Mitsubishi FUSO Canter / Rosa / Fighter Repair Service Manual 1996-2016
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi FUSO Canter, Rosa, Fighter 1996-2016, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi FUSO Canter / Rosa / Fighter workshop service 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.
FILE LIST:
1996-2001 Fuso Service Manual (FE, FG, FK, FM).pdf
2002-2004 Fuso Service Manual (FE, FG, FH, FK, FM).pdf
2005 Fuso Service Manual (FE, FG, FK, FM).pdf
2008 Fuso Service Manual (FE, FG, FK, FM).pdf
2012-2016 Fuso Service Manual (FE, FG).pdf
2012 Fuso Canter Service Manual (FE, FG).pdf
FUSO
4D3 Engine TWDE0207OCT02 (Existing Cab)
4D3EURO3 Engine TWDE0416FEB05
4D3EURO3 ROSA Engine TWDE0220JUL03
4M4EURO3 Engine TWDE0206Oct02 (Existing Cab)
4M4EURO3 Engine TWDE0417FEB05
4M5EPA04Canter TWDE0803MAR08
4M5EPA04 Rosa EngineTWDE0722DEC07
4M5 (JP05) Rosa Diesel Engine For Australia 00ELB0001 JAN 2011
4P10 (EURO 5) Canter Diesel Engine For Australia 00ELT0002 APR 11
6D16 Engine TWGE0212NOV02
6M6EPA04 Engine TWGE0801FEB08
6M6EURO3 Engine TWGE0213NOV02
M05-D001-13 Commion Rail Parts and Replac Proced.PDF
M06-T002-13 Omission To Shop Manual.pdf
M07-T003-35 Air Comp Bolt Tension.PDF
M08-D005-00 Check Method of Injector.pdf
M08-T006-11 Correction To Shop Manual.pdf
M09-D002-11 Change of Cylinder Head Gasket.pdf
6M6EURO3 Engine TWGE0317DEC03
M05-D001-13 Common Rail Parts and Repair Procd.PDF
M06-T002-13 Omission To Shop Manual.pdf
M07-T003-35 Air Comp Bolt Tension.PDF
M08-D005-00 Check Method of Injector.pdf
M08-T012-13 Correction To Shop (service) Manuals.pdf
M09-D002-11 Change of Cylinder Head Gasket.pdf
6M6EURO3 Supplement TWME0318-2MAR05
6M7EPA04 Engine TWJE0718DEC07
6M7EURO3 Engine Supp TWJE0215-1SEP04
CLICK HERE TO ACCESS CRUISE CONTROL SUPPLEMENT.pdf
6M7EURO3 Engine TWJE0215JAN03
L03-T003-13 Correction To Shop Manuals 6M7 Engine.pdf
L04-T004-13 Correction To Shop Manual 6M7 Engine.pdf
L07-T005-00 Hose Clamp Tension.PDF
L09-D004-13 Supply Pump Relief Relocate.PDF
L09-T008-13 Corrections To Shop Manuals 6M70.pdf
DOUBLE CLICK TO OPEN MANUAL.pdf
CanterEPA04 Chassis TWSE0804MAR08
CanterEPA04 Electrical THSE0802MAR08
CanterEPA04 Supplement TWSE0804-1SEP08
CanterEPA04 Supplement TWSE0804-2JUN09
Canter Euro 3 ADR80-00 EPA07 SERIES 60 DDEC VI (DDC-SVC-MAN-0005)
General Informaton.pdf
Section 10 - Power Take-Off.pdf
Section 11 - Special Equipment.pdf
Section 12 - Operation and Verification.pdf
Section 13 - Engine Tune-Up.pdf
Section 14 - Preventive Maintenance.pdf
Section 15 - Storage.pdf
Section 1 - Engine.pdf
Section 2 - Fuel System.pdf
Section 3 - Lubrication System.pdf
Section 4 - Cooling System.pdf
Section 5 - Fuel, Lubricating Oil, and Coolant.pdf
Section 6 - Air Intake System.pdf
Section 7 - Exhaust System.pdf
Section 8 - Exhaust Gas Recirculation Components.pdf
Section 9 - Electrical Equipment.pdf
CanterEURO3 Chassis TWSE0208OCT02 (Existing cab)
CanterEURO3 Chassis TWSE0418FEB05
CanterEURO3 Dump Body
CanterEURO3 Electrical THSE0407FEB05
Canter (EURO 5) Chassis For Australia 00ELT0003 APR 11
Canter (EURO 5) Electrical For Australia 00ELT0004 APR 11
FighterEPA04 Chassis TWME0802FEB08
FighterEPA04 Electrical THME0801FEB08
FighterEPA04 Supplement TWME0802-1JUL08
FighterEURO3 Chassis Supp TWME0318-1OCT04
FighterEURO3 Chassis TWME0214DEC02
FighterEURO3 Chassis TWME0318DEC03
FighterEURO3 Electrical THME0204NOV02
FighterEURO3 Electrical THME0308SEP03
HDTEPA04 Chassis TWLE0719DEC07
A
G05-T003-26 Kingpin Measure.PDF
L02-T001-37 Tie Rod End Play.pdf
L08-T005-26 Correction To Shop Manual.PDF
L09-T002-35 Correction To Shop Manual.pdf
HDTEPA04 Electrical THLE0708DEC07
HDTEPA04 Supplement TWLE0719-1APR09
HDTEURO3 Chassis & Elect Supp TWLE0216-1DEC04
HDTEURO3 Chassis TWLE0216JAN03
A
G04-D007-26 Front Hub Grease Amount.PDF
G05-T003-26 Kingpin Measure Proced.PDF
FP FS FV Chassis (Euro3 )
FP FS FV Chassis opening page.pdf
HDTEURO3 Electrical THLE0205JAN03
A
G01-T002-16 Starter Grease.pdf
Index
Electrical Manual
Electrical_Manual.pdf
FP,FS,FV Opening Page.pdf
HEV (JP05) Canter Chassis for Australia TWSE0912 JUN 09
HEV (JP05) Canter Electrical for Australia THSE0909 JUN 09
ROSAEPA04 AC BM372-1 BCS186-X-0004
ROSAEPA04 Chassis TWSE0723DEC07
S03-D020-00 Grease to Clutch and Brake Pedal.PDF
S07-T015-35 Establishment Of Brake Drum Cutting Procedure ROSA.pdf
S09-T003-63 Correction To Shop Manual.pdf
ROSAEPA04 Electrical THSE0710DEC07
A
G01-T002-16 Change In Starter Grease.pdf
ROSAEURO3 Chassis TWSE0221JUL03
S03-D018-31 Tire & Wheel Ass Instal Proc.pdf
S03-D020-00 Additional Grease To Clutch and Brake.pdf
S07-T015-35 Estab Of Brake Drum Cut Proc.pdf
S09-T003-63 Correction To Shop Manual Rosa (Auto Door System).pdf
S09-T004-33 Correction To Shop Manual (Suspension System).pdf
ROSA Chassis For Australia
ROSA Chassis For Australia 2.pdf
ROSA Chassis For Australia CONTENTS PAGE.pdf
ROSA Chassis For Australia.pdf
ROSA Chassis For Australia OPENING PAGE.pdf
ROSA Chassis TWSE0218 Electrical THSE0206 SEP 2002
DOUBLE CLICK TO USE MANUALS.pdf
ROSA_chassis.pdf
ROSA_electrical.pdf
ROSAEURO3 Electrical THSE0207JUL03
ROSA BE6 Electrical For Australia THSE0207 JUL 2003.pdf
ROSA (EURO 3) Engine, Chassis, and Electrical Supplement For Australia TWSE0329-5 JUL 2007
Rosa Euro 3 Engine, Chassis, Electrical Supplement for Australia TWSE0329-5
ROSAEURO3 Supplement Manual TWSE0329-5JUL07
Rosa (JP05) Chassis for Australia 00ELB0002 JAN 2011
Rosa (JP05) Electrical for Australia 00ELB0003 JAN 2011
"2002-2004.All Models.pdf"
2002 2003 2004 Mitsubishi Fuso Truck (FE / FG / FH / FK / FM Series) Service Manual; 4,655 pages
"2005.All Models.pdf"
2005 2006 2007 Mitsubishi Fuso Truck (FE / FG / FK / FM Series) Service Manual; 3,164 pages
"2008-2010.All Models.pdf"
2008 2009 2010 Mitsubishi Fuso Truck (FE / FG / FK / FM Series) Service Manual; 5,181 pages
"2012-2016.All Models.pdf"
2012 2013 2014 2015 2016 Mitsubishi Fuso Canter Service Manual; 5,261 pages
Publication NO.:
00ELT0001 (2012)
00ELT0014 (2013)
00ELT0031 (2014)
00ELT0032 (2014 1/2)
00ELT0059 (2015-2016)
"00ELT0001-00.pdf"
2012 Canter (FE / FG Series) Service Manual; 2,664 pages
"bonus": 2.2 GB PDF
Mitsubishi Fuso ROSA (BE, BE6, BC6..)
Mitsubishi Fuso Canter (FE, FE534, FE639, FE649, FE659, FG, FG649, FP, FP-R, FS, FV...)
Mitsubishi Fuso Fighter (FK, FM, FN...)
4D3 Engine TWDE0207OCT02 (Existing Cab)
4D3EURO3 Engine TWDE0416FEB05
4D3EURO3 ROSA Engine TWDE0220JUL03
4M4EURO3 Engine TWDE0206Oct02 (Existing Cab)
4M4EURO3 Engine TWDE0417FEB05
4M5 (JP05) Rosa Diesel Engine For Australia 00ELB0001 JAN 2011
4M5EPA04 Rosa EngineTWDE0722DEC07
4M5EPA04Canter TWDE0803MAR08
4M42 JP05 Engine for Australia (HEV Canter) TWDE0911 JUN 2009
4P10 (EURO 5) Canter Diesel Engine For Australia 00ELT0002 APR 11
6D16 Engine TWGE0212NOV02
6M6EPA04 Engine TWGE0801FEB08
6M6EURO3 Engine TWGE0213NOV02
6M6EURO3 Engine TWGE0317DEC03
6M6EURO3 Supplement TWME0318-2MAR05
6M7EPA04 Engine TWJE0718DEC07
6M7EURO3 Engine Supp TWJE0215-1SEP04
6M7EURO3 Engine TWJE0215JAN03
Canter (EURO 5) Chassis For Australia 00ELT0003 APR 11
Canter (EURO 5) Electrical For Australia 00ELT0004 APR 11
Canter Euro 3 ADR80-00 EPA07 SERIES 60 DDEC VI (DDC-SVC-MAN-0005)
CanterEPA04 Chassis TWSE0804MAR08
CanterEPA04 Electrical THSE0802MAR08
CanterEPA04 Supplement TWSE0804-1SEP08
CanterEPA04 Supplement TWSE0804-2JUN09
CanterEURO3 Chassis TWSE0208OCT02 (Existing cab)
CanterEURO3 Chassis TWSE0418FEB05
CanterEURO3 Dump Body
CanterEURO3 Electrical THSE0407FEB05
FighterEPA04 Chassis TWME0802FEB08
FighterEPA04 Electrical THME0801FEB08
FighterEPA04 Supplement TWME0802-1JUL08
FighterEURO3 Chassis Supp TWME0318-1OCT04
FighterEURO3 Chassis TWME0214DEC02
FighterEURO3 Chassis TWME0318DEC03
FighterEURO3 Electrical THME0204NOV02
FighterEURO3 Electrical THME0308SEP03
HDTEPA04 Chassis TWLE0719DEC07
HDTEPA04 Electrical THLE0708DEC07
HDTEPA04 Supplement TWLE0719-1APR09
HDTEURO3 Chassis & Elect Supp TWLE0216-1DEC04
HDTEURO3 Chassis TWLE0216JAN03
HDTEURO3 Electrical THLE0205JAN03
HEV (JP05) Canter Chassis for Australia TWSE0912 JUN 09
HEV (JP05) Canter Electrical for Australia THSE0909 JUN 09
ROSA (EURO 3) Engine, Chassis, and Electrical Supplement For Australia TWSE0329-5 JUL 2007
Rosa (JP05) Chassis for Australia 00ELB0002 JAN 2011
Rosa (JP05) Electrical for Australia 00ELB0003 JAN 2011
Rosa Euro 3 Engine, Chassis, Electrical Supplement for Australia TWSE0329-5
ROSAEPA04 AC BM372-1 BCS186-X-0004
ROSAEPA04 Chassis TWSE0723DEC07
ROSAEPA04 Electrical THSE0710DEC07
ROSAEURO3 Chassis TWSE0221JUL03
ROSAEURO3 Electrical THSE0207JUL03
ROSAEURO3 Supplement Manual TWSE0329-5JUL07
…
PRODUCT DETAILS:
Total Pages: 26,332 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
1996-2001 Fuso Service Manual (FE, FG, FK, FM)....1
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
Injection Nozzle....758
Inspection of Other Devices....762
Electric Circuit and Part Installation Locations....772
Group 13 - Fuel and Engine Control....774
Table of Contents....775
Specifications....776
Structure and Operation....778
Troubleshooting....798
Inspection and Adjustment Mounted in Vehicle....802
Inspection and Adjustment of Fuel Injection Timing....802
Inspection and Adjustment of No-Load Minimum and Maximum Revolution....805
Inspection and Adjustment of Idling Actuator with Cab Cooler....806
Pre-Stroke Control Injection Pump System....808
Troubleshooting Procedure....808
Electric Circuit and Position of Parts Installation....814
Inspection by Individual Diagnosis Code....816
Inspection of Temporary Faults....834
Engine Control....836
Fuel Tank....841
Water Separator....842
Fuel Filter....844
Injection Pump....846
Injection Nozzle....850
Group 14 - Cooling....854
Group 14A - '01 Minor Change - Cooling 4M50T2....855
Table of Contents....856
Specifications....857
Structure and Operation....857
Troubleshooting....859
On-Vehicle Inspection and Adjustment....861
Replacing Coolant and Cleaning Cooling System....861
Air Bleeding of Cooling System....863
Gas Leak Testing....863
Radiator....865
Cooling Fan, V-Ribbed Belt and Water Pump....873
Water Hose & Pipe....879
Thermostat....881
Group 14 - Cooling....883
Table of Contents....884
Specifications....885
Structure and Operation....885
Troubleshooting....889
Inspection and Adjustment Mounted in Vehicle....891
Replacing Coolant and Cleaning Cooling System....891
Air Bleeding of Cooling System....893
Gas Leakage Test....893
Radiator....895
Cooling Fan and V-Belt....897
Water Pump....901
Thermostat....903
Group 15 - Intake and Exhaust....906
Group 15A - '01 Minor Change - Intake and Exhaust 4M50T2....907
Table of Contents....908
Specifications....909
Structure and Operation....909
Air Cleaner....909
Turbocharger Assembly....910
Troubleshooting....911
On-Vehicle Inspection and Adjustment....912
Measurement of Turbocharger Boost Pressure....912
Air Duct and Air Cleaner....915
Turbocharger....918
Intercooler....923
Intake Manifold....925
Exhaust Manifold....927
Exhaust Pipe and Muffler....928
Group 15 - Intake and Exhaust....929
Table of Contents....930
Specifications....931
Structure and Operation....931
Troubleshooting....934
Inspection and Adjustment Mounted in Vehicle....935
Measurement of Turbo Boost Pressure....935
Air Duct and Air Cleaner....937
Turbocharger....941
Intercooler....947
Intake Manifold....949
Exhaust Manifold....951
Exhaust Pipe and Muffler....953
Group 21 - Clutch....955
Table of Contents....956
Specifications....957
Structure and Operation....957
Troubleshooting....960
Inspection and Adjustment Mounted in Vehicle....961
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding....961
Clutch Pedal Free Play....963
Clutch Pedal....965
Clutch Master Cylinder....967
Clutch Power Cylinder....969
Work Before Removal and Installation of Clutch Body....971
Clutch Body....973
Clutch Control....977
Group 22 - Manual Transmission....978
Table of Contents....979
Specifications....980
Structure and Operation....980
Troubleshooting....983
Work Before Removal and Installation of Transmission Assembly....985
Removal and Installation of Transmission Assembly....986
Gear Shifter Upper....988
Rear Cover and Reverse Idler Gear....994
Transmission Body....998
Drive Pinion Assembly....1006
Mainshaft Assembly....1008
Countershaft Assembly Non-Backlash Mechanism....1014
Transmission Control....1018
Group 23 - Automatic Transmission....1029
Group 23 - '99 Minor Change - Automatic Transmission....1030
Table of Contents....1031
Specifications....1032
Structure and Operation....1034
Troubleshooting Procedures....1070
Troubleshooting....1072
On-Vehicle Inspection and Adjustment....1082
Stall Test....1082
Time Lag Test....1083
Line Pressure Test....1084
Road Test....1086
Inspection of Automatic Transmission Fluid (ATF)....1088
Changing Automatic Transmission Fluid (ATF)....1089
Removal and Installation of Automatic Transmission Assembly....1090
Oil Cooler....1095
Automatic Transmission Control....1098
Replacement of Automatic Transmission Parts....1108
Inspection and Adjustment of Other Devices....1114
Group 23 - Automatic Transmission....1120
Table of Contents....1121
Specifications....1122
Structure and Operation....1123
Troubleshooting Procedure....1170
Electric Circuit and Parts Installation Position....1181
Inspection by Individual Diagnosis Code....1183
Inspection by Symptom....1210
Inspection of Temporary Fault....1225
Inspection Using the Check Box (Harness Checker)....1226
Inspection and Adjustment Mounted in Vehicle....1230
Stall Test....1230
Line Pressure Test....1231
Road Test....1233
Inspection of Automatic Transmission Fluid....1235
Replacement of Automatic Transmission Fluid....1236
Work Before Removal and Installation of Automatic Transmission Assembly....1238
Removal and Installation of Automatic Transmission Assembly....1239
Oil Cooler....1244
Automatic Transmission Control....1248
Replacement of Relative Parts of Automatic Transmission Body....1260
Group 24 - Transfer....1265
Group 24 - '98 Minor Change - Transfer FG....1265
Table of Contents....1266
Specifications....1267
Structure and Operation....1267
Troubleshooting....1269
Removal and Installation of Transfer Assembly....1271
Front Drive....1275
Idler Gear and Rear Drive....1281
Transfer Control....1287
Group 25 - Propeller Shaft....1295
Group 25 - '98 Minor Change - Propeller Shaft....1296
Table of Contents....1297
Specifications....1298
Structure and Operation....1298
Troubleshooting....1299
Removal and Installation of Propeller Shaft....1300
Rear Propeller Shaft....1302
Balancing Propeller Shaft....1306
Group 25 - Propeller Shaft....1307
Table of Contents....1308
Specifications....1309
Structure and Operation....1309
Troubleshooting....1310
Removal and Installation of Propeller Shaft....1311
Rear Propeller Shaft....1313
Front Propeller Shaft....1317
Balancing Propeller Shaft....1321
Group 26 - Front Axle....1322
Group 26 - Front Axle....1323
Table of Contents....1324
Specifications....1325
Structure and Operation....1325
Inspection and Adjustment Mounted in Vehicle....1327
Adjustment of Wheel Alignment....1327
Adjustment of Steering Angle....1330
Measurement of Side Slip....1330
Work Before Removal and Installation of Front Axle....1331
Wheel Hub and Rotor....1333
Front Axle, Knuckle and Kingpin....1339
Group 26B - '98 Minor Change - Front Axle....1346
Table of Contents....1347
Specifications....1348
Structure and Operation....1348
Troubleshooting....1351
On-Vehicle Inspection and Adjustment....1353
Adjustment of Wheel Alignment....1353
Adjustment of Steering Angle....1356
Measurement of Side Slip....1357
Work Before Removal and Installation of Front Axle....1358
Wheel Hub and Brake Drum....1360
Knuckle and Drive Shaft....1368
Axle Housing....1374
Reduction and Differential....1376
Group 27 - Rear Axle....1389
Table of Contents....1390
Specifications....1391
Structure and Operation....1392
Troubleshooting....1394
Work Before Removal and Installation of Rear Axle....1396
Wheel Hub and Brake Drum FE639....1397
Wheel Hub and Rotor FE649....1405
Axle Housing....1413
Reduction and Differential....1417
Group 31 - Wheel and Tire....1431
Table of Contents....1432
Specifications....1433
Troubleshooting....1433
Wheel and Tire....1434
Group 33 - Front Suspension....1438
Group 33 - '98 Minor Change - Front Suspension....1439
Table of Contents....1440
Structure and Operation....1441
Troubleshooting....1442
Work Before Removal and Installation of Front Suspension....1443
Removal and Installation of Leaf Spring Assembly....1445
FE....1445
FG....1447
Leaf Spring Assembly....1451
FE....1451
FG....1453
Shock Absorber....1455
FE....1455
FG....1456
Stabilizer FE....1457
Group 33 - Front Suspension....1459
Table of Contents....1460
Structure and Operation....1461
Troubleshooting....1462
Work Before Removal and Installation of Front Suspension....1463
Removal and Installation of Leaf Spring Assembly....1465
Leaf Spring Assembly....1467
Shock Absorber....1469
Stabilizer....1471
Group 34 - Rear Suspension....1473
Group 34 - '98 Minor Change - Rear Suspension....1474
Table of Contents....1475
Structure and Operation....1476
Troubleshooting....1477
Work Before Removal and Installation of Rear Suspension....1478
Removal and Installation of Leaf Spring Assembly....1480
FE....1480
FG....1484
Leaf Spring Assembly....1488
Shock Absorber....1491
Stabilizer FE....1492
Group 34 - Rear Suspension....1494
Table of Contents....1495
Structure and Operation....1496
Troubleshooting....1497
Work Before Removal and Installation of Rear Suspension....1498
Removal and Installation of Leaf Spring Assembly....1500
Leaf Spring Assembly....1504
Shock Absorber....1507
Stabilizer....1508
Group 35 - Brake....1510
Group 35A - '00 Minor Change - Anti-Lock Brake System (ABS)....1511
Table of Contents....1512
Specifications....1513
Structure and Operation....1513
On-Vehicle Inspection and Adjustment....1520
Periodic Inspection Procedures....1520
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope....1521
Hydraulic Unit Operation Check....1522
Troubleshooting....1524
Troubleshooting Procedures....1524
Diagnosis Code Indication....1525
Diagnosis Code Chart....1528
Actuator Drive Chart....1528
Service Data....1529
Wheel Speed Sensor and Rotor....1531
Front Axle: Disc Brake....1531
Front Axle: Drum Brake....1535
Rear Axle: Disc Brake....1541
Rear Axle: Drum Brake....1547
Electric Circuit and Part Installation Locations....1553
Group 35 - '98 Minor Change - Brake....1555
Table of Contents....1556
Specifications....1557
Structure and Operation....1558
Troubleshooting....1587
On-Vehicle Inspection and Adjustment....1593
Replacement of Brake Fluid....1593
Air Bleeding of Brake System....1595
Inspection and Adjustment of Brake Pedal Free Play....1597
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel....1597
Inspection and Replacement of Disc Brake Pad....1598
Drum Brake Lining Thickness Inspection and Replacement....1601
Inspection of Brake Shoe Clearance....1601
Inspection of Brake Booster (Master Vac)....1602
Inspection of Bypass Valve....1607
Brake Master Cylinder....1609
Brake Pedal and Brake Booster (Master Vac)....1611
Front Wheel Brake....1613
FE639: Disc Brake....1613
FE649: Disc Brake....1617
FG639: Drum Brake....1621
Rear Wheel Brake....1627
FE639, FG639: Drum Brake....1627
FE649: Disc Brake....1635
Vacuum Pump....1639
Load Sensing Valve....1640
Exhaust Brake System....1641
Group 35 - Brake....1647
Table of Contents....1648
Specifications....1649
Structure and Operation....1650
Troubleshooting....1673
Inspection and Adjustment Mounted in Vehicle....1679
Replacement of Brake Fluid....1679
Air Bleeding of Brake System....1681
Inspection and Adjustment of Brake Pedal Free Play....1683
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel....1683
Inspection and Replacement of Disc Brake Pad....1684
Drum Brake Lining Thickness Inspection and Replacement....1687
Inspection of Brake Shoe Clearance....1687
Inspection of Brake Booster (Master Vac)....1688
Inspection of Bypass Valve....1693
Brake Master Cylinder....1695
Brake Pedal and Brake Booster (Master Vac)....1697
Front Wheel Brake....1699
FE639: Disc Brake....1699
FE649: Disc Brake....1703
Rear Wheel Brake....1707
FE639: Drum Brake....1707
FE649: Disc Brake....1715
Vacuum Pump....1719
Load Sensing Valve....1721
Exhaust Brake System....1723
Group 36 - Parking Brake....1729
Table of Contents....1730
Specifications....1731
Structure and Operation....1731
Troubleshooting....1733
Inspection and Adjustment Mounted in Vehicle....1734
Adjustment of Parking Brake Shoe Clearance and Ratchet Bar Pulling Stroke....1734
Parking Brake Control....1735
Parking Brake Assembly....1737
Backing Plate and Shoe Assembly....1739
Group 37 - Steering....1741
Group 37 - '98 Minor Change - Steering....1742
Table of Contents....1743
Specifications....1744
Structure and Operation....1745
Troubleshooting....1750
On-Vehicle Inspection and Adjustment....1753
Change of Power Steering Fluid....1753
Bleeding of Power Steering System....1754
Steering Wheel Play....1754
Performance Verification Test of Power Steering System....1755
Steering System....1756
Steering Column Subassembly....1762
Power Steering Booster....1766
FE....1766
FG....1772
Power Steering Oil Pump....1778
Power Steering Oil Tank....1782
Power Steering Fluid Line....1783
Drag Link....1784
Tie Rod Assembly....1786
Group 37 - Steering....1788
Table of Contents....1789
Specifications....1790
Structure and Operation....1791
Troubleshooting....1796
Inspection and Adjustment Mounted in Vehicle....1799
Change of Power Steering Fluid....1799
Bleeding of Power Steering System....1800
Steering Wheel Play....1800
Performance Verification Test of Power Steering System....1801
Steering System....1802
Steering Column Subassembly....1806
Power Steering Booster....1810
Power Steering Oil Pump....1816
Power Steering Oil Tank....1820
Power Steering Fluid Line....1821
Drag Link....1822
Tie Rod Assembly....1824
Group 41 - Frame....1826
Table of Contents....1827
Specifications....1828
Structure and Operation....1828
Inspection and Repair of Frames....1828
Group 42 - Cab....1833
Table of Contents....1834
Specifications....1835
Structure and Operation....1836
Troubleshooting....1846
Inspection and Adjustment Mounted in Vehicle....1850
Adjustment of Cab Tilt....1850
Adjustment of Door Fitting....1851
Removal and Installation of Cab....1853
Front Cab Mounting....1861
Rear Cab Mounting....1863
Cab Tilt Link....1865
Door....1868
Cab Exterior Fitting....1873
Mirror....1877
Wiper and Washer....1879
Cab Interior Fitting....1882
Instrument Panel....1884
Window Glass....1887
Group 54 - Electrical....1889
Group 54 - '98 Minor Change - Electrical....1890
Table of Contents....1891
Specifications Alternator....1892
Structure and Operation Alternator....1893
Troubleshooting....1895
100-On-Vehicle Inspection and Adjustment....1896
106-Alternator....1898
401-Meter Cluster....1906
810-Four-Wheel Drive Circuit....1908
Group 54 - Electrical....1910
Table of Contents....1911
Connector Configuration Chart....1913
1-Power, Charging and Ground....1933
Specifications....1934
Structure and Operation....1935
Troubleshooting....1938
100-Inspection and Adjustment Mounted in Vehicle....1940
Inspection of Alternator....1940
Inspection of Regulator....1941
101-Battery....1942
104-Fuse....1946
106-Alternator....1948
110-Power Circuit....1954
115-Reserve Power Circuit....1964
125-Battery Charging Circuit....1966
130-Ground....1968
2-Starting, Preheating and Stopping Engine....1973
Specifications....1974
Structure and Operation....1975
Troubleshooting....1982
200-Inspection and Adjustment Mounted in Vehicle....1984
Inspection of Engine Preheating System....1984
201-Starter....1985
210-Engine Starting Circuit....1998
Manual Transmission....1998
Automatic Transmission....2002
212-Sub-Starter Circuit....2006
Manual Transmission....2006
Automatic Transmission....2008
215-Engine Stopping Circuit....2010
220-Engine Preheating Circuit....2014
225-Engine Warming Up Circuit....2018
3-Lighting....2020
Specifications....2021
Structure and Operation....2023
Troubleshooting....2025
300-Inspection and Adjustment Mounted in Vehicle....2027
Headlamp Aiming....2027
310-Headlamp Circuit....2029
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuits....2031
325-Stop Lamp Circuit....2033
330-Turn Signal Lamp and Hazard Lamp Circuits....2035
340-Backup Lamp Circuit....2037
Manual Transmission....2037
Automatic Transmission....2041
345-Cab Lamp Circuit....2045
348-Illumination Lamp Circuit....2049
349-Marker Lamp and Identification Lamp Circuits....2051
352-Van Body Dome Light Circuit....2053
4-Meter....2055
Specifications....2056
Troubleshooting....2057
401-Meter Cluster....2058
410-Tachometer Circuit....2064
420-Fuel Gauge Circuit....2066
425-Water Temperature Gauge Circuit....2070
5-Indicator and Warning....2072
Troubleshooting....2073
500-Inspection and Adjustment Mounted in Vehicle....2076
Inspection of Brake Fluid Level Switch....2076
510-Parking Brake Indicator Circuit....2077
515-Brake Warning Circuit....2079
535-Engine Oil Level and Oil Pressure Warning Circuit....2083
537-Overheating Warning Circuit....2085
540-Brake Pad Warning Circuit....2087
550-Cab Tilt Warning Circuit....2091
6-Cab Side Electrics....2093
Specifications....2094
Troubleshooting....2094
601-Switch....2096
604-Relay and Control Unit....2100
606-Warning Buzzer....2103
610-Cigarette Lighter Circuit....2104
612-Audio Circuit....2106
614-Wiper and Washer Circuit....2108
616-Horn Circuit....2112
618-Heater Circuit....2114
7-Chassis Electrics....2117
701-Magnetic Valve....2118
710-Exhaust Brake Circuit....2120
Manual Transmission....2120
Automatic Transmission....2124
8-Engine and Transmission Electrics....2127
801-Engine Electrics....2128
802-Transmission Electrics....2132
9-Others....2134
Structure and Operation....2135
910-Multipurpose Timing Control Unit Circuit....2141
Group 55 - Air Conditioner and Heater....2143
Group 55A - Air-Conditioner....2144
Foreword/Table of Contents....2145
Specifications....2146
Outlines of Refrigeration System....2147
Construction....2149
Troubleshooting....2156
Removal and Installation....2163
Treatment After Installation....2166
Maintenance....2172
Cooling Unit Assembly....2173
Compressor & Clutch Assembly....2175
Group 55B - Heater....2178
Table of Contents....2179
Specifications....2180
Structure and Operation....2181
Troubleshooting....2187
Heater Hose....2188
Heater Control....2190
Air Duct....2193
Heater Unit and Blower Assembly....2194
96-01 FH Service Manual....2195
How to Read this Manual....2198
Table of Contents....2199
How This Manual is Compiled....2200
General Explanation of This Manual....2201
Terms and Units....2211
Group 00 - General....2212
2001 Model Year Changes....2213
Foreword/Group Index....2214
2001 Model Changes....2215
Group 00 - General....2217
Power Train Table....2218
Vehicle Identification Number....2218
Precautions for Maintenance Operation....2219
Group 01 - Maintenance Schedule....2220
Maintenance Operations....2221
Battery....2221
Fuse....2225
Group 14 - Cooling....2227
Radiator, Fan Shroud....2228
Group 54 - Electrical....2234
101-Battery....2237
104-Fuse....2240
629-Mirror Heater Circuit....2241
2000 Model Year Changes....2243
Foreword/Group Index....2244
2000 Model Changes....2245
Group 00 - General....2250
Power Train Table....2251
Vehicle Identification Number....2251
Group 42 - Cab....2252
Structure & Operation....2253
Troubleshooting....2255
Door....2257
Group 54 - Electrical....2262
Specifications....2264
Structure and Operation....2264
104-Fuse....2265
106-Alternator....2267
110-Power Circuit....2273
115-Reserve Power Circuit....2275
210-Engine Starting Circuit....2277
Manual Transmission....2277
Automatic Transmission....2279
313-Daytime Running Light Circuit....2281
401-Meter Cluster....2285
622-Power Window and Auto Door Lock Circuit....2287
710-Exhaust Brake Circuit Manual Transmission....2291
1999 Model Year Changes....2294
Foreword/Group Index....2295
1999 Model Changes....2296
Group 00 - General....2305
Power Train Table....2306
Vehicle Identification Number....2306
Connector Configuration Chart....2307
Group 37 - Steering....2308
Steering System....2309
Group 54 - Electrical....2315
210-Engine Starting Circuit....2317
345-Cab Lamp Circuit....2321
510-Parking Brake Indicator Circuit....2323
515-Brake Warning Circuit....2325
536-Engine Oil Pressure Warning Circuit....2327
710-Exhaust Brake Circuit Manual Transmission....2329
1998 Model Year Changes....2333
Table of Contents....2334
Foreword....2335
1998 Model Changes....2336
Vehicle Identification Number: '98 Model....2345
Injection Pump Drive Case....2346
1997 Model Year Changes....2350
Table of Contents....2351
Foreword....2352
1997 Model Changes....2353
Cab Interior Fitting....2355
220-Engine Preheating and Cold Start Circuit....2357
Manual Transmission....2357
Automatic Transmission....2359
Group 00 - General....2361
Table of Contents....2362
Model Coding System....2363
Power Train Table....2364
Chassis Number and Engine Number....2364
Power Train Label....2365
Vehicle Identification Number....2365
Precautions For Maintenance Operation....2367
Table of Standard Tightening Torques....2379
Connector Configuration Chart....2383
Group 01 - Maintenance Schedule....2404
Group 01 - '98 Minor Change - Maintenance Schedule....2405
Table of Contents....2406
How to Read the Maintenance Schedule Tables....2407
Maintenance Schedule Tables....2408
Maintenance Operations....2412
Replacement of Oil Filter....2412
Replacement of Fuel Filter....2413
Draining of Water Separator Condensation....2414
Cleaning of Fuel Feed Pump Gauze Filter....2414
Bleeding of Air from Fuel Line....2415
Adjustment of V-Belt Tension....2416
Cleaning and Replacement of Air Cleaner Element....2418
Inspection of Clutch Pedal Free Play....2419
Tire....2419
Inspection of Brake Pedal Free Play....2425
Inspection of Clearance between Brake Pedal and Floor Panel....2425
Inspection of Brake Lining Thickness....2426
Battery....2426
Fuse....2429
Lubrication....2431
Engine Oil....2432
Clutch Fluid (Brake Fluid)....2434
Manual Transmission Gear Oil....2436
Automatic Transmission Fluid and Oil Filter....2437
Rear Axle Gear Oil....2440
Power Steering Fluid....2441
Brake Fluid....2443
Greasing Various Areas of Chassis....2447
Group 01 - Maintenance Schedule....2449
Table of Contents....2450
How to Read the Maintenance Schedule Tables....2451
Maintenance Schedule Tables....2452
Maintenance Operations....2456
Replacement of Oil Filter....2456
Replacement of Fuel Filter....2457
Draining of Water Separator Condensation....2458
Cleaning of Fuel Feed Pump Gauze Filter....2458
Bleeding of Air from Fuel Line....2459
Adjustment of V-Belt Tension....2460
Cleaning and Replacement of Air Cleaner Element....2462
Inspection of Clutch Pedal Free Play....2463
Tire....2463
Inspection of Brake Lining Thickness....2469
Battery....2469
Fuse....2473
Lubrication....2475
Engine Oil....2476
Clutch Fluid (Brake Fluid)....2478
Manual Transmission Gear Oil....2480
Automatic Transmission Fluid and Oil Filter....2481
Rear Axle Gear Oil....2484
Power Steering Fluid....2485
Brake Fluid....2487
Greasing Various Areas of Chassis....2491
Group 10 - Removal and Installation of Engine....2493
Table of Contents....2494
Removal and Installation of Engine....2495
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses....2495
Removal and Installation of Engine Related Parts....2497
Removal and Installation of Engine....2499
Group 11 - Engine....2501
Table of Contents....2502
Specifications....2503
Structure and Operation....2504
Troubleshooting....2507
Inspection and Adjustment Mounted in Vehicle....2508
Inspection of Engine Compression....2508
Inspection and Adjustment of Valve Clearance....2510
Cylinder Head and Valve Mechanism....2511
Timing Gear....2525
Camshaft....2529
Piston, Connecting Rod and Cylinder Sleeve....2535
Flywheel....2549
Crankshaft and Crankcase....2553
Group 12 - Lubrication....2560
Table of Contents....2561
Specifications....2562
Structure and Operation....2563
Troubleshooting....2571
Inspection and Adjustment Mounted in Vehicle....2572
Replacement of Oil Filter....2572
Replacement of Engine Oil....2573
Measurement of Oil Pressure....2574
Oil Pan, Oil Strainer and Oil Jet....2576
Oil Pump....2578
Oil Cooler and Oil Filter....2582
Group 13 - Fuel and Engine Control....2584
Group 13 - '99 Minor Change - Fuel and Engine Control....2585
Table of Contents....2586
Specifications....2587
Structure and Operation....2589
Troubleshooting....2619
Reading and Erasing Diagnosis Codes....2623
Service Procedures Using MUT-II....2629
Inspection Based on Diagnosis Code....2631
On-Vehicle Inspection and Adjustment....2635
Checking and Adjusting Injection Timing....2635
Bleeding Air from Fuel System....2636
Cleaning Gauze Filter....2636
Replacing Fuel Filter....2637
Engine Control....2638
Fuel Tank....2643
Fuel Filter....2644
Water Separator....2645
Injection Pump....2647
Injection Pump Drive Case....2653
Injection Nozzle....2657
Inspection of Other Devices....2661
Electric Circuit and Part Installation Locations....2671
Group 13 - Fuel and Engine Control....2673
Table of Contents....2674
Specifications....2675
Structure and Operation....2677
Troubleshooting....2697
Inspection and Adjustment Mounted in Vehicle....2701
Inspection and Adjustment of Fuel Injection Timing....2701
Inspection and Adjustment of No-Load Minimum and Maximum Revolution....2702
Pre-Stroke Control Injection Pump System....2703
Troubleshooting Procedure....2703
Electric Circuit and Position of Parts Installation....2709
