Mitsubishi Fuso FE FG FK FM 2005 Workshop Repair Service Manual PDF - MMTBSFUSOEM05OPEK.zip
This complete service and repair guide, featuring Electrical Wiring Diagrams, covers the 2005 Mitsubishi Fuso FE, FG, FK, and FM Series trucks. It contains every technical detail needed to service, troubleshoot, fix, and rebuild these vehicles just as a professional technician would.
The official workshop service and repair manual includes:
* 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 2005 Service Manual (TWME0404&TWSE0405).pdf
PRODUCT DETAILS:
Total Pages: 3,143 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
2005 Service Manual....1
2005 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....13
Vehicle Identification Number....14
Precautions for Maintenance Operation....15
Jacking Up the Vehicle....27
Diagnosis Codes....29
1. Connecting Multi-Use Tester....29
2. Accessing/Erasing Diagnosis Codes 'Common Rail, Exhaust Gas Recirculation, Pre-heater'....33
3. Accessing/Erasing Diagnosis Codes 'Automatic Transmission'....35
4. Accessing/Erasing Diagnosis Codes 'Anti-lock Brake System'....37
Table of Standard Tightening Torques....39
Group 01 - Maintenance Schedule....42
Table of Contents....43
How to Read the Maintenance Schedule Tables....44
Maintenance Schedule Tables....46
Maintenance Operations....50
Lubrication Tables....56
Lubrication....58
Group 11 - Engine....62
Table of Contents....63
Specifications....64
Structure and Operation....65
1. Exploded View....65
2. Cylinder Head, Cylinder Head Gasket, Camshaft, and Camshaft Frame....66
3. Valve Mechanism....67
4. Connecting Rod....68
5. Piston....68
6. Timing Gears....69
7. Flywheel....69
8. Balance Shafts....70
9. Crankcase and Main Bearings....71
10. Oil Seals....73
Troubleshooting....74
On-Vehicle Inspection and Adjustment....76
1. Measuring Compression Pressure....76
2. Inspection and Adjustment of Valve Clearance....78
Engine Removal and Installation....80
'Tilt Cab'....80
'Fixed Cab'....88
Rocker Cover....90
Rockers and Camshafts....92
Cylinder Head and Valve Mechanism....104
Pistons, Connecting Rod and Cylinder Liners....118
Flywheel....132
Front Case....136
Timing Gears and Balance Shafts....138
Crankshaft and Crankcase....146
Balance Shaft Bushings....154
Group 12 - Lubrication....159
Table of Contents....160
Specifications....161
Structure and Operation....162
1. Lubrication System....162
2. Oil Pump....163
3. Oil Cooler....164
4. Oil Filter....165
5. Lubrication of Engine Components....166
Troubleshooting....169
On-Vehicle Inspection and Adjustment....171
1. Oil Filter Replacement....171
2. Engine Oil Replacement....175
3. Oil Pressure Measurement....177
Oil Pan, Oil Strainer and Oil Jets....179
Oil Pump....181
Oil Filter....185
Oil Cooler....189
Group 13 - Fuel and Engine Control....191
Group 13A - Fuel and Engine Control....192
Table of Contents....193
Specifications....194
Structure and Operation....195
1. Fuel System (Flow of Fuel)....195
2. Engine Control....196
3. Fuel Filter....197
Troubleshooting....198
On-Vehicle Inspection and Adjustment....200
1. Inspecting and Adjusting No-load Minimum and Maximum Speeds....200
2. Air-bleeding of Fuel System....201
3. Fuel Filter Replacement....202
Fuel Tank....204
Fuel Filter....206
Engine Control....208
Common Rail....211
Supply Pump....212
Injector....214
Group 13E - Electronically Controlled Fuel System....216
Table of Contents....217
Specifications....218
Structure and Operation....219
1. Overview....219
2. Electronic Control System....228
3. Electronic Control Unit Connection Diagram....234
Troubleshooting....236
1. Inspection Procedure....236
2. Cautions to Observe when Performing Inspections....237
3. Inspection Based on Diagnosis Codes....238
4. Multi-Use Tester Service Data....252
5. Actuator Tests Performed Using Multi-Use Tester....254
6. Inspections Performed at Electronic Control Unit Connectors....256
Inspection of Electrical Equipment....259
Installed Locations of Parts....266
Electric Circuit Diagram....272
Group 14 - Cooling....278
Table of Contents....279
Specifications....280
Structure and Operation....282
1. Cooling System (Flow of Coolant)....282
2. Thermostat....283
3. Water Pump....283
Troubleshooting....284
On-Vehicle Inspection and Adjustment....286
1. Coolant Replacement and Cleaning of Cooling System....286
2. Air Bleeding of Cooling System....288
3. Air/Gas Leakage Test....288
Disconnection and Connection of Hoses and Pipes....290
Radiator....294
Cooling Fan, V-Belt and Water Pump....302
Tension Pulley....305
Thermostat....306
Pressure Cap and Water Outlet Case....308
Group 15 - Intake and Exhaust....310
Table of Contents....311
Specifications....312
Structure and Operation....312
1. Air Cleaner....312
2. Turbocharger....313
3. Muffler....314
Troubleshooting....315
On-Vehicle Inspection and Adjustment....316
1. Measurement of Turbocharger Boost Pressure....316
Air Duct and Air Cleaner 'Except Crew Cab'....318
Air Duct and Air Cleaner 'Crew Cab'....322
Turbocharger....326
Intercooler....332
