Specifications...616
Structure and Operation...617
Fuel System (Fuel flow)...617
Engine Control...618
Fuel Filter...619
On-Vehicle Inspection and Adjustment...620
Checking Minimum and Maximum No-Load Speeds...620
Bleeding Air from Fuel System...621
Replacing Fuel Filter...621
Engine Control...624
Fuel Tank...627
Fuel Filter...628
Injection Pump...630
Injection Nozzle...634
Group 13E - '01 Minor Change - Fuel and Engine Control '4M50T2'...643
Table of Contents...644
Specifications...645
Structure and Operation...646
General...646
Electronic Control System...648
Pin Configuration of Engine Control Unit...652
Troubleshooting...657
Inspection Procedures...657
Connection of Multi-Use Tester II...659
Reading and Erasing Diagnostic Trouble Codes...660
Diagnostic Trouble Codes and Check Items...662
Service Data of Multi-Use Tester II...671
Actuator Test by Multi-Use Tester II...673
Checks at Connector of Control Unit...675
Checks On Intermittent Troubles...678
Inspection of Electrical Equipment...679
Locations of Parts...687
Group 13 - '99 Minor Change - Fuel and Engine Control...692
Table of Contents...693
Specifications...694
Structure and Operation...696
Troubleshooting...724
Reading and Erasing Diagnosis Codes...728
Service Procedures Using M.U.T.-II...734
Inspection Based on Diagnosis Code...736
On-Vehicle Inspection and Adjustment...740
Checking and Adjusting Injection Timing...740
Bleeding Air from Fuel System...743
Cleaning Gauze Filter...743
Replacing Fuel Filter...744
Engine Control...745
Fuel Tank...750
Fuel Filter...751
Water Separator...752
Injection Pump...754