Inspection by Individual Diagnosis Code....2711
Inspection of Temporary Faults....2729
Engine Control....2731
Fuel Tank....2736
Water Separator....2737
Fuel Filter....2739
Injection Pump....2741
Injection Nozzle....2747
Group 14 - Cooling....2751
Table of Contents....2752
Specifications....2753
Structure and Operation....2753
Troubleshooting....2757
Inspection and Adjustment Mounted in Vehicle....2759
Replacing Coolant and Cleaning Cooling System....2759
Air Bleeding of Cooling System....2761
Gas Leakage Test....2761
Radiator and Fan Shroud....2763
Surge Tank....2767
Cooling Fan and V-Belt....2769
Water Pump....2772
Thermostat....2773
Group 15 - Intake and Exhaust....2775
Table of Contents....2776
Specifications....2777
Structure and Operation....2777
Troubleshooting....2780
Inspection and Adjustment Mounted in Vehicle....2781
Measurement of Turbo Boost Pressure....2781
Air Duct and Air Cleaner....2783
Turbocharger....2787
Intercooler....2792
Intake Manifold....2793
Exhaust Manifold....2794
Exhaust Pipe and Muffler....2795
Group 21 - Clutch....2797
Table of Contents....2798
Specifications....2799
Structure and Operation....2799
Troubleshooting....2802
Inspection and Adjustment Mounted in Vehicle....2803
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding....2803
Clutch Pedal Free Play....2805
Clutch Pedal....2807
Clutch Master Cylinder....2811
Clutch Power Cylinder....2813
Work Before Removal and Installation of Clutch Body....2815
Clutch Body....2817
Clutch Control....2827
Group 22 - Manual Transmission....2829
Group 22 - '00 Minor Change - Manual Transmission M050S5, S6....2830
Table of Contents....2831
Specifications....2832
Structure and Operation....2833
Troubleshooting....2839
Work Before Removal and Installation of Transmission Assembly....2840
Removal and Installation of Transmission Assembly....2842
Gear Shifter Upper and Interlock Plate....2845
Extension Housing, Rear Cover and Parking Brake Assembly....2850
6th Gear S6 and Reverse Idler Gear....2854
Transmission Body....2862
Drive Pinion Assembly....2876
Mainshaft Assembly....2878
Countershaft Assembly....2886
Transmission Control....2890
Group 22 - Manual Transmission....2895
Table of Contents....2896
Specifications....2897
Structure and Operation....2898
Troubleshooting....2905
Work Before Removal & Installation of Transmission Assembly....2906
Removal and Installation of Transmission Assembly....2907
Gear Shifter Upper and Interlock Plate....2911
Rear Cover and Parking Brake Assembly....2917
Reverse Idler Gear....2921
Transmission Body....2923
Drive Pinion Assembly....2935
Mainshaft Assembly....2937
Countershaft Assembly....2945
Transmission Control....2949
Puller and Installer Kit....2954
Group 23 - Automatic Transmission....2955
Table of Contents....2956
Specifications....2957
Structure and Operation....2958
Troubleshooting....2961
Inspection and Adjustment Mounted In Vehicle....2963
Work Before Removal & Installation of Automatic Transmission Assembly....2966
Removal and Installation of Automatic Transmission Assembly....2967
Oil Seal and Speedometer Worm....2971
Oil Pan and Oil Filter....2974
Automatic Transmission Control....2975
Oil Cooler....2981
Oil Filter....2983
Group 25 - Propeller Shaft....2985
Table of Contents....2986
Specifications....2987
Structure and Operation....2987
Troubleshooting....2988
Removal and Installation of Propeller Shaft....2989
Rear Propeller Shaft....2991
Front Propeller Shaft....2995
Balancing Propeller Shaft....2999
Group 26 - Front Axle....3000
Table of Contents....3001
Specifications....3002
Structure and Operation....3002
Inspection and Adjustment Mounted In Vehicle....3004
Adjustment of Wheel Alignment....3004
Adjustment of Steering Angle....3008
Measurement of Side Slip....3008
Work Before Removal & Installation of Front Axle....3009
Wheel Hub and Brake Drum....3010
Front Axle, Knuckle and Kingpin....3018
Group 27 - Rear Axle....3024
Table of Contents....3025
Specifications....3026
Structure and Operation....3026
Troubleshooting....3028
Work Before Removal and Installation of Rear Axle....3030
Wheel Hub and Brake Drum....3032
Axle Housing....3042
Reduction and Differential....3046
Group 31 - Wheel and Tire....3064
Table of Contents....3065
Specifications....3066
Troubleshooting....3066
Wheel and Tire....3067
Group 33 - Front Suspension....3072
Table of Contents....3073
Structure and Operation....3074
Troubleshooting....3075
Work Before Removal & Installation of Front Suspension....3076
Removal and Installation of Leaf Spring Assembly....3078
Leaf Spring Assembly....3084
Shock Absorber....3086
Stabilizer....3087
Group 34 - Rear Suspension....3088
Table of Contents....3089
Structure and Operation....3090
Troubleshooting....3091
Work Before Removal & Installation of Rear Suspension....3092
Removal and Installation of Leaf Spring Assembly....3094
Leaf Spring Assembly....3098
Shock Absorber....3100
Stabilizer....3101
Group 35 - Brake....3102
Group 35A - '00 Minor Change - Anti-Lock Brake System (ABS)....3103
Table of Contents....3104
Specifications....3105
Structure and Operation....3105
On-Vehicle Inspection and Adjustment....3112
Periodic Inspection Procedures....3112
Adjustment of Wheel Speed Sensor Clearance....3113
Inspection of Wheel Speed Sensor Signal Waveform using Oscilloscope....3114
Hydraulic Unit Operation Check....3115
Troubleshooting....3117
Troubleshooting Procedures....3117
Diagnosis Code Indication....3118
Diagnosis Code Chart....3121
Actuator Drive Chart....3122
Service Data....3122
Wheel Speed Sensor and Rotor....3123
Front Axle....3123
Rear Axle....3129
Electric Circuit and Part Installation Locations....3137
Group 35 - '98 Minor Change - Brake....3139
Table of Contents....3140
Specifications....3141
Structure and Operation....3143
Troubleshooting....3161
On-Vehicle Inspection and Adjustment....3167
Replacement of Brake Fluid....3167
Air Bleeding of Brake System....3169
Inspection and Adjustment of Brake Pedal Free Play....3171
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel....3171
Thickness Inspection and Replacement of Brake Lining....3172
Inspection of Brake Shoe Clearance....3172
Inspection of Brake Booster (Hydraulic Booster)....3173
Brake Master Cylinder....3175
Brake Pedal and Brake Booster (Hydraulic Booster)....3177
Brake Booster (Hydraulic Booster)....3179
Front Wheel Brake....3181
Rear Wheel Brake....3189
Vacuum Pump....3197
Exhaust Brake System....3199
Group 35 - Brake....3206
Table of Contents....3207
Specifications....3208
Structure and Operation....3210
Troubleshooting....3232
Inspection and Adjustment Mounted In Vehicle....3236
Replacement of Brake Fluid....3236
Air Bleeding of Brake System....3238
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel....3240
Thickness Inspection and Replacement of Brake Lining....3241
Inspection of Brake Shoe Clearance....3241
Inspection and Maintenance of Air Dryer....3242
Handling of Connectors....3243
Brake Pedal....3244
Dual Brake Valve....3248
Brake Booster (Airmaster)....3255
Front Wheel Brake....3262
Rear Wheel Brake....3270
Air Compressor....3278
Air Dryer....3286
Air Pressure Governor....3290
Fluid Tank....3292
Check Valve....3293
Safety Valve....3293
Supply Valve....3294
Exhaust Brake System....3296
Group 36 - Parking Brake....3303
Table of Contents....3304
Specifications....3305
Structure and Operation....3305
Troubleshooting....3307
Inspection and Adjustment Mounted In Vehicle....3308
Adjustment of Parking Brake Shoe Clearance and Lever Stroke....3308
Parking Brake Control....3309
Parking Brake Assembly....3311
Support Plate and Shoe Assembly....3315
ø203.2 mm {8 in.} Drum ....3315
ø254 mm {10 in.} Drum ....3317
Group 37 - Steering....3319
Group 37 - '98 Minor Change - Steering....3320
Table of Contents....3321
Specifications....3322
Structure and Operation....3323
Troubleshooting....3329
On-Vehicle Inspection and Adjustment....3332
Change of Power Steering Fluid....3332
Bleeding of Power Steering System....3332
Steering Wheel Play....3333
Performance Verification Test of Power Steering System....3334
Steering System....3336
Steering Column Subassembly....3342
Power Steering Booster....3346
Power Steering Oil Pump....3358
Power Steering Oil Tank....3362
Power Steering Fluid Line....3364
Drag Link....3366
Tie Rod Assembly....3368
Group 37 - Steering....3370
Table of Contents....3371
Specifications....3372
Structure and Operation....3373
Troubleshooting....3378
Inspection and Adjustment Mounted In Vehicle....3381
Change of Power Steering Fluid....3381
Bleeding of Power Steering System....3381
Steering Wheel Play....3382
Performance Verification Test of Power Steering System....3383
Steering System....3384
Steering Column Subassembly....3388
Power Steering Booster....3392
Power Steering Oil Pump....3404
Power Steering Oil Tank....3408
Power Steering Fluid Line....3409
Drag Link....3410
Tie Rod Assembly....3412
Group 41 - Frame....3414
Table of Contents....3415
Specifications....3416
Structure and Operation....3416
Inspection and Repair of Frames....3416
Group 42 - Cab....3421
Table of Contents....3422
Specifications....3423
Structure and Operation....3424
Troubleshooting....3434
Inspection and Adjustment Mounted In Vehicle....3438
Adjustment of Cab Tilt....3438
Adjustment of Door Fitting....3439
Removal and Installation of Cab....3441
Front Cab Mounting....3449
Rear Cab Mounting....3451
Cab Tilt Link....3453
Door....3456
Cab Exterior Fitting....3461
Mirror....3465
Wiper and Washer....3467
Cab Interior Fitting....3470
Instrument Panel....3472
Window Glass....3475
Group 54 - Electrical....3477
Group 54 - '98 Minor Change - Electrical....3478
Table of Contents....3479
1-Power, Charging and Ground....3481
Specifications....3482
Structure and Operation....3482
Troubleshooting....3483
100-On-Vehicle Inspection and Adjustment....3484
Inspection of Alternator....3484
Inspection of Regulator....3485
104-Fuse....3486
106-Alternator....3488
110-Power Circuit....3494
115-Reserve Power Circuit....3502
125-Battery Charging Circuit....3504
130-Ground....3506
2-Starting, Preheating and Stopping Engine....3514
210-Engine Starting Circuit Manual Transmission....3515
220-Engine Preheating Circuit Manual Transmission....3517
3-Lighting....3519
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuit....3520
325-Stop Lamp Circuit....3522
352-Van Body Dome Light Circuit....3524
4-Meter....3526
401-Meter Cluster....3527
5-Indicator and Warning....3533
Troubleshooting....3534
500-On-Vehicle Inspection and Adjustment....3538
Inspection of Brake Fluid Level Switch....3538
Inspection of Power Steering Fluid Level Sensor....3539
510-Parking Brake Indicator Circuit....3540
515-Brake Warning Circuit....3542
530-Water Level Warning Circuit....3546
536-Engine Oil Pressure Warning Circuit....3548
537-Overheating Warning Circuit....3550
547-Automatic Transmission Fluid Temperature Warning Circuit....3552
549-Power Steering Fluid Level Warning Circuit....3554
6-Cab Side Electrics....3558
Specifications....3559
Troubleshooting....3560
616-Horn Circuit....3561
7-Chassis Electrics....3563
701-Magnetic Valve Manual Transmission....3564
710-Exhaust Brake Circuit Manual Transmission....3566
8-Engine and Transmission Electrics....3568
801-Engine Electrics....3569
802-Transmission Electrics Manual Transmission....3573
Manual Transmission....3573
Automatic Transmission....3575
850-Transmission Power Take-Off Circuit Option....3577
9-Others....3579
905-Joint Connector....3580
Group 54 - Electrical....3582
Table of Contents....3583
Connector Configuration Chart....3585
1-Power, Charging and Ground....3605
Specifications....3606
Structure and Operation....3607
Troubleshooting....3610
100-Inspection and Adjustment Mounted in Vehicle....3612
Inspection of Alternator....3612
Inspection of Regulator....3613
101-Battery....3614
104-Fuse....3618
106-Alternator....3620
110-Power Circuit....3626
125-Battery Charging Circuit....3634
130-Ground....3636
2-Starting, Preheating and Stopping Engine....3644
Specifications....3645
Structure and Operation....3646
Troubleshooting....3655
200-Inspection and Adjustment Mounted in Vehicle....3657
Inspection of Engine Preheating System....3657
201-Starter....3658
210-Engine Starting Circuit....3671
Manual Transmission....3671
Automatic Transmission....3675
212-Sub-Starter Circuit Manual Transmission....3679
Manual Transmission....3679
Automatic Transmission....3681
215-Engine Stopping Circuit....3683
220-Engine Preheating and Cold Start Circuit Manual Transmission....3687
Manual Transmission....3687
Automatic Transmission....3691
3-Lighting....3694
Specifications....3695
Structure and Operation....3697
Troubleshooting....3699
300-Inspection and Adjustment Mounted in Vehicle....3701
Headlamp Aiming....3701
310-Headlamp Circuit....3703
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuits....3705
325-Stop Lamp Circuit....3707
330-Turn Signal Lamp and Hazard Lamp Circuits....3711
340-Backup Lamp Circuit....3713
345-Cab Lamp Circuit....3717
348-Illumination Lamp Circuit....3721
349-Marker Lamp and Identification Lamp Circuits....3723
352-Van Body Dome Light Circuit....3725
4-Meter....3727
Specifications....3728
Troubleshooting....3729
401-Meter Cluster....3730
410-Speedometer and Tachometer Circuits....3736
420-Fuel Gauge Circuit....3738
425-Water Temperature Gauge Circuit....3742
5-Indicator and Warning....3744
Troubleshooting....3745
500-Inspection and Adjustment Mounted in Vehicle....3748
Inspection of Brake Fluid Level Switch....3748
510-Parking Brake Indicator Circuit....3749
515-Brake Warning Circuit....3751
530-Water Level Warning Circuit....3755
536-Engine Oil Pressure Warning Circuit....3759
537-Overheating Warning Circuit....3761
547-Automatic Transmission Fluid Teperature Warning Circuit....3763
550-Cab Tilt Warning Circuit....3767
6-Cab Side Electrics....3769
Specifications....3770
Troubleshooting....3770
601-Switch....3772
604-Relay and Control Unit....3776
606-Warning Buzzer....3779
610-Cigarette Lighter Circuit....3780
612-Audio Circuit....3782
614-Wiper and Washer Circuit....3784
616-Horn Circuit....3788
618-Heater Circuit....3790
7-Chassis Electrics....3793
701-Magnetic Valve....3794
710-Exhaust Brake Circuit Manual Transmission....3796
718-Air Dryer Circuit....3800
8-Engine and Transmission Electrics....3802
801-Engine Electrics....3803
802-Transmission Electrics Manual Transmission....3807
Manual Transmission....3807
Automatic Transmission....3809
850-Transmission Power Take-Off Circuit Option....3811
9-Others....3813
Structure and Operation....3814
905-Joint Connector....3818
910-Multipurpose Timing Control Unit Circuit....3820
Group 55 - Air Conditioner and Heater....3822
Group 55A - Air-conditioner....3823
Foreword/Table of Contents....3824
1. Specifications....3825
2. Outlines of Refrigeration System....3826
3. Construction....3828
4. Troubleshooting....3835
5. Removal and Installation....3842
6. Treatment After Installation....3845
7. Maintenance....3851
8. Cooling Unit Assembly....3852
9. Compressor & Clutch Assembly....3854
Group 55B - Heater....3857
Table of Contents....3858
Specifications....3859
Structure and Operation....3860
Troubleshooting....3866
Heater Hose....3867
Heater Control....3869
Air Duct....3872
Heater Unit and Blower Assembly....3873
96-01 FK/FM Service Manual....3874
How to Read this Manual....3875
Table of Contents....3876
How This Manual Is Compiled....3877
General Explanation of This Manual....3878
Terms and Units....3888
Group 00 - General....3889
FKFM 2001 Model Year Changes....3890
Foreword/Group Index....3891
2001 Model Changes....3892
00 - General....3896
Power Train Table....3897
Vehicle Identification Number....3898
Precautions for Maintenance Operation....3899
01 - Maintenance Schedule....3900
Maintenance Operations....3901
Battery....3901
Fuse....3905
11 - Engine....3907
Structure and Operation....3908
Flywheel Power Take-Off....3910
Timing Gears....3914
Crankshaft and Crankcase....3918
35A - Brake (Air Over Hydraulic Brake)....3927
Specifications....3928
Structure and Operation....3929
Air Dryer....3930
54 - Electrical....3933
101-Battery....3936
104-Fuse....3939
629-Mirror Heater Circuit....3940
850-Transmission Power Take-Off Circuit....3942
FKFM 2000 Model Year Changes....3945
Foreword/Group Index....3946
2000 Model Changes....3947
00 - General....3954
Power Train Table....3955
Vehicle Identification Number....3956
35C - Anti-Lock Brake System (ABS)....3957
Wheel Speed Sensor and Rotor Rear Axle....3958
42 - Cab....3964
Structure and Operation....3965
Troubleshooting....3969
Door....3971
54 - Electrical....3976
Specifications....3978
Structure and Operation....3978
104-Fuse....3980
106-Alternator....3981
115-Reserve Power Circuit....3989
313-Daytime Running Light Circuit....3991
401-Meter Cluster....3995
622-Power Window and Auto Door Lock Circuit....3997
FKFM 1999 Model Changes....4001
Foreword/Group Index....4002
1999 Model Changes....4003
00 - General....4013
Power Train Table....4014
Vehicle Identification Number....4015
Connector Configuration Chart....4016
35A - Brake (Air Over Hydraulic Brake)....4018
Specifications....4019
Brake Booster (Airmaster)....4021
37 - Steering....4027
Steering System....4028
54 - Electrical....4032
210-Engine Starting Circuit....4035
410-Speedometer Circuit....4039
515-Brake Warning Circuit Air Over Hydraulic Brake....4043
710-Exhaust Brake Circuit Manual Transmission....4047
FKFM 1998 Model Changes....4051
Foreword....4052
1998 Model Changes....4053
Vehicle Identificatin Number....4057
Power Shift Assembly....4059
54 - Electrical....4064
Specifications....4065
Structure and Operation....4066
201-Starter....4067
FKFM 1997 Model Changes....4078
Foreword....4079
1997 Model Changes....4080
Power Train Table....4081
Flywheel and Timing Gear....4082
21 - Clutch....4084
Specifications....4085
Structure and Operation....4086
Troubleshooting....4087
Clutch Body C6 (AR 350)....4088
Specifications....4092
Wheel and Tire....4093
220-Engine Preheating & Cold Start Circuit Manual Transmission....4094
220-Engine Preheating & Cold Start Circuit Automatic Transmission....4096
Group 00 - General....4098
Table of Contents....4099
Model Coding System....4100
Power Train Table....4101
Chassis Number & Engine Number....4102
Power Train Label....4102
Vehicle Identification Number....4103
Precautions for Maintenance Operation....4104
Table of Standard Tightening Torques....4116
Connector Configuration Chart....4120
Group 01 - Maintenance Schedule....4141
Table of Contents....4142
How To Read The Maintenance Schedule Tables....4143
Maintenance Schedule Tables....4144
Maintenance Operations....4148
Replacement of Oil Filter....4148
Replacement of Fuel Filter....4149
Draining of Water Separator Condensation....4150
Cleaning of Fuel Feed Pump Gauze Filter....4150
Bleeding of Air from Fuel Line....4151
Adjustment of V-Belt Tension....4152
Cleaning and Replacement of Air Cleaner Element....4154
Inspection of Clutch Pedal Free Play....4155
Tire....4156
Inspection of Brake Lining Thickness....4162
Battery....4162
Fuse....4165
Lubrication....4167
Engine Oil....4168
Clutch Fluid (Brake Fluid)....4170
Manual Transmission Gear Oil....4172
Automatic Transmission Fluid and Oil Filter....4173
Rear Axle Gear Oil....4176
Power Steering Fluid....4177
Brake Fluid....4179
Greasing Various Areas of Chassis....4183
Group 10 - Removal and Installation of Engine....4185
Table of Contents....4186
Removal and Installation of Engine....4187
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses....4187
Removal and Installation of Engine Related Parts....4189
Removal and Installation of Engine....4191
Group 11 - Engine....4193
Table of Contents....4194
Specifications....4195
Structure and Operation....4196
Troubleshooting....4200
Inspection and Adjustment Mounted In Vehicle....4201
Inspection of Engine Compression....4201
Inspection and Adjustment of Valve Clearance....4203
Cylinder Head and Valve Mechanism....4205
Piston, Connecting Rod and Cylinder Sleeve....4219
Flywheel and Timing Gear....4233
Camshaft....4243
Crankshaft and Crankcase....4249
Group 12 - Lubrication....4256
Table of Contents....4257
Specifications....4258
Structure and Operation....4259
Troubleshooting....4266
Inspection and Adjustment Mounted In Vehicle....4267
Replacement of Oil Filter....4267
Replacement of Engine Oil....4268
Measurement of Oil Pressure....4269
Oil Pan and Oil Jet....4270
Oil Pump and Oil Strainer....4272
Oil Filter....4274
Oil Cooler....4276
Regulator Valve....4278
Group 13 - Fuel and Engine Control....4279
Group 13 - Fuel and Engine Control '99 Minor Change....4280
Table of Contents....4281
Specifications....4282
Structure and Operation....4284
Troubleshooting....4316
Reading and Erasing Diagnosis Codes....4320
Service Procedures Using MUT-II....4326
Inspection Based On Diagnosis Code....4328
On-Vehicle Inspection and Adjustment....4332
Checking and Adjusting Injection Timing....4332
Bleeding Air from Fuel System....4333
Cleaning Gauze Filter....4333
Replacing Fuel Filter....4334
Engine Control....4335
Fuel Tank....4340
Fuel Filter....4341
Water Separator....4342
Injection Pump....4344
Injection Nozzle....4348
Inspection of Other Devices....4352
Electrical Circuit and Part Installation Locations....4362
Group 13 - Fuel and Engine Control....4364
Table of Contents....4365
Specifications....4366
Structure and Operation....4368
Troubleshooting....4388
Inspection and Adjustment Mounted In Vehicle....4392
Inspection and Adjustment of Fuel Injection Timing....4392
Inspection and Adjustment of No-load Minimum and Maximum Revolution....4393
Pre-Stroke Control Injection Pump System....4394
Troubleshooting Procedure....4394
Electric Circuit and Position of Parts Installation....4400
Inspection by Individual Diagnosis Code....4402
Inspection of Temporary Faults....4420
Engine Control....4422
Fuel Tank....4426
Water Separator....4427
Fuel Filter....4428
Injection Pump....4430
Injection Nozzle....4434
Group 14 - Cooling....4438
Table of Contents....4439
Specifications....4440
Structure and Operation....4441
Troubleshooting....4445
Inspection and Adjustment Mounted In Vehicle....4446
Replacing Coolant and Cleaning Cooling System....4446
Air Bleeding of Cooling System....4448
Gas Leakage Test....4448
Radiator and Fan Shroud....4450
Cooling Fan and V-Belt....4454
Water Pump....4458
Thermostat....4462
Group 15 - Intake and Exhaust....4464
Table of Contents....4465
Specifications....4466
Structure and Operation....4466
Troubleshooting....4470
Inspection and Adjustment Mounted In Vehicle....4472
Measurement of Turbo Boost Pressure....4472
Air Duct and Air Cleaner....4474
Turbocharger....4476
Intercooler....4488
Intake Manifold....4490
Exhaust Manifold....4492
Exhaust Pipe and Muffler....4494
Group 21 - Clutch....4496
Table of Contents....4497
Specifications....4498
Structure and Operation....4498
Troubleshooting....4503
Inspection and Adjustment Mounted In Vehicle....4504
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding Clutch Power Cylinder....4504
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding Clutch Booster....4506
Inspection of Function Clutch Booster....4508
Clutch Pedal Free Play Clutch Power Cylinder....4509
Clutch Pedal Free Play Clutch Booster....4510
Clutch Pedal C6, C7 (M070S6)....4512
Clutch Pedal C7 (M8S2x5)....4516
Clutch Master Cylinder....4520
Clutch Power Cylinder C6, C7 (M070S6)....4522
Clutch Booster C7 (M8S2x5)....4524
Work Before Removal and Installation of Clutch Body....4530
Clutch Body C6....4532
Clutch Body C7....4542
Clutch Control....4552
Group 22 - Manual Transmission....4554
Group 22A - Manual Transmission M060S5, S6, M070S6 TWME9620....4555
Table of Contents....4556
Specifications....4557
Structure and Operation....4557
Troubleshooting....4566
Work Before Removal and Installation of Transmission Assembly....4567
Removal and Installation of Transmission Assembly....4569
Gear Shifter Upper and Interlock Plate....4573
Power Shift Assembly....4579
Extension Housing, Rear Cover and Parking Brake Assembly....4585
6th Gear S6 Over-Drive(O/D) & Reverse Idler Gear S5, S6 Over-Drive(O/D)....4589
Reverse Gear and Reverse Idler Gear S6 Direct-Drive(D/D)....4597
Transmission Body....4603
Drive Pinion Assembly....4619
Mainshaft Assembly S5, S6 Over-Drive (O/D)....4621
Mainshaft Assembly S6 Direct-Drive (D/D)....4629
Countershaft Assembly....4639
Transmission Control....4643
Puller and Installer Kit....4647
Group 22A - Manual Transmission M060S5, S6, M070S6 TWME9503-22A....4648
Table of Contents....4649
Specifications....4650
Structure and Operation....4650
Troubleshooting....4659
Work Before Removal and Installation of Transmission Assembly....4660
Removal and Installation of Transmission Assembly....4662
Gear Shifter Upper and Interlock Plate....4666
Power Shift Assembly....4672
Extension Housing, Rear Cover and Parking Brake Assembly....4678
Reverse Idler Gear S5 ....4682
Reverse Gear and Reverse Idler Gear S6 ....4684
Transmission Body....4690
Drive Pinion Assembly....4704
Mainshaft Assembly....4706
S5....4706
S6....4714
Countershaft Assembly....4724
Transmission Control....4728
Puller and Installer Kit....4732
Group 22B - Manual Transmission M8S2x5 ....4733
Table of Contents....4734
Specifications....4735
Structure and Operation....4736
Troubleshooting....4745
Work Before Removal and Installation of Transmission Assembly....4747
Removal and Installation of Transmission Assembly....4749
Gear Shifter Upper....4753
Power Shift Assembly....4757
Gear Shifter Lower....4763
Rear Cover....4767
Splitter....4771
Splitter Upper Assembly....4777
Power Cylinder....4778
Transmission Body....4779
Mainshaft Assembly....4787
Counter Shaft Assembly....4795
Transmission Control....4797
Splitter Control....4801
Group 23 - Automatic Transmission....4804
Group 23 - Automatic Transmission 2001 Model Year Change....4805
Foreword / Index....4806
Model Changes (For FM657 with Automatic Transmission)....4807
Group 00 General - Table of Contents....4810
Power Train Table....4811
Group 23 Automatic Transmission - Table of Contents....4812
Specifications....4813
Structure and Operation....4815
1. Automatic Transmission Assembly....4815
2. Automatic Transmission Control System....4816
3. Oil Cooler System....4817
Troubleshooting....4818
On-Vehicle Inspection and Adjustment....4823
1. Stall Test....4823
2. Line Pressure Test....4824
3. Inspection of Automatic Transmission Fluid....4826
4. Replacement of Automatic Transmission Fluid....4827
5. Level Check of Automatic Transmission Fluid....4829
6. Replacement of Oil Filter....4830
Oil Cooler....4831
Electrical Wiring Diagram....4833
Group 35B Brake (Full Air-Wedge Type-Brake) - Table of Contents....4834
Specifications....4835
Structure and Operation....4837
Troubleshooting....4842
Inspection and Adjustment On Vehicle....4843
Thickness Inspection and Replacement of Brake Lining....4843
Front Wheel Brake....4845
Rear Wheel Brake....4855
Expander Assembly....4865
Group 54 Electrical - Table of Contents....4871
410-Speedometer Circuit....4874
604-Relay and Control Unit....4876
710-Exhaust Brake Circuit....4880
802-Transmission Electrics....4883
Group 23 - Automatic Transmission....4884
Table of Contents....4885
Specifications....4886
Structure and Operation....4887
Troubleshooting....4890
Inspection and Adjustment Mounted In Vehicle....4892
Work Before Removal & Installation of Automatic Transmission Assembly....4895
Removal and Installation of Automatic Transmission Assembly....4896
Oil Seal and Speedometer Worm....4900
Oil Pan and Oil Filter....4903
Automatic Transmission Control....4904
Oil Cooler....4912
Oil Filter....4914
Group 25 - Propeller Shaft....4915
Table of Contents....4916
Specifications....4917
Structure and Operation....4917
Troubleshooting....4918
Removal and Installation of Propeller Shaft....4919
Rear Propeller Shaft....4921
P4....4921
P8....4925
P10....4929
Front Propeller Shaft....4933
P4....4933
P8....4937
P10....4943
Balancing Propeller Shaft....4948
Group 26 - Front Axle....4950
Table of Contents....4951
Specifications....4952
Structure and Operation....4952
Inspection and Adjustment Mounted In Vehicle....4956
Adjustment of Wheel Alignment....4956
Adjustment of Steering Angle....4960
Measurement of Side Slip....4960
Work Before Removal and Installation of Front Axle....4961
Wheel Hub and Brake Drum....4962
Front Axle, Knuckle and Kingpin FK....4972
Front Axle, Knuckle and Kingpin FM....4978
Group 27 - Rear Axle....4985
Table of Contents....4986
Specifications....4987
Structure and Operation....4988
Troubleshooting....4991
Work Before Removal and Installation of Rear Axle....4993
Wheel Hub and Brake Drum....4995
Axle Housing....5007
Reduction and Differential....5011
Group 31 - Wheel and Tire....5031
Table of Contents....5032
Specifications....5033
Troubleshooting....5033
Wheel and Tire....5034
Group 33 - Front Suspension....5039
Table of Contents....5040
Structure and Operation....5041
Troubleshooting....5042
Work Before Removal and Installation of Front Suspension....5043
Removal and Installation of Leaf Spring Assembly....5045
Leaf Spring Assembly....5049
Shock Absorber....5051
Group 34 - Rear Suspension....5052
Table of Contents....5053
Structure and Operation....5054
Troubleshooting....5055
Work Before Removal and Installation of Rear Suspension....5056
Removal and Installation of Leaf Spring Assembly....5058
Leaf Spring Assembly....5064
Group 35 - Brake....5066
Group 35C - Anti-Lock Brake System (ABS) '99 Minor Change....5067
Table of Contents....5068
Specifications....5069
Structure and Operation....5069
On-Vehicle Inspection and Adjustment....5087
Periodic Inspection Procedures....5087
Adjustment of Wheel Speed Sensor Clearance....5089
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope....5091
Troubleshooting....5092
Troubleshooting Procedures....5092
Troubleshooting Flowchart....5093
Tester....5095
Procedure of Inspection Using MUT-II....5097
Procedure of Inspection Using Diagnosis Switch....5103
Wheel Speed Sensor and Rotor....5107
Front Axle....5107
Rear Axle....5125
Control Valve....5146
Electric Circuit and Part Installation Locations....5147
Group 35A - Brake Air Over Hydraulic Brake....5149
Table of Contents....5150
Specifications....5151
Structure and Operation....5153
Troubleshooting....5181
Inspection and Adjustment Mounted In Vehicle....5183
Replacement of Brake Fluid....5183
Air Bleeding of Brake System....5185
Inspection and Adjustment of Brake Pedal Free Play....5187
Thickness Inspection and Replacement of Brake Lining....5188
Inspection of Brake Shoe Clearance....5188
Inspection and Maintenance of Air Dryer....5189
Handling of Connector....5191
Brake Pedal....5193
Dual Brake Valve....5195
Brake Booster (Airmaster)....5202
Front Wheel Brake....5209
Rear Wheel Brake....5219
Air Compressor....5229
Air Dryer....5237
Air Pressure Governor....5241
Fluid Tank....5243
Check Valve / Safety Valve....5244
Supply Valve....5245
Exhaust Brake System....5247
Group 35B - Brake Full Air Brake....5251
Table of Contents....5252
Specifications....5253
Structure and Operation....5254
Troubleshooting....5275
Inspection and Adjustment Mounted In Vehicle....5279
Inspection and Adjustment of Brake Pedal Free Play....5279
Thickness Inspection and Replacement of Brake Lining....5279
Inspection of Automatic Slack Adjuster Function....5280
Inspection and Maintenance of Air Dryer....5282
Handling of Connector....5283
Brake Pedal....5285
Dual Brake Valve....5287
Relay Valve....5295
Quick Release Valve....5297
Front Wheel Brake....5299
Rear Wheel Brake....5311
Air Compressor....5325
Air Dryer....5333
Air Pressure Governor....5337
Check Valve / Safety Valve....5339
Supply Valve....5341
Exhaust Brake System....5343
Group 36 - Parking Brake....5347
Group 36A - Parking Brake Center Parking Brake....5348
Table of Contents....5349
Specifications....5350
Structure and Operation....5350
Troubleshooting....5352
Inspection and Adjustment Mounted In Vehicle....5353
Adjustment of Parking Brake Shoe Clearance and Lever Stroke....5353
Parking Brake Control....5354
Parking Brake Assembly....5356
Support Plate and Shoe Assembly....5360
Group 36B - Parking Brake Wheel Parking Brake....5362
Table of Contents....5363
Structure and Operation....5364
Troubleshooting....5369
Parking Brake Control Valve....5370
Spring Brake Valve....5372
Double Check Valve....5375
Group 37 - Steering....5376
Table of Contents....5377
Specifications....5378
Structure and Operation....5379
Troubleshooting....5386
Inspection and Adjustment Mounted In Vehicle....5389
Change of Power Steering Fluid....5389
Bleeding of Power Steering System....5389
Steering Wheel Play....5390
Performance Verification Test of Power Steering System....5391
Steering System....5392
Linkage and Bracket....5396
Power Steering Booster....5398
Power Steering Oil Pump....5410
Power Steering Oil Tank....5414
Power Steering Fluid Line....5415
Drag Link....5416
Tie Rod Assembly....5418
Group 41 - Frame....5421
Table of Contents....5422
Specifications....5423
Structure and Operation....5423
Inspection and Repair of Frames....5423
Group 42 - Cab....5428
Table of Contents....5429
Specifications....5430
Structure and Operation....5432
Troubleshooting....5445
Inspection and Adjustment Mounted In Vehicle....5450
Adjustment of Cab Tilt....5450
Adjustment of Cab Tilt Lock Switch....5451
Adjustment of Door Fitting....5452
Removal and Installation of Cab....5454
Front Cab Mounting....5462
Rear Cab Mounting....5465
Cab Tilt Link....5466
Door....5470
Cab Exterior Fitting....5476
Mirror....5482
Wiper and Washer....5484
Cab Interior Fitting....5488