Intake Manifold....334
Exhaust Manifold....335
Exhaust Pipe....336
Muffler....338
Group 17 - Emission Control....339
Table of Contents....340
Structure and Operation....341
1. Exhaust Gas Recirculation System....341
2. Crankcase Emission Control System....346
Exhaust Gas Recirculation System....347
1. Inspection Procedure....347
2. Cautions to Observe when Performing Inspections....348
3. Inspections Based on Diagnosis Codes....349
4. Multi-Use Tester Service Data....351
5. Actuator Tests Performed Using Multi-Use Tester....351
6. Inspections Performed at Electronic Control Unit Connectors....352
7. Inspection of Electrical Equipment....353
8. Installed Locations of Parts....354
9. Electric Circuit Diagram....359
Exhaust Gas Recirculation Valve, Pipe and Cooler....363
Crankcase Emission Control System....365
Group 21 - Clutch....367
Table of Contents....368
Specifications....369
Structure and Operation....370
1. Clutch Control....370
2. Clutch Master Cylinder....371
3. Clutch Proper and Clutch Direct Power Cylinder....373
Troubleshooting....375
On-Vehicle Inspection and Adjustment....377
1. Replacement of Brake Fluid (Clutch System)....377
2. Air Bleeding of Brake Fluid (Clutch System)....379
3. Inspection of Clutch Disk Wear Limit....381
Clutch Pedal....383
Clutch Master Cylinder....387
Clutch Proper....389
Clutch Control....393
Group 22 - Manual Transmission....398
Table of Contents....399
Specifications....400
Structure and Operation....402
1. Transmission....402
2. Synchromesh Mechanism....404
3. Interlock Mechanism....407
4. Speedometer Gear Bushing....407
Troubleshooting....408
On-Vehicle Inspection and Adjustment....410
1. Inspection and Replacement of Transmission Oil....410
Removal and Installation of Transmission Assembly....412
Gear Shifter Upper....414
Rear Cover 'S5' and Parking Brake....420
Extension Housing 'S6' and Parking Brake....424
Reverse Idler Gear....428
6th Gear 'S6'....432
Transmission Body....438
Drive Pinion....454
Mainshaft....456
Countershaft....466
Transmission Control....468
Bearing Puller and Installer....473
Group 23 - Automatic Transmission....474
Table of Contents....475
Specifications....476
Structure and Operation....477
1. Overview....477
2. Electronic Control System....488
3. Electronic Control Unit Connection Diagram....494
Troubleshooting....496
1. Inspection Procedure....496
2. Cautions to Observe When Performing Inspections....497
3. Inspections Based on Diagnosis Codes....498
4. Multi-Use Tester Service Data....507
5. Inspections Performed at Electronic Control Unit Connectors....510
6. Likely Causes of Symptoms....513
On-Vehicle Inspection and Adjustment....518
1. Stall Test....518
2. Time Lag Test....519
3. Line Pressure Test....520
4. Road Test....522
5. Inspection of ATF....523
6. Replacement of ATF....524
7. Dealer Adjust....526
Removal and Installation of Automatic Transmission....530
Automatic Transmission Control....538
Oil Cooler....546
'Models Except Crew Cab'....546
'Crew Cab'....548
Replacement of Parts of Automatic Transmission Main Body....550
Inspection of Electrical Equipment....554
Installed Locations of Parts....558
Electric Circuit Diagram....562
Group 24 - Transfer....568
Table of Contents....569
Specifications....570
Structure and Operation....571
1. Transfer....571
2. Speedometer Gear Bushing....572
Troubleshooting....573
On-Vehicle Inspection and Adjustment....574
1. Inspection and Replacement of Transfer Oil....574
Removal and Installation of Transmission (with Transfer)....576
Removal and Installation of Transfer....578
Front Drive....580
Rear Drive....584
Transfer....590
Transfer Control....598
Group 25 - Propeller Shaft....602
Table of Contents....603
Specifications....604
Structure and Operation....604
1. Configuration of Propeller Shaft Connection....604
2. Propeller Shaft 'without Center Bearing'....605
3. Propeller Shaft 'with Center Bearing'....606
Troubleshooting....607
Removal and Installation of Propeller Shaft 'Between T/M (or T/F) and Rear Axle....608
Removal and Installation of Propeller Shaft 'Between Front Axle and T/F'....612
Propeller Shaft 'P2'....614
Propeller Shaft 'P3'....620
Group 26 - Front Axle....630
Group 26A - Front Axle 'FE'....631
Table of Contents....632
Specifications....633
Structure and Operation....634
1. Wheel Hub and Rotor....634
2. Knuckle and Kingpin, Front Axle....635
Troubleshooting....636
On-Vehicle Inspection and Adjustment....637
1. Inspection and Adjustment of Wheel Alignment....637
2. Inspection and Adjustment of Steering Angle....641
3. Inspection of Side Slip....642
4. Inspection of Play in Tie Rod End Ball Joint....642
Wheel Hub and Rotor....643
Knuckle and Kingpin, Front Axle....651
Tie Rod....659
Group 26B - Front Axle 'FG'....661
Table of Contents....662
Specifications....663
Structure and Operation....663
1. Wheel Hub and Brake Drum....663
2. Free Wheel Hub....664
3. Drive Shaft and Steering Knuckle, Axle Housing....665
4. Reduction and Differential....666
Troubleshooting....667
On-Vehicle Inspection and Adjustment....671