Mitsubishi Fuso FE FG FH FK FM 2002-2004 Workshop Service Repair Manual PDF - MMTBSFUSOEM0204OPEK.zip
A complete factory-level service and repair manual, featuring Electrical Wiring Diagrams, covering the Mitsubishi Fuso FE, FG, FH, FK and FM Series from 2002 to 2004. It delivers every technical detail needed to service, troubleshoot, fix, and rebuild these trucks the way professional technicians do.
The Mitsubishi Fuso FE.FG.FH.FK.FM Series 2002-2004 workshop service repair manual contains:
* 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.
FE.FG.FH.FK.FM Series 2002-2004 Fuso Service Manual (TWME0103&TWME0202&TWSE0101).pdf
PRODUCT DETAILS:
Total Pages: 4,655 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
'02-'04 S/M...1
FE-FG...0
Forward...2
How to Read this Manual...3
Index...4
How This Manual Is Structured...5
Terms...18
Group 00 - General...19
Index...20
Model Coding System...21
Power Train Table...22
Chassis No. & Engine No./Power Train Label...23
Vehicle Identification No...24
Precautions for Maintenance Operation...25
Table of Standard Tightening Torques...37
Connector Configuration Chart...41
Group 01 - Maintenance Schedule...83
Index...84
How To Read the Maintenance Schedule Tables...85
Maintenance Schedule Tables...87
Maintenance Operations...89
Lubrication Tables...111
Lubrication...113
Group 11A - Engine 4M5...131
Index...132
Specifications...133
Structure & Operation...135
Troubleshooting...145
On-Vehicle Inspection & Adjustment...147
Removal & Installation of Engine...151
Rocker Cover, Rocker Assemblies & Camshafts...155
Cylinder Head & Valve Mechanism...169
Front Case...183
Timing Gears & Balance Shafts...187
Pistons, Connecting Rods & Cylinder Liners...195
Flywheel...207
Crankshaft & Crankcase...211
Balance Shaft Bushings...0
Group 11B - Engine 4D3...224
Index...225
Specifications...226
Structure & Operation...227
Troubleshooting...230
Inspection & Adjustment Mounted in Vehicle...231
Removal & Installation of Engine...236
Cylinder Head & Valve Mechanism...240
Timing Gear...254
Camshaft...258
Piston, Connecting Rods & Cylinder Sleeve...264
Flywheel Without Flywheel Power Take-Off...278
Flywheel With Flywheel Power Take-Off...282
Crankshaft & Crankcase...290
Group 12A - Lubrication 4M5...297
Index...298
Specifications...299
Structure & Operation...301
Troubleshooting...310
On-Vehicle Inspection & Adjustment...311
Oil Pan, Oil Strainer & Oil Jet...315
Oil Pump...317
Oil Filter...321
Oil Cooler...323
Group 12B - Lubrication 4D3...326
Index...327
Specifications...328
Structure & Operation...329
Troubleshooting...336
Inspection & Adjustment Mounted in Vehicle...337
Oil Pan, Oil Strainer & Oil Jet...340
Oil Pump...342
Oil Cooler & Oil Filter...346
Group 13A - Fuel & Engine Control 4M5...348
Index...349
Specifications...350
Structure & Operation...351
On-Vehicle Inspection & Adjustment...354
Engine Control...358
Fuel Tank...362
Fuel Filter...363
Injection Pump...364
Injection Nozzle...368
Group 13B - Fuel & Engine Control 4D3...377
Index...378
Specifications...379
Structure & Operation...380
Troubleshooting...385
On-Vehicle Inspection & Adjustment...387
Engine Control...391
Fuel Tank...397
Fuel Filter...398
Water Separator...399
Injection Pump...401
Injection Nozzle...405
Group 13EA - Electronically Controlled Fuel System 4M5...409
Index...410
Specifications...411
Structure & Operation...412
Troubleshooting...423
Inspection of Electrical Equipment...445
Locations of Parts...453
Electrical Wiring Diagram...457
Group 13EB - Electronically Controlled Fuel System 4D3...458
Index...459
Structure & Operation...460
Troubleshooting...478
Inspection of Electrical Equipment...489
Locations of Parts...497
Electrical Wiring Diagram...498
Group 14A - Cooling 4M5...499
Index...500
Specifications/Structure & Operation...501
Troubleshooting...503
On-Vehicle Inspection & Adjustment...505
Radiator...509
Cooling Fan, V-Ribbed Belt, V-Belt & Water Pump...517
Water Hose & Pipe...521
Thermostat...523
Group 14B - Cooling 4D3...525
Index...526
Specifications/Structure & Operations...527
Troubleshooting...529
Inspection & Adjustment Mounted In Vehicle...531
Radiator...535
Cooling Fan & V-Belt...537
Water Pump...541
Thermostat...543
Group 15A - Intake & Exhaust 4M5...546
Index...547
Specifications/Structure & Operation...548
Troubleshooting...550
On-Vehicle Inspection & Adjustment...551
Air Duct & Air Cleaner Except Crew Cab...554
Air Duct & Air Cleaner Crew Cab...558
Turbocharger...561
Intercooler...566
Intake Manifold...568
Exhaust Manifold...570
Exhaust Pipe & Muffler...572
Group 15B - Intake & Exhaust 4D3...574
Index...575
Specifications/Structure & Operation...576