Instrument Panel....5494
Window Glass....5498
Group 54 - Electrical....5501
Table of Contents....5502
Connector Configuration Chart....5504
1-Power, Charging and Ground....5524
Specifications....5525
Structure and Operation....5526
Troubleshooting....5530
100-Inspection and Adjustment Mounted In Vehicle....5531
Inspection of Alternator....5531
Inspection of Regulator....5532
101-Battery....5533
104-Fuse....5537
106-Alternator....5539
110-Power Circuit....5545
115-Reserve Power Circuit....5555
125-Battery Charging Circuit....5557
130-Ground....5559
2-Starting, Preheating and Stopping Engine....5567
Specifications....5568
Structure and Operation....5570
Troubleshooting....5582
200-Inspection and Adjustment Mounted In Vehicle....5584
Inspection of Engine Preheating System....5584
201-Starter....5585
210-Engine Starting Circuit....5596
212-Sub-Starter Circuit....5600
215-Engine Stopping Circuit....5604
220-Engine Preheating and Cold Start Circuit....5608
Manual Transmission....5608
Automatic Transmission....5612
3-Lighting....5615
Specifications....5616
Structure and Operation....5618
Troubleshooting....5620
300-Inspection and Adjustment Mounted In Vehicle....5622
Headlamp Aiming....5622
310-Headlamp Circuit....5624
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuits....5626
325-Stop Lamp Circuit....5628
330-Turn Signal Lamp and Hazard Lamp Circuits....5632
340-Backup Lamp Circuit....5634
345-Cab Lamp Circuit....5638
348-Illumination Lamp Circuit....5642
349-Marker Lamp and Identification Lamp Circuits....5644
352-Van Body Dome Light Circuit....5646
4-Meter....5648
Specifications....5649
Troubleshooting....5650
401-Meter Cluster....5651
410-Speedometer and Tachometer Circuits....5657
420-Fuel Gauge Circuit....5659
425-Water Temperature Gauge Circuit....5663
5-Indicator and Warning....5665
Troubleshooting....5666
500-Inspection and Adjustment Mounted In Vehicle....5671
Inspection of Brake Fluid Level Switch Air Over Hydraulic Brake....5671
510-Parking Brake Indicator Circuit....5672
Center Parking Brake....5672
Wheel Parking Brake....5674
515-Brake Warning Circuit....5678
530-Water Level Warning Circuit....5682
536-Engine Oil Pressure Warning Circuit....5686
537-Overheating Warning Circuit....5688
547-Automatic Transmission Fluid Temperature Warning Circuit....5690
548-Transmission High/Low Indicator Circuit 10-speed transmission....5694
550-Cab Tilt Warning Circuit....5696
6-Cab Side Electrics....5698
Specifications....5699
Troubleshooting....5699
601-Switch....5701
604-Relay and Control Unit....5705
606-Warning Buzzer....5708
610-Cigarette Lighter Circuit....5709
612-Audio Circuit....5711
614-Wiper and Washer Circuit....5713
616-Horn Circuit....5717
618-Heater Circuit....5719
7-Chassis Electrics....5722
701-Magnetic Valve....5723
710-Exhaust Brake Circuit Manual Transmission....5725
718-Air Dryer Circuit....5729
8-Engine and Transmission Electrics....5732
801-Engine Electrics....5733
802-Transmission Electrics....5737
Manual Transmission (5-Speed, 6-Speed Transmission)....5737
Manual Transmission (10-speed Transmission)....5739
Automatic Transmission....5741
850-Transmission Power Take-Off Circuit Option....5743
9-Others....5745
Structure and Operation....5746
910-Multipurpose Timing Control Unit Circuit....5750
Group 55 - Air Conditioner and Heater....5752
Group 55A - Air-Conditioner....5753
Foreword/Table of Contents....5754
Specifications....5755
Outlines of Refrigeration System....5756
Construction....5758
Troubleshooting....5765
Removal and Installation....5772
Treatment After Installation....5775
Maintenance....5781
Cooling Unit Assembly....5782
Compressor & Clutch Assembly....5784
Group 55B - Heater....5787
Table of Contents....5788
Specifications....5789
Structure and Operation....5789
Troubleshooting....5795
Heater Hose....5797
Heater Control....5799
Air Duct....5802
Heater Unit and Blower....5803
Air Outlet Ventilation....5804
2002-2004 Fuso Service Manual (FE, FG, FH, FK, FM)....5805
'02-'04 S/M....5805
FE-FG....0
Forward....5806
How to Read this Manual....5807
Index....5808
How This Manual Is Structured....5809
Terms....5822
Group 00 - General....5823
Index....5824
Model Coding System....5825
Power Train Table....5826
Chassis No. & Engine No./Power Train Label....5827
Vehicle Identification No.....5828
Precautions for Maintenance Operation....5829
Table of Standard Tightening Torques....5841
Connector Configuration Chart....5845
Group 01 - Maintenance Schedule....5887
Index....5888
How To Read the Maintenance Schedule Tables....5889
Maintenance Schedule Tables....5891
Maintenance Operations....5893
Lubrication Tables....5915
Lubrication....5917
Group 11A - Engine 4M5....5935
Index....5936
Specifications....5937
Structure & Operation....5939
Troubleshooting....5949
On-Vehicle Inspection & Adjustment....5951
Removal & Installation of Engine....5955
Rocker Cover, Rocker Assemblies & Camshafts....5959
Cylinder Head & Valve Mechanism....5973
Front Case....5987
Timing Gears & Balance Shafts....5991
Pistons, Connecting Rods & Cylinder Liners....5999
Flywheel....6011
Crankshaft & Crankcase....6015
Group 11B - Engine 4D3....6028
Index....6029
Specifications....6030
Structure & Operation....6031
Troubleshooting....6034
Inspection & Adjustment Mounted in Vehicle....6035
Removal & Installation of Engine....6040
Cylinder Head & Valve Mechanism....6044
Timing Gear....6058
Camshaft....6062
Piston, Connecting Rods & Cylinder Sleeve....6068
Flywheel Without Flywheel Power Take-Off....6082
Flywheel With Flywheel Power Take-Off....6086
Crankshaft & Crankcase....6094
Group 12A - Lubrication 4M5....6101
Index....6102
Specifications....6103
Structure & Operation....6105
Troubleshooting....6114
On-Vehicle Inspection & Adjustment....6115
Oil Pan, Oil Strainer & Oil Jet....6119
Oil Pump....6121
Oil Filter....6125
Oil Cooler....6127
Group 12B - Lubrication 4D3....6130
Index....6131
Specifications....6132
Structure & Operation....6133
Troubleshooting....6140
Inspection & Adjustment Mounted in Vehicle....6141
Oil Pan, Oil Strainer & Oil Jet....6144
Oil Pump....6146
Oil Cooler & Oil Filter....6150
Group 13A - Fuel & Engine Control 4M5....6152
Index....6153
Specifications....6154
Structure & Operation....6155
On-Vehicle Inspection & Adjustment....6158
Engine Control....6162
Fuel Tank....6166
Fuel Filter....6167
Injection Pump....6168
Injection Nozzle....6172
Group 13B - Fuel & Engine Control 4D3....6181
Index....6182
Specifications....6183
Structure & Operation....6184
Troubleshooting....6189
On-Vehicle Inspection & Adjustment....6191
Engine Control....6195
Fuel Tank....6201
Fuel Filter....6202
Water Separator....6203
Injection Pump....6205
Injection Nozzle....6209
Group 13EA - Electronically Controlled Fuel System 4M5....6213
Index....6214
Specifications....6215
Structure & Operation....6216
Troubleshooting....6227
Inspection of Electrical Equipment....6249
Locations of Parts....6257
Electrical Wiring Diagram....6261
Group 13EB - Electronically Controlled Fuel System 4D3....6262
Index....6263
Structure & Operation....6264
Troubleshooting....6282
Inspection of Electrical Equipment....6293
Locations of Parts....6301
Electrical Wiring Diagram....6302
Group 14A - Cooling 4M5....6303
Index....6304
Specifications/Structure & Operation....6305
Troubleshooting....6307
On-Vehicle Inspection & Adjustment....6309
Radiator....6313
Cooling Fan, V-Ribbed Belt, V-Belt & Water Pump....6321
Water Hose & Pipe....6325
Thermostat....6327
Group 14B - Cooling 4D3....6329
Index....6330
Specifications/Structure & Operations....6331
Troubleshooting....6333
Inspection & Adjustment Mounted In Vehicle....6335
Radiator....6339
Cooling Fan & V-Belt....6341
Water Pump....6345
Thermostat....6347
Group 15A - Intake & Exhaust 4M5....6350
Index....6351
Specifications/Structure & Operation....6352
Troubleshooting....6354
On-Vehicle Inspection & Adjustment....6355
Air Duct & Air Cleaner Except Crew Cab....6358
Air Duct & Air Cleaner Crew Cab....6362
Turbocharger....6365
Intercooler....6370
Intake Manifold....6372
Exhaust Manifold....6374
Exhaust Pipe & Muffler....6376
Group 15B - Intake & Exhaust 4D3....6378
Index....6379
Specifications/Structure & Operation....6380
Troubleshooting....6383
Inspection & Adjustment Mounted In Vehicle....6384
Air Duct & Air Cleaner....6386
Turbocharger....6390
Intercooler....6396
Intake Manifold....6398
Exhaust Manifold....6400
Exhaust Pipe & Muffler....6402
Group 21 - Clutch....6404
Index....6405
Specifications/Structure & Operation....6406
Troubleshooting....6409
Inspection & Adjustment Mounted In Vehicle....6410
Clutch Pedal....6414
Clutch Master Cylinder....6416
Clutch Power Cylinder....6418
Work Before Removal & Installation of Clutch Body....6420
Clutch Body....6422
Clutch Control....6426
Group 22 - Manual Transmission....6427
Index....6428
Specifications/Structure & Operations....6429
Troubleshooting....6432
Work Before Removal & Installation of Transmission Assembly....6434
Removal & Installation of Transmission Assembly....6435
Gear Shifter Upper....6437
Rear Cover & Reverse Idler Gear....6443
Transmission Body....6447
Drive Pinion Assembly....6455
Mainshaft Assembly....6457
Countershaft Assembly....6463
Transmission Control....6467
Group 23 - Automatic Transmission....6480
Index....6481
Specifications....6482
Structure & Operation....6483
Troubleshooting Procedures....6520
On-Vehicle Inspection & Adjustment....6532
Removal & Installation of Automatic Transmission Assembly....6540
Oil Cooler....6546
Automatic Transmission Control....6550
Replacement of Automatic Transmission Parts....6560
Inspection & Adjustment of Other Devices....6566
Location of Parts....6568
Electrical Wiring Diagram....6569
Group 24 - Transfer....6571
Index....6572
Specifications/Structure & Operation....6573
Troubleshooting....6575
Removal & Installation of Transfer Assembly....6577
Front Drive....6581
Idler Gear & Rear Drive....6587
Transfer Control....6593
Group 25 - Propeller Shaft....6601
Index....6602
Specifications....6603
Structure & Operation....6604
Troubleshooting....6605
Removal & Installation of Propeller Shaft Transmission, Transfer To Rear Axle....6607
Removal & Installation of Propeller Shaft Front Axle To Transfer....6608
Rear Propeller Shaft P2 : FG639....6609
Rear Propeller Shaft P2 : FG649....6613
Rear Propeller Shaft P3....6617
Front Propeller Shaft....6621
Balancing Propeller Shaft....6625
Group 26A - Front Axle....6627
Index....6628
Specifications/Structure & Operation....6629
Inspection & Adjustment Mounted In Vehicle....6631
Work Before Removal & Installation of Front Axle....6635
Wheel Hub & Rotor....6637
Front Axle, Knuckle & Kingpin....6646
Group 26B - Front Axle....6653
Index....6654
Specifications/Structure & Operation....6655
Troubleshooting....6659
On-Vehicle Inspection & Adjustment....6661
Work Before Removal & Installation of Front Axle....6667
Wheel Hub & Brake Drum....6669
Knuckle & Drive Shaft....6679
Axle Housing....6685
Reduction & Differential....6687
Group 27 - Rear Axle....6700
Index....6701
Specifications....6702
Structure & Operation....6703
Troubleshooting....6707
Work Before Removal & Installation of Rear Axle....6709
Wheel Hub & Brake Drum FE639, FG....6710
Wheel Hub & Rotor FE640, FE649....6720
Axle Housing....6730
Reduction & Differential....6734
Muliplate Limited Slip Differential Assembly....6748
FEFG group 27 '04 minor changes.pdf....0
Group 27 - Rear Axle....6754
Index....6755
Specifications....6756
Structure and Operation....6757
Troubleshooting....6761
Work Before Removal and Installation of Rear Axle....6763
Wheel Hub and Brake Drum FE639, FG....6764
Wheel Hub and Rotor FE640, FE649....6774
Axle Housing....6784
Reduction and Differential....6788
Multiplate Limited Slip Differential Assembly....6802
Group 31 - Wheel & Tire....6808
Index....6809
Specifications/Troubleshooting....6810
Wheel & Tire....6811
Group 33 - Front Suspension....6815
Index....6816
Structure & Operation....6817
Troubleshooting....6818
Work Before Removal & Installation of Front Suspension....6819
Removal & Installation of Leaf Spring Assembly FE....6821
Removal & Installation of Leaf Spring Assembly FG....6823
Leaf Spring Assembly FE....6827
Leaf Spring Assembly FG....6829
Shock Absorber FE....6831
Shock Absorber FG....6832
Stabilizer FE....6833
Group 34 - Rear Suspension....6835
Index....6836
Structure & Operation....6837
Troubleshooting....6838
Work Before Removal & Installation of Rear Suspension....6839
Removal & Installation of Leaf Spring Assembly FE....6841
Removal & Installation of Leaf Spring Assembly FG....6845
Leaf Spring Assembly....6849
Shock Absorber....6852
Stabilizer FE....6853
Group 35A - Brake....6855
Index....6856
Specifications....6857
Structure & Operation....6858
Troubleshooting....6879
On-Vehicle Inspection & Adjustment....6885
Brake Master Cylinder....6901
Brake Pedal & Brake Booster (Master VAC)....6903
Front Wheel Brake FE639 (Except FE639 6 : Disc Brake....6905
Front Wheel Brake FE639 6, FE640 : Disc Brake....6909
Front Wheel Brake Drum Brake....6913
Rear Wheel Brake Drum Brake....6919
Rear Wheel Brake Disc Brake....6927
Vacuum Pump....6931
Exhaust Brake System....6933
Group 35E - Anti-Lock Brake System (ABS)....6937
Index....6938
Specifications/Structure & Operation....6939
On-Vehicle Inspection & Adjustment....6952
Troubleshooting....6956
Electric Circuit & Part Installation Locations....6962
Group 36 - Parking Brake....6964
Index....6965
Specifications/Structure & Operation....6966
Troubleshooting....6967
Inspection & Adjustment Mounted In Vehicle....6968
Parking Brake Control....6970
Parking Brake Assembly....6972
Backing Plate & Shoe Assembly....6974
Group 37 - Steering....6976
Index....6977
Specifications....6978
Structure & Operation....6979
Troubleshooting....6984
On-Vehicle Inspection & Adjustment....6987
Steering System....6990
Steering Column Subassembly....6996
Power Steering Booster FE....7000
Power Steering Booster FG....7006
Power Steering Oil Pump....7012
Power Steering Oil Tank....7016
Power Steering Fluid Line....7017
Drag Link....7018
Tie Rod Assembly....7020
FEFG group 37 - '04 minor changes.pdf....0
Group 37 - Steering....7022
Index....7023
Specifications....7024
Structure and Operation....7025
Troubleshooting....7030
On-Vehicle Inspection and Adjustment....7033
Steering System....7036
Steering Column Subassembly....7042
Power Steering Booster....7046
Power Steering Oil Pump....7052
Power Steering Oil Tank....7056
Power Steering Fluid Line....7057
Drag Link....7058
Tie Rod Assembly....7060
Group 41 - Frame....7062
Index....7063
Specifications/Structure & Operation/Inspection & Repair of Frames....7064
Inspection & Repair of Frames....7066
Group 42 - Cab....7069
Index....7070
Specifications....7071
Structure & Operation....7072
Troubleshooting....7081
Inspection & Adjustment Mounted In Vehicle....7086
Removal & Installation of Cab Tilt Cab....7090
Removal & Installation of Cab Fixed Cab....7097
Front Cab Mounting....7105
Rear Cab Mounting....7109
Cab Tilt Link....7111
Door....7114
Front Door....7115
Rear Door Crew Cab....7120
Cab Exterior Fitting....7123
Mirror....7127
Wiper & Washer....7129
Cab Interior Fitting....7133
Instrument Panel....7135
Window Glass....7139
Group 54 - Electrical....7141
Index....7142
How To Read This Group....7145
0-General....7149
Specifications....7150
Structure & Operation....7154
Troubleshooting....7174
1-Power, Charge & Ground Circuit....7182
110-Power Circuit....7183
115-Reserve Power Circuit....7192
125-Battery Charging Circuit....7193
130-Ground....7195
2-Starting & Preheating Circuit....7201
210-Engine Starting Circuit....7202
220-Engine Preheating Circuit....7204
225-Engine Warm-Up Circuit....7205
3-Lighting Circuit....7207
310-Headlamp Circuit....7208
313-Daytime Running Light Circuit....7210
320-Tail, Clearance & License Plate Lamp Circuit....7212
325-Stop Lamp Circuit....7213
330-Turn Signal & Hazard Lamp Circuit....7214
340-Backup Lamp Circuit....7215
345-Cab Lamp Circuit....7217
348-Illumination Lamp Circuit....7218
349-Marker & Identification Lamp Circuit....7219
352-Van Body Dome Light Circuit....7220
4-Meter Circuit....7221
401-Meter Cluster Internal Circuit....7222
410-Tachometer Circuit....7224
412-Speed Sensor Circuit....7226
420-Fuel Gauge Circuit....7227
425-Water Temperature Gauge Circuit....7228
5-Indicator & Warning Lamp Circuit....7229
510-Parking Brake Indicator Circuit....7230
515-Brake Warning Circuit....7231
535-Engine Oil Level & Oil Pressure Warning Circuit....7232
537-Overheating Warning Circuit....7233
540-Brake PadWarning Circuit....7234
550-Cab Tilt Warning Circuit....7235
566-Fuel Filter Warning Circuit....7236
6-Cab Side Electrical Circuit....7237
610-Cigarette Lighter Circuit....7238
612-Audio Circuit....7239
614-Wiper & Washer Circuit....7240
616-Horn Circuit....7241
618-Heater Circuit....7242
622-Power Window & Auto Door Lock Circuit....7243
629-Mirror Heater Circuit....7244
7-Chassis Side Electrical Circuit....7245
710-Exhaust Brake Circuit....7246
8-Engine & Transmission Side Electrical Circuit....7249
810-Four-Wheel Drive Circuit....7250
850-Transmission Power Take-Off Circuit....7251
9-Others Circuit....7252
910-Multipurpose Timing Control Unit Circuit....7253
10-Parts Installation Position....7255
A-Switch....7256
B-Relay & Electronic Control Unit....7258
C-Fuse, Meter, Sensor & Motor....7260
D-Heater & Air-Conditioner....7262
E-Door....7264
F-Roof....7265
J-Joint of Main Harness Connectors....7266
R-Engine....7268
S-Transmission....7270
T-Switch & Sensor....7271
U-Battery, Fuse & Connector....7272
V-Magnetic Valve, Motor & Actuator....7272
W-Buzzer & Lamp....7272
11-Inspection of Parts....7273
001 to 179 Switch....7274
180 to 249 Switch....7280
250 to 349 Sensor....7283
350 to 409 Control Unit....7285
410 to 509 Motor....7286
510 to 559 Actuator....7288
560 to 609 Magnetic Valve....7289
610 to 649 Buzzer & Horn....7290
650 to 699 Lamp....7291
750 to 859 Other....7292
860 Battery....7294
870 to 889 Fuse....7298
890 Meter Cluster....7302
12-Starter & Alternator....7305
930 Starter 4D3....7306
930 Starter 4M5....7320
940 Alternator 4D3....7334
940 Alternator 4M5....7340
950 Inspection of Alternator....7346
951 Inspection of Regulator....7347
13-On-Vehicle Inspection & Adjustment....7348
955 Inspection of Preheating System....7349
960 Headlamp Aiming....7351
965 Inspection of Brake Fluid Level Switch....7353
Group 55A - Air-conditioner....7354
Forward & Table of Contents....7355
Specifications....7356
Outlines of Refrigeration System....7357
Construction....7359
Troubleshooting....7366
Removal & Installation....7373
Treatment After Installation....7376
Maintenance....7382
Cooling Unit Assembly....7383
Compressor & Clutch Assembly....7385
Group 55B - Heater....7388
Index....7389
Specifications....7390
Structure & Operation....7391
Troubleshooting....7397
Heater Hose....7398
Heater Control....7400
Air Duct....7403
Heater Unit & Blower Assembly....7404
FH....0
FORWORD/GRP INDEX....7405
HOW TO READ THIS MANUAL....7406
INDEX....7407
HOW THIS MANUAL IS STRUCTURED....7408
TERMS....7421
GROUP 00 - GENERAL....7422
INDEX....7423
MODEL CODING SYSTEM....7424
POWER TRAIN TABLE....7425
CHASSIS NUMBER & ENGINE NUMBER/POWER TRAIN TABLE....7426
VEHICLE IDENTIFICATION NUMBER....7427
PRECAUTIONS FOR MAINTENANCE OPERATION....7428
TABLE OF STANDARD TIGHTENING TORQUES....7440
CONNECTOR CONFIGURATION CHART....7444
GROUP 01 - MAINTENANCE SCHEDULE....7490
INDEX....7491
HOW TO READ THE MAINTENANCE SCHEDULE TABLES....7492
MAINTENANCE SCHEDULE TABLES....7493
MAINTENANCE OPERATIONS....7498
LUBRICATION TABLES....7521
LUBRICATION....7522
GROUP 11A - ENGINE 4M5....7544
INDEX....7545
SPECIFICATIONS....7546
STRUCTURE AND OPERATION....7548
TROUBLESHOOTING....7558
ON-VEHICLE INSPECTION & ADJUSTMENT....7560
REMOVAL & INSTALLATION OF ENGINE....7564
ROCKER COVER, ROCKER ASSEMBLIES & CAMSHAFTS....7568
CYLINDER HEAD & VALVE MECHANISM....7582
FRONT CASE....7596
FRONT CASE....7598
TIMING GEARS AND BALANCE SHAFTS....7600
PISTONS, CONNECTING RODS & CYLINDER LINERS....7608
FLYWHEEL....7620
CRANKSHAFT & CRANKCASE....7624
BALANCE SHAFT BUSHINGS....7632
GROUP 11B - ENGINE 6D3....7637
INDEX....7638
SPECIFICATIONS....7639
STRUCTURE & OPERATION....7640
TROUBLESHOOTING....7643
ON-VEHICLE INSPECTION & ADJUSTMENT....7644
REMOVAL & INSTALLATION OF ENGINE....7647
CYLINDER HEAD & VALVE MECHANISM....7649
TIMING GEAR....7663
CAMSHAFT....7667
PISTON, CONNECTING ROD & CYLINDER SLEEVE....7673
FLYWHEEL....7687
CRANKSHAFT & CRANKCASE....7691
GROUP 12A - LUBRICATION 4M5....7698
INDEX....7699
SPECIFICATIONS....7700
STRUCTURE & OPERATION....7702
TROUBLESHOOTING....7711
ON-VEHICLE INSPECTION & ADJUSTMENT....7712
OIL PAN, OIL STRAINER & OIL JET....7716
OIL PUMP....7718
OIL FILTER....7722
OIL COOLER....7724
GROUP 12B - LUBRICATION 6D3....7727
INDEX....7728
SPECIFICATIONS....7729
STRUCTURE & OPERATION....7730
TROUBLESHOOTING....7738
ON-VEHICLE INSPECTION & ADJUSTMENT....7739
OIL PAN, OIL STRAINER & OIL JET....7743
OIL PUMP....7745
OIL COOLER & OIL FILTER....7749
GROUP 13A - FUEL & ENGINE CONTROL 4M5....7751
INDEX....7752
SPECIFICATIONS....7753
STRUCTURE & OPERATION....7754
ON-VEHICL INSPECTION & ADJUSTMENT....7757
ENGINE CONTROL....7761
FUEL TANK....7765
FUEL FILTER....7766
INJECTION PUMP....7767
INJECTION NOZZLE....7771
GROUP 13B - FUEL & ENGINE CONTROL 6D3....7780
INDEX....7781
SPECIFICATIONS....7782
STRUCTURE & OPERATION....7783
TROUBLESHOOTING....7790
ON-VEHICLE INSPECTION & ADJUSTMENT....7792
ENGINE CONTROL....7796
FUEL TANK....7801
FUEL FILTER....7802
WATER SEPARATOR....7803
INJECTION PUMP....7804
INJECTION PUMP DRIVE CASE....7810
INJECTION NOZZLE....7814
GROUP 13EA - ELECTRONICALLY CONTROLLED FUEL SYSTEM 4M5....7818
INDEX....7819
SPECIFICATIONS....7820
STRUCTURE & OPERATION....7821
TROUBLESHOOTING....7832
INSPECTION OF ELECTRICAL EQUIPMENT....7854
LOCATION OF PARTS....7862
ELECTRICAL WIRING DIAGRAM....7866
GROUP 13EB - ELECTRONICALLY CONTROLLED FUEL SYSTEM 6D3....7867
INDEX....7868
STRUCTURE & OPERATION....7869
TROUBLESHOOTING....7887
INSPECTION OF ELECTRICAL EQUIPMENT....7899
LOCATION OF PARTS....7907
ELECTRICAL WIRING DIAGRAM....7908
GROUP 14A - COOLING 4M5....7909
INDEX....7910
SPECIFICATIONS/STRUCTURE & OPERATION....7911
TROUBLESHOOTING....7913
ON-VEHICLE INSPECTION & ADJUSTMENT....7915
RADIATOR & FAN SHROUD....7919
RADIATOR....7921
COOLING FAN, V-RIBBED BELT, V-BELT & WATER PUMP....7929
WATER HOSE & PIPE....7933
THERMOSTAT....7934
GROUP 14B - COOLING 6D3....7935
INDEX....7936
SPECIFICATIONS/STRUCTURE & OPERATION....7937
TROUBLESHOOTING....7941
ON-VEHICLE INSPECTION & ADJUSTMENT....7943
RADIATOR & FAN SHROUD....7947
SURGE TANK....7955
COOLING FAN & V-BELT....7957
WATER PUMP....7960
THERMOSTAT....7961
GROUP 15A - INTAKE & EXHAUST 4M5....7963
INDEX....7964
SPECIFICATIONS/STRUCTURE & OPERATION....7965
TROUBLESHOOTING....7968
ON-VEHICLE INSPECTION & ADJUSTMENT....7969
AIR DUCT & AIR CLEANER....7971
TURBOCHARGER....7975
INTERCOOLER....7980
INTAKE MANIFOLD....7981
EXHAUST MANIFOLD....7983
EXHAUST PIPE & MUFFLER....7985
GROUP 15B - INTAKE & EXHAUST 6D3....7987
INDEX....7988
SPECIFICATIONS/STRUCTURE & OPERATION....7989
TROUBLESHOOTING....7992
ON-VEHICLE INSPECTION & ADJUSTMENT....7993
AIR DUCT & AIR CLEANER....7995
TURBOCHARGER....7999
INTERCOOLER....8004
INTAKE MANIFOLD....8005
EXHAUST MANIFOLD....8006
EXHAUST PIPE & MUFFLER....8007
GROUP 21 - CLUTCH....8009
INDEX....8010
SPECIFICATIONS/STRUCTURE & OPERATION....8011
TROUBLESHOOTING....8014
ON-VEHICLE INSPECTION & ADJUSTMENT....8015
CLUTCH PEDAL....8019
CLUTCH MASTER CYLINDER....8023
CLUTCH POWER CYLINDER....8025
WORK BEFORE REMOVAL & INSTALLATION OF CLUTCH BODY....8027
CLUTCH BODY....8029
CLUTCH CONTROL....8039
GROUP 22 - MANUAL TRANSMISSION....8041
INDEX....8042
SPECIFICATIONS....8043
STRUCTURE & OPERATION....8044
TROUBLESHOOTING....8050
WORK BEFORE REMOVAL & INSTALLATION OF TRANSMISSION ASSEMBLY....8051
REMOVAL & INSTALLATION OF TRANSMISSION ASSEMBLY....8053
GEAR SHIFTER UPPER & INTERLOCK PLATE....8056
EXTENSION HOUSING, REAR COVER & PARKING BRAKE ASSEMBLY....8061
6TH GEAR S6 AND REVERSE IDLER GEAR....8065
TRANSMISSION BODY....8073
DRIVE PINION ASSEMBLY....8087
MAINSHAFT ASSEMBLY....8089
COUNTERSHAFT ASSEMBLY....8097
TRANSMISSION CONTROL....8101
PULLER & INSTALLER KIT....8106
GROUP 23A - AUTOMATIC TRANSMISSION FH210....8107
INDEX....8108
SPECIFICATIONS....8109
STRUCTURE & OPERATION....8110
TROUBLESHOOTING PROCEDURES....8147
TROUBLESHOOTING....8149
ON-VEHICLE INSPECTION & ADJUSTMENT....8159
REMOVAL & INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY....8167
OIL COOLER....8173
AUTOMATIC TRANSMISSION CONTROL....8175
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS....8185
INSPECTION & ADJUSTMENT OF OTHER DEVICES....8191
LOCATION OF PARTS....8192
ELECTRICAL WIRING DIAGRAM....8193
GROUP 23B - AUTOMATIC TRANSMISSION FH211....8194
INDEX....8195
SPECIFICATIONS....8196
STRUCTURE & OPERATION....8197
TROUBLESHOOTING....8200
ON-VEHICLE INSPECTION & ADJUSTMENT....8202
WORK BEFORE REMOVAL & INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMLBY....8205
REMOVAL & INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY....8206
OIL SEAL & SPEEDOMETER WORM....8210
OIL PAN & OIL FILTER....8213
AUTOMATIC TRANSMISSION CONTROL....8214
OIL COOLER....8219
OIL FILTER....8220
GROUP 25 - PROPELLER SHAFT....8222
INDEX....8223
SPECIFICATIONS/STRUCTURE & OPERATION....8224
TROUBLESHOOTING....8225
REMOVAL & INSTALLATION OF PROPELLER SHAFT....8226
REAR PROPELLER SHAFT....8228
FRONT PROPELLER SHAFT....8232
BALANCING PROPELLER SHAFT....8236
GROUP 26 - FRONT AXLE....8237
INDEX....8238
SPECIFICATIONS/STRUCTURE & OPERATION....8239
ON-VEHICLE INSPECTION & ADJUSTMENT....8241
WORK BEFORE REMOVAL & INSTALLATION OF FRONT AXLE....8246
WHEEL HUB & BRAKE DRUM....8247
FRONT AXLE, KNUCKLE & KINGPIN....8259
GROUP 27 - REAR AXLE....8265
INDEX....8266
SPECIFICATIONS/STRUCTURE & OPERATION....8267
TROUBLESHOOTING....8269
WORK BEFORE REMOVAL & INSTALLATION OF REAR AXLE....8271
WHEEL HUB & BRAKE DRUM....8273
AXLE HOUSING....8287
REDUCTION & DIFFERENTIAL....8291
GROUP 31 - WHEEL & TIRE....8309
INDEX....8310
SPECIFICATIONS/TROUBLESHOOTING....8311
WHEEL & TIRE....8312
GROUP 33 - FRONT SUSPENSION....8317
INDEX....8318
STRUCTURE & OPERATION....8319
TROUBLESHOOTING....8320
WORK BEFORE REMOVAL & INSTALLATION OF FRONT SUSPENSION....8321
REMOVAL & INSTALLATION OF LEAF SPRING ASSEMBLY FH210....8323
REMOVAL & INSTALLATION OF LEAF SPRING ASSEMBLY FH211....8327
LEAF SPRING ASSEMBLY....8331
SHOCK ABSORBER....8333
STABILIZER....8334
GROUP 34 - REAR SUSPENSION....8335
INDEX....8336
STRUCTURE & OPERATION....8337
TROUBLESHOOTING....8338
WORK BEFORE REMOVAL & INSTALLATION OF REAR SUSPENSION....8339
REMOVAL & INSTALLATION OF LEAF SPRING ASSEMBLY....8341
LEAF SPRING ASSEMBLY....8347
GROUP 35A - BRAKE....8349
INDEX....8350
SPECIFICATIONS....8351
STRUCTURE & OPERATION....8353
TROUBLESHOOTING....8371
ON-VEHICLE INSPECTION & ADJUSTMENT....8377
BRAKE MASTER CYLINDER....8387
BRAKE PEDAL & BRAKE BOOSTER (HYDRAULIC BOOSTER)....8389
BRAKE BOOSTER (HYDRAULIC BOOSTER)....8391
FRONT WHEEL BRAKE....8393
REAR WHEEL BRAKE....8401
VACUUM PUMP FH210....8409
VACUUM PUMP FH211....8410
EXHAUST BRAKE SYSTEM....8411
GROUP 35E - ANTI-LOCK BRAKE SYSTEM (ABS)....8418
INDEX....8419
SPECIFICATIONS/STRUCTURE & OPERATION....8420
ON-VEHICLE INSPECTION & ADJUSTMENT....8433
TROUBLESHOOTING....8438
ELECTRICAL CIRCUIT AND PART INSTALLATION LOCATIONS....8444
GROUP 36A - PARKING BRAKE FH210....8447
INDEX....8448
SPECIFICATIONS/STRUCTURE & OPERATION....8449
TROUBLESHOOTING....8451
ON-VEHICLE INSPECTION & ADJUSTMENT....8452
PARKING BRAKE CONTROL....8453
PARKING BRAKE ASSEMBLY....8455
BACKING PLATE & SHOE ASSEMBLY....8457
GROUP 36B - PARKING BRAKE FH211....8459
INDEX....8460
SPECIFICATIONS/STRUCTURE & OPERATION....8461
TROUBLESHOOTING....8463
ON-VEHICLE INSPECTION & ADJUSTMENT....8464
PARKING BRAKE CONTROL....8465
PARKING BRAKE ASSEMBLY....8467
SUPPORT PLATE & SHOE ASSEMBLY ø203.2mm {8 in} Drum....8471
SUPPORT PLATE & SHOE ASSEMBLY ø254mm {10 in} Drum....8473
GROUP 37 - STEERING....8475
INDEX....8476
SPECIFICATIONS....8477
STRUCTURE & OPERATION....8478
TROUBLESHOOTING....8485
ON-VEHICLE INSPECTION & ADJUSTMENT....8488
STEERING SYSTEM....8491
STEERING COLUMN SUBASSEMBLY....8497
POWER STEERING BOOSTER....8501
POWER STEERING OIL PUMP KAYABA....8513
POWER STEERING OIL PUMP Unisia JKC Steering Systems....8517
POWER STEERING OIL TANK....8521
POWER STEERING FLUID LINE....8523
DRAG LINK....8525
TIE ROD ASSEMBLY....8527
GROUP 41 - FRAME....8529
INDEX....8530
SPECIFICATIONS....8531
STRUCTURE & OPERATION....8531
INSPECTION & REPAIR OF FRAMES....8531
GROUP 42 - CAB....8536
INDEX....8537
SPECIFICATIONS....8538
STRUCTURE & OPERATION....8539
TROUBLESHOOTING....8550
ON-VEHICLE INSPECTION & ADJUSTMENT....8555
REMOVAL & INSTALLATION OF CAB....8558
FRONT CAB MOUNTING....8566
REAR CAB MOUNTING....8568
CAB TILT LINK....8570
DOOR....8573
CAB EXTERIOR FITTING....8578
MIRROR....8582
WIPER & WASHER....8584
CAB INTERIOR FITTING....8587
INSTRUMENT PANEL....8589
WINDOW GLASS....8592
GROUP 54 - ELECTRICAL....8594
TABLE OF CONTENTS....8595
HOW TO READ THIS GROUP....8598
0-GENERAL....8602
SPECIFICATIONS....8603
STRUCTURE & OPERATION....8607
TROUBLESHOOTING....8633
1-POWER, CHARGE & GROUND CIRCUIT....8641
110-POWER CIRCUIT....8642
115-RESERVE POWER CIRCUIT....8651
125-BATTERY CHARGING CIRCUIT....8652
130-GROUND....8654
2-STARTING & PREHEATING CIRCUIT....8669
210-ENGINE STARTING CIRCUIT....8670
220-ENGINE PREHEATING CIRCUIT....8673
3-LIGHTING CIRCUIT....8676
310-HEADLAMP CIRCUIT....8677
313-DAYTIME RUNNING LIGHT CIRCUIT....8679
320-TAIL, CLEARANCE & LICENSE PLATE LAMP CIRCUIT....8681
325-STOP LAMP CIRCUIT....8682
330-TURN SIGNAL & HAZARD LAMP CIRCUIT....8683
340-BACKUP LAMP CIRCUIT....8684
345-CAB LAMP CIRCUIT....8686
348-ILLUMINATION LAMP CIRCUIT....8687
349-MARKER & IDENTIFICATION LAMP CIRCUIT....8688
352-VAN BODY DOME LIGHT CIRCUIT....8689
4-METER CIRCUIT....8691
401-METER CLUSTER INTERNAL CIRCUIT....8692
410-TACHOMETER CIRCUIT....8696
412-SPEEDOMETER CIRCUIT....8698
420-FUEL GAUGE CIRCUIT....8700
425-WATER TEMPERATURE GAUGE CIRCUIT....8701
5-INDICATOR & WARNING LAMP CIRCUIT....8702
510-PARKING BRAKE INDICATOR CIRCUIT....8703
515-BRAKE WARNING CIRCUIT....8705
530-WATER LEVEL WARNING CIRCUIT....8706
535-ENGINE OIL LEVEL & PRESSURE WARNING CIRCUIT....8707
536-ENGINE OIL PRESSURE WARNING CIRCUIT....8708
537-OVERHEATING WARNING CIRCUIT....8710
547-ATF TEMPERATURE WARNING CIRCUIT....8711
549-POWER STEERING FLUID LEVEL WARNING CIRCUIT....8712
550-CAB TILT WARNING CIRCUIT....8713
566-FUEL FILTER WARNING CIRCUIT....8714
6-CAB SIDE ELECTRICAL CIRCUIT....8715
610-CIGARETTE LIGHTER CIRCUIT....8716
612-AUDIO CIRCUIT....8717
614-WIPER & WASHER CIRCUIT....8718
616-HORN CIRCUIT....8719
618-HEATER CIRCUIT....8720
622-POWER WINDOW & AUTO DOOR LOCK CIRCUIT....8721
629-MIRROR HEATER CIRCUIT....8722
7-CHASSIS SIDE ELECTRICAL CIRCUIT....8724
710-EXHAUST BRAKE CIRCUIT....8725
8-ENGINE & TRANSMISSION SIDE ELECTRICAL CIRCUIT....8727
850-TRANSMISSION POWER TAKE-OFF CIRCUIT....8728
9-OTHERS CIRCUIT....8730
910-MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT....8731
10-PARTS INSTALLATION POSITION....8735
A - SWITCH....8736
B - RELAY & ELECTRONIC CONTROL UNIT....8738
C - FUSE, METER, SENSOR & MOTOR....8740
D - HEATER....8742
E - DOOR....8743
F - ROOF....8744
J - JOINT OF MAIN HARNESS CONNECTORS....8746
R - ENGINE....8748
S - TRANSMISSION....8750
T - SWITCH & SENSOR....8752
U - BATTERY, FUSE & CONNECTOR....8753
V - MAGNETIC VALVE, MOTOR....8753
W - HORN & BUZZER....8753
11-INSPECTION OF PARTS....8754
001 to 179 SWITCH....8755
180 to 249 RELAY....8762
250 to 349 SENSOR....8765
350 to 409 CONTROL UNIT....8768
410 to 509 MOTOR....8771
510 to 559 ACTUATOR....8772
560 to 609 MAGNETIC VALVE....8773
610 to 649 BUZZER & HORN....8774
650 to 699 LAMP....8775
750 to 859 OTHER....8776
860 BATTERY....8778
870 to 889 FUSE....8781
890 METER CLUSTER....8785
12-STARTER & ALTERNATOR....8789
930 STARTER....8790
940 ALTERNATOR....8818
950 INSPECTION OF ALTERNATOR....8834
951 INSPECTION OF REGULATOR....8835
13-ON-VEHICLE INSPECTION & ADJUSTMENT....8836
955 INSPECTION OF PREHEATING SYSTEM....8837
960 HEADLAMP AIMING....8839
965 INSPECTION OF BRAKE FLUID LEVEL SWITCH....8841
966 INSPECTION OF POWER STEERING FLUID LEVEL SENSOR....8842
GROUP 55A - AIR-CONDITIONER....8843
6D34....8843
FORWORD....8844
TABLE OF CONTENTS....8844
SPECIFICATIONS....8845
OUTLINES OF REFRIGERATION SYSTEM....8846
CONSTRUCTION....8848
TROUBLESHOOTING....8856
REMOVAL & INSTALLATION....8863
TREATMENT AFTER INSTALLATION....8866
MAINTENANCE....8872
COOLING UNIT ASSEMBLY....8873
COMPRESSOR & CLUTCH ASSEMBLY....8875
4M50....8878
FOREWORD....8879
TABLE OF CONTENTS....8879
SPECIFICATIONS....8880
OUTLINES OF REFRIGERATION SYSTEM....8881
CONSTRUCTION....8883
TROUBLESHOOTING....8891
REMOVAL & INSTALLATION....8898
TREATMENT AFTER INSTALLATION....8901
MAINTENANCE....8907
COOLING UNIT ASSEMBLY....8908
COMPRESSOR & CLUTCH ASSEMBLY....8910
GROUP 55B - HEATER....8913
INDEX....8914
SPECIFICATIONS....8915
STRUCTURE & OPERATION....8916
TROUBLESHOOTING....8922
HEATER HOSE....8923
HEATER CONTROL....8925
AIR DUCT....8928
HEATER UNIT & BLOWER ASSEMBLY....8929
FK-FM....0
Forward....8930
How To Read This Manual....8931
Index....8932
How This Manual Is Structured....8933
Terms....8946
Group 00 - General....8947
Index....8948
Model Coding System....8949
Power Train Table....8950
Chassis Number & Engine Number....8951
Power Train Label....8951
Vehicle Identification Number....8952
Precautions For Maintenance Operation....8953
Table of Standard Tightening Torques....8965
Connector Configuration Chart....8969
Group 01 - Maintenance Schedule....9011
Index....9012
How to Read The Maintenance Schedule Tables....9013
Maintenance Schedule Tables....9014
Maintenance Operations....9018
Lubrication Tables....9037
Lubrication....9038
Group 11 - Engine....9058
Index....9059
Specifications....9060
Structure & Operation....9061
Untitled....9066
Troubleshooting....9066
On-Vehicle Inspection & Adjustment....9067
Removal & Installation of Engine....9070
Cylinder Head & Valve Mechanism....9072
Piston, Connecting Rod & Cylinder Sleeve....9086
Flywheel Power Take-Off....9100
Flywheel....9104
Timing Gear....9110
Camshaft....9114
Crankshaft & Crankcase....9120
Group 12 - Lubrication....9129
Index....9130
Specifications....9131
Structure & Operation....9132
Troubleshooting....9139
On-Vehicle Inspection & Adjustment....9140
Oil Pan & Oil Jet....9143
Oil Pump & Oil Strainer....9145
Oil Filter....9147
Oil Cooler....9149
Regulator Valve....9151
Group 13 - Fuel & Engine Control....9152
Index....9153
Specifications....9154
Structure & Operation....9156
Troubleshooting....9182
Reading & Erasing Diagnosis Codes....9186
Service Procedures Using Multi-Use Tester II....9192
Inspection Based On Diagnosis Code....9194
On-Vehicle Inspection & Adjustment....9198
Engine Control....9201
Fuel Tank....9206
Fuel Filter....9207
Water Separator....9208
Injection Pump....9210
Injection Nozzle....9214
Inspection of Other Devices....9218
Electric Circuit & Part Installation Locations....9229
Group 14 - Cooling....9231
Index....9232
Specifications....9233
Structure & Operation....9234
Troubleshooting....9238
On-Vehicle Inspection & Adjustment....9239
Radiator & Fan Shroud....9243
Cooling Fan & V-Belt....9247
Water Pump....9251
Thermostat....9253
Group 15 - Intake & Exhaust....9255
Index....9256
Specifications/Structure & Operation....9257
Troubleshooting....9261
On-Vehicle Inspection & Adjustment....9263
Air Duct & Air Cleaner....9265
Turbocharger....9267
Intercooler....9279
Intake Manifold....9281
Exhaust Manifold....9283
Exhaust Pipe & Muffler....9285
Group 21 - Clutch....9287
Index....9288
Specifications/Structure & Operation....9289
Troubleshooting....9294
On-Vehicle Inspection & Adjustment....9295
Clutch Pedal C6 (M060S6), C7 (M070S6)....9303
Clutch Pedal C7 (M8S2x5)....9307
Clutch Master Cylinder....9311
Clutch Power Cylinder C6 (M060S6), C7 (M070S6)....9313
Clutch Booster C7 (M8S2x5)....9315
Work Before Removal & Installation of Clutch Body....9321
Clutch Body C6....9323
Clutch Body C7....9333
Clutch Control....9343
Group 22A - Manual Transmission M080S6, M070S6....9345
Index....9346
Specifications/Structure & Operation....9347
Troubleshooting....9356
Work Before Removal & Installation of Transmission Assembly....9357
Removal & Installation of Transmission Assembly....9359
Gear Shifter Upper & Interlock Plate....9363
Power Shift Assembly....9369
Extension Housing, Rear Cover & Parking Brake Assembly....9375
6th Gear Over-Drive (O/D) & Reverse Idler Gear Over-Drive (O/D)....9379
Reverse Gear & Reverse Idler Gear Direct-Drive (D/D)....9387
Transmission Body....9393
Drive Pinion Assembly....9409
Mainshaft Assembly Over-Drive (O/D)....9411
Mainshaft Assembly Direct-Drive (D/D)....9419
Countershaft Assembly....9429
Transmission Control....9433
Puller & Installer Kit....9437
Group 22B - Manual Transmission M8S2x5....9438
Index....9439
Specifications....9440
Structure & Operation....9441
Troubleshooting....9450
Work Before Removal & Installation of Transmission Assembly....9452
Removal & Installation of Transmission Assembly....9454
Gear Shifter Upper....9458
Power Shift Assembly....9462
Gear Shifter Lower....9468
Rear Cover....9472
Splitter....9476
Splitter Upper Assembly....9482
Power Cylinder....9483
Transmission Body....9484
Mainshaft Assembly....9492
Countershaft Assembly....9500
Transmission Control....9502
Splitter Control....9506
Group 23A - Automatic Transmission FK617, FM617....9509
Index....9510
Specifications....9511
Structure & Operation....9512
Troubleshooting....9515
On-Vehicle Inspection & Adjustment....9517
Work Before Removal & Installation of Automatic Transmission Assembly....9520
Removal & Installation of Automatic Transmission Assembly....9521
Oil Seal & Speedometer Worm....9525
Oil Pan & Oil Filter....9528
Automatic Transmission Control....9529
Oil Cooler....9535
Oil Filter....9537
Group 23B - Automatic Transmission FM657....9538
Index....9539
Specifications....9540
Structure & Operation....9542
Troubleshooting....9545
On-Vehicle Inspection & Adjustment....9550
Oil Cooler....9558
Electric Circuit & Part Installation Locations....9560
Group 25 - Propeller Shaft....9562
Index....9563
Specifications/Structure & Operation....9564
Troubleshooting....9565
Removal & Installation of Propeller Shaft....9568
Rear Propeller Shaft P4....9570
Rear Propeller Shaft P8....9574
Rear Propeller Shaft P10....9578
Front Propeller Shaft P4....9582
Front Propeller Shaft P8....9586
Front Propeller Shaft P10....9592
Balancing Propeller Shaft....9597
Group 26 - Front Axle....9599
Index....9600
Specifications/Structure & Operation....9601
On-Vehicle Inspection & Adjustment....9607
Work Before Removal & Installation of Front Axle....9612
Wheel Hub & Brake Drum FK....9613
Wheel Hub & Brake Drum FM (Air-Over Hydraulic Brake)....9625
Wheel Hub & Brake Drum FM (Full-Air Brake)....9637
Front Axle, Knuckle & Kingpin FK....9661
Front Axle, Knuckle & Kingpin FM (Air-Over Hydraulic Brake)....9667
Group 27 - Rear Axle....9681
Index....9682
Specifications....9683
Structure & Operation....9684
Troubleshooting....9687
Work Before Removal & Installation of Rear Axle....9689
Wheel Hub & Brake Drum FK....9691
Wheel Hub & Brake Drum FM....9705
Axle Housing....9721
Reduction & Differential....9725
Group 31 - Wheel & Tire....9745
Index....9746
Specifications/Troubleshooting....9747
Wheel & Tire....9748
Group 33 - Front Suspension....9753
Index....9754
Structure & Operation....9755
Troubleshooting....9756
Work Before Removal & Installation of Front Suspension....9757
Removal & Installation of Leaf Spring Assembly....9759
Leaf Spring Assembly....9763
Shock Absorber....9765
Group 34 - Rear Suspension....9766
Index....9767
Structure & Operation....9768
Troubleshooting....9769
Work Before Removal & Installation of Rear Suspension....9770
Removal & Installation of Leaf Spring Assembly....9772
Leaf Spring Assembly....9778
Group 35A - Brake Air Over Hydraulic Brake....9780
Index....9781
Specifications....9782
Structure & Operation....9784
Troubleshooting....9810
On-Vehicle Inspection & Adjustment....9814
Handling of Connector & Nylon Tube Piping....9822
Brake Pedal....9824
Dual Brake Valve....9826
Brake Booster (Airmaster)....9834
Front Wheel Brake....9840
Rear Wheel Brake....9850
Air Compressor....9860
Air Dryer....9868
Air Pressure Governor....9872
Fluid Tank....9874
Check Valve/Safety Valve....9875
Supply Valve....9876
Exhaust Brake System....9878
Group 35B - Brake Full Air Brake....9882
Index....9883
Specifications....9884
Structure & Operation....9886
Troubleshooting....9913
On-Vehicle Inspection & Adjustment....9917
Handling of Connector & Nylon Tube Piping....9921
Brake Pedal....9922
Dual Brake Valve....9924
Relay Valve....9932
Quick Release Valve....9934
Front Wheel Brake Manual Transmission....9936
Front Wheel Brake Automatic Transmission....9946
Rear Wheel Brake Manual Transmission....9956
Rear Wheel Brake Automatic Transmission....9970
Expander Assembly....9980
Air Compressor....9986
Air Dryer....9994
Air Pressure Governor....9998
Check Valve/Safety Valve....10000
Supply Valve....10001
Exhaust Brake System....10002
Group 35E - Anti-Lock Brake System (ABS)....10006
Index....10007
Specifications/Structure & Operation....10008
On-Vehicle Inspection & Adjustment....10022
Troubleshooting....10027
Electrical Circuit & Part Installation Locations....10042
Group 36A - Parking Brake Center Parking Brake....10044
Index....10045
Specifications/Structure & Operation....10046
Troubleshooting....10048
On-Vehicle Inspection & Adjustment....10049
Parking Brake Control....10050
Parking Brake Assembly....10052
Support Plate & Shoe Assembly....10056
Group 36B - Parking Brake Wheel Parking Brake....10058
Index....10059
Structure & Operation....10060
Troubleshooting....10065
Parking Brake Control Valve....10066
Spring Brake Valve....10068
Double Check Valve....10071
Group 37 - Steering....10072
Index....10073
Specifications....10074
Structure & Operation....10075
Troubleshooting....10082
On-Vehicle Inspection & Adjustment....10085
Steering System....10088
Linkage & Bracket....10092
Power Steering Booster....10094
Power Steering Oil Pump....10106
Power Steering Oil Tank....10110
Power Steering Fluid Line....10111
Drag Link....10112
Tie Rod Assembly....10114
Group 41 - Frame....10117
Index....10118
Specifications/Structure & Operation/Inspection & Repair of Frames....10119
Group 42 - Cab....10124
Index....10125
Specifications....10126
Structure & Operation....10128
Troubleshooting....10144
On-Vehicle Inspection & Adjustment....10150
Removal & Installation of Cab....10154
Front Cab Mounting....10162
Rear Cab Mounting....10165
Cab Tilt Link....10166
Door....10170
Cab Exterior Fitting....10176
Mirror....10182
Wiper & Washer....10184
Cab Interior Fitting....10188
Instrument Panel....10194
Window Glass....10198
Group 54 - Electrical....10202
Index....10203
How To Read This Group....10206
0 General....10210
Specifications....10211
Structure & Operation....10215
Troubleshooting....10231
1 Power, Charge & Ground Circuit....10239
110-Power Circuit....10240
115-Reserve Power Circuit....10249
125-Battery Charging Circuit....10250
130-Ground....10251
2 Starting & Preheating Circuit....10266
210-Engine Starting Circuit....10267
220-Engine Preheating Circuit....10268
3-Lighting Circuit....10271
310-Headlamp Circuit....10272
313-Daytime Running Light Circuit....10274
320-Tail, Clearance & License Plate Lamp Circuit....10276
325-Stop Lamp Circuit....10277
330-Turn Signal & Hazard Lamp Circuit....10278
340-Backup Lamp Circuit....10279
345-Cab Lamp Circuit....10280
348-Illumination Lamp Circuit....10281
349-Marker & Identification Lamp Circuit....10282
325-Van Body Dome Light Circuit....10283
4 Meter Circuit....10284
401-Meter Cluster Internal Circuit....10285
410-Tachometer Circuit....10287
412-Speedometer Circuit....10288
420-Fuel Gauge Circuit....10290
425-Water Temperature Gauge Circuit....10291
5 Indicator & Warning Lamp Circuit....10292
510-Parking Brake Indicator Circuit....10293
515-Brake Warning Circuit....10295
530-Water Level Warning Circuit....10297
536-Engine Oil Pressure Warning Circuit....10298
537-Overheating Warning Circuit....10299
547-ATF Temperature Warning Circuit....10300
548-Transmission High/Low Indicator Circuit....10301
550-Cab Tilt Warning Circuit....10302
6 Cab Side Electrical Circuit....10303
610-Cigarette Lighter Circuit....10304
612-Audio Circuit....10305
614-Wiper & Washer Circuit....10306
616-Horn Circuit....10307
618-Heater Circuit....10308
622-Power Window & Auto Door Lock Circuit....10309
629-Mirror Heater Circuit....10310
7 Chassis Side Electrical Circuit....10311
710-Exhaust Brake Circuit....10312
718-Air Dryer Circuit....10314
8 Engine & Transmission Side Electrical Circuit....10315
850-Transmission Power Take-Off Circuit....10316
9 Others Circuit....10317
910-Multipurpose Timing Control Unit Circuit....10318
10 Parts Installation Position....10320
A-Switch....10321
B-Relay & Electronic Control Unit....10323
C-Fuse, Meter, Sensor, Buzzer & Motor....10325
D-Heater....10327
E-Door & Mirror....10328
F-Roof....10329
G-Cab....10331
J-Joint of Main Harness Connectors....10333
R-Engine....10335
S-Transmission....10337
T-Switch & Sensor....10339
U-Battery, Fuse & Connector....10341
V-Magnetic Valve, Motor & Actuator....10342
W-Buzzer....10342
11 Instpection of Parts....10343
001 to 179-Switch....10344
180 to 249-Relay....10352
250 to 349-Sensor....10355
350 to 409-Control Unit....10358
410 to 509-Motor....10359
510 to 559-Actuator....10361
560 to 609-Magnetic Valve....10362
610 to 649-Buzzer & Horn....10363
650 to 699-Lamp....10364
750 to 859-Other....10365
860-Battery....10367
870 to 889-Fuse....10370
890-Meter Cluster....10374
12 Starter & Alternator....10378
930-Starter....10379
940-Alternator....10393
950-Inspection of Alternator....10400
951-Inspection of Regulator....10401
13 On-Vehicle Inspection & Adjustment....10402
955-Inspection of Preheating System....10403
960-Headlamp Aiming....10405
965-Inspection of Brake Fluid Level Switch....10407
Group 55A - Air Conditioner....10408
Forward & Table of Contents....10409
Specifications....10410
Outlines of Refrigeration System....10411
Construction....10413
Troubleshooting....10420
Removal & Installation....10427
Treatment After Installation....10430
Maintenance....10436
Cooling Unit Assembly....10437
Compressor & Clutch Assembly....10439
Group 55B - Heater....10442
Index....10443
Specifications/Structure & Operation....10444
Troubleshooting....10450
Heater Hose....10452
Heater Control....10454
Air Duct....10457
Heater Unit & Blower....10458
Air Outlet Ventilation....10459
2005 Fuso Service Manual (FE, FG, FK, FM)....10460
2005 Service Manual....10460
2005 FE/FG Service Manual....10461
Group 00 - General....10462
Table of Contents....10463
Equipment Type Codes List....10464
Power Train Table....10465
How to Read this Manual....10466
Chassis Number, Engine Number, Power Train Label....10472
Vehicle Identification Number....10473
Precautions for Maintenance Operation....10474
Jacking Up the Vehicle....10486
Diagnosis Codes....10488
1. Connecting Multi-Use Tester....10488
2. Accessing/Erasing Diagnosis Codes Common Rail, Exhaust Gas Recirculation, Pre-heater....10492
3. Accessing/Erasing Diagnosis Codes Automatic Transmission....10494
4. Accessing/Erasing Diagnosis Codes Anti-lock Brake System....10496
Table of Standard Tightening Torques....10498
Group 01 - Maintenance Schedule....10501
Table of Contents....10502
How to Read the Maintenance Schedule Tables....10503
Maintenance Schedule Tables....10505
Maintenance Operations....10509
Lubrication Tables....10515
Lubrication....10517
Group 11 - Engine....10521
Table of Contents....10522
Specifications....10523
Structure and Operation....10524
1. Exploded View....10524
2. Cylinder Head, Cylinder Head Gasket, Camshaft, and Camshaft Frame....10525
3. Valve Mechanism....10526
4. Connecting Rod....10527
5. Piston....10527
6. Timing Gears....10528
7. Flywheel....10528
8. Balance Shafts....10529
9. Crankcase and Main Bearings....10530
10. Oil Seals....10532
Troubleshooting....10533
On-Vehicle Inspection and Adjustment....10535
1. Measuring Compression Pressure....10535
2. Inspection and Adjustment of Valve Clearance....10537
Engine Removal and Installation....10539
Tilt Cab....10539
Fixed Cab....10547
Rocker Cover....10549
Rockers and Camshafts....10551
Cylinder Head and Valve Mechanism....10563
Pistons, Connecting Rod and Cylinder Liners....10577
Flywheel....10591
Front Case....10595
Timing Gears and Balance Shafts....10597
Crankshaft and Crankcase....10605
Balance Shaft Bushings....10613
Group 12 - Lubrication....10618
Table of Contents....10619
Specifications....10620
Structure and Operation....10621
1. Lubrication System....10621
2. Oil Pump....10622
3. Oil Cooler....10623
4. Oil Filter....10624
5. Lubrication of Engine Components....10625
Troubleshooting....10628
On-Vehicle Inspection and Adjustment....10630
1. Oil Filter Replacement....10630
2. Engine Oil Replacement....10634
3. Oil Pressure Measurement....10636
Oil Pan, Oil Strainer and Oil Jets....10638
Oil Pump....10640
Oil Filter....10644
Oil Cooler....10648
Group 13 - Fuel and Engine Control....10650
Group 13A - Fuel and Engine Control....10651
Table of Contents....10652
Specifications....10653
Structure and Operation....10654
1. Fuel System (Flow of Fuel)....10654
2. Engine Control....10655
3. Fuel Filter....10656
Troubleshooting....10657
On-Vehicle Inspection and Adjustment....10659
1. Inspecting and Adjusting No-load Minimum and Maximum Speeds....10659
2. Air-bleeding of Fuel System....10660
3. Fuel Filter Replacement....10661
Fuel Tank....10663
Fuel Filter....10665
Engine Control....10667
Common Rail....10670
Supply Pump....10671
Injector....10673
Group 13E - Electronically Controlled Fuel System....10675
Table of Contents....10676
Specifications....10677
Structure and Operation....10678
1. Overview....10678
2. Electronic Control System....10687
3. Electronic Control Unit Connection Diagram....10693
Troubleshooting....10695
1. Inspection Procedure....10695
2. Cautions to Observe when Performing Inspections....10696
3. Inspection Based on Diagnosis Codes....10697
4. Multi-Use Tester Service Data....10711
5. Actuator Tests Performed Using Multi-Use Tester....10713
6. Inspections Performed at Electronic Control Unit Connectors....10715
Inspection of Electrical Equipment....10718
Installed Locations of Parts....10725
Electric Circuit Diagram....10731
Group 14 - Cooling....10737
Table of Contents....10738
Specifications....10739
Structure and Operation....10741
1. Cooling System (Flow of Coolant)....10741
2. Thermostat....10742
3. Water Pump....10742
Troubleshooting....10743
On-Vehicle Inspection and Adjustment....10745
1. Coolant Replacement and Cleaning of Cooling System....10745
2. Air Bleeding of Cooling System....10747
3. Air/Gas Leakage Test....10747
Disconnection and Connection of Hoses and Pipes....10749
Radiator....10753
Cooling Fan, V-Belt and Water Pump....10761
Tension Pulley....10764
Thermostat....10765
Pressure Cap and Water Outlet Case....10767
Group 15 - Intake and Exhaust....10769
Table of Contents....10770
Specifications....10771
Structure and Operation....10771
1. Air Cleaner....10771
2. Turbocharger....10772
3. Muffler....10773
Troubleshooting....10774
On-Vehicle Inspection and Adjustment....10775
1. Measurement of Turbocharger Boost Pressure....10775
Air Duct and Air Cleaner Except Crew Cab....10777
Air Duct and Air Cleaner Crew Cab....10781
Turbocharger....10785
Intercooler....10791
Intake Manifold....10793
Exhaust Manifold....10794
Exhaust Pipe....10795
Muffler....10797
Group 17 - Emission Control....10798
Table of Contents....10799
Structure and Operation....10800
1. Exhaust Gas Recirculation System....10800
2. Crankcase Emission Control System....10805
Exhaust Gas Recirculation System....10806
1. Inspection Procedure....10806
2. Cautions to Observe when Performing Inspections....10807
3. Inspections Based on Diagnosis Codes....10808
4. Multi-Use Tester Service Data....10810
5. Actuator Tests Performed Using Multi-Use Tester....10810
6. Inspections Performed at Electronic Control Unit Connectors....10811
7. Inspection of Electrical Equipment....10812
8. Installed Locations of Parts....10813
9. Electric Circuit Diagram....10818
Exhaust Gas Recirculation Valve, Pipe and Cooler....10822
Crankcase Emission Control System....10824
Group 21 - Clutch....10826
Table of Contents....10827
Specifications....10828
Structure and Operation....10829
1. Clutch Control....10829
2. Clutch Master Cylinder....10830
3. Clutch Proper and Clutch Direct Power Cylinder....10832
Troubleshooting....10834
On-Vehicle Inspection and Adjustment....10836
1. Replacement of Brake Fluid (Clutch System)....10836
2. Air Bleeding of Brake Fluid (Clutch System)....10838
3. Inspection of Clutch Disk Wear Limit....10840
Clutch Pedal....10842
Clutch Master Cylinder....10846
Clutch Proper....10848
Clutch Control....10852
Group 22 - Manual Transmission....10857
Table of Contents....10858
Specifications....10859
Structure and Operation....10861
1. Transmission....10861
2. Synchromesh Mechanism....10863
3. Interlock Mechanism....10866
4. Speedometer Gear Bushing....10866
Troubleshooting....10867
On-Vehicle Inspection and Adjustment....10869
1. Inspection and Replacement of Transmission Oil....10869
Removal and Installation of Transmission Assembly....10871
Gear Shifter Upper....10873
Rear Cover S5 and Parking Brake....10879
Extension Housing S6 and Parking Brake....10883
Reverse Idler Gear....10887
6th Gear S6....10891
Transmission Body....10897
Drive Pinion....10913
Mainshaft....10915
Countershaft....10925
Transmission Control....10927
Bearing Puller and Installer....10932
Group 23 - Automatic Transmission....10933
Table of Contents....10934
Specifications....10935
Structure and Operation....10936
1. Overview....10936
2. Electronic Control System....10947
3. Electronic Control Unit Connection Diagram....10953
Troubleshooting....10955
1. Inspection Procedure....10955
2. Cautions to Observe When Performing Inspections....10956
3. Inspections Based on Diagnosis Codes....10957
4. Multi-Use Tester Service Data....10966
5. Inspections Performed at Electronic Control Unit Connectors....10969
6. Likely Causes of Symptoms....10972
On-Vehicle Inspection and Adjustment....10977
1. Stall Test....10977
2. Time Lag Test....10978
3. Line Pressure Test....10979
4. Road Test....10981
5. Inspection of ATF....10982
6. Replacement of ATF....10983
7. Dealer Adjust....10985
Removal and Installation of Automatic Transmission....10989
Automatic Transmission Control....10997
Oil Cooler....11005
Models Except Crew Cab....11005
Crew Cab....11007
Replacement of Parts of Automatic Transmission Main Body....11009
Inspection of Electrical Equipment....11013
Installed Locations of Parts....11017
Electric Circuit Diagram....11021
Group 24 - Transfer....11027
Table of Contents....11028
Specifications....11029
Structure and Operation....11030
1. Transfer....11030
2. Speedometer Gear Bushing....11031
Troubleshooting....11032
On-Vehicle Inspection and Adjustment....11033
1. Inspection and Replacement of Transfer Oil....11033
Removal and Installation of Transmission (with Transfer)....11035
Removal and Installation of Transfer....11037
Front Drive....11039
Rear Drive....11043
Transfer....11049
Transfer Control....11057
Group 25 - Propeller Shaft....11061
Table of Contents....11062
Specifications....11063
Structure and Operation....11063
1. Configuration of Propeller Shaft Connection....11063
2. Propeller Shaft without Center Bearing....11064
3. Propeller Shaft with Center Bearing....11065
Troubleshooting....11066
Removal and Installation of Propeller Shaft Between T/M (or T/F) and Rear Axle....11067
Removal and Installation of Propeller Shaft Between Front Axle and T/F....11071
Propeller Shaft P2....11073
Propeller Shaft P3....11079
Group 26 - Front Axle....11089
Group 26A - Front Axle FE....11090
Table of Contents....11091
Specifications....11092
Structure and Operation....11093
1. Wheel Hub and Rotor....11093
2. Knuckle and Kingpin, Front Axle....11094
Troubleshooting....11095
On-Vehicle Inspection and Adjustment....11096
1. Inspection and Adjustment of Wheel Alignment....11096
2. Inspection and Adjustment of Steering Angle....11100
3. Inspection of Side Slip....11101
4. Inspection of Play in Tie Rod End Ball Joint....11101
Wheel Hub and Rotor....11102
Knuckle and Kingpin, Front Axle....11110
Tie Rod....11118
Group 26B - Front Axle FG....11120
Table of Contents....11121
Specifications....11122
Structure and Operation....11122
1. Wheel Hub and Brake Drum....11122
2. Free Wheel Hub....11123
3. Drive Shaft and Steering Knuckle, Axle Housing....11124
4. Reduction and Differential....11125
Troubleshooting....11126
On-Vehicle Inspection and Adjustment....11130
1. Inspection and Adjustment of Wheel Alignment....11130
2. Inspection and Adjustment of Steering Angle....11134
3. Inspection of Side Slip....11134
4. Inspection of Play at Tie Rod End Ball Joint....11135
5. Inspection and Replacement of Axle Oil....11135
Wheel Hub and Brake Drum....11138
Drive Shaft and Steering Knuckle....11148
Tie Rod....11154
Axle Housing....11156
Reduction and Differential....11158
Group 27 - Rear Axle....11173
Table of Contents....11174
Specifications....11175
Structure and Operation....11176
1. Wheel Hub and Rotor....11176
2. Wheel Hub and Brake Drum....11177
3. Reduction and Differential....11178
4. Limited Slip Differential....11179
Troubleshooting....11181
On-Vehicle Inspection and Adjustment....11183
1. Inspection and Replacement of Axle Oil....11183
Wheel Hub and Rotor....11185
Wheel Hub and Brake Drum....11195
Axle Housing....11205
Reduction and Differential....11209
Group 31 - Wheel and Tire....11236
Table of Contents....11237
Specifications....11238
Troubleshooting....11239
Wheel and Tire....11240
Group 33 - Front Suspension....11245
Table of Contents....11246
Structure and Operation....11247
1. Front Suspension Elements....11247
Troubleshooting....11248
Stabilizer FE....11249
Shock Absorber FE....11251
Shock Absorber FG....11253
Leaf Spring FE....11255
Leaf Spring FG....11259
Group 34 - Rear Suspension....11263
Table of Contents....11264
Structure and Operation....11265
1. Rear Suspension Elements....11265
Troubleshooting....11266
Shock Absorber....11267
Leaf Spring....11269
Stabilizer....11287
Group 35 - Brake....11290
Group 35A - Brake....11291
Table of Contents....11292
Specifications....11293
Structure and Operation....11295
1. Brake System....11295
2. Vacuum Pump....11298
3. Vacuum Booster and Brake Master Cylinder....11299
4. Hydraulic Booster and Brake Master Cylinder....11305
5. Flow Priority Valve....11311
6. Front Disc Brake....11312
7. Front Drum Brake....11313
8. Rear Disc Brake....11316
9. Rear Drum Brake....11317
10. Exhaust Brake System....11318
Troubleshooting....11321
On-Vehicle Inspection and Adjustment....11325
1. Replacement of Brake Fluid....11325
2. Air Bleeding of Brake System....11327
3. Inspection and Adjustment of Brake Pedal Free Play....11331
4. Inspection and Adjustment of Brake Pedal Depressed Height from Floor....11331
5. Inspection of Brake Pedal Full Stroke and Adjustment of Installed Height of Brake Pedal....11332
6. Inspection and Replacement of Disc Brake Pad....11333
7. Measurement of Disc Brake Drag Torque....11336
8. Inspection of Drum Brake Lining Thickness....11336
9. Initial Setting of Clearance between Brake Drum and Shoe....11337
10. Inspection of Check Valve in Vacuum Line Hose....11338
11. Inspection of Vacuum Pump....11338
12. Inspection of Vacuum Booster....11339
13. Inspection of Hydraulic Booster....11346
Vacuum Pump....11349
Brake Master Cylinder with Vacuum Booster....11351
Brake Master Cylinder with Hydraulic Booster....11355
Brake Pedal & Vacuum Booster, Hydraulic Booster....11357
Front Disc Brake 235 mm {9.25 in.} Disc....11359
Front Disc Brake 252 mm {9.92 in.} Disc....11363
Front Drum Brake....11367
Rear Disc Brake 235 mm {9.25 in.} Disc....11373
Rear Disc Brake 252 mm {9.92 in.} Disc....11375
Rear Drum Brake....11377
Exhaust Brake System....11383
Group 35E - Anti-lock Brake System (ABS)....11385
Table of Contents....11386
Specifications....11387
Structure and Operation....11389
1. Overview....11389
2. Electronic Control System....11399
3. Electronic Control Unit Schematic Diagram....11403
Troubleshooting....11405
1. Diagnosis Procedure....11405
2. Precautions when Carrying Out Diagnosis....11406
3. Diagnosis Based on Diagnosis Codes....11407
4. Multi-Use Tester Service Data....11413
5. Actuator Test Using Multi-Use Tester....11415
6. Inspection at Hydraulic Unit (Electronic Control Unit) Connector....11416
On-Vehicle Inspection and Adjustment....11419
1. Functional Check....11419
2. Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope....11420
3. Inspection of Hydraulic Unit (Electronic Control Unit) Operation....11421
4. Inspection after Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)....11422
Hydraulic Unit Connector Coupling and Uncoupling....11423
Inspection of Electrical Components....11425
Components Location....11429
Electrical Wiring Diagram....11433
Group 36 - Parking Brake....11435
Table of Contents....11436
Specifications....11437
Structure and Operation....11438
1. Components and Parts....11438
2. Parking Brake Lever....11438
3. Parking Brake....11439
Troubleshooting....11440
On-Vehicle Inspection and Adjustment....11441
1. Inspection and Adjustment of Parking Brake Shoe Clearance....11441
2. Inspection and Adjustment of Parking Brake Lever....11442
Parking Brake Control....11445
Parking Brake....11449
FE (Manual Transmission)....11449
FE (Automatic Transmission)....11451
FG....11453
Group 37 - Steering....11455
Table of Contents....11456
Specifications....11457
Structure and Operation....11459
1. Steering System....11459
2. Oil Flow....11459
3. Power Steering Gear (Backlash Compensation Mechanism)....11460
4. Power Steering Oil Pump Kayaba Industry Product....11461
5. Power Steering Oil Pump Unisia JKC Product....11463
Troubleshooting....11465
On-Vehicle Inspection and Adjustment....11467
1. Change of Power Steering Fluid....11467
2. Bleeding of Power Steering System....11468
3. Performance Verification Test of Power Steering System....11469
4. Steering Wheel Play....11470
5. Steering Column Looseness....11470
6. Drag Link Ball Joint Backlash....11470
Steering Column....11471
Power Steering Gear and Drag Link....11481
Power Steering Oil Pump Kayaba Industry Product....11503
Power Steering Oil Pump Unisia JKC Product....11507
Power Steering Oil Tank....11511
Group 41 - Frame....11513
Table of Contents....11514
Specifications....11515
Structure and Operation....11516
Frame....11517
Group 42 - Cab....11521
Table of Contents....11522
Specifications....11523
Structure and Operation....11524
1. Front Cab Mounting....11524
2. Rear Cab Mounting Except Crew Cab....11525
3. Center and Rear Cab Mountings Crew Cab....11525
4. Cab Tilt Link Except Crew Cab....11526
Troubleshooting....11527
On-Vehicle Inspection and Adjustment....11529
1. Adjustment of Cab Tilt System Except Crew Cab....11529
Removal and Installation of Cab....11531
Except Crew Cab....11531
Crew Cab....11535
Front Cab Mounting....11539
Except Crew Cab....11539
Crew Cab....11541
Rear Cab Mounting Except Crew Cab....11543
Center and Rear Cab Mountings Crew Cab....11544
Cab Tilt Link Except Crew Cab....11545
Cab Stay Except Crew Cab....11547
Group 43 - Door....11548
Table of Contents....11549
Specifications....11550
Structure and Operation....11551
1. Front Door Lock System....11551
2. Rear Door Lock System Crew Cab....11551
3. Front Door Glass Opening and Closing Mechanism....11552
4. Rear Door Glass Opening and Closing Mechanism Crew Cab....11554
Troubleshooting....11556
On-Vehicle Inspection and Adjustment....11558
1. Adjustment of Front Door Alignment....11558
2. Adjustment of Rear Door Alignment Crew Cab....11561
Front Door....11564
Rear Door Crew Cab....11572
Group 51 - Exterior....11578
Table of Contents....11579
Structure and Operation....11580
1. Wiper and Washer System....11580
Troubleshooting....11581
Mirror....11582
Wiper and Washer....11584
Front Cover....11586
Front Grille, Front Corner Panel and Headlamp....11588
Fender....11592
Step....11594
Garnish Crew Cab....11596
Wheel House....11597
Window Glass....11598
Group 52 - Interior....11601
Table of Contents....11602
Seat....11603
Driver....11603
Passenger....11605
Rear....11607
Seat Belt....11609
Instrument Panel....11615
Trim and Scuff Plate....11635
Except Crew Cab....11635
Crew Cab....11639
Head Lining....11641
Except Crew Cab....11641
Crew Cab....11643
Group 54 - Electrical....11645
Table of Contents....11646
How to Read this Group....11649
54-00 - General....11653
Precautions for Maintenance Operation....11654
Specifications....11664
Structure and Operation....11667
1. Starter....11667
2. Alternator....11668
3. Headlamps....11671
4. Meter Cluster....11672
5. Daytime Running Light System....11680
6. Wiper Control....11682
7. Starter Continuous Energizing Preventing Function and Preheating Function....11684
Troubleshooting....11688
54-01 - Power, Charge and Ground Circuit....11695
High-Current Fuse Box....11696
Fuse Box....11698
110 - Power Circuit....11700
115 - Reserve Power Circuit....11710
125 - Battery Charging Circuit....11711
130 - Ground....11712
54-02 - Starting Circuit....11727
210 - Engine Starting Circuit....11728
220 - Engine Preheating Circuit....11730
54-03 - Lighting Circuit....11731
310 - Headlamp Circuit....11732
313 - Daytime Running Light Circuit....11734
320 - Tail, Clearance and License Plate Lamps Circuit....11736
325 - Stop Lamp Circuit....11737
330 - Turn Signal and Hazard Lamp Circuit....11738
340 - Backup Lamp Circuit....11740
345 - Cab Lamp Circuit....11742
348 - Illumination Lamp Circuit....11744
349 - Identification Lamp and Side Marker Lamp Circuit....11745
352 - Van Body Dome Light Circuit....11746
54-04 - Meter Circuit....11747
401 - Meter Cluster Internal Circuit....11748
412 - Speedometer Circuit....11749
420 - Fuel Gauge Circuit....11750
425 - Water Temperature Gauge Circuit....11751
54-05 - Indicator and Warning Lamp Circuit....11752
510 - Parking Brake Indicator Circuit....11753
515 - Brake Warning Circuit....11755
535 - Engine Oil Level Warning Circuit....11757
536 - Engine Oil Pressure Warning Circuit....11758
537 - Overheating Warning Circuit....11759
540 - Brake Pad Warning Circuit....11760
550 - Cab Tilt Warning Circuit....11761
566 - Fuel Filter Warning Circuit....11762
54-06 - Cab Side Electrical Circuit....11763
610 - Cigarette Lighter Circuit....11764
612 - Audio Circuit....11765
614 - Wiper and Washer Circuit....11766
616 - Horn Circuit....11767
620 - Air-Conditioner Circuit....11768
622 - Power Window and Auto Door Lock Circuit....11770
629 - Mirror Heater Circuit....11771
54-07 - Chassis Side Electrical Circuit....11772
710 - Exhaust Brake Circuit....11773
54-08 - Engine and Transmission Side Electrical Circuit....11775
810 - Four-Wheel Drive Circuit FG....11776
850 - Transmission Power Take-Off Circuit....11777
54-09 - Other Circuit....11778
905 - Joint Connector (J/C)....11779
907 - Diagnosis Switch, Memory Clear Switch....11784
54-10 - Parts Installation Positions....11785
A - Switch....11786
B - Relay and Electronic Control Unit....11789
C - Fuse, Meter, Sensor, Buzzer, Motor and Actuator....11790
D - Air-Conditioner Option....11791
E - Door....11792
F - Roof....11793
J - Joint of Main Harness Connectors....11794
R - Engine....11796
S - Transmission....11797
T - Switch and Sensor....11800
U - Fuse and Connector....11801
V - Magnetic Valve and Motor....11803
W - Buzzer and Connector....11803
54-11 - Inspection of Parts....11804
#001 to #179 - Switch....11805
#180 to #249 - Relay....11811
#250 to #349 - Sensor....11813
#350 to #409 - Control Unit....11814
#410 to #509 - Motor....11815
#510 to #539 - Actuator....11816
#560 to #609 - Magnetic Valve....11817
#610 to #649 - Buzzer, Horn....11818
#650 to #699 - Lamp....11820
#750 to #859 - Other....11821
#860 - Battery....11823
54-12 - Starter adn Alternator....11826
#930 - Starter....11827
#940 - Alternator....11841
54-13 - On-Vehicle Inspection and Adjustment....11849
#950 - Inspection of Alternator....11850
#951 - Inspection of Regulator....11851
#955 - Inspection of Preheating System....11852
#956 - Inspection of Starter Continuous Energizing Preventing Function....11856
#960 - Headlamp Aiming....11860
54-14 - Connector Configuration Chart....11862
Connector Configuration Chart....11863
Group 55 - A/C & Heater....11931
Group 55A - Air-Conditioner....11932
Table of Contents....11933
Specifications....11934
Structure and Operation....11936
1. Air-Conditioner System....11936
2. Engine Room....11937
3. Cabin Room....11938
4. Compressor....11939
5. Magnetic Clutch....11940
6. Check Valve....11940
7. Side Condensor Assembly....11941
8. Relief Valve....11941
9. Receiver Assembly....11942
10. Evaporator Assembly....11942
11. Expansion Valve....11943
12. Dual Pressure Switch....11943
13. Power Relay....11944
14. Air-Conditioner Switch....11944
15. Thermostat....11944
16. Control System....11946
Troubleshooting....11948
On-Vehicle Inspection and Adjustment....11950
1. Recovery of Refrigerant....11950
2. Inspection and Adjustment of V-Belt....11950
3. Inspection of Magnetic Clutch....11951
4. Recharging the System with Refrigerant....11952
5. Checking Refrigerant Charge Level....11954
6. Adding Refrigerant....11955
7. Inspection of Receiver Assembly....11956
8. Inspection of Dual Pressure Switch....11956
Connecting Air-Conditioner Piping....11957
Compressor....11958
Condenser, Receiver....11960
Cooling Unit....11962
Air-Conditioner Circuit....11964
Group 55B - Heater....11965
Table of Contents....11966
Specifications....11967
Structure and Operation....11969
1. Heater....11969
2. Air Duct....11970
3. Heater Control....11971
Troubleshooting....11975
Heater Control....11977
Air Duct....11981
Heater Unit, Blower....11983
2005 FK/FM Service Manual....11985
Group 00 - General....11986
Table of Contents....11987
Model Coding System....11988
Power Train Table....11990
Chassis Number and Engine Number....11992
Power Train Label....11992
Vehicle Identification Number....11993
Precautions for Maintenance Operation....11994
Diagnosis Codes....12006
1. Connecting Multi-Use Tester....12006
2. Accessing/Erasing Diagnosis Codes Common Rail, Exhaust gas recirculation, Pre-heater....12010
3. Accessing/Erasing Diagnosis Codes Auto Cruise....12012
4. Accessing/Erasing Diagnosis Codes Anti-lock Brake System....12014
Table of Standard Tightening Torques....12016
Connector Configuration Chart....12020
Group 01 - Maintenance Schedule....12088
Table of Contents....12089
How to Read the Maintenance Schedule Tables....12090
Maintenance Schedule Tables....12091
Maintenance Operations....12097
Lubrication Tables....12103
Lubrication....12104
Group 11 - Engine....12107
Table of Contents....12108
Specifications....12109
Structure and Operation....12110
1. Engine Proper....12110
2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket....12111
3. Valve Mechanism....12112
4. Connecting Rods....12112
5. Pistons....12113
6. Timing Gears....12113
7. Flywheel....12115
Troubleshooting....12116
On-Vehicle Inspection and Adjustment....12117
1. Measuring Compression Pressure....12117
2. Inspecting and Adjusting Valve Clearance....12121
Engine Removal and Installation....12125
Rocker Cover, Rocker and Bracket Assembly, Camshaft....12127
Cylinder Head, Valve Mechanism....12137
Pistons, Connecting Rods and Cylinder Liners....12155
Flywheel....12169
Manual Transmission....12169
Automatic Transmission....12175
Timing Gears....12179
Crankshaft and Crankcase....12185
Group 12 - Lubrication....12194
Table of Contents....12195
Specifications....12196
Structure and Operation....12197
1. Lubrication System....12197
2. Oil Pump....12198
3. Oil Filter....12198
4. Oil Cooler....12199
5. Engine Oil Pressure Switch and Regulator Valve....12199
6. Lubrication of Related Parts....12200
Troubleshooting....12203
On-Vehicle Inspection and Adjustment....12204
1. Oil Filter Replacement....12204
2. Engine Oil Replacement....12206
3. Oil Pressure Measurement....12207
Oil Pan and Oil Jet....12208
Oil Pump and Oil Strainer....12210
Oil Filter....12213
Oil Cooler....12214
Regulator Valve....12216
Group 13 - Fuel and Engine Control....12217
Group 13A - Fuel and Engine Control....12218
Table of Contents....12219
Specifications....12220
Structure and Operation....12221
1. Fuel System....12221
2. Engine Control....12222
3. Fuel Filter....12223
Troubleshooting....12224
On-Vehicle Inspection and Adjustment....12226
1. Checking No-load Minimum and Maximum Speeds....12226
2. Air Bleeding of Fuel System....12227
3. Replacement of Fuel Filter....12228
Engine Control....12230
Fuel Tank....12233
Fuel Filter....12234
Common Rail Assembly....12236
Supply Pump....12238
Injector, Fuel Temperature Sensor....12242
Group 13E - Electronically Controlled Fuel System....12244
Table of Contents....12245
Common Rail System....12246
Specifications....12246
Structure and Operation....12248
1. Overview....12248
2. Electronic Control System....12256
3. Electronic Control Unit Connection Diagram....12262
Troubleshooting....12264
1. Inspection Procedure....12264
2. Cautions to Observe When Performing Inspections....12265
3. Inspections Based on Diagnosis Codes....12266
4. Multi-Use Tester Service Data....12283
5. Actuator Tests Performed Using Multi-Use Tester....12286
6. Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit....12288
7. Inspections Performed at Electronic Control Unit Connectors....12289
Inspection of Electrical Equipment....12292
Installed Locations of Parts....12300
Electric Circuit Diagram....12306
Auto Cruise System....12314
Structure and Operation....12314
1. General Description....12314
2. Electronic Control System....12314
3. Electronic Control Unit Connection Diagram....12318
Troubleshooting....12320
1. Inspection Procedure....12320
2. Cautions to Observe When Performing Inspections....12321
3. Inspection Based on Diagnosis Codes....12322
4. Multi-Use Tester Service Data....12325
5. Actuator Tests Performed using Multi-Use Tester....12326
6. Inspections Performed at Electronic Control Unit Connectors....12327
Inspection of Electrical Equipment....12328
Installed Locations of Parts....12330
Electric Circuit Diagram....12336
Group 14 - Cooling....12337
Table of Contents....12338
Specifications....12339
Structure and Operation....12339
1. Cooling System (Coolant Flow)....12339
2. Water Pump....12340
3. Thermostat....12340
Troubleshooting....12341
On-Vehicle Inspection and Adjustment....12343
1. Replacing Coolant and Cleaning Cooling System....12343
2. Air Bleeding of Cooling System....12345
3. Gas Leak Testing....12345
Radiator and Fan Shroud....12347
Cooling Fan and V-Belt....12355
Water Pump....12359
Thermostat....12367
Group 15 - Intake and Exhaust....12369
Table of Contents....12370
Specifications....12371
Structure and Operation....12372
1. Air Cleaner....12372
2. Turbocharger Assembly....12372
Troubleshooting....12374
On-Vehicle Inspection and Adjustment....12375
Measurement of Turbocharger Boost Pressure....12375
Air Duct....12377
Air Cleaner....12379
Turbocharger....12381
Intercooler....12386
Intake Manifold....12387
Exhaust Manifold....12388
Exhaust Pipe and Muffler....12389
Group 17 - Emission Control....12391
Table of Contents....12392
Structure and Operation....12393
1. Exhaust Gas Recirculation System....12393
2. Crankcase Emission Control System....12397
On-Vehicle Inspection and Adjustment....12398
1. Replacement of PCV Valve Element....12398
Exhaust Gas Recirculation System....12399
1. Inspection Procedure....12399
2. Cautions to Observe when Performing Inspections....12400
3. Inspections Based on Diagnosis Codes....12401
4. Multi-Use Tester Service Data....12403
5. Actuator Tests Performed Using Multi-Use Tester....12403
6. Inspection of Electrical Equipment....12403
Installed Locations of Parts....12405
Electric Circuit Diagram....12411
Exhaust Gas Recirculation Valve, Exhaust Gas Recirculation Solenoid Valve, Exhaust Gas Recirculation Pipe, Exhaust Gas Recirculation Cooler....12415
Crankcase Emission Control System....12419
Group 21 - Clutch....12421
Table of Contents....12422
Specifications....12423
Structure and Operation....12423
Troubleshooting....12428
On-Vehicle Inspection and Adjustment....12429
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding Clutch Power Cylinder....12429
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding Clutch Booster....12431
Inspection of Function Clutch Booster....12433
Clutch Pedal Free Play Clutch Power Cylinder....12434
Clutch Pedal Free Play Clutch Booster....12435
Clutch Pedal M060S6, M070S6....12437
Clutch Pedal Eaton FS-8209....12441
Clutch Master Cylinder....12445
Clutch Power Cylinder M060S6, M070S6....12447
Clutch Booster Eaton FS-8209....12449
Work Before Removal and Installation of Clutch Body....12457
Clutch Body....12459
Clutch Control M060S6, M070S6....12475
Clutch Control Eaton FS-8209....12477
Group 22 - Manual Transmission....12479
Group 22A - Manual Transmission M060S6, M070S6....12480
Table of Contents....12481
Specifications....12482
Structure and Operation....12482
Troubleshooting....12491
Work Before Removal and Installation of Transmission Assembly....12492
Removal and Installation of Transmission Assembly....12494
Gear Shifter Upper and Interlock Plate....12497
Power Shift Assembly....12502
Extension Housing and Parking Brake Assembly....12508
6th Gear and Reverse Idler Gear M060....12512
Reverse Gear and Reverse Idler Gear M070....12520
Transmission Body....12526
Drive Pinion Assembly....12542
Mainshaft Assembly Over-Drive (M060)....12544
Mainshaft Assembly Direct-Drive (M070)....12552
Countershaft Assembly....12564
Transmission Control....12568
Puller and Installer Kit....12572
Group 22B - Manual Transmission M060S9 (Eaton FS-8209)....12573
Table of Contents....12574
Specifications....12575
Removal and Installation of Transmission Assembly....12577
Transmission Control....12581
High-Low Control....12585
Group 23 - Automatic Transmission....12588
Group 23A - Automatic Transmission M065A5 (Allison LCT1000, LCT2400)....12589
Table of Contents....12590
Specifications....12591
Structure and Operation....12595
1. Outline....12595
2. Electronic Control System....12599
3. Electronic Control Unit Connection Diagram....12603
Troubleshooting....12605
1. Failure by Equipment....12605
2. Measures for Transitory Failure....12611
On-Vehicle Inspection and Adjustment....12613
1. Stall Test....12613
2. Line Pressure Test....12614
3. Inspection of Automatic Transmission Fluid....12615
4. Replacement of Automatic Transmission Fluid....12616
5. Replacement of Oil Filter....12617
Preparatory Work for Removal and Installation of Automatic Transmission Assembly....12618
Removal and Installation of Automatic Transmission Assembly....12619
Parking Brake Assembly....12621
Oil Pan, Suction Filter and Level Gauge....12623
Automatic Transmission Control....12625
Oil Cooler....12633
Inspection of Electrical Equipment....12635
Installed Locations of Parts....12639
Electric Circuit Diagram....12643
Group 23B - Automatic Transmission M100A6 (Allison MD3060P)....12647
Table of Contents....12648
Specifications....12649
Structure and Operation....12651
1. Automatic Transmission Assembly....12651
2. Automatic Transmission Control System....12652
3. Oil Cooler System....12653
Troubleshooting....12654
On-Vehicle Inspection and Adjustment....12659
1. Stall Test....12659
2. Line Pressure Test....12660
3. Inspection of Automatic Transmission Fluid....12662
4. Replacement of Automatic Transmission Fluid....12663
5. Level Check of Automatic Transmission Fluid....12665
6. Replacement of Oil Filter....12666
Oil Cooler....12667
Installed Locations of Parts....12669
Electric Circuit Diagram....12673
Group 25 - Propeller Shaft....12675
Table of Contents....12676
Specifications....12677
Structure and Operation....12677
Troubleshooting....12679
Removal and Installation of Propeller Shaft....12681
Rear Propeller Shaft....12683
P8....12683
P10, P12....12687
Front Propeller Shaft....12691
P8....12691
P10, P12....12697
Balancing Propeller Shaft....12702
Group 26 - Front Axle....12704
Table of Contents....12705
Specifications....12706
Structure and Operation....12706
On-Vehicle Inspection and Adjustment....12712
Adjustment of Wheel Alignment....12712
Adjustment of Steering Angle....12716
Measurement of Side Slip....12716
Work Before Removal and Installation of Front Axle....12717
Wheel Hub and Brake Drum....12718
FK....12718
FM (Air-Over Hydraulic Brake)....12732
FM (Full-Air Brake)....12746
Front Axle, Knuckle and Kingpin....12760
FK....12760
FM (Air-Over Hydraulic Brake)....12766
FM (Full-Air Brake)....12774
Group 27 - Rear Axle....12780
Table of Contents....12781
Specifications....12782
Structure and Operation....12783
Troubleshooting....12786
Work Before Removal and Installation of Rear Axle....12788
Wheel Hub and Brake Drum....12790
FK....12790
FM....12804
Axle Housing....12820
Reduction and Differential D050H, D8H....12824
Reduction and Differential D10H....12844
Group 31 - Wheel and Tire....12864
Table of Contents....12865
Specifications....12866
Troubleshooting....12866
Wheel and Tire....12867
Group 33 - Front Suspension....12872
Table of Contents....12873
Structure and Operation....12874
Troubleshooting....12875
Work Before Removal and Installation of Front Suspension....12876
Removal and Installation of Leaf Spring Assembly....12878
Leaf Spring Assembly....12882
Shock Absorber....12884
Group 34 - Rear Suspension....12885
Group 34A - Rear Suspension LEAF....12886
Table of Contents....12887
Structure and Operation....12888
Troubleshooting....12889
Work Before Removal and Installation of Rear Suspension....12890
Removal and Installation of Leaf Spring Assembly....12892
Leaf Spring Assembly....12898
Group 34B - Rear Suspension AIR....12900
Table of Contents....12901
Specifications....12902
Structure and Operation....12903
1. Air Suspension....12903
2. Air Suspension System....12904
3. Leveling Valve....12906
Troubleshooting....12908
On-Vehicle Inspection and Adjustment....12909
Adjustment of Air Spring Height....12909
Work Before Removal and After Installation of Rear Suspension....12910
Shock Absorber....12912
Removal and Installation of Leaf Spring Assembly and Air Spring....12914
Leaf Spring Assembly....12918
Air Spring....12920
Leveling Valve....12922
Group 35 - Brake....12925
Group 35A - Brake Air Over Hydraulic Brake....12926
Table of Contents....12927
Specifications....12928
Structure and Operation....12930
Troubleshooting....12949
On-Vehicle Inspection and Adjustment....12953
Replacement of Brake Fluid....12953
Air Bleeding of Brake System....12955
Inspection and Adjustment of Brake Pedal Free Play....12957
Thickness Inspection and Replacement of Brake Lining....12958
Inspection of Brake Shoe Clearance....12958
Inspection and Maintenance of Air Dryer....12958
Inspection and Adjustment of Air Dryer's Air Pressure Governor....12960
Handling of Connector and Nylon Tube Piping....12962
Air Compressor....12964
Air Dryer....12970
Brake Pedal....12974
Dual Brake Valve....12976
Brake Booster (Airmaster)....12984
Front Wheel Brake....12990
320 mm {12.6 in.} Drum Brake....12990
400 mm {15.7 in.} Drum Brake....12998
Rear Wheel Brake....13008
320 mm {12.6 in.} Drum Brake....13008
400 mm {15.7 in.} Drum Brake....13016
Fluid Tank....13026
Check Valve....13027
Safety Valve....13027
Supply Valve....13028
Exhaust Brake System....13030
Group 35B - Brake Full Air Brake....13033
Table of Contents....13034
Specifications....13035
Structure and Operation....13037
Troubleshooting....13054
On-Vehicle Inspection and Adjustment....13058
Inspection and Adjustment of Brake Pedal Free Play....13058
Thickness Inspection and Replacement of Brake Lining....13058
Handling of Connector and Nylon Tube Piping....13063
Air Compressor....13065
Air Dryer....13071
Brake Pedal....13075
Dual Brake Valve....13077
Relay Valve....13085
Quick Release Valve....13087
Front Wheel Brake....13089
Rear Wheel Brake....13099
Expander Assembly....13109
Check Valve....13115
Safety Valve....13115
Supply Valve....13116
Exhaust Brake System....13117
Group 35E - Anti-Lock Brake System (ABS)....13120
Table of Contents....13121
Specifications....13122
Structure and Operation....13122
On-Vehicle Inspection and Adjustment....13136
Periodic Inspection Procedures....13136
Adjustment of Wheel Speed Sensor Clearance Air-Over Hydraulic Brake....13138
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope....13139
Troubleshooting....13140
Inspection Procedures....13140
Inspection Flowchart....13141
Diagnosis Code Chart....13142
Service Data Chart....13144
Actuator Drive Chart....13145
Locations of Parts....13146
Electrical Wiring Diagram....13150
Group 36 - Parking Brake....13153
Group 36A - Parking Brake Center Parking Brake....13154
Table of Contents....13155
Specifications....13156
Structure and Operation....13156
Troubleshooting....13158
On-Vehicle Inspection and Adjustment....13159
Adjustment of Parking Brake Shoe Clearance and Lever Stroke....13159
Parking Brake Control....13160
Parking Brake Assembly....13162
Support Plate and Shoe Assembly....13166
Group 36B - Parking Brake Wheel Parking Brake....13168
Table of Contents....13169
Structure and Operation....13170
Troubleshooting....13175
Parking Brake Control Valve....13176
Spring Brake Valve....13178
Double Check Valve....13181
Group 37 - Steering....13182
Table of Contents....13183
Specifications....13184
Structure and Operation....13185
Troubleshooting....13194
On-Vehicle Inspection and Adjustment....13197
Change of Power Steering Fluid....13197
Bleeding of Power Steering System....13197
Steering Wheel Play....13198
Performance Verification Test of Power Steering System....13199
Steering System....13200
Linkage and Bracket....13206
Power Steering Booster....13208
Power Steering Oil Pump....13222
FK, FM61, FM64....13222
FM65....13228
Power Steering Oil Tank....13233
Drag Link....13234
Tie Rod Assembly....13236
Group 41 - Frame....13239
Table of Contents....13240
Specifications....13241
Structure and Operation....13241
Inspection and Repair of Frames....13241
Group 42 - Cab....13246
Table of Contents....13247
Specifications....13248
Structure and Operation....13250
Troubleshooting....13260
On-Vehicle Inspection and Adjustment....13266
Adjustment of Door Fitting....13266
Removal and Installation of Cab....13268
Front Cab Mounting....13274
Rear Cab Mounting....13277
Cab Stay....13278
Cab Tilt Link....13280
Door....13282
Mirror....13288
Seat....13290
Driver....13290
Passenger....13296
Seat Belt....13298
Wiper and Washer....13300
Instrument Panel....13306
Scuff Plate and Trim....13310
Headlining....13312
Front Panel....13316
Radiator Grille and Corner Panel....13318
Step....13320
Fender....13322
Mud Guard....13324
Window Glass....13326
Group 54 - Electrical....13329
Table of Contents....13330
How to Read This Group....13333
0 - General....13337
Specifications....13338
Structure and Operation....13342
1. Starter....13342
2. Alternator....13344
3. Lamp....13347
4. Daytime Running Light (DRL) System....13348
5. MUTIC (Multipurpose Timing Control Unit)....13350
6. Engine Electronic Control Unit....13354
Troubleshooting....13361
1. Fault Diagnosis Function....13361
2. Power and Charging....13372
3. Engine Starting, Preheating and Stopping....13373
4. Lighting....13374
5. Meter....13377
6. Cigarette Lighter and Audio....13378
7. Accessory Noise Generation Source....13378
8. Horn....13379
1 - Power, Charge and Ground Circuit....13380
104 - Relay and Fuse Box Circuit....13381
110 - Power Circuit....13382
111 - Electronic Control Unit Power Circuit....13392
115 - Reserve Power Circuit....13393
125 - Battery Charging Circuit....13394
130 - Ground....13395
2 - Starting and Preheating Circuit....13415
210 - Engine Starting Circuit....13416
220 - Engine Preheating Circuit....13418
3 - Lighting Circuit....13420
310 - Headlamp Circuit....13421
313 - Daytime Running Light Circuit....13423
320 - Tail, Clearance and License Plate Lamp Circuit....13425
325 - Stop Lamp Circuit....13426
330 - Turn Signal and Hazard Lamp Circuit....13427
340 - Backup Lamp Circuit....13428
345 - Cab Lamp Circuit....13431
348 - Illumination Lamp Circuit....13432
349 - Marker and Identification Lamp Circuit....13433
352 - Van Body Dome Light Circuit....13434
4 - Meter Circuit....13435
401 - Meter Cluster Internal Circuit....13436
410 - Tachometer Circuit....13438
412 - Speedometer Circuit....13439
420 - Fuel Gauge Circuit....13442
425 - Water Temperature Gauge Circuit....13443
5 - Indicator and Warning Lamp Circuit....13444
510 - Parking Brake Indicator Circuit....13445
515 - Brake Warning Circuit....13447
530 - Water Level Warning Circuit....13449
535 - Engine Oil Level Warning Circuit....13450
536 - Engine Oil Pressure Warning Circuit....13451
537 - Overheating Warning Circuit....13452
548 - Transmission High/Low Indicator Circuit....13453
550 - Cab Tilt Warning Circuit....13454
566 - Fuel Filter Warning Circuit....13455
6 - Cab Side Electrical Circuit....13456
610 - Cigarette Lighter Circuit....13457
612 - Audio Circuit....13458
614 - Wiper and Washer Circuit....13459
616 - Horn Circuit....13460
620 - Air-Conditioner Circuit....13461
622 - Power Window and Auto Door Lock Circuit....13462
629 - Mirror Heater Circuit....13463
7 - Chassis Side Electrical Circuit....13464
710 - Exhaust Brake Circuit....13465
718 - Air Dryer Circuit....13468
722 - Air Suspension Circuit....13469
8 - Engine and Transmission Side Electrical Circuit....13471
850 - Transmission Power Take-Off Circuit....13472
9 - Others Circuit....13473
910 - Multipurpose Timing Control Unit Circuit....13474
10 - Parts Installation Position....13475
A - Switch....13476
B - Relay and Electronic Control Unit....13478
C - Fuse, Meter, Sensor, Buzzer and Motor....13480
D - Heater....13482
E - Door and Mirror....13483
F - Roof....13484
G - Cab....13486
J - Joint of Main Harness Connectors....13488
R - Engine....13490
S - Transmission....13492
T - Switch and Sensor....13494
U - Fuse and Connector....13498
V - Magnetic Valve....13500
W - Buzzer....13500
11 - Inspection of Parts....13502
#001 to #179 - Switch....13503
#180 to #249 - Relay....13512
#250 to #349 - Sensor....13515
#350 to #409 - Control Unit....13518
#410 to #509 - Motor....13519
#510 to #559 - Actuator....13520
#560 to #609 - Magnetic Valve....13521
#610 to #649 - Buzzer and Horn....13522
#650 to #699 - Lamp....13523
#750 to #859 - Other....13524
#860 - Battery....13526
#870 to #889 - Fuse....13529
#890 - Meter Cluster....13533
12 - Starter and Alternator....13537
#930 - Starter....13538
#940 - Alternator....13552
#950 - Inspection of Alternator....13559
#951 - Inspection of Regulator....13560
13 - On-Vehicle Inspection and Adjustment....13561
#955 - Inspection of Preheating System....13562
#960 - Adjustment of Headlamp Aiming....13564
#965 - Inspection of Brake Fluid Level Switch....13566
Group 55 - A/C & Heater....13567
Group 55A - Air-Conditioner....13568
Table of Contents....13569
Specifications....13570
Structure and Operation....13571
1. Air System....13571
2. Refrigerating Circuit....13572
3. Engine Room....13573
4. Cabin Room....13574
5. Compressor....13575
6. Magnetic Clutch....13576
7. Check Valve....13576
8. Side Condenser Assembly....13577
9. Relief Valve....13577
10. Receiver Assembly....13578
11. Cooling Unit Assembly....13578
12. Expansion Valve....13579
13. Dual Pressure Switch....13579
14. Power Relay....13580
15. Air-Conditioner Switch....13580
16. Thermostat....13580
17. Control System....13582
Troubleshooting....13584
On-Vehicle Inspection and Adjustment....13586
1. Recovery of Refrigerant....13586
2. Inspection and Adjustment of V-Belt....13586
3. Inspection of Magnetic Clutch....13587
4. Charging System with Refrigerant....13588
5. Inspection of Refrigerant....13590
6. Replenishment of Refrigerant....13591
7. Inspection of Receiver Assembly....13592
Connection of Air-Conditioner Piping....13593
Compressor and Tension Pulley....13594
Side Condenser Assembly and Receiver Assembly....13598
Cooling Unit....13600
Air-Conditioner Circuit....13604
Group 55B - Heater....13606
Table of Contents....13607
Specifications....13608
Structure and Operation....13609
Troubleshooting....13614
Heater Hose....13616
Heater Control....13618
Air Duct....13621
Heater Unit and Blower....13622
Air Outlet Ventilation....13623
2008 Fuso Service Manual (FE, FG, FK, FM)....13624
2008 Service Manual....13624
2008 FE/FG Service Manual....13625
Group 00 - General....13626
Table of Contents....13627
Equipment Type Codes List....13628
Power Train Table....13629
How To Read This Manual....13630
Chassis Number, Engine Number, Power Train Label....13634
Vehicle Identification Number....13635
Precautions for Maintenance Operation....13636
Jacking Up the Vehicle....13648
Diagnosis Codes....13650
1. Diagnosis Codes....13650
2. Reading and Erasing the Diagnosis Code....13651
Table of Standard Tightening Torques....13656
Group 01 - Maintenance Schedule....13659
Table of Contents....13660
How to Read the Maintenance Schedule Tables....13661
Maintenance Schedule Tables....13663
Maintenance Operations....13667
Lubrication Tables....13673
Lubrication....13675
Group 11 - Engine....13679
Table of Contents....13680
Specifications....13681
Structure and Operation....13682
1. Exploded View....13682
2. Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame....13683
3. Valve Mechanism....13684
4. Connecting Rod....13685
5. Piston....13685
6. Timing Gears....13686
7. Flywheel....13686
8. Balance Shafts....13687
9. Crankcase and Main Bearings....13688
10. Oil Seals....13690
Troubleshooting....13691
On-Vehicle Inspection and Adjustment....13693
1. Measuring Compression Pressure....13693
2. Inspection and Adjustment of Valve Clearances....13695
3. Removal and Installation of Injector Crew Cab (Fixed Type)....13697
Engine Removal and Installation....13699
Tilt Cab....13699
Fixed Cab....13707
Rocker Cover....13709
Rockers and Camshafts....13711
Cylinder Head and Valve Mechanism....13725
Pistons, Connecting Rod and Cylinder Liners....13741
Flywheel....13755
Front Case....13759
Timing Gears and Balance Shafts....13763
Crankshaft and Crankcase....13771
Balance Shaft Bushings....13779
Group 12 - Lubrication....13784
Table of Contents....13785
Specifications....13786
Structure and Operation....13787
1. Lubrication System....13787
2. Oil Pump....13788
3. Oil Cooler....13789
4. Oil Filter....13790
5. Lubrication of Engine Components....13791
Troubleshooting....13794
On-Vehicle Inspection and Adjustment....13796
1. Oil Filter Replacement....13796
2. Engine Oil Replacement....13800
3. Engine Oil Level Inspection....13802
4. Oil Pressure Measurement....13803
Oil Pan, Oil Strainer and Oil Jets....13804
Oil Pump....13806
Oil Filter....13810
Oil Cooler....13814
Group 13A - Fuel and Engine Control....13816
Table of Contents....13817
Specifications....13818
Structure and Operation....13819
1. Fuel System (Flow of Fuel)....13819
2. Engine Control....13820
3. Fuel Filter....13821
Troubleshooting....13822
On-Vehicle Inspection and Adjustment....13824
1. Inspecting and Adjusting No-Load Minimum and Maximum Speeds....13824
2. Air-Bleeding of Fuel System....13825
3. Fuel Filter Replacement....13826
Fuel Tank....13828
Outside Frame Type....13828
Inside Frame Type....13830
Fuel Filter....13832
Engine Control....13836
Common Rail....13840
Supply Pump....13844
Injector....13848
Group 13EA - Common Rail System....13851
Table of Contents....13852
Specifications....13853
Structure and Operation....13854
1. Overview....13854
2. Electronic Control System....13863
3. Electronic Control Unit Connection Diagram....13871
Troubleshooting....13873
1. Diagnosis Procedure....13873
2. Diagnostic Precautions....13873
3. Inspection Based on Fault Codes....13874
4. Multi-Use Tester Service Data....14815
5. Mode 06 Data....14819
6. Actuator Tests Performed Using Multi-Use Tester....14821
Registration and Alteration of Data In Engine Electronic Control Unit....14825
1. Operation at Electronic Control Unit Replacement....14825
2. Resetting the Diesel Particulate Filter Related Information (Resetting Electronic Control Unit)....14825
Inspection of Electrical Equipment....14827
Installed Locations of Parts....14837
Electric Circuit Diagram....14843
Group 13EB - Auto Cruise and Vehicle Speed Limitation System....14848
Table of Contents....14849
Structure and Operation....14850
1. General Description....14850
2. Electronic Control System....14850
3. Electronic Control Unit Connection Diagram....14854
Troubleshooting....14856
1. Diagnosis Procedure....14856
2. Diagnostic Precautions....14857
3. Inspection Based on Diagnosis Codes....14858
4. Multi-Use Tester Service Data....14862
5. Actuator Tests Performed Using Multi-Use Tester....14863
6. Works Required When Replacing the Multifunction Vehicle Control Unit (MVCU)....14863
7. Inspection Performed at Electronic Control Unit Connectors....14864
Inspection of Electrical Equipment....14865
Installed Locations of Parts....14866
Electric Circuit Diagram....14870
Group 14 - Cooling....14872
Table of Contents....14873
Specifications....14874
Structure and Operation....14876
1. Cooling System (Flow of Coolant)....14876
2. Thermostat....14877
3. Water Pump....14877
Troubleshooting....14878
On-Vehicle Inspection and Adjustment....14880
1. Inspection and Adjustment of Belt Tension....14880
2. Inspection of Cracks or Damage of the Belt....14885
3. Coolant Replacement and Cleaning of Cooling System....14886
4. Air Bleeding of Cooling System....14888
5. Air/Gas Leakage Test....14888
Disconnection and Connection of Hoses and Pipes....14890
Radiator, Fan Shroud....14894
Cooling fan, Belt and Water Pump....14902
Tension Pulley....14905
Thermostat....14906
Pressure Cap and Water Outlet Case....14908
Group 15 - Intake and Exhaust....14910
Table of Contents....14911
Specifications....14912
Structure and Operation....14912
1. Air Cleaner....14912
2. Turbocharger....14913
3. Turbocharger Control System....14914
4. Diesel Particulate Filter Regeneration Control System....14918
Troubleshooting....14928
On-Vehicle Inspection and Adjustment....14930
1. Measurement of Turbocharger Boost Pressure....14930
2. Cleaning and Inspection of Air Cleaner Element....14931
3. Diesel Particulate Filter Unit Inspection for Clogging and Cleaning the Diesel Particulate Filter Unit....14932
4. Resetting the DPF-Related Information (Resetting Electronic Control Unit)....14936
Air Duct and Air Cleaner....14940
Except Crew Cab....14940
Crew Cab....14944
Turbocharger....14948
Intercooler....14954
Intake Manifold....14958
Exhaust Manifold....14960
Exhaust Pipe....14962
Diesel Particulate Filter....14964
Group 17 - Emission Control....14970
Table of Contents....14971
Structure and Operation....14972
1. Exhaust Gas Recirculation System....14972
2. Crankcase Emission Control System....14977
Exhaust Gas Recirculation Valve, Pipe and Cooler....14978
Crankcase Emission Control System....14982
Group 21 - Clutch....14985
Table of Contents....14986
Specifications....14987
Structure and Operation....14988
1. Clutch Control....14988
2. Clutch Master Cylinder....14989
3. Clutch Proper and Clutch Direct Power Cylinder....14991
Troubleshooting....14993
On-Vehicle Inspection and Adjustment....14995
1. Replacement of Brake Fluid (Clutch System)....14995
2. Air Bleeding of Brake Fluid (Clutch System)....14997
3. Inspection of Clutch Disc Wear Limit....14999
Clutch Pedal....15001
Clutch Master Cylinder....15005
Clutch Proper....15007
Clutch Control....15011
Group 22 - Manual Transmission....15016
Table of Contents....15017
Specifications....15018
Structure and Operation....15020
1. Transmission....15020
2. Synchromesh Mechanism....15022
3. Interlock Mechanism....15025
4. Speedometer Gear Bushing....15025
Troubleshooting....15026
On-Vehicle Inspection and Adjustment....15028
1. Inspection of Transmission Oil Leak....15028
2. Inspection of Looseness in Transmission Mounting Bolts....15028
3. Inspection of Play In Companion Flange and Looseness in Lock Nut....15029
4. Inspection and Replacement of Transmission Oil....15029
Removal and Installation of Transmission....15032
Gear Shifter Upper....15036
Rear Cover S5 and Parking Brake....15042
Extension Housing S6 and Parking Brake....15046
Reverse Idler Gear....15052
6th Gear S6....15056
Transmission Body....15062
Drive Pinion....15078
Mainshaft....15080
Countershaft....15090
Transmission Control....15092
Bearing Puller and Installer....15096
Group 23 - Automatic Transmission....15097
Table of Contents....15098
Specifications....15099
Structure and Operation....15100
1. Overview....15100
2. Electronic Control System....15106
3. Electronic Control Unit Connection Diagram....15111
Troubleshooting....15113
1. Diagnosis Procedure....15113
2. Diagnostic Precautions....15113
3. Inspections Based on Diagnosis Codes....15114
4. Multi-Use Tester Service Data....15412
5. Possible Causes of Symptoms....15415
On-Vehicle Inspection and Adjustment....15419
1. Inspection of Automatic Transmission Oil Leakage....15419
2. Check for Looseness in Automatic Transmission Mounting Bolts....15419
3. Inspection of Play in Companion Flange and Looseness in Lock Nut....15420
4. Inspection of Automatic Transmission Fluid....15420
5. Replacement of Automatic Transmission Fluid....15421
6. Stall Test....15423
7. Time Lag Test....15424
8. Line Pressure Test....15425
9. Road Test....15427
10. Dealer Adjust....15428
Removal and Installation of Automatic Transmission....15431
Parking Brake....15437
Automatic Transmission Control....15439
Oil Cooler....15449
Except Crew Cab....15449
Crew Cab....15451
Replacement of Part of Automatic Transmission Main Body....15453
Inspection of Electrical Equipment....15457
Installed Locations of Parts....15461
Electric Circuit Diagram....15465
Group 24 - Transfer....15469
Table of Contents....15470
Specifications....15471
Structure and Operation....15472
1. Transfer....15472
2. Speedometer Gear Bushing....15473
Troubleshooting....15474
On-Vehicle Inspection and Adjustment....15475
1. Inspection of Looseness in Transmission and Transfer Mounting Bolts....15475
2. Inspection of Play and Looseness in Companion Flange....15475
3. Inspection and Replacement of Transfer Oil....15476
Removal and Installation of Transmission (With Transfer)....15477
Removal and Installation of Transfer....15481
Front Drive....15483
Rear Drive....15489
Transfer....15495
Transfer Control (High-Low Switching)....15503
Group 25 - Propeller Shaft....15507
Table of Contents....15508
Specifications....15509
Structure and Operation....15509
1. Configuration of Propeller Shaft Connection....15509
2. Propeller Shaft Without Center Bearing....15510
3. Propeller Shaft With Center Bearing....15511
Troubleshooting....15512
Removal and Installation of Propeller Shaft....15513
Between T/M (or T/F) and Rear Axle....15513
Between Front Axle and T/F....15515
Propeller Shaft....15517
P2....15517
P3....15523
Group 26A - Front Axle FE....15534
Table of Contents....15535
Specifications....15536
Structure and Operation....15537
1. Wheel Hub and Rotor....15537
2. Knuckle and Kingpin, Front Axle....15538
Troubleshooting....15539
On-Vehicle Inspection and Adjustment....15540
1. Inspection and Adjustment of Wheel Alignment....15540
2. Inspection and Adjustment of Steering Angle....15544
3. Inspection of Side Slip....15545
4. Inspection of Tie Rod End Ball Joint....15545
Wheel Hub and Rotor....15546
Knuckle and Kingpin, Front Axle....15556
Tie Rod....15564
Group 26B - Front Axle FG....15566
Table of Contents....15567
Specifications....15568
Structure and Operation....15568
1. Wheel Hub and Brake Drum....15568
2. Free Wheel Hub....15569
3. Drive Shaft and Steering Knuckle, Axle Housing....15570
4. Reduction and Differential....15571
Troubleshooting....15572
On-Vehicle Inspection and Adjustment....15576
1. Inspection and Adjustment of Wheel Alignment....15576
2. Inspection and Adjustment of Steering Angle....15580
3. Inspection of Side Slip....15580
4. Inspection of Tie Rod End Ball Joint....15581
5. Inspection and Replacement of Axle Oil....15581
Wheel Hub and Brake Drum....15584
Drive Shaft and Steering Knuckle....15596
Tie Rod....15602
Axle Housing....15604
Reduction and Differential....15606
Group 27 - Rear Axle....15621
Table of Contents....15622
Specifications....15623
Structure and Operation....15624
1. Wheel Hub and Rotor....15624
2. Wheel Hub and Brake Drum....15625
3. Reduction and Differential....15626
4. Limited Slip Differential....15627
Troubleshooting....15629
On-Vehicle Inspection and Adjustment....15631
1. Inspection and Replacement of Axle Oil....15631
Wheel Hub and Rotor....15633
Wheel Hub and Brake Drum....15643
Axle Housing....15655
Reduction and Differential....15659
Group 31 - Wheel and Tire....15686
Table of Contents....15687
Specifications....15688
Troubleshooting....15689
Wheel and Tire....15690
Group 33 - Front Suspension....15695
Table of Contents....15696
Structure and Operation....15697
1. Front Suspension Elements....15697
Troubleshooting....15698
Stabilizer....15699
Shock Absorber....15701
FE....15701
FG....15703
Leaf Spring....15705
FE....15705
FG....15709
Group 34 - Rear Suspension....15713
Table of Contents....15714
Structure and Operation....15715
1. Rear Suspension Elements....15715
Troubleshooting....15716
Shock Absorber....15717
Leaf Spring....15719
Stabilizer....15735
Group 35A - Brake....15738
Table of Contents....15739
Specifications....15740
Structure and Operation....15742
1. Brake System....15742
2. Vacuum Pump....15745
3. Vacuum Booster and Brake Master Cylinder Except FE85....15746
4. Hydraulic Booster and Brake Master Cylinder FE85....15752
5. Flow Priority Valve FE85....15758
6. Front Disc Brake FE....15759
7. Front Drum Brake FG....15760
8. Rear Disc Brake FE....15763
9. Rear Drum Brake FG....15764
10. Exhaust Brake System FE....15765
Troubleshooting....15768
On-Vehicle Inspection and Adjustment....15772
1. Replacement of Brake Fluid....15772
2. Air Bleeding of Brake System....15774
3. Inspection and Adjustment of Brake Pedal Free Play....15778
4. Inspection and Adjustment of Brake Pedal Pressed Height from Floor....15778
5. Inspection of Brake Pedal Full Stroke and Adjustment of Installed Height of Brake Pedal....15779
6. Inspection and Replacement of Disc Brake Pad FE....15780
7. Measurement of Disc Brake Drag Torque FE....15783
8. Inspection of Drum Brake Lining Thickness FG....15783
9. Initial Setting of Clearance Between Brake Drum and Shoe FG....15784
10. Inspection of Check Valve in Vacuum Line Hose....15785
11. Inspection of Vacuum Pump....15785
12. Inspection of Vacuum Booster Except FE85....15786
13. Inspection of Hydraulic Booster FE85....15791
Vacuum Pump....15793
Brake Master Cylinder....15794
With Vacuum Booster....15794
With Hydraulic Booster....15798
Brake Pedal & Vacuum Booster, Hydraulic Booster....15800
Front Disc Brake....15802
235 mm {9.25 in.} Disc....15802
252 mm {9.92 in.} Disc....15806
Front Drum Brake....15810
Rear Disc Brake....15816
235 mm {9.25 in.} Disc....15816
252 mm {9.92 in.} Disc....15818
Rear Drum Brake....15820
Exhaust Brake System....15826
Group 35E - Anti-Lock Brake System (ABS)....15828
Table of Contents....15829
Specifications....15830
Structure and Operation....15832
1. Overview....15832
2. Electronic Control System....15842
3. Electronic Control Unit Schematic Diagram....15846
Troubleshooting....15848
1. Diagnosis Procedure....15848
2. Diagnostic Precautions....15848
3. Diagnosis Based on Diagnosis Codes....15849
4. Multi-Use Tester Service Data....15855
5. Actuator Test Using Multi-Use Tester....15857
6. Inspection at Hydraulic Unit (Electronic Control Unit) Connector....15858
On-Vehicle Inspection and Adjustment....15860
1. Functional Check....15860
2. Inspection of Hydraulic Unit (Electronic Control Unit) Operation....15861
3. Inspection After Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)....15862
4. Oscilloscopic Inspection Through Wheel Speed Sensor Signal Waveform....15863
Hydraulic Unit Connector Coupling and Uncoupling....15864
Inspection of Electrical Components....15866
Components Location....15868
Electrical Wiring Diagram....15870
Group 36 - Parking Brake....15872
Table of Contents....15873
Specifications....15874
Structure and Operation....15875
1. Components and Parts....15875
2. Parking Brake Lever....15875
3. Parking Brake....15876
Troubleshooting....15877
On-Vehicle Inspection and Adjustment....15878
1. Adjustment of Parking Brake Shoe Clearance....15878
2. Inspection and Adjustment of Parking Brake Lever....15879
Parking Brake Control....15882
Parking Brake....15886
FE (Manual Transmission)....15886
FE (Automatic Transmission)....15888
FG....15890
Group 37 - Steering....15892
Table of Contents....15893
Specifications....15894
Structure and Operation....15896
1. Steering System....15896
2. Oil Flow....15896
3. Power Steering Gear (Backlash Compensation Mechanism)....15897
4. Power Steering Oil Pump KYB Product....15898
5. Power Steering Oil Pump Unisia JKC Steering Systems Product....15900
Troubleshooting....15902
On-Vehicle Inspection and Adjustment....15904
1. Change of Power Steering Fluid....15904
2. Bleeding of Power Steering System....15905
3. Performance Verification Test of Power Steering System....15906
4. Steering Wheel Play....15907
5. Steering Column Looseness....15907
6. Inspection of Drag Link Ball Joint....15907
Steering Column....15908
Power Steering Gear Assembly and Drag Link....15918
Power Steering Oil Pump....15936
KYB Product....15936
Unisia JKC Steering Systems Product....15940
Power Steering Oil Tank....15944
Group 41 - Bumper and Frame....15946
Table of Contents....15947
Specifications....15948
Structure and Operation....15949
Front Bumper....15950
Frame....15952
Group 42 - Cab....15957
Table of Contents....15958
Specifications....15959
Structure and Operation....15960
1. Front Cab Mounting....15960
2. Rear Cab Mounting Except Crew Cab....15961
3. Center and Rear Cab Mountings Crew Cab....15961
4. Cab Tilt Link Except Crew Cab....15962
Troubleshooting....15963
On-Vehicle Inspection and Adjustment....15965
1. Adjustment of Cab Tilt System Except Crew Cab....15965
Removal and Installation of Cab....15967
Except Crew Cab....15967
Crew Cab....15971
Front Cab Mounting....15975
Except Crew Cab....15975
Crew Cab....15977
Rear Cab Mounting Except Crew Cab....15979
Center and Rear Cab Mountings Crew Cab....15980
Cab Tilt Link Except Crew Cab....15981
Cab Stay Except Crew Cab....15983
Group 43 - Door....15984
Table of Contents....15985
Specifications....15986
Structure and Operations....15987
1. Front Door Lock System....15987
2. Rear Door Lock System Crew Cab....15987
3. Front Door Glass Opening and Closing Mechanism....15988
4. Rear Door Glass Opening and Closing Mechanism Crew Cab....15990
Troubleshooting....15992
On-Vehicle Inspection and Adjustment....15994
1. Adjustment of Front Door Alignment....15994
2. Adjustment of Rear Door Alignment Crew Cab....15997
Front Door....16000
Rear Door Crew Cab....16008
Group 51 - Exterior....16015
Table of Contents....16016
Structure and Operation....16017
1. Wiper and Washer System....16017
Troubleshooting....16018
Mirror....16019
Wiper and Washer....16021
Front Cover....16023
Front Grille, Front Corner Panel and Headlamp....16025
Fender....16029
Step....16031
Garnish Crew Cab....16033
Wheel House....16034
Window Glass....16035
Group 52 - Interior....16038
Table of Contents....16039
Seat....16040
Driver....16040
Passenger....16042
Rear....16044
Seat Belt....16046
Instrument Panel....16052
Trim and Scuff Plate....16066
Except Crew Cab....16066
Crew Cab....16070
Head Lining....16072
Except Crew Cab....16072
Crew Cab....16074
Group 54 - Electrical....16076
Table of Contents....16077
How to Read This Group....16080
54-00A - General....16084
Precautions for Maintenance Operation....16085
54-00B - Specifications....16095
Specifications....16096
54-00C - Structure and Operation....16099
1. Starter....16100
2. Alternator....16101
3. Headlamps....16104
4. Meter Cluster....16105
5. Daytime Running Light System....16114
6. Wiper Control....16116
7. Starter Continuous Energizing Preventing Function and Preheating Function....16118
54-00D - Troubleshooting....16121
Troubleshooting....16122
54-01 - Power, Charge and Ground Circuit....16130
High-Current Fuse Box....16131
Fuse Box....16133
110 - Power Circuit....16135
115 - Reserve Power Circuit....16148
125 - Battery Charging Circuit....16149
130 - Ground....16151
54-02 - Starting, Stopping and Preheating Circuit....16169
210 - Engine Starting Circuit....16170
215 - Engine Stopping Circuit....13851
220 - Engine Preheating Circuit....16172
54-03 - Lighting Circuit....16174
310 - Headlamp Circuit....16175
313 - Daytime Running Light Circuit....16177
320 - Tail, Clearance and License Plate Lamps Circuit....16179
325 - Stop Lamp Circuit....16181
330 - Turn Signal and Hazard Lamp Circuit....16183
340 - Backup Lamp Circuit....16185
345 - Cab Lamp Circuit....16187
348 - Illumination Lamp Circuit....16189
349 - Identification Lamp and Side Marker Lamp Circuit....16190
352 - Van Body Dome Light Circuit....16191
54-04 - Meter Circuit....16192
401 - Meter Cluster Internal Circuit....16193
410 - Tachometer Circuit....16195
412 - Speedometer Circuit....16196
420 - Fuel Gauge Circuit....16197
425 - Water Temperature Gauge Circuit....16198
54-05 - Indicator and Warning Lamp Circuit....16199
510 - Parking Brake Indicator Circuit....16200
515 - Brake Warning Circuit....16202
535 - Engine Oil Level Warning Circuit....16204
536 - Engine Oil Pressure Warning Circuit....16205
537 - Overheating Warning Circuit....16206
540 - Brake Pad Warning Circuit....16207
550 - Cab Tilt Warning Circuit....16208
566 - Fuel Filter Warning Circuit....16209
54-06 - Cab Side Electrical Circuit....16210
610 - Cigarette Lighter Circuit....16211
612 - Audio Circuit....16212
614 - Wiper and Washer Circuit....16213
616 - Horn Circuit....16214
620 - Air-Conditioner Circuit....16215
622 - Power Window and Central Door Lock Circuit....16217
629 - Mirror Heater Circuit....16218
54-07 - Chassis Side Electrical Circuit....16219
710 - Exhaust Brake Circuit....16220
54-08 - Engine and Transmission Electrical Circuit....16222
810 - Four-Wheel Drive Circuit FG....16223
850 - Transmission Power Take-Off Circuit....16224
54-09 - Other Circuit....16225
905 - Joint Connector (J/C)....16226
907 - Diagnosis Switch and Memory Clear Switch....16230
Electronically Controlled Fuel System Electric Circuit Diagram....13851
Auto Cruise System Electric Circuit Diagram....14848
Automatic Transmission System Electric Circuit Diagram....15097
Anit-Lock Brake System Electric Circuit Diagram....15828
54-10 - Electrical Equipment Installation Positions....16231
A - Switch....16232
B - Relay and Electronic Control Unit....16236
C - Fuse, Meter, Sensor, Buzzer, Motor and Actuator....16238
D - Air-Conditioner....16239
E - Door....16240
F - Roof....16241
J - Joints of Main Harness Connectors....16242
R - Engine....16244
S - Transmission....16246
T - Switch and Sensor....16249
U - Fuse, Relay and Connectors....16250
V - Magnetic Valve and Motor....16253
W - Buzzer and Connectors....16253
54-11 - Inspection of Electrical Equipment....16254
#001 to #179 - Switch....16255
#180 to #249 - Relay....16261
#250 to #349 - Sensor....16262
#350 to #409 - Control Unit....16263
#410 to #509 - Motor....16264
#510 to #539 - Actuator....16266
#560 to #609 - Magnetic Valve....16266
#610 to #649 - Buzzer, Horn....16267
#650 to #699 - Lamp....16269
#750 to #859 - Other....16270
#860 - Battery....16272
#890 - Meter....16275
54-12 - Starter and Alternator....16276
#930 - Starter....16277
#940 - Alternator....16291
54-13 - On-Vehicle Inspection and Adjustment....16299
#950 - Inspection of Alternator....16300
#951 - Inspection of Regulator....16301
#955 - Inspection of Preheating System....16302
#960 - Headlamp Aiming....16304
54-14 - Connector Configuration Chart....16306
Connector Configuration Chart....16307
Group 55 - Heater, Air-Conditioner and Ventilation....16389
Table of Contents....16390
Specifications....16391
Structure and Operation....16393
1. Heater....16393
2. Air Conditioner....16394
3. Air Duct....16395
4. Heater Control....16396
Troubleshooting....16399
On-Vehicle Inspection and Adjustment....16401
1. Recovery of Refrigerant....16401
2. Recharging the System With Refrigerant....16402
3. Checking Refrigerant Charge Level....16404
4. Adding Refrigerant....16405
Connecting Air Conditioner Piping....16406
Compressor....16407
Condenser, Receiver....16409
Heater Control....16411
Air Duct....16415
Heater and Cooling Unit, Blower....16417
2008 FK/FM Service Manual....16420
Group 00 - General....16421
Table of Contents....16422
Equipment Type Codes List....16423
Power Trains Table....16425
How To Read This Manual....16427
Chassis Number, Engine Number, Power Train Label....16431
Vehicle Identification Number....16432
Precautions for Maintenance Operation....16433
Jacking Up the Vehicle....16445
Diagnosis Codes....16447
1. Diagnosis Codes....16447
2. Reading and Erasing the Diagnosis Code....16448
Table of Standard Tightening Torques....16455
Group 01 - Maintenance Schedule....16458
Table of Contents....16459
How To Read the Maintenance Schedule Tables....16460
Maintenance Schedule Tables....16462
Maintenance Operations....16470
Lubrication Tables....16476
Lubrication....16478
Group 11 - Engine....16482
Table of Contents....16483
Specifications....16484
Structure and Operation....16485
1. Engine Proper....16485
2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket....16486
3. Valve Mechanism....16487
4. Connecting Rod....16487
5. Piston....16488
6. Timing Gears....16488
7. Flywheel....16490
Troubleshooting....16491
On-Vehicle Inspection and Adjustment....16492
1. Measuring Compression Pressure....16492
2. Inspection and Adjustment of Valve Clearances....16496
Engine Removal and Installation....16500
Rocker Cover, Rocker and Bracket, Camshaft....16502
Cylinder Head and Valve Mechanism....16512
Piston and Connecting Rod, Cylinder Liner....16532
Flywheel....16546
Manual Transmission....16546
Automatic Transmission....16554
Timing Gears....16558
Crankshaft and Crankcase....16564
Group 12 - Lubrication....16574
Table of Contents....16575
Specifications....16576
Structure and Operation....16577
1. Lubrication System....16577
2. Oil Pump....16578
3. Oil Cooler....16579
4. Oil Filter....16580
5. Lubrication of Engine Components....16581
Troubleshooting....16585
On-Vehicle Inspection and Adjustment....16586
1. Oil Filter Replacement....16586
2. Engine Oil Replacement....16588
3. Engine Oil Level Inspection....16589
4. Oil Pressure Measurement....16590
Oil Pan, Oil Jets and Oil Level Sensor....16591
Oil Pump, Oil Strainer....16594
Oil Filter....16597
Oil Cooler....16598
Regulator Valve....16600
Group 13A - Fuel and Engine Control....16601
Table of Contents....16602
Specifications....16603
Structure and Operation....16604
1. Fuel System (Flow of Fuel)....16604
2. Engine Control....16605
3. Fuel Filter....16606
Troubleshooting....16607
On-Vehicle Inspection and Adjustment....16609
1. Inspecting No-Load and Maximum Speeds....16609
2. Air-Bleeding of Fuel System....16610
3. Fuel Filter Replacement....16611
Fuel Tank....16613
Fuel Filter....16614
Engine Control....16617
Common Rail....16623
Supply Pump....16625
Injector....16627
Group 13EA - Common Rail System....16630
Table of Contents....16631
Specifications....16632
Structure and Operation....16634
1. Overview....16634
2. Electronic Control System....16642
3. Electronic Control Unit Connection Diagram....16652
Troubleshooting....16654
1. Diagnosis Procedure....16654
2. Diagnostic Precautions....16654
3. Inspections Based on Fault Codes....16655
4. Multi-Use Tester Service Data....17374
5. Actuator Tests Performed Using Multi-Use Tester....17379
6. Registration and Alteration of Data in Engine Electronic Control Unit....17382
7. Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit....17383
Inspection of Electrical Equipment....17384
Installed Locations of Parts....17394
Electric Circuit Diagram....17402
Group 13EB - Auto Cruise and Vehicle Speed Limitation System....17411
Table of Contents....17412
Structure and Operation....17413
1. General Description....17413
2. Electronic Control System....17413
3. Electronic Control Unit Connection Diagram....17417
Troubleshooting....17419
1. Diagnostic Procedure....17419
2. Diagnostic Precautions....17419
3. Inspection Based on Diagnosis Codes....17420
4. Multi-Use Tester Service Data....17424
5. Actuator Tests Performed Using Mulit-Use Tester....17425
6. Works Required When Replacing the Multifunction Vehicle Control Unit (MVCU)....17425
7. Inspections Performed at Electronic Control Unit Connectors....17426
Inspection of Electrical Equipment....17427
Installed Locations of Parts....17429
Electric Circuit Diagram....17435
Group 14 - Cooling....17439
Table of Contents....17440
Specifications....17441
Structure and Operation....17442
1. Cooling System (Flow of Coolant)....17442
2. Thermostat....17443
3. Water Pump....17443
Troubleshooting....17444
On-Vehicle Inspection and Adjustment....17445
1. Inspection and Adjustment of Belt Tension....17445
2. Inspection of Cracks or Damage of the Belt....17447
3. Coolant Replacement and Cleaning of Cooling System....17448
4. Air Bleeding of Cooling System....17450
5. Gas Leakage Test....17450
Disconnection and Connection of Hoses and Pipes....17451
Radiator and Fan Shroud....17455
Cooling Fan, Belt and Water Pump....17465
Thermostat....17467
Group 15 - Intake and Exhaust....17469
Table of Contents....17470
Specifications....17471
Structure and Operation....17472
1. Air Cleaner....17472
2. Turbocharger....17473
3. Reducing Valve....17475
4. Diesel Particulate Filter Regeneration Control System....17476
Troubleshooting....17485
On-Vehicle Inspection and Adjustment....17487
1. Measurement of Turbocharger Boost Pressure....17487
2. Cleaning and Inspection of Air Cleaner Element....17489
3. Diesel Particulate Filter Unit Inspection for Clogging and Cleaning the Diesel Particulate Filter Unit....17490
4. Resetting the DPF-Related Information (Resetting Electronic Control Unit)....17494
Air Cleaner and Air Duct....17497
Turbocharger....17501
Intercooler....17507
Intake Manifold....17509
Exhaust Manifold....17511
Exhaust Pipe....17513
Diesel Particulate Filter....17519
Group 17 - Emission Control....17525
Table of Contents....17526
Structure and Operation....17527
1. Exhaust Gas Recirculation System....17527
2. Blowby Gas Return System....17532
On-Vehicle Inspection and Adjustment....17533
1. Replacement of PCV Valve Element....17533
EGR Valve, EGR Pipe and EGR Cooler....17535
Blowby Gas Return System....17537
Group 21 - Clutch....17538
Table Of Contents....17539
Specifications....17540
Structure and Operation....17541
1. Clutch Control....17541
2. Clutch Master Cylinder....17542
3. Clutch Proper....17544
Troubleshooting....17546
On-Vehicle Inspection and Adjustment....17548
1. Replacement of Brake Fluid (Clutch System)....17548
2. Air Bleeding of Brake Fluid (Clutch System)....17550
3. Clutch Pedal Play....17552
4. Clearance Between Clutch Pedal and Floor....17553
5. Clutch Action....17553
Clutch Pedal....17554
Clutch Master Cylinder....17558
Clutch Power Cylinder....17560
Clutch Proper....17562
Clutch Control....17574
Group 22A - Manual Transmission M060S6, M070S6....17576
Table of Contents....17577
Specifications....17578
Structure and Operation....17579
1. Transmission....17579
2. Synchromesh Mechanism....17580
3. Power Shift....17583
4. Interlock Mechanism....17585
Troubleshooting....17586
On-Vehicle Inspection and Adjustment....17588
1. Inspection of Transmission Oil Leakage....17588
2. Inspection of Looseness in Transmission Mounting Bolts....17588
3. Inspection of Play and Looseness in Companion Flange....17588
4. Inspection and Replacement of Transmission Oil....17589
Removal and Installation of Transmission....17590
Gear Shifter Upper and Interlock Plate....17594
Power Shift....17600
Extension Housing and Parking Brake....17608
Reverse Idler Gear M060....17614
6th Gear M060....17616
Reverse Gear and Reverse Idler Gear M070....17622
Transmission Body....17626
Drive Pinion....17644
Mainshaft....17646
M060....17646
M070....17658
Countershaft....17670
Transmission Control....17674
Puller and Installer Kit....17678
Group 23A - Automatic Transmission M065A5 (Allison 1000RDS, 2200RDS)....17679
Table of Contents....17680
Specifications....17681
Structure and Operation....17683
1. Outline....17683
2. Electronic Control System....17688
3. Electronic Control Unit Connection Diagram....17691
Troubleshooting....17693
1. Failure by Equipment....17693
On-Vehicle Inspection and Adjustment....17697
1. Inspection of Automatic Transmission Oil Leakage....17697
2. Check for Looseness in Automatic Transmission Mounting Bolts and Nuts....17697
3. Inspection of Play and Looseness in Companion Flange....17698
4. Inspection of Automatic Transmission Cooling System....17698
5. Inspection of Automatic Transmission Fluid....17699
6. Replacement of Automatic Transmission Fluid....17701
7. Replacement of Oil Filter....17702
8. Stall Test....17703
9. Line Pressure Test....17705
10. Road Test....17706
Removal and Installation of Automatic Transmission....17707
Parking Brake FK61....17711
Automatic Transmission Control....17713
Oil Cooler....17719
Parts Replacement of Automatic Transmission Proper....17721
Inspection of Electrical Equipment....17723
Installed Locations of Parts....17727
Electrical Circuit Diagram....17733
Group 23B - Automatic Transmission M100A6 (Allison 3000RDS)....17737
Table of Contents....17738
Specifications....17739
Structure and Operation....17741
1. Automatic Transmission....17741
2. Automatic Transmission Control System....17742
3. Oil Cooler System....17743
4. Electronic Control Unit Connection Diagram....17745
Troubleshooting....17747
1. Reading/Clearing of Diagnosis Codes....17747
2. List of Diagnosis Codes....17748
On-Vehicle Inspection and Adjustment....17751
1. Inspection of Automatic Transmission Oil Leakage....17751
2. Check for Looseness in Automatic Transmission Mounting Bolts....17751
3. Inspection of Play and Looseness in Companion Flange....17752
4. Inspection of Automatic Transmission Cooling System....17752
5. Inspection of Automatic Transmission Fluid....17753
6. Replacement of Automatic Transmission Fluid....17755
7. Level Check of Automatic Transmission Fluid....17757
8. Replacement of Oil Filter....17758
9. Stall Test....17759
10. Line Pressure Test....17760
11. Road Test....17763
Oil Cooler....17765
Inspection of Electrical Equipment....17769
Installed Locations of Parts....17771
Electrical Circuit Diagram....17777
Group 25 - Propeller Shaft....17781
Table of Contents....17782
Specifications....17783
Structure and Operation....17783
1. Configuration of Propeller Shaft Connection....17783
2. Propeller Shaft Without Center Bearing....17784
3. Propeller Shaft With Center Bearing....17784
Troubleshooting....17785
Removal and Installation of Propeller Shaft....17787
Propeller Shaft....17789
P8....17789
P10....17803
Group 26A - Front Axle FK61....17817
Table of Contents....17818
Specifications....17819
Structure and Operation....17820
1. Wheel Hub and Brake Drum....17820
2. Front Axle, Knuckle and Kingpin....17820
Troubleshooting....17821
On-Vehicle Inspection and Adjustment....17823
1. Inspection and Adjustment of Wheel Alignment....17823
2. Inspection and Adjustment of Steering Angle....17827
3. Inspection of Side Slip....17827
4. Inspection of Tie Rod End Ball Joint....17828
5. Inspection of Wheel Bearing for Play....17828
6. Inspection of Knuckle Joint for Play....17828
Wheel Hub and Brake Drum....17829
Front Axle, Knuckle and Kingpin....17843
Tie Rod....17851
Group 26B - Front Axle FK62, FK65, FM....17854
Table of Contents....17855
Specifications....17856
Structure and Operation....17857
1. Wheel Hub and Brake Drum....17857
2. Front Axle, Knuckle and Kingpin....17858
Troubleshooting....17859
On-Vehicle Inspection and Adjustment....17860
1. Inspection and Adjustment of Wheel Alignment....17860
2. Inspection and Adjustment of Steering Angle....17864
3. Inspection of Side Slip....17864
4. Inspection of Tie Rod End Ball Joint....17865
5. Inspection of Wheel Bearing for Play....17865
6. Inspection of Knuckle Joint for Play....17865
Wheel Hub and Brake Drum....17866
Front Axle, Knuckle and Kingpin....17882
FK....17882
FM....17890
Tie Rod....17898
Group 27 - Rear Axle....17901
Table of Contents....17902
Specifications....17903
Structure and Operation....17904
1. Wheel Hub and Brake Drum....17904
2. Reduction and Differential....17906
Troubleshooting....17907
On-Vehicle Inspection and Adjustment....17909
1. Adjustment of Wheel Speed Sensor Gap....17909
2. Inspection and Replacement of Differential Oil....17911
3. Inspection of Wheel Bearing for Play....17912
Wheel Hub and Brake Drum....17913
Axle Housing....17933
Reduction and Differential....17937
Group 31 - Wheel and Tire....17958
Table of Contents....17959
Specifications....17960
Troubleshooting....17961
On-Vehicle Inspection and Adjustment....17962
1. Inspection of Wheel Nut, Hub Bolt and Disc Wheel....17962
Wheel and Tire....17964
Group 33 - Front Suspension....17972
Table of Contents....17973
Structure and Operation....17974
1. Front Suspension....17974
Troubleshooting....17975
Shock Absorber....17976
Leaf Spring....17978
Group 34A - Rear Suspension LEAF....17985
Table of Contents....17986
Structure and Operation....17987
1. Rear Suspension....17987
Troubleshooting....17988
Shock Absorber....17989
Leaf Spring....17991
Group 34B - Rear Suspension AIR....18000
Table of Contents....18001
Specifications....18002
Structure and Operation....18002
1. Air Suspension....18002
2. Air Suspension System....18003
3. Leveling Valve....18004
Troubleshooting....18005
On-Vehicle Inspection and Adjustment....18006
1. Adjustment of Air Spring Height....18006
Leveling Valve....18007
Air Spring....18010
Shock Absorber....18014
Leaf Spring....18016
Lateral Rod....18018
Supply Valve....18021
Group 35A - Brake AIR-OVER HYDRAULIC BRAKE....18021
Table of Contents....18022
Specifications....18023
Structure and Operation....18025
1. Brake System....18025
2. Air Compressor....18027
3. Air Dryer....18028
4. Dual Brake Valve....18031
5. Brake Booster....18037
6. Fluid Tank....18039
7. Front Drum Brake....18040
8. Rear Drum Brake....18043
9. Supply Valve....18044
10. Quick Release Valve....18044
Troubleshooting....18045
On-Vehicle Inspection and Adjustment....18048
1. Exhaust Noise from Brake Valve....18048
2. Air Pressure Build-Up....18048
3. Replacement of Brake Fluid....18049
4. Air Bleeding of Brake System....18051
5. Inspection and Adjustment of Brake Pedal Free Play....18054
6. Inspection of Drum Brake Lining Thickness....18054
7. Initial Adjustment of Clearance Between Brake Drum and Shoe....18055
8. Maintenance and Inspection of Air Dryer....18057
9. Inspection and Adjustment of Air Dryer's Air Pressure Governor....18058
Handling of Nylon Tube for Air Line....18061
Compression Type....18061
Tube Identification Colors....18063
Handling of Connector....18064
Air Compressor....18065
Air Dryer....18069
Brake Pedal....18073
Dual Brake Valve....18075
Brake Booster....18081
Fluid Tank....18087
Front Wheel Brake....18089
Rear Wheel Brake....18097
Check Valve....18105
Safety Valve....18106
Supply Valve....18107
Quick Release Valve....18109
Group 35B - Brake FULL AIR BRAKE....18111
Table of Contents....18112
Specifications....18113
Structure and Operation....18115
1. Brake System....18115
2. Air Compressor....18021
3. Air Dryer....18021
4. Dual Brake Valve....18021
5. Front Drum Brake....18119
6. Rear Drum Brake....18123
7. Relay Valve....18125
8. Quick Release Valve....18021
9. Supply Valve....18021
Troubleshooting....18127
On-Vehicle Inspection and Adjustment....18131
1. Exhaust Noise from Brake Valve....18021
2. Air Pressure Build-Up....18021
3. Inspection and Adjustment of Brake Pedal Free Play....18021
4. Inspection of Brake Lining Thickness....18131
5. Initial Adjustment of Clearance Between Brake Drum and Shoe....18132
6. Maintenance and Inspection of Air Dryer....18021
7. Inspection and Adjustment of Air Dryer's Air Pressure Governor....18021
Handling of Nylon Tube for Air Line....18021
Compression Type....18021
Tube Identification Colors....18021
Handling of Connector....18021
Air Compressor....18021
Air Dryer....18021
Brake Pedal....18021
Dual Brake Valve....18021
Front Wheel Brake....18133
Rear Wheel Brake....18143
Expander....18155
Check Valve....18021
Safety Valve....18021
Relay Valve....18163
Supply Valve....18021
Quick Release Valve....18021
Group 35E - Anti-Lock Brake System (ABS)....18165
Table of Contents....18166
Specifications....18167
Structure and Operation....18169
1. General Description....18169
2. Electronic Control System....18175
3. Electronic Control Unit Schematic Diagram....18177
Troubleshooting....18179
1. Diagnosis Procedure....18179
2. Diagnostic Precautions....18179
3. Inspections Based on Diagnosis Codes....18180
4. Multi-Use Tester Service Data....18197
5. Electronic Control Unit Information Display....18197
6. Actuator Test Using Multi-Use Tester....18198
7. Inspection at Electronic Control Unit Connector....18201
On-Vehicle Inspection and Adjustment....18203
1. Functional Check....18203
2. Oscilloscopic Inspection through Wheel Speed Sensor Signal Waveform....18207
Inspection of Electrical Components....18209
Components Location....18211
Electrical Wiring Diagram....18215
Group 36A - Parking Brake CENTER PARKING BRAKE....18218
Table of Contents....18219
Specifications....18220
Structure and Operation....18221
1. Parking Brake System....18221
2. Parking Brake Lever....18222
3. Parking Brake....18222
Troubleshooting....18223
On-Vehicle Inspection and Adjustment....18224
1. Adjustment of Parking Brake Shoe Clearance....18224
2. Inspection and Adjustment of Parking Brake Lever....18225
Parking Brake Control....18226
Parking Brake....18230
Group 36B - Parking Brake WHEEL PARKING BRAKE....18232
Table of Contents....18233
Structure and Operation....18234
1. Parking Brake System....18234
2. Parking Brake Control Valve....18235
3. Spring Brake Valve....18236
4. Relay Valve (With Double Check Valve)....18239
Troubleshooting....18240
On-Vehicle Inspection and Adjustment....18242
1. Manual Release of Parking Brake....18242
Parking Brake Control Valve....18244
Spring Brake Valve....18246
Double Check Valve....18249
Relay Valve (With Double Check Valve)....18250
Group 37 - Steering....18252
Table of Contents....18253
Specifications....18254
Structure and Operation....18256
1. Steering System....18256
2. Fluid Flow....18256
3. Power Steering Booster....18257
4. Power Steering Oil Pump....18259
Troubleshooting....18262
On-Vehicle Inspection and Adjustment....18266
1. Change of Power Steering Fluid....18266
2. Bleeding of Power Steering System....18267
3. Performance Verification Test of Power Steering System....18268
4. Steering Wheel Play....18269
5. Steering Column Looseness....18269
6. Inspection of Drag Link Ball Joint....18269
Steering Column....18270
Power Steering Booster and Drag Link....18276
Power Steering Oil Pump....18300
FK....18300
FM....18304
Power Steering Oil Tank....18310
Group 41 - Bumper and Frame....18311
Table of Contents....18312
Specifications....18313
Structure and Operation....18314
1. Frame....18314
Front Bumper....18315
Frame....18317
Group 42 - Cab....18322
Table of Contents....18323
Specifications....18324
Structure and Operation....18326
1. Front Cab Mounting....18326
2. Rear Cab Mounting....18328
3. Cab Tilt Link....18329
Troubleshooting....18330
Removal and Installation of Cab....18334
Front Cab Mounting....18340
Rear Cab Mounting....18344
Cab Tilt Link....18346
Cab Stay....18348
Group 43 - Door....18349
Table of Contents....18350
Specifications....18351
Structure and Operation....18353
1. Door Locking System....18353
2. Door Glass Opening System....18354
Troubleshooting....18355
On-Vehicle Inspection and Adjustment....18357
1. Adjustment of Door Alignment....18357
Door....18359
Group 51 - Exterior....18369
Table of Contents....18370
Structure and Operation....18371
1. Wiper and Washer System....18371
Troubleshooting....18372
Mirror....18373
Wiper and Washer....18375
Front Panel....18381
Front Grille....18385
Corner Panel....18387
Fender....18389
Step....18391
No. 1 Step....18391
No. 2 Step....18393
Wheel House....18395
Window Glass....18399
Group 52 - Interior....18403
Table of Contents....18404
Specifications....18405
Structure and Operation....18407
1. Air Suspension Seat....18407
2. Emergency Locking Retractor Type Seat Belt....18409
Troubleshooting....18410
Driver Seat....18411
Side Seat....18415
Seat Belt....18416
Instrument Panel....18417
Floor Console....18428
Scuff Plate, Trim....18429
Head Lining....18433
Group 54 - Electrical....18436
Table of Contents....18437
How To Read This Group....18440
54-00A - General....18444
Precautions for Maintenance Operation....18445
54-00B - Specifications....18455
Specifications....18456
54-00C - Structure and Operation....18459
1. Starter....18460
2. Alternator....18461
3. Headlamps....18464
4. Meter Cluster....18465
5. Daytime Running Light (DRL) System....18476
6. MUTIC (Multipurpose Timing Control Unit)....18478
7. Starter Continuous Energizing Preventing Function and Preheating Function....18481
54-00D - Troubleshooting....18485
Troubleshooting....18486
54-01 - Power, Charge and Ground Circuit....18494
High-Current Fuse Box....18495
Relay and Fuse Box....18497
104 - Relay and Fuse Box Circuit....18499
110 - Power Circuit....18500
115 - Reserve Power Circuit....18512
125 - Battery Charging Circuit....18513
130 - Ground....18515
54-02 - Starting and Preheating Circuit....18535
210 - Engine Starting Circuit....18536
215 - Engine Stopping Circuit....16630
220 - Engine Preheating Circuit....18542
54-03 - Lighting Circuit....18543
310 - Headlamp Circuit....18544
313 - Daytime Running Light Circuit....18546
320 - Tail, Clearance, and License Plate Lamps Circuit....18548
325 - Stop Lamp Circuit....18549
330 - Turn Signal and Hazard Lamp Circuit....18550
340 - Backup Lamp Circuit....18552
345 - Cab Lamp Circuit....18555
348 - Illumination Lamp Circuit....18556
349 - Identification and Side Marker Lamp Circuit....18557
352 - Van Body Dome Light Circuit....18558
54-04 - Meter Circuit....18559
401 - Meter Cluster Internal Circuit....18560
410 - Tachometer Circuit....18562
412 - Speedometer Circuit....18563
420 - Fuel Gauge Circuit....18566
425 - Water Temperature Gauge Circuit....18567
436 - Air Gauge Circuit....18568
54-05 - Indicator and Warning Lamp Circuit....18569
510 - Parking Brake Indicator Circuit....18570
515 - Brake Warning Circuit....18572
530 - Water Level and Overheating Warning Circuit....18574
535 - Engine Oil Level Warning Circuit....18575
536 - Engine Oil Pressure Warning Circuit....18576
538 - Engine Oil Filter Warning Circuit....18577
550 - Cab Tilt Warning Circuit....18578
566 - Fuel Filter Warning Circuit....18579
54-06 - Cab Side Electrical Circuit....18580
610 - Cigarette Lighter Circuit....18581
612 - Audio Circuit....18582
614 - Wiper and Washer Circuit....18583
616 - Horn Circuit....18584
620 - Air-Conditioner Circuit....18585
622 - Power Window and Central Door Lock Unit....18587
629 - Mirror Heater Circuit....18588
54-07 - Chassis Side Electrical Circuit....18589
710 - Exhaust Brake Circuit....18590
718 - Air Dryer Circuit....18593
722 - Air Suspension Circuit....18594
54-08 - Engine and Transmission Side Electrical Circuit....18596
850 - Transmission Power Take-Off Circuit....18597
54-09 - Other Circuit....18598
905 - Joint Connector (J/C)....18599
Common Rail System Electric Circuit Diagram....16630
Cruise Control System Electric Circuit Diagram....17411
Automatic Transmission System Electric Circuit Diagram....17679
(Allison 1000RDS, 2200RDS)....17679
(Allison 3000RDS)....17737
Anti-Lock Brake System Electric Circuit Diagram....18165
54-10 - Electrical Equipment Installation Positions....18606
A - Switch....18607
B - Relay and Electronic Control Unit....18609
C - Meter, Sensor, Buzzer and Motor....18613
D - Air-Conditioner....18615
E - Door and Mirror....18616
F - Roof....18617
G - Cab....18618
H - Cab Tilt....18619
J - Joints of Main Harness Connectors....18621
R - Engine....18624
S - Transmission....18625
T - Switch and Sensor....18627
U - Fuse and Connectors....18631
V - Magnetic Valve....18633
W - Buzzer....18633
X - Other....18635
54-11 - Inspection of Electrical Equipment....18638
#001 to #179 - Switch....18639
#180 to #249 - Relay....18646
#250 to #349 - Sensor....18647
#350 to #409 - Control Unit....18650
#410 to #509 - Motor....18651
#510 to #539 - Actuator....18652
#560 to #609 - Magnetic Valve....18653
#610 to #649 - Buzzer, Horn....18654
#650 to #699 - Lamp....18654
#750 to #859 - Other....18655
#860 - Battery....18658
#890 - Meter....18661
54-12 - Starter and Alternator....18662
#930 - Starter....18663
#940 - Alternator....18677
54-13 - On-Vehicle Inspection and Adjustment....18684
#950 - Inspection of Alternator....18685
#951 - Inspection of Regulator....18686
#955 - Inspection of Preheating System....18687
#960 - Headlamp Aiming....18689
#965 - Inspection of Brake Fluid Level Switch....18691
54-14 - Connector Configuration Chart....18692
Connector Configuration Chart....18693
Group 55 - Heater, Air-Conditioner and Ventilation....18775
Table of Contents....18776
Specifications....18777
Structure and Operation....18779
1. Heater....18779
2. Air-Conditioner....18780
3. Air Duct....18781
4. Air-Conditioner Control....18782
Troubleshooting....18784
On-Vehicle Inspection and Adjustment....18785
1. Recovery of Refrigerant....18785
2. Recharging the System with Refrigerant....18786
3. Checking Refrigerant Charge Level....18788
4. Adding Refrigerant....18789
5. Cleaning and Replacement of Evaporator....18790
6. Cleaning and Replacement of Heater Core....18792
Connecting Air-Conditioner Piping....18795
Compressor....18796
Condenser....18797
Air-Conditioner Control....18799
Air Duct....18801
Cooling and Heater Unit, Blower....18803
2012 Fuso Canter Service Manual (FE, FG)....18805
Canter 2012 Service Manual....18805
Foreword/Index....18806
Group 00 - General....18807
Index....18808
Equipment Type Codes List....18809
Power Train Table....18810
How to Read This Manual....18811
Chassis Number, Engine Number, Power Train Label....18819
Vehicle Identification Number....18820
Precautions for Maintenance Operation....18821
1. Handling Precautions for Electric Circuits....18826
2. Service Precautions for Alternators....18829
3. Intermittent Faults....18831
4. Precautions for Arc Welding....18832
5. Cautions When Handling DEF....18833
6. Precautions When Repainting....18833
7. Precautions When Handling a Vehicle with DUONIC System....18833
8. Precautions on Cleaning When Servicing the Engine and Transmission....18834
Jacking Up the Vehicle....18837
Diagnosis Codes....18841
1. Diagnosis Codes....18841
2. Reading and Erasing the Diagnosis Code....18847
Table of Standard Tightening Torques....18851
Group 01 - Maintenance Schedule....18854
Index....18855
How to Read the Maintenance Schedule Tables....18856
Maintenance Schedule Tables....18858
Maintenance Operations....18862
Lubrication Tables....18864
Lubrication....18866
Group 11 - Engine....18870
Index....18871
Specifications....18872
Structure and Operation....18873
1. Engine Proper....18873
2. Timing System....18873
3. Main Bearing....18875
4. Connecting Rod, Piston....18875
5. Rocker Arms, Tappets....18878
Troubleshooting....18879
Engine Removal and Installation....18880
Tilt Cab....18880
Fixed Cab....18884
Work for Overhauling Engine....18888
Timing Gear Case....18918
Timing, Gear, Chain....18924
Overhead, Cylinder Head....18938
Piston and Connecting Rod....18958
Flywheel....18968
Crankshaft and Crankcase....18972
Group 12 - Lubrication....18985
Index....18986
Specifications....18987
Structure and Operation....18988
1. Lubrication System....18988
2. Oil Pump/Vacuum Unit....18989
3. Oil Filter....18991
4. Oil Cooler....18991
Troubleshooting....18992
On-Vehicle Inspection and Adjustment....18993
1. Oil Filter Replacement....18993
2. Engine Oil Replacement....18995
3. Inspection of Engine Oil Level....18997
4. Inspection of Engine Oil Leaks....18997
5. Oil Pressure Measurement....18998
Oil Pan, Oil Strainer....18999
Oil Pump/Vacuum Unit....19002
Oil Filter, Oil Cooler....19003
Group 13 - Fuel and Engine Control....19006
Index....19007
Fuels....19008
Specifications....19009
Structure and Operation....19010
1. High Pressure Electronic Injection System....19010
Troubleshooting....19018
On-Vehicle Inspection and Adjustment....19020
1. Inspecting and Adjusting No-Load Minimum and Maximum Speeds....19020
2. Air-Bleeding of Fuel System....19021
3. Fuel Filter Replacement....19021
4. Fuel Hose Replacement....19024
Fuel Tank, Fuel Pump....19026
FE....19026
FG....19028
Fuel Filter....19030
Accelerator Pedal....19034
High Pressure Fuel Pump....19036
Common Rail, Injector....19040
Group 13E - Common Rail System....19044
Index....19045
Specifications....19046
Structure and Operation....19048
1. High Pressure Electronic Injection System....19048
2. Engine Electronic Control System....19050
Troubleshooting....19066
1. Inspections Based on Diagnosis Codes....19066
2. FUSO Diagnostics Service Data (Actual Values)....19844
3. FUSO Diagnostics Actuator Data (Actuations)....19851
4. Alteration and Reset of Coding Data in Engine Electronic Control Unit....19853
Inspection of Electrical Equipment....19856
Installed Locations of Parts....19866
Electric Circuit Diagram....19896
Group 14 - Cooling....19902
Index....19903
Specifications....19904
Structure and Operation....19905
1. Cooling System....19905
2. Water Pump....19906
3. Thermostat....19906
Troubleshooting....19907
On-Vehicle Inspection and Adjustment....19908
1. Inspection of Auto Tensioner....19908
2. Inspection of Coolant Level....19911
3. Inspection of Coolant Leaks....19911
4. Coolant Replacement and Cleaning of Cooling System....19911
5. Air Bleeding of Cooling System....19915
6. Air/Gas Leakage Test....19915
7. Inspection of Cracks or Damage of the Belt....19915
Disconnection and Connection of Hoses and Pipes....19916
Radiator....19924
Pressure Cap, Surge Tank....19926
Reservoir Tank....19928
Cooling Fan....19930
Belt, Water Pump, Damper Pulley....19934
Thermostat....19940
Group 15 - Intake and Exhaust....19942
Index....19943
Specifications....19944
Structure and Operation....19945
1. Air Cleaner....19945
2. Turbocharging System....19946
3. EBS (Exhaust Brake System) Valve....19951
Troubleshooting General....19952
On-Vehicle Inspection and Adjustment....19953
1. Exhaust Emission Condition....19953
2. Cleaning and Inspection of Air Cleaner Element....19953
3. Installation, Looseness, and Damage of Exhaust Pipe Muffler....19954
4. Functions of Muffler....19955
Air Duct and Air Cleaner....19956
Except Crew Cab....19956
Crew Cab....19962
Turbocharger....19968
Exhaust Manifold....19974
Intercooler....19976
Intake Manifold....19980
Front Pipe....19984
Group 17 - Emission Control....19986
Index....19987
Specifications....19988
Structure and Operation....19989
1. EGR (Exhaust Gas Recirculation) System....19989
2. Blowby Gas Return System....19991
3. BlueTec System....19992
Troubleshooting....19999
On-Vehicle Inspection and Adjustment....20000
1. Leakage of Diesel Exhaust Fluid....20000
2. Damage and Improper Installation of Diesel Exhaust Fluid Lines....20001
3. Replacement of Diesel Exhaust Fluid (AdBlue)....20002
4. Measures to be Taken if Diesel Exhaust Fluid Tank is Filled with Incorrect Diesel Exhaust Fluid Solution....20003
EGR (Exhaust Gas Recirculation) Unit....20004
Blowby Gas Return System....20010
DEF (Diesel Exhaust Fluid) Tank....20012
DPF (Diesel Particulate Filter)....20014
SCR (Selective Catalytic Reduction)....20018
Group 17E - BlueTec System....20022
Index....20023
Structure and Operation....20024
1. Overview....20024
2. Electronic Control System....20025
Troubleshooting....19044
Inspection of Electrical Equipment....19044
Installed Locations of Parts....19044
Electric Circuit Diagram....19044
Group 21 - Clutch....20032
Index....20033
Troubleshooting....20034
Damper....20036
Group 22 - Transmission DUONIC....20038
Index....20039
Specifications....20040
Structure and Operation....20042
1. Overview....20042
2. Valve Body....20043
3. Dual Clutch....20044
4. Transmission....20048
5. Synchromesh Mechanism....20053
6. Transmission Power Take-Off....20056
Troubleshooting....20058
On-Vehicle Inspection and Adjustment....20062
1. Transmission Oil Leakage and Oil Quantity....20062
2. Inspection of Looseness in Engine to Clutch Housing Connection....20065
3. Inspection of Transmission Cooling System for Leakage, Damage and Installation Condition....20065
4. Inspection of Looseness in Propeller Shaft Connection....20065
5. Replacement of Transmission Oil....20066
6. Replacement of Clutch Control Oil....20068
7. Inspection of Transmission Mounting Cushion Rubber....20069
Removal and Installation of Transmission....20070
Valve Body, Dual Clutch....20076
Gear Shift Unit....20092
Extension Housing and Parking Brake FE....20096
Transfer Case Adapter FG....20106
Reverse Idler Gear Without Large Capacity Power Take-Off....20114
Reverse Idler Gear With Large Capacity Power Take-Off....20116
Transmission Body....20122
Outer Drive Pinion....20142
Inner Drive Pinion....20148
Mainshaft....20150
Countershaft....20160
Transmission Control....20170
Oil Cooler....20174
Transmission Power Take-Off Standard Type....20176
Transmission Power Take-Off Large-Capacity Type....20184
Group 22E - DUONIC....20194
Index....20195
Specifications....20196
Structure and Operation....20198
1. Overview....20198
2. Electronic Control System....20199
3. Electronic Control Unit Schematic Diagram....20208
Troubleshooting....20210
1. Inspection Based on Diagnosis Codes....20210
2. Service Data (Actual Measurements) of FUSO Diagnostics....20331
3. Actuator Tests Available in FUSO Diagnostics....20340
4. Inputs and Outputs to/from Electronic Control Unit....20341
5. Coding Data in Electronic Control Unit....20342
6. Initialization of DUONIC System....20343
Inspection of Electrical Parts....20346
Installed Locations of Parts....20352
Electric Circuit Diagram....20374
Group 24 - Transfer....20376
Index....20377
Specifications....20378
Structure and Operation....20379
1. Transfer....20379
Troubleshooting....20380
On-Vehicle Inspection and Adjustment....20382
1. Inspection of Transmission and Transfer Oil Leakage....20382
2. Inspection of Looseness in Transmission and Transfer Mounting Bolts....20382
3. Inspection of Play and Looseness in Companion Flange....20383
4. Inspection and Replacement of Transfer Oil....20384
Removal and Installation of Transmission (With Transfer)....20386
Removal and Installation of Transfer....20392
Front Drive....20394
Rear Drive....20400
Transfer....20404
Group 25 - Propeller Shaft....20412
Index....20413
Specifications....20414
Structure and Operation....20414
1. Configuration of Propeller Shaft Connection....20414
2. Propeller Shaft Without Center Bearing....20415
Troubleshooting....20417
Removal and Installation of Propeller Shaft....20418
Between T/M (or Transfer) and Rear Axle....20418
Between Front Axle and Transfer....20420
Propeller Shaft....20422
P2....20422
P3....20428
Group 26A - Front Axle FE....20439
Index....20440
Specifications....20441
Structure and Operation....20442
1. Wheel Hub and Rotor....20442
2. Knuckle and Kingpin, Front Axle....20443
Troubleshooting....20444
On-Vehicle Inspection and Adjustment....20445
1. Inspection and Adjustment of Wheel Alignment....20445
2. Inspection and Adjustment of Steering Angle....20449
3. Inspection of Side Slip....20449
4. Inspection of Tie Rod End Ball Joint....20450
5. Inspection of Wheel Bearing for Play....20450
6. Inspection of Knuckle Joint for Play....20450
Wheel Hub and Rotor....20451
Knuckle and Kingpin, Front Axle....20461
Tie Rod....20471
Group 26B - Front Axle FG....20473
Index....20474
Specifications....20475
Structure and Operation....20475
1. Wheel Hub and Brake Drum....20475
2. Free Wheel Hub....20476
3. Drive Shaft and Steering Knuckle, Axle Housing....20477
4. Reduction and Differential....20478
Troubleshooting....20479
On-Vehicle Inspection and Adjustment....20483
1. Inspection and Adjustment of Wheel Alignment....20483
2. Inspection and Adjustment of Steering Angle....20487
3. Inspection of Side Slip....20487
4. Inspection of Tie Rod End Ball Joint....20488
5. Inspection and Replacement of Differential Oil....20489
6. Inspection of Wheel Bearing for Play....20490
7. Inspection of Knuckle Joint for Play....20490
Wheel Hub and Brake Drum....20491
Drive Shaft and Steering Knuckle....20505
Tie Rod....20511
Axle Housing....20513
Reduction and Differential....20515
Group 27 - Rear Axle....20529
Index....20530
Specifications....20531
Structure and Operation....20532
1. Wheel Hub and Rotor....20532
2. Wheel Hub and Brake Drum....20533
3. Reduction and Differential....20534
4. Limited Slip Differential....20535
Troubleshooting....20537
On-Vehicle Inspection and Adjustment....20539
1. Inspection and Replacement of Axle Oil....20539
2. Inspection of Wheel Bearing for Play....20540
Wheel Hub and Rotor....20541
FE52....20541
FEC7, FEC9....20553
Wheel Hub and Brake Drum....20565
Axle Housing....20575
Reduction and Differential....20579
Group 31 - Wheel and Tire....20604
Index....20605
Specifications....20606
Troubleshooting....20607
On-Vehicle Inspection and Adjustment....20608
1. Inspection of Looseness in Wheel Nuts....20608
2. Inspection of Tire....20609
Wheel and Tire....20612
Group 33 - Front Suspension....20619
Index....20620
Structure and Operation....20621
1. Front Suspension Elements....20621
Troubleshooting....20622
Stabilizer FE....20623
Shock Absorber....20625
FE....20625
FG....20627
Leaf Spring....20629
FE....20629
FG....20637
Group 34 - Rear Suspension....20642
Index....20643
Structure and Operation....20644
1. Rear Suspension Elements....20644
Troubleshooting....20645
Stabilizer FEC7, FEC9....20646
Shock Absorber....20647
Leaf Spring....20648
Group 35 - Brake....20662
Index....20663
Specifications....20664
Structure and Operation....20666
1. Brake System....20666
2. Vacuum Pump....20667
3. Vacuum Booster and Brake Master Cylinder....20668
4. Front Disc Brake FE....20672
5. Front Drum Brake FG....20673
6. Rear Disc Brake FE....20676
7. Rear Drum Brake FG....20677
Troubleshooting....20678
On-Vehicle Inspection and Adjustment....20682
1. Replacement of Brake Fluid....20682
2. Air Bleeding of Brake System....20684
3. Inspection and Adjustment of Brake Pedal....20688
4. Inspection and Replacement of Disc Brake Pad FE....20690
5. Measurement of Disc Brake Drag Torque FE....20692
6. Inspection of Drum Brake Lining Thickness FG....20692
7. Initial Setting of Clearance between Brake Drum and Shoe FG....20693
8. Inspection of Check Valve in Vacuum Line Hose....20694
9. Inspection of Vacuum Pump....20695
10. Inspection of Vacuum Booster....20695
Brake Master Cylinder....20700
Brake Pedal & Vacuum Booster....20702
Front Disc Brake....20706
Front Drum Brake....20712
Rear Disc Brake....20720
Rear Drum Brake....20726
Group 35E - Anti-Lock Brake System (ABS)....20732
Index....20733
Specifications....20734
Structure and Operation....20736
1. Overview....20736
2. Electronic Control System....20753
3. Electronic Control Unit Schematic Diagram....20756
Troubleshooting....20758
1. Inspections According to Diagnosis Codes....20758
2. FUSO Diagnostics Service Data (Measured Values)....20780
3. Actuator Test (Control) Using FUSO Diagnostics....20781
4. Electronic Control Unit Coding....20782
5. Rewriting of Coding Data....20782
6. Electronic Control Unit Input/Output Tables....20782
On-Vehicle Inspection and Adjustment....20784
1. Functional Check....20784
2. Inspection of Hydraulic Unit (Electronic Control Unit) Operation....20785
3. Inspection after Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)....20786
Hydraulic Unit (Electronic Control Unit)....20788
Inspection of Electrical Parts....20792
Installed Locations of Parts....20794
Electrical Circuit Diagram....20806
Group 36 - Parking Brake....20808
Index....20809
Specifications....20810
Structure and Operation....20811
1. Components and Parts....20811
2. Parking Brake Lever....20811
3. Parking Brake....20812
Troubleshooting....20813
On-Vehicle Inspection and Adjustment....20814
1. Inspection of Parking Brake Drum Mounting for Looseness....20814
2. Adjustment of Parking Brake Shoe Clearance....20814
3. Inspection and Adjustment of Parking Brake Lever....20815
Parking Brake Control....20818
Parking Brake....20820
Group 37 - Steering....20822
Index....20823
Specifications....20824
Structure and Operation....20826
1. Steering System....20826
2. Oil Flow....20826
3. Power Steering Gear Assembly....20827
4. Power Steering Oil Pump....20829
Troubleshooting....20830
On-Vehicle Inspection and Adjustment....20832
1. Steering Wheel Play....20832
2. Steering Column Looseness....20832
3. Inspection of Rods and Arms for Looseness....20832
4. Inspection of Power Steering System Mounts for Looseness....20833
5. Inspection and Replacement of Power Steering Oil....20833
6. Performance Verification Test of Power Steering System....20835
7. Inspection of Drag Link Ball Joint....20836
8. Inspection of Steering Wheel Operation during Running....20836
Steering Column....20838
Power Steering Gear Assembly and Drag Link....20844
Power Steering Oil Tank....20860
Group 41 - Bumper and Frame....20861
Index....20862
Specifications....20863
Structure and Operation....20864
Front Bumper....20865
Frame....20867
Group 42 - Cab....20871
Index....20872
Specifications....20873
Structure and Operation....20874
1. Front Cab Mounting....20874
2. Rear Cab Mounting Except Crew Cab....20875
3. Center and Rear Cab Mountings Crew Cab....20875
4. Cab Tilt Link Except Crew Cab....20876
Troubleshooting....20877
On-Vehicle Inspection and Adjustment....20879
1. Adjustment of Cab Tilt System Except Crew Cab....20879
Removal and Installation of Cab....20881
Except Crew Cab....20881
Crew Cab....20885
Front Cab Mounting....20889
Except Crew Cab....20889
Crew Cab....20891
Rear Cab Mounting Except Crew Cab....20893
Center and Rear Cab Mountings Crew Cab....20895
Cab Tilt Link Except Crew Cab....20897
Cab Stay Except Crew Cab....20899
Group 43 - Door....20900
Index....20901
Specifications....20902
Structure and Operation....20903
1. Front Door Lock System....20903
2. Rear Door Lock System Crew Cab....20903
3. Front Door Glass Opening and Closing Mechanism....20904
4. Rear Door Glass Opening and Closing Mechanism Crew Cab....20905
5. Keyless Entry System....20906
Troubleshooting....20910
On-Vehicle Inspection and Adjustment....20914
1. Adjustment of Front Door Alignment....20914
2. Adjustment of Rear Door Alignment Crew Cab....20916
3. Inspection of Keyless Entry System....20918
4. Method of Transmitting Code to Keyless Entry Electrical Control Unit....20919
Front Door....20922
Rear Door Crew Cab....20930
Group 51 - Exterior....20937
Index....20938
Structure and Operation....20939
1. Wiper and Washer System....20939
Troubleshooting....20940
Mirror....20941
Wiper and Washer....20943
Front Cover....20945
Front Grille, Front Corner Panel and Headlamp....20947
Fender FG....20952
Step....20953
Garnish Crew Cab....20955
Wheel House....20956
Window Glass....20957
Group 52 - Interior....20960
Index....20961
Driver Seat....20962
Passenger Seat....20963
Rear Seat Crew Cab....20964
Seat Belt....20966
Instrument Panel....20972
Trim and Scuff Plate....20988
Except Crew Cab....20988
Crew Cab....20992
Head Lining....20996
Except Crew Cab....20996
Crew Cab....21000
Group 54 - Electrical....21003
Index....21004
54-00A - General....18807
54-00B - Specifications....21007
Specifications....21008
54-00C - Structure and Operation....21011
1. Starter....21012
2. Alternator....21013
3. Headlamps....21015
4. Meter Cluster....21016
5. Signal Detect and Actuation Modules....21028
6. Immobilizer....21046
54-00D - Troubleshooting....21049
Troubleshooting....21050
54-01 - Power, Charge and Ground Circuit....21060
High-Current Fuse Box....21061
Fuse Box....21063
105 SAM Internal Circuit....21065
110 Power Circuit....21067
115 Reserve Power Circuit....21081
125 Battery Charging Circuit....21082
130 Ground....21083
54-02 - Engine Starting, Stopping and Preheating Circuit....21098
210 Engine Starting Circuit....21099
220 Engine Preheating Circuit....19044
54-03 - Lighting Circuit....21101
310 Headlamp Circuit....21102
313 Daytime Running Light Circuit....21103
315 Fog Lamp Circuit....21104
320 Tail, Parking and License Plate Lamps Circuit....21105
325 Stop Lamp Circuit....21106
330 Turn Signal and Hazard Lamp Circuit....21107
340 Backup Lamp Circuit....21108
345 Cab Lamp Circuit....21110
348 Illumination Lamp Circuit....21112
349 Identification and Side Marker Lamp Circuit....21113
352 Van Body Dome Light Circuit....21114
54-04 - Meter Circuit....21115
401 Meter Cluster Internal Circuit....21116
410 Tachometer Circuit....21118
412 Speedometer Circuit....21119
415 Tachograph Circuit....21120
420 Fuel Gauge Circuit....21121
425 Water Temperature Gauge Circuit....21122
54-05 - Indicator and Warning Lamp Circuit....21123
510 Parking Brake Indicator Circuit....21124
515 Brake Warning Circuit....21125
536 Engine Oil Pressure Warning Circuit....21126
537 Overheating Warning Circuit....21127
550 Cab Tilt Warning Circuit....21128
554 Starter Key Removal Reminder Alarm Circuit....21129
566 Fuel Filter Circuit....21130
54-06 - Cab Side Electrical Circuit....21131
610 Cigarette Lighter Circuit....21132
612 Audio Circuit....21133
614 Wiper and Washer ....21134
616 Horn Circuit....21135
620 Heater and Air-Conditioner Circuit....21136
622 Power Window and Central Door Lock Circuit....21138
629 Mirror Heater Circuit....21139
654 Keyless Entry Circuit....21140
54-08 - Engine and Transmission Side Electrical Circuit....21141
810 Four-Wheel Drive Circuit....21142
850 Transmission Power Take-Off Circuit....21143
54-09 - Other Circuit....21144
905 Joint Connector (J/C)....21145
Common Rail System Electric Circuit Diagram....19044
DUONIC System Electric Circuit Diagram....20194
Anti-Lock Brake System Electric Circuit Diagram....20732
Fully Automatic Air-Conditioner System Electric Circuit Diagram....21423
54-10 - Electrical Equipment Installation Positions....21147
Cab Side....21148
A - Switch and Sensor....21148
B - Relay and Electronic Control Unit....21152
C - Meter and Motor....21156
D - Air-Conditioner....21158
E - Door....21162
F - Roof....21163
G - Cab....21164
H - Tilt....21165
J - Joints of Main Harness Connectors....21166
P - Others....21170
Engine and Transmission....21172
R - Engine....21172
S - Transmission....21174
Chassis Side....21176
T - Switch and Sensor....21176
U - Fuse, Relay and Electronic Control Unit....21182
V - Magnetic Valve, Motor and Buzzer....21184
W - Joints of Main Harness Connectors....21186
X - Others....21190
54-11 - Inspection of Electrical Equipment....21194
#001 to #179 Switch....21195
#180 to #249 Relay....21200
#250 to #349 Sensor....21201
#350 to #409 Control Unit....21204
#410 to #509 Motor....21205
#510 to #539 Actuator....21208
#560 to #609 Magnetic Valve....21209
#610 to #649 Buzzer, Horn....21210
#650 to #699 Lamp....21211
#750 to #859 Other....21212
#860 Battery....21215
#890 Meter....21218
54-12 - Starter and Alternator....21219
#930 Starter....21220
#940 Alternator....21238
54-13 - On-Vehicle Inspection and Adjustment....21240
#950 Inspection of Alternator....21241
#951 Inspection of Regulator....21242
#960 Headlamp Aiming....21243
#961 Fog Lamp Aiming....21245
#984 Inspection of Immobilizer....21247
#985 Inspection of Signal Detect and Actuation Modules....21251
#986 Inspection of Meter Cluster....21287
54-14 Connector Configuration Chart....21290
Connector Configuration Chart....21291
Group 55 - Heater, Air-Conditioner, and Ventilation....21388
Index....21389
Specifications....21390
Structure and Operation....21391
1. Heater....21391
2. Air Conditioner....21392
3. Compressor....21393
4. Air Duct....21396
5. Heater Control....21397
6. Rear Heater Crew Cab....21401
Troubleshooting....21402
On-Vehicle Inspection and Adjustment....21405
1. Operation Check of Air Conditioner....21405
2. Recovery of Refrigerant....21409
3. Recharging the System with Refrigerant....21410
Connecting Air Conditioner Piping....21412
Compressor....21413
Condenser, Receiver....21414
Heater Control Manual Air Conditioner....21416
Air Duct....21420
Heater and Cooling Unit, Blower....21421
Rear Heater Crew Cab....21422
Group 55E - Full Automatic Air-Conditioner....21423
Index....21424
Specifications....21425
Structure and Operation....21427
1. Overview....21427
2. Electronic Control System....21428
3. Electronic Control Unit Schematic Diagram....21430
Troubleshooting....21431
1. Inspection According to Diagnosis Code (Trouble Codes)....21431
2. FUSO Diagnostics Service Data (Measured Values)....21437
3. Actuator Test (Control) Using FUSO Diagnostics....21439
4. Electronic Control Unit Input/Output Table....21441
Inspection of Electrical Parts....21443
Installed Locations of Parts....21449
Electrical Circuit Diagram....21467
2012-2016 Fuso Service Manual (FE, FG)....21469
2012 to 2016 Canter Service Manual....21469
Group Index....21470
Modification Summary....21471
Modification Summary (2013 Model Year)....21472
Modification Summary (2014 Model Year)....21475
Modification Summary (2014 1/2 Model Year)....21477
Modification Summary (2015 to 2016 Model Years)....21481
Group 00 - General....21485
Group 00 - General (2012 Model Year)....21486
Index....21487
Equipment Type Codes List....21488
Power Train Table....21489
How To Read This Manual....21490
Chassis Number, Engine Number, Power Train Label....21498
Vehicle Identification Number....21499
Precautions for Maintenance Operation....21500
1. Handling Precautions for Electric Circuits....21505
2. Service Precautions for Alternators....21508
3. Intermittent Faults....21510
4. Precautions for Arc Welding....21511
5. Cautions When Handling DEF....21512
6. Precautions When Repainting....21512
7. Precautions When Handling a Vehicle with DUONIC System....21512
8. Precautions on Cleaning When Servicing the Engine and Transmission....21513
Jacking Up the Vehicle....21516
Diagnosis Codes....21520
1. Diagnosis Codes....21520
2. Reading and Erasing the Diagnosis Code....21526
Table of Standard Tightening Torques....21530
Group 00 - General (2013 Model Year)....21533
Index....21534
Precautions for Maintenance Operation....21535
Group 00 - General (2014 to 2014 1/2 Model Years)....21537
Index....21538
Equipment Type Codes List....21539
Power Train Table....21540
How to Read This Manual....21541
Chassis Number, Engine Number, Power Train Label....21549
Vehicle Identification Number....21550
Precautions for Maintenance Operation....21551
1. Handling Precatuions for Electric Circuits....21556
2. Service Precautions for Alternators....21559
3. Intermittent Faults....21560
4. Precautions for Arc Welding....21562
5. Cautions When Handling DEF....21563
6. Precautions When Repainting....21563
7. Precautions When Handling a Vehicle with DUONIC System....21563
8. Precautions on Cleaning When Servicing the Engine and Transmission....21564
Jacking Up the Vehicle....21567
Diagnosis Codes....21571
1. Diagnosis Codes....21571
2. Reading and Erasing the Diagnosis Code....21577
Table of Standard Tightening Torques....21581
Group 00 - General (2015 to 2016 Model Years)....21587
Index....21588
Power Train Table....21589
Vehicle Identification Number....21590
Group 01 - Maintenance Schedule....21591
Group 01 - Maintenance Schedule (2012 to 2014 1/2 Model Years)....21592
Index....21593
How To Read the Maintenance Schedule Tables....21594
Maintenance Schedule Tables....21596
Maintenance Operations....21600
Lubrication Tables....21602
Lubrication....21604
Group 01 - Maintenance Schedule (2015 to 2016 Model Years)....21608
Index....21609
How to Read the Maintenance Schedule Tables....21610
1. For Maintenance Schedule in Severe Use....21611
2. Maintenance Schedule....21611
Maintenance Schedule Tables....21612
Lubrication Tables....21618
Group 11 - Engine....21620
Index....21621
Specifications....21622
Structure and Operation....21623
1. Engine Proper....21623
2. Timing System....21623
3. Main Bearing....21625
4. Connecting Rod, Piston....21625
5. Rocker Arms, Tappets....21628
Troubleshooting....21629
Engine Removal and Installation....21630
Tilt Cab....21630
Fixed Cab....21634
Work for Overhauling Engine....21638
Timing Gear Case....21668
Timing Gear, Chain....21674
Overhead, Cylinder Head....21688
Piston and Connecting Rod....21708
Flywheel....21718
Crankshaft and Crankcase....21722
Group 12 - Lubrication....21735
Index....21736
Specifications....21737
Structure and Operation....21738
1. Lubrication System....21738
2. Oil Pump/Vacuum Unit....21739
3. Oil Filter....21741
4. Oil Cooler....21741
Troubleshooting....21742
On-Vehicle Inspection and Adjustment....21743
1. Oil Filter Replacement....21743
2. Engine Oil Replacement....21745
3. Inspection of Engine Oil Level....21747
4. Inspection of Engine Oil Leaks....21747
5. Oil Pressure Measurement....21748
Oil Pan, Oil Strainer....21749
Oil Pump/Vacuum Unit....21753
Oil Filter, Oil Cooler....21754
Group 13 - Fuel and Engine Control....21757
Index....21758
Specifications....21760
Structure and Operation....21761
1. High Pressure Electronic Injection System....21761
Troubleshooting....21769
On-Vehicle Inspection and Adjustment....21771
1. Inspecting and Adjusting No-load Minimum and Maximum Speeds....21771
2. Air-bleeding of Fuel System....21772
3. Fuel Filter Replacement....21772
4. Fuel Hose Replacement....21775
Fuel Tank, Fuel Pump....21777
FE....21777
FG....21779
Fuel Filter....21781
Accelerator Pedal....21785
High Pressure Fuel Pump....21787
Common Rail, Injector....21791
Group 13E - Common Rail System....21795
Group 13E - Common Rail System (2012 to 2014 Model Years)....21796
Index....21797
Specifications....21798
Structure and Operation....21800
1. High Pressure Electronic Injection System....21800
2. Engine Electronic Control System....21802
Troubleshooting....21818
1. Inspections Based on Diagnosis Codes....21818
2. FUSO Diagnostics Service Data (Actual Values)....22429
3. FUSO Diagnostics Actuator Test (Actuations)....22445
4. Alteration and Reset of Coding Data in Engine Electronic Control Unit....22447
5. Inspections to be Made and NOx Error Occurrence....22450
6. Inspections to be Made at Injector Error Occurrence....22467
7. Inspection When an Error in the Exhaust Gas Recirculation and Exhaust Brake Valve System Error Occurrence....22469
8. Inspection When a Diesel Particulate Filter-related Sensor System Error Occurrence....22472
9. Inspection When a DEF Dosing Module System Error Occurrence....22473
10. Inspections to be Made at Blow-by Pressure Sensor Error Occurrence....22474
11. Inspections to be Made at CAN Error Occurrence....22476
Inspection of Electrical Equipment....22478
Installed Locations of Parts....22490
Electric Circuit Diagram....22518
Group 13E - Common Rail System (2014 1/2 Model Year)....22524
Index....22525
Specifications....21757
Structure and Operation....22526
1. High Pressure Electronic Injection System....22526
2. Engine Electronic Control System....22528
Troubleshooting....22542
1. Inspections Based on Diagnosis Codes....22542
2. Fuso Diagnostics Service Data (Actual Values)....23214
3. Fuso Diagnostics Actuator Test (Actuations)....23230
4. Alteration and Reset of Coding Data in Electronic Control Unit....23232
5. Inspections to be Made at NOx Error Occurrence....23235
6. Inspections to be Made at Injector Error Occurrence....23253
7. Inspection When an Error in the Exhaust Gas Recirculation and Exhaust Brake Valve System Error Occurrence....23255
8. Inspection When a Diesel Particulate Filter-related Sensor System Error Occurrence....23258
9. Inspection When a DEF Dosing Module System Error Occurrence....23259
10. Inspections to be Made at Blow-by Pressure Sensor Error Occurrence....23260
11. Inspection to be Made at CAN Error Occurrence....23262
Inspection of Electrical Equipment....25744
Installed Locations of Parts....25744
Electric Circuit Diagram....25744
Group 13E - Common Rail System (2015 to 2016 Model Years)....23264
Index....23265
Specifications....21757
Structure and Operation....23266
1. High Pressure Electronic Injection System....23266
2. Engine Electronic Control System....23268
Troubleshooting....23282
1. Inspections Based on Diagnosis Codes....23282
2. Fuso Diagnostics Service Data (Actual Values)....23951
3. Fuso Diagnostics Actuator Test (Actuations)....23967
4. Alteration and Reset of Coding Data in Electronic Control Unit....23969
5. Inspections to be Made at NOx Error Occurrence....23972
6. Inspections to be Made at Injector Error Occurrence....23990
7. Inspection When an Error in the Exhaust Gas Recirculation and Exhaust Brake Valve System Error Occurrence....23992
8. Inspection When a Diesel Particulate Filter-related Sensor System Error Occurrence....23995
9. Inspection When a DEF Dosing Modulator System Error Occurrence....23996
10. Inspections to be Made at Blow-by Pressure Sensor Error Occurrence....23997
11. Inspections to be Made at CAN Error Occurrence....23999
Inspection of Electrical Equipment....25744
Installed Locations of Parts....25744
Electric Circuit Diagram....25744
Group 14 - Cooling....24002
Group 14 - Cooling (2012 to 2014 Model Years)....24003
Index....24004
Specifications....24005
Structure and Operation....24006
1. Cooling System....24006
2. Water Pump....24007
3. Thermostat....24007
Troubleshooting....24008
On-Vehicle Inspection and Adjustment....24009
1. Inspection of Auto Tensioner....24009
2. Inspection of Coolant Level....24012
3. Inspection of Coolant Leaks....24012
4. Coolant Replacement and Cleaning of Cooling System....24012
5. Air Bleeding of Cooling System....24016
6. Air/Gas Leakage Test....24016
7. Inspection of Cracks or Damage of the Belt....24016
Disconnection and Connection of Hoses and Pipes....24017
Radiator....24027
Pressure Cap, Surge Tank....24029
Reservoir Tank....24031
Cooling Fan....24033
Belt, Water Pump, Damper Pulley....24037
Thermostat....24043
Group 14 - Cooling (2014 1/2 to 2016 Model Years)....24045
Index....24046
Specifications....24047
Structure and Operation....24048
1. Cooling System....24048
2. Water Pump....24049
3. Thermostat....24049
Troubleshooting....24050
On-Vehicle Inspection and Adjustment....24051
1. Inspection of Auto Tensioner....24051
2. Inspection of Coolant Level....24054
3. Inspection for Coolant Leaks....24054
4. Coolant Replacement and Cleaning of Cooling System....24054
5. Air Bleeding of Cooling System....24058
6. Air/Gas Leakage Test....24058
7. Inspection of Cracks or Damage of the Belt....24058
Disconnection and Connection of Hoses and Pipes....24059
Radiator....24069
Pressure Cap, Surge Tank....24071
Reservoir Tank....24073
Cooling Fan....24075
Belt, Water Pump, Damper Pulley....24079
Thermostat....24085
Group 15 - Intake and Exhaust....24087
Group 15 - Intake and Exhaust (2012 to 2014 Model Years)....24088
Index....24089
Specifications....24090
Structure and Operation....24091
1. Air Cleaner....24091
2. Turbocharger System....24092
3. EBS (Exhaust Brake System) Valve....24097
Troubleshooting General....24098
On-Vehicle Inspection and Adjustment....24099
1. Exhaust Emission Condition....24099
2. Cleaning and Inspection of Air Cleaner Element....24099
3. Installation, Looseness, and Damage of Exhaust Pipe and Muffler....24100
4. Functions of Muffler....24101
Air Duct and Air Cleaner....24102
Except Crew Cab....24102
Crew Cab....24108
Turbocharger....24114
Exhaust Manifold....24122
Intercooler....24124
Intake Manifold....24126
Front Pipe....24132
Group 15 - Intake and Exhaust (2014 1/2 to 2016 Model Years)....24134
Index....24135
Specifications....24136
Structure and Operation....24137
1. Air Cleaner....24137
2. Turbocharging System....24138
3. EBS (Exhaust Brake System) Valve....24143
Troubleshooting General....24144
On-Vehicle Inspection and Adjustment....24145
1. Exhaust Emission Condition....24145
2. Cleaning and Inspection of Air Cleaner Element....24145
3. Installation, Looseness, and Damage of Exhaust Pipe and Muffler....24146
4. Functions of Muffler....24147
Air Duct and Air Cleaner....24148
Except Crew Cab....24148
Crew Cab....24154
Turbocharger....24160
Exhaust Manifold....24168
Intercooler....24170
Intake Manifold....24174
Front Pipe....24178
Group 17 - Emission Control....24180
Group 17 - Emission Control (2012 to 2014 Model Years)....24181
Index....24182
Specifications....24183
Structure and Operation....24184
1. EGR (Exhaust Gas Recirculation) System....24184
2. Blowby Gas Return System....24186
3. Bluetec System....24187
Troubleshooting....24194
On-Vehicle Inspection and Adjustment....24195
1. Leakage of Diesel Exhaust Fluid....24195
2. Damage and Improper Installation of Diesel Exhaust Fluid Lines....24196
3. Replacement of Diesel Exhaust Fluid (AdBlue)....24197
4. Measures to be Taken if Diesel Exhaust Fluid Tank is Fitted with Incorrect Diesel Exhaust Fluid Solution....24198
EGR (Exhaust Gas Recirculation) Unit....24199
Blowby Gas Return System....24205
DEF (Diesel Exhaust Fluid) Tank....24207
DPF (Diesel Particulate Filter)....24211
SCR (Selective Catalytic Reduction)....24215
Group 17 - Emission Control (2014 1/2 to 2016 Model Years)....24219
Index....24220
Specifications....24221
Structure and Operation....24222
1. EGR (Exhaust Gas Recirculation) System....24222
2. Blowby Gas Return System....24224
3. BlueTec System....24225
Troubleshooting....24232
On-Vehicle Inspection and Adjustment....24233
1. Leakage of Diesel Exhaust Fluid....24233
2. Damage and Improper Installation of Diesel Exhaust Fluid Lines....24234
3. Replacement of Diesel Exhaust Fluid....24235
4. Measures to be Taken if Diesel Exhaust Fluid Tank is Filled with Incorrect Diesel Exhaust Fluid Solution....24236
EGR (Exhaust Gas Recirculation) Unit....24237
Blowby Gas Return System....24245
DEF (Diesel Exhaust Fluid) Tank....24247
DPF (Diesel Particulate Filter)....24251
SCR (Selective Catalytic Reduction)....24255
Group 17E - BlueTec System....24259
Group 17E - BlueTec System (2012 to 2014 Model Years)....24260
Index....24261
Structure and Operation....24262
1. Overview....24262
2. Electronic Control System....24263
Troubleshooting....21795
Inspection of Electrical Equipment....21795
Installed Locations of Parts....21795
Electric Circuit Diagram....21795
Group 17E - BlueTec System (2014 1/2 to 2016 Model Years)....24270
Index....24271
Structure and Operation....24272
1. Overview....24272
2. Electronic Control System....24273
3. Electronic Control Unit Schematic Diagram....21795
Troubleshooting....21795
Inspection of Electrical Equipment....21795
Installed Locations of Parts....21795
Electric Circuit Diagram....21795
Group 21 - Clutch....24285
Index....24286
Troubleshooting....24287
Damper....24289
Group 22 - Transmission DUONIC....24291
Group 22 - Transmission DUONIC (2012 Model Year)....24292
Index....24293
Specifications....24294
Structure and Operation....24296
1. Overview....24296
2. Valve Body....24297
3. Dual Clutch....24298
4. Transmission....24302
5. Synchromesh Mechanism....24307
6. Transmission Power Take-off....24310
Troubleshooting....24312
On-Vehicle Inspection and Adjustment....24316
1. Transmission Oil Leakage and Oil Quantity....24316
2. Inspection of Looseness in Engine to Clutch Housing Connection....24319
3. Inspection of Transmission Cooling System for Leakage, Damage and Installation Condition....24319
4. Inspection of Looseness in Propeller Shaft Connection....24319
5. Replacement of Transmission Oil....24320
6. Replacement of Clutch Control Oil....24322
7. Inspection of Transmission Mounting Cushion Rubber....24323
8. Inspection of Transmission Control....24324
Removal and Installation of Transmission....24326
Valve Body, Dual Clutch....24332
Gear Shift Unit....24348
Extension Housing and Parking Brake FE....24352
Transfer Case Adapter FG....24362
Reverse Idler Gear Without Large-Capacity Power Take-off....24368
Reverse Idler Gear With Large-Capacity Power Take-off....24372
Transmission Body....24376
Outer Drive Pinion....24396
Inner Drive Pinion....24402
Mainshaft....24404
Countershaft....24414
Transmission Control....24424
Oil Cooler....24428
Transmission Power Take-off Standard Type....24430
Transmission Power Take-off Large-Capacity Type....24438
Group 22 - Transmission DUONIC (2013 to 2014 Model Years)....24448
Index....24449
Transmission Power Take-off Large-Capacity Type....24450
Group 22 - Transmission DUONIC (2014 1/2 to 2016 Model Years)....24460
Index....24461
Specifications....24462
Structure and Operation....24464
1. Overview....24464
2. Valve Body....24465
3. Dual Clutch....24466
4. Transmission....24470
5. Synchromesh Mechanism....24475
6. Transmission Power Take-off....24478
Troubleshooting....24480
On-Vehicle Inspection and Adjustment....24484
1. Transmission Oil Leakage and Oil Quantity....24484
2. Inspection of Looseness in Engine to Clutch Housing Connection....24487
3. Inspection of Transmission Cooling System for Leakage, Damage and Installation Condition....24487
4. Inspection of Looseness in Propeller Shaft Connection....24487
5. Replacement of Transmission Oil....24488
6. Replacement of Clutch Control Oil....24490
7. Inspection of Transmission Mounting Cushion Rubber....24491
8. Inspection of Transmission Control....24492
Removal and Installation of Transmission....24494
Valve Body, Dual Clutch....24500
Gear Shift Unit....24516
Extension Housing and Parking Brake FE....24520
Transfer Case Adapater FG....24529
Reverse Idler Gear Without Large-Capacity Power Take-off....24536
Reverse Idler Gear With Large-Capacity Power Take-off....24540
Transmission Body....24544
Outer Drive Pinion....24564
Inner Drive Pinion....24570
Mainshaft....24572
Countershaft....24582
Transmission Control....24592
Oil Cooler....24596
Transmission Power Take-off Standard Type....24602
Transmission Power Take-off Large-Capacity Type....24610
Group 22E - DUONIC....24620
Group 22E - DUONIC (2012 to 2014 Model Years)....24621
Index....24622
Specifications....24623
Structure and Operation....24625
1. Overview....24625
2. Electronic Control System....24626
3. Electronic Control Unit Schematic Diagram....24635
Troubleshooting....24637
1. Inspection Based on Diagnosis Codes....24637
2. Service Data (Actual Measurements) of Fuso Diagnostics....24759
3. Actuator Tests Available in Fuso Diagnostics....24771
4. Inputs and Outputs to/from Electronic Control Unit....24772
5. Coding Data in Electronic Control Unit....24773
6. Initialization of DUONIC System....24774
7. Troubleshooting by Symptom....24777
Inspection of Electrical Parts....24779
Installed Locations of Parts....24785
Electric Circuit Diagram....24807
Group 22E - DUONIC (2014 1/2 to 2016 Model Years)....24809
Index....24810
Specifications....24811
Structure and Operation....24813
1. Overview....24813
2. Electronic Control System....24814
3. Electronic Control Unit Schematic Diagram....24825
Troubleshooting....24827
1. Inspections based on Diagnosis Codes....24827
2. Fuso Diagnostics Service Data (Actual Values)....24951
3. Fuso Diagnostics Actuator Test (Actuations)....24974
4. Electronic Control Unit Input/Output Table....24975
5. Coding Data in Electronic Control Unit....24976
6. Initialization of DUONIC System....24977
7. Troubleshooting by Symptom....24981
Inspection of Electrical Parts....25744
Installed Locations of Parts....25744
Electric Circuit Diagram....25744
Group 24 - Transfer....24983
Index....24984
Specifications....24985
Structure and Operation....24986
1. Transfer....24986
Troubleshooting....24987
On-Vehicle Inspection and Adjustment....24989
1. Inspection of Transmission and Transfer Oil Leakage....24989
2. Inspection of Looseness in Transmission and Transfer Mounting Bolts....24989
3. Inspection of Play and Looseness in Companion Flange....24990
4. Inspection and Replacement of Transfer Oil....24991
Removal and Installation of Transmission (With Transfer)....24993
Removal and Installation of Transfer....24999
Front Drive....25001
Rear Drive....25007
Transfer....25011
Group 25 - Propeller Shaft....25019
Index....25020
Specifications....25021
Structure and Operation....25021
1. Configuration of Propeller Shaft Connection....25021
2. Propeller Shaft Without Center Bearing....25022
Troubleshooting....25024
Removal and Installation of Propeller Shaft....25025
Between T/M (Or Transfer) and Rear Axle....25025
Between Front Axle and Transfer....25027
Propeller Shaft....25029
P2....25029
P3....25035
Group 26A - Front Axle FE....25046
Index....25047
Specifications....25048
Structure and Operation....25049
1. Wheel Hub and Rotor....25049
2. Knuckle and Kingpin, Front Axle....25050
Troubleshooting....25051
On-Vehicle Inspection and Adjustment....25052
1. Inspection and Adjustment of Wheel Alignment....25052
2. Inspection and Adjustment of Steering Angle....25056
3. Inspection of Side Slip....25056
4. Inspection of Tie Rod End Ball Joint....25057
5. Inspection of Wheel Bearing for Play....25057
6. Inspection of Knuckle Joint for Play....25057
Wheel Hub and Rotor....25058
Knuckle and Kingpin, Front Axle....25068
Tie Rod....25078
Group 26B - Front Axle FG....25080
Index....25081
Specifications....25082
Structure and Operation....25082
1. Wheel Hub and Brake Drum....25082
2. Free Wheel Hub....25083
3. Drive Shaft and Steering Knuckle, Axle Housing....25084
4. Reduction and Differential....25085
Troubleshooting....25086
On-Vehicle Inspection and Adjustment....25090
1. Inspection and Adjustment of Wheel Alignment....25090
2. Inspection and Adjustment of Steering Angle....25094
3. Inspection of Side Slip....25094
4. Inspection of Tie Rod End Ball Joint....25095
5. Inspection and Replacement of Differential Oil....25096
6. Inspection of Wheel Bearing for Play....25097
7. Inspection of Knuckle Joint for Play....25097
Wheel Hub and Brake Drum....25098
Drive Shaft and Steering Knuckle....25112
Tie Rod....25118
Axle Housing....25120
Reduction and Differential....25122
Group 27 - Rear Axle....25136
Group 27 - Rear Axle (2012 to 2014 1/2 Model Years)....25137
Index....25138
Specifications....25139
Structure and Operation....25140
1. Wheel Hub and Rotor....25140
2. Wheel Hub and Brake Drum....25141
3. Reduction and Differential....25142
4. Limited Slip Differential....25143
Troubleshooting....25145
On-Vehicle Inspection and Adjustment....25147
1. Inspection and Replacement of Axle Oil....25147
2. Inspection of Wheel Bearing for Play....25148
Wheel Hub and Rotor....25149
FE52....25149
FEC7, FEC9....25161
Wheel Hub and Brake Drum....25173
Axle Housing....25183
Reduction and Differential....25187
Group 27 - Rear Axle (2015 to 2016 Model Years)....25212
Index....25213
Specifications....25214
Structure and Operation....25215
1. Wheel Hub and Rotor....25215
Wheel Hub and Rotor....25216
FE52....25216
FEC7, FEC9, FECX....25228
Group 31 - Wheel and Tire....25239
Index....25240
Specifications....25241
Troubleshooting....25242
On-Vehicle Inspection and Adjustment....25243
1. Inspection of Looseness in Wheel Nuts....25243
2. Inspection of Tire....25244
Wheel and Tire....25247
Group 33 - Front Suspension....25254
Group 33 - Front Suspension (2012 to 2014 1/2/ Model Years)....25255
Index....25256
Structure and Operation....25257
1. Front Suspension Elements....25257
Troubleshooting....25258
Stabilizer FE....25259
Shock Absorber....25261
FE....25261
FG....25263
Leaf Spring....25265
FE....25265
FG....25273
Group 33 - Front Suspension (2015 to 2016 Model Years)....25278
Index....25279
Structure and Operation....25280
1. Front Suspension Elements....25280
Leaf Spring....25282
FE....25282
FG....25290
Group 34 - Rear Suspension....25295
Index....25296
Structure and Operation....25297
1. Rear Suspension Elements....25297
Troubleshooting....25298
Stabilizer FEC7, FEC9....25299
Shock Aborber....25300
Leaf Spring....25301
Group 35 - Brake....25315
Group 35 - Brake (2012 to 2014 1/2 Model Years)....25316
Index....25317
Specifications....25318
Structure and Operation....25320
1. Brake System....25320
2. Vacuum Pump....25321
3. Vacuum Booster and Brake Master Cylinder....25322
4. Front Disc Brake FE....25326
5. Front Drum Brake FG....25327
6. Rear Disc Brake FE....25330
7. Rear Drum Brake FG....25331
Troubleshooting....25332
On-Vehicle Inspection and Adjustment....25336
1. Replacement of Brake Fluid....25336
2. Air Bleeding of Brake System....25338
3. Inspection and Adjustment of Brake Pedal....25342
4. Inspection and Replacement of Disc Brake Pad FE....25344
5. Measurement of Disc Brake Drag Torque FE....25346
6. Inspection of Drum Brake Lining Thickness FG....25346
7. Initial Setting of Clearance Between Brake Drum and Shoe FG....25347
8. Inspection of Check Valve in Vacuum Line Hose....25348
9. Inspection of Vacuum Pump....25349
10. Inspection of Vacuum Booster....25349
Brake Master Cylinder....25354
Brake Pedal & Vacuum Booster....25356
Front Disc Brake....25360
Front Drum Brake....25366
Rear Disc Brake....25374
Rear Drum Brake....25380
Group 35 - Brake (2015 to 2016 Model Years)....25386
Index....25387
On-Vehicle Inspection and Adjustment....25388
1. Inspection and Adjustment of Brake Pedal....25388
2. Inspection of Vacuum Booster....25390
Group 35E - Anti-lock Brake System (ABS)....25395
Group 35E - Anti-lock Brake System (ABS) (2012 to 2014 Model Years)....25396
Index....25397
Specifications....25398
Structure and Operation....25400
1. Overview....25400
2. Electronic Control System....25417
3. Electronic Control Unit Schematic Diagram....25420
Troubleshooting....25422
1. Inspections According to Diagnosis Codes....25422
2. Fuso Diagnostics Service Data (Measured Values)....25444
3. Actuator Test (Control) Using Fuso Diagnostics....25445
4. Electronic Control Unit Coding....25446
5. Rewriting of Coding Data....25446
6. Electronic Control Unit Input/Output Diagram....25446
On-Vehicle Inspection and Adjustment....25448
1. Functional Check....25448
2. Inspection of Hydraulic Unit (Electronic Control Unit) Operation....25449
3. Inspection After Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)....25450
Hydraulic Unit (Electronic Control Unit)....25452
Inspection of Electrical Parts....25456
Installed Locations of Parts....25458
Electrical Circuit Diagram....25470
Group 35E - Anti-lock Brake System (ABS) (2014 1/2 to 2016 Model Years)....25472
Index....25473
Specifications....25474
Structure and Operation....25476
1. Overview....25476
2. Electronic Control System....25493
3. Electronic Control Unit Schematic Diagram....25496
Troubleshooting....25498
1. Inspections Based on Diagnosis Codes....25498
2. Fuso Diagnostics Service Data (Actual Values)....25522
3. Fuso Diagnostics Actuator Test (Actuations)....25526
4. Coding Data in Electronic Control Unit....25527
5. Electronic Control Unit Input/Output Table....25527
On-Vehicle Inspection and Adjustment....25528
1. Functional Check....25528
2. Inspection of Hydraulic Unit (Electronic Control Unit) Operation....25529
3. Inspection After Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)....25530
Hydraulic Unit (Electronic Control Unit)....25532
Inspection of Electrical Parts....25744
Installed Locations of Parts....25744
Electric Circuit Diagram....25744
Group 36 - Parking Brake....25535
Index....25536
Specifications....25537
Structure and Operation....25538
1. Components and Parts....25538
2. Parking Brake Lever....25538
3. Parking Brake....25539
Troubleshooting....25540
On-Vehicle Inspection and Adjustment....25541
1. Inspection of Parking Brake Drum Mounting for Looseness....25541
2. Adjustment of Parking Brake Shoe Clearance....25541
3. Inspection and Adjustment of Parking Brake Lever....25542
Parking Brake Control....25545
Parking Brake....25547
Group 37 - Steering....25549
Index....25550
Specifications....25551
Structure and Operation....25553
1. Steering System....25553
2. Oil Flow....25553
3. Power Steering Gear Assembly....25554
4. Power Steering Oil Pump....25556
Troubleshooting....25557
On-Vehicle Inspection and Adjustment....25559
1. Steering Wheel Play....25559
2. Steering Column Looseness....25559
3. Inspection of Rods and Arms for Looseness....25559
4. Inspection of Power Steering System Mounts for Looseness....25560
5. Inspection and Replacement of Power Steering Oil....25560
6. Performance Verification Test of Power Steering System....25562
7. Inspection of Drag Link Ball Joint....25563
8. Inspection of Steering Wheel Operation During Running....25563
Steering Column....25565
Power Steering Gear Assembly and Drag Link....25571
Power Steering Oil Tank....25587
Group 41 - Bumper and Frame....25588
Index....25589
Specifications....25590
Structure and Operation....25591
Front Bumper....25592
Frame....25594
Group 42 - Cab....25598
Group 42 - Cab (2012 to 2014 1/2 Model Years)....25599
Index....25600
Specifications....25601
Structure and Operation....25602
1. Front Cab Mounting....25602
2. Rear Cab Mounting Except Crew Cab....25603
3. Center and Rear Cab Mountings Crew Cab....25603
4. Cab Tilt Link Except Crew Cab....25604
Troubleshooting....25605
On-Vehicle Inspection and Adjustment....25607
1. Adjustment of Cab Tilt System Except Crew Cab....25607
Removal and Installation of Cab....25609
Except Crew Cab....25609
Crew Cab....25613
Front Cab Mounting....25617
Except Crew Cab....25617
Crew Cab....25619
Rear Cab Mounting Except Crew Cab....25621
Center and Rear Cab Mountings Crew Cab....25623
Cab Tilt Link Except Crew Cab....25625
Cab Stay Except Crew Cab....25627
Group 42 - Cab (2015 to 2016 Model Years)....25628
Index....25629
Cab Tilt Link Except Crew Cab....25630
Group 43 - Door....25633
Index....25634
Specifications....25635
Structure and Operation....25636
1. Front Door Lock System....25636
2. Rear Door Lock System Crew Cab....25636
3. Front Door Glass Opening and Closing Mechanism....25637
4. Rear Door Glass Opening and Closing Mechanism Crew Cab....25638
5. Keyless Entry System....25639
Troubleshooting....25643
On-Vehicle Inspection and Adjustment....25647
1. Adjustment of Front Door Alignment....25647
2. Adjustment of Rear Door Alignment Crew Cab....25649
3. Inspection of Keyless Entry System....25651
4. Method of Transmitting Code to Keyless Entry Electrical Control Unit....25652
Front Door....25655
Rear Door Crew Cab....25663
Group 51 - Exterior....25670
Index....25671
Structure and Operation....25672
1. Wiper and Washer System....25672
Troubleshooting....25673
Mirror....25675
Wiper and Washer....25677
Front Cover....25679
Front Grille, Front Corner Panel and Headlamp....25681
Fender FG....25686
Step....25687
Garnish Crew Cab....25689
Wheel House....25690
Window Glass....25691
Group 52 - Interior....25694
Group 52 - Interior (2012 Model Year)....25695
Index....25696
Driver Seat....25697
Passenger Seat....25698
Rear Seat Crew Cab....25699
Seat Belt....25701
Instrument Panel....25707
Trim and Scuff Plate....25723
Except Crew Cab....25723
Crew Cab....25727
Head Lining....25731
Except Crew Cab....25731
Crew Cab....25735
Group 52 - Interior (2013 to 2016 Model Years)....25738
Index....25739
Driver Seat....25740
Passenger Seat....25742
Group 54 - Electrical....25744
Group 54 - Electrical (2012 to 2014 Model Years)....25745
Index....25746
54-00A - General....21486
54-00B - Specifications....25749
Specifications....25750
54-00C - Structure and Operation....25753
1. Starter....25754
2. Alternator....25755
3. Headlamps....25757
4. Meter Cluster....25758
5. Signal Detect and Actuation Modules....25770
6. Immobilizer....25790
54-00D - Troubleshooting....25793
Troubleshooting....25794
54-01 - Power, Charge and Ground Circuit....25821
High-Current Fuse Box....25822
Fuse Box....25824
105 - SAM Internal Circuit....25826
110 - Power Circuit....25828
115 - Reserve Power Circuit....25842
125 - Battery Charging Circuit....25843
130 - Ground....25844
54-02 - Engine Starting, Stopping and Preheating Circuit....25859
210 - Engine Starting Circuit....25860
220 - Engine Preheating Circuit....21796
54-03 - Lighting Circuit....25862
310 - Headlamp Circuit....25863
313 - Daytime Running Light Circuit....25864
315 - Fog Lamp Circuit....25865
320 - Tail, Parking and License Plate Lamps Circuit....25866
325 - Stop Lamp Circuit....25867
330 - Turn Signal and Hazard Lamp Circuit....25868
340 - Backup Lamp Circuit....25869
345 - Cab Lamp Circuit....25871
348 - Illumination Lamp Circuit....25873
349 - Identification and Side Marker Lamp Circuit....25874
352 - Van Body Dome Light Circuit....25875
54-04 Meter Circuit....25876
401 - Meter Cluster Internal Circuit....25877
410 - Tachometer Circuit....25879
412 - Speedometer Circuit....25880
415 - Tachograph Circuit....25881
420 - Fuel Gauge Circuit....25882
425 - Water Temperature Gauge Circuit....25883
54-05 - Indicator and Warning Lamp Circuit....25884
510 - Parking Brake Indicator Circuit....25885
515 - Brake Warning Circuit....25886
536 - Engine Oil Pressure Warning Circuit....25887
537 - Overheating Warning Circuit....25888
550 - Cab Tilt Warning Circuit....25889
554 - Starter Key Removal Reminder Alarm Circuit....25890
566 - Fuel Filter Circuit....25891
54-06 - Cab Side Electrical Circuit....25892
610 - Cigarette Lighter Circuit....25893
612 - Audio Circuit....25894
614 - Wiper and Washer Circuit....25895
616 - Horn Circuit....25896
620 - Heater and Air-conditioner Circuit....25897
622 - Power Window and Central Door Lock Circuit....25899
629 - Mirror Heater Circuit....25900
654 - Keyless Entry Circuit....25901
54-08 - Engine and Transmission Side Electrical Circuit....25902
810 - Four-Wheel Drive Circuit....25903
850 - Transmission Power Take-off Circuit....25904
54-09 - Other Circuit....25905
905 - Joint Connector (J/C)....25906
Common Rail System Electric Circuit Diagram....21796
DUONIC System Electric Circuit Diagram....24621
Anti-lock Brake System Electric Circuit Diagram....25396
Fully Automatic Air-conditioner System Electric Circuit Diagram....26665
54-10 - Electrical Equipment Installation Positions....25908
Cab Side....25909
A - Switch and Sensor....25909
B - Relay and Electronic Control Unit....25913
C - Meter and Motor....25917
D - Air-conditioner....25919
E - Door....25923
F - Roof....25924
G - Cab....25925
H - Tilt....25926
J - Joints of Main Harness Connectors....25927
P - Others....25931
Engine and Transmission....25933
R - Engine....25933
S - Transmission....25935
Chassis Side....25937
T - Switch and Sensor....25937
U - Fuse, Relay and Electronic Control Unit....25943
V - Magnetic Valve, Motor and Buzzer....25945
W - Joints of Main Harness Connectors....25947
X - Others....25951
54-11 - Inspection of Electrical Equipment....25956
#001 to #179 Switch....25957
#180 to #249 Relay....25962
#250 to #349 Sensor....25963
#350 to #409 Control Unit....25966
#410 to #509 Motor....25967
#510 to #539 Actuator....25970
#560 to #609 Magnetic Valve....25971
#610 to #649 Buzzer, Horn....25972
#650 to #699 Lamp....25973
#750 to #859 Other....25974
#860 Battery....25977
#890 Meter....25980
54-12 - Starter and Alternator....25982
#930 Starter....25983
#940 Alternator....26001
54-13 - On-Vehicle Inspection and Adjustment....26004
#950 Inspection of Alternator....26005
#951 Inspection of Regulator....26006
#960 Headlamp Aiming....26007
#961 Fog Lamp Aiming....26009
#984 Inspection of Immobilizer....26011
#985 Inspection of Signal Detect and Actuation Modules....26021
#986 Inspection of Meter Cluster....26063
54-14 - Connector Configuration Chart....26066
Connector Configuration Chart....26067
Group 54 - Electrical (2014 1/2 to 2016 Model Years)....26164
Index....26165
54-00A - General....21485
54-00B - Specifications....26168
Specifications....26169
54-00C - Structure and Operation....26172
1. Starter....26173
2. Alternator....26174
3. Headlamps....26176
54-00D - Troubleshooting....26177
Troubleshooting....26178
54-01 - Power, Charge and Ground Circuit....26208
High-Current Fuse Box....26209
Fuse Box....26211
105 - SAM Internal Circuit....26213
110 - Power Circuit....26215
115 - Reserve Power Circuit....26230
125 - Battery Charging Circuit....26231
130 - Ground....26232
54-02 - Engine Starting, Stopping and Preheating Circuit....26248
210 - Engine Starting Circuit....26249
220 - Engine Preheating Circuit....26302
54-03 - Lighting Circuit....26251
310 - Headlamp Circuit....26252
313 - Daytime Running Light Circuit....26253
315 - Fog Lamp Circuit....26254
320 - Tail, Parking and License Plate Lamps Circuit....26255
325 - Stop Lamp Circuit....26256
330 - Turn Signal and Hazard Lamp Circuit....26257
340 - Backup Lamp