Troubleshooting...579
Inspection & Adjustment Mounted In Vehicle...580
Air Duct & Air Cleaner...582
Turbocharger...586
Intercooler...592
Intake Manifold...594
Exhaust Manifold...596
Exhaust Pipe & Muffler...598
Group 21 - Clutch...600
Index...601
Specifications/Structure & Operation...602
Troubleshooting...605
Inspection & Adjustment Mounted In Vehicle...606
Clutch Pedal...610
Clutch Master Cylinder...612
Clutch Power Cylinder...614
Work Before Removal & Installation of Clutch Body...616
Clutch Body...618
Clutch Control...622
Group 22 - Manual Transmission...623
Index...624
Specifications/Structure & Operations...625
Troubleshooting...628
Work Before Removal & Installation of Transmission Assembly...630
Removal & Installation of Transmission Assembly...631
Gear Shifter Upper...633
Rear Cover & Reverse Idler Gear...639
Transmission Body...643
Drive Pinion Assembly...651
Mainshaft Assembly...653
Countershaft Assembly...659
Transmission Control...663
Group 23 - Automatic Transmission...676
Index...677
Specifications...678
Structure & Operation...679
Troubleshooting Procedures...716
On-Vehicle Inspection & Adjustment...728
Removal & Installation of Automatic Transmission Assembly...736
Oil Cooler...742
Automatic Transmission Control...746
Replacement of Automatic Transmission Parts...756
Inspection & Adjustment of Other Devices...762
Location of Parts...764
Electrical Wiring Diagram...765
Group 24 - Transfer...767
Index...768
Specifications/Structure & Operation...769
Troubleshooting...771
Removal & Installation of Transfer Assembly...773
Front Drive...777
Idler Gear & Rear Drive...783
Transfer Control...789
Group 25 - Propeller Shaft...797
Index...798
Specifications...799
Structure & Operation...800
Troubleshooting...801
Removal & Installation of Propeller Shaft Transmission, Transfer To Rear Axle...803
Removal & Installation of Propeller Shaft Front Axle To Transfer...804
Rear Propeller Shaft P2 : FG639...805
Rear Propeller Shaft P2 : FG649...809
Rear Propeller Shaft P3...813
Front Propeller Shaft...817
Balancing Propeller Shaft...821
Group 26A - Front Axle...823
Index...824
Specifications/Structure & Operation...825
Inspection & Adjustment Mounted In Vehicle...827
Work Before Removal & Installation of Front Axle...831
Wheel Hub & Rotor...833
Front Axle, Knuckle & Kingpin...842
Group 26B - Front Axle...849
Index...850
Specifications/Structure & Operation...851
Troubleshooting...855
On-Vehicle Inspection & Adjustment...857
Work Before Removal & Installation of Front Axle...863
Wheel Hub & Brake Drum...865
Knuckle & Drive Shaft...875
Axle Housing...881
Reduction & Differential...883
Group 27 - Rear Axle...896
Index...897
Specifications...898
Structure & Operation...899
Troubleshooting...903
Work Before Removal & Installation of Rear Axle...905
Wheel Hub & Brake Drum FE639, FG...906
Wheel Hub & Rotor FE640, FE649...916
Axle Housing...926
Reduction & Differential...930
Muliplate Limited Slip Differential Assembly...944
FEFG group 27 '04 minor changes.pdf...0
Group 27 - Rear Axle...950
Index...951
Specifications...952
Structure and Operation...953
Troubleshooting...957
Work Before Removal and Installation of Rear Axle...959
Wheel Hub and Brake Drum FE639, FG...960
Wheel Hub and Rotor FE640, FE649...970
Axle Housing...980
Reduction and Differential...984
Multiplate Limited Slip Differential Assembly...998
Group 31 - Wheel & Tire...1004
Index...1005
Specifications/Troubleshooting...1006
Wheel & Tire...1007
Group 33 - Front Suspension...1011
Index...1012
Structure & Operation...1013
Troubleshooting...1014
Work Before Removal & Installation of Front Suspension...1015
Removal & Installation of Leaf Spring Assembly FE...1017
Removal & Installation of Leaf Spring Assembly FG...1019
Leaf Spring Assembly FE...1023
Leaf Spring Assembly FG...1025
Shock Absorber FE...1027
Shock Absorber FG...1028
Stabilizer FE...1029
Group 34 - Rear Suspension...1031
Index...1032
Structure & Operation...1033
Troubleshooting...1034
Work Before Removal & Installation of Rear Suspension...1035
Removal & Installation of Leaf Spring Assembly FE...1037
Removal & Installation of Leaf Spring Assembly FG...1041
Leaf Spring Assembly...1045
Shock Absorber...1048
Stabilizer FE...1049
Group 35A - Brake...1051
Index...1052
Specifications...1053
Structure & Operation...1054
Troubleshooting...1075
On-Vehicle Inspection & Adjustment...1081
Brake Master Cylinder...1097
Brake Pedal & Brake Booster (Master VAC)...1099
Front Wheel Brake FE639 (Except FE639 6 : Disc Brake...1101
Front Wheel Brake FE639 6, FE640 : Disc Brake...1105
Front Wheel Brake Drum Brake...1109
Rear Wheel Brake Drum Brake...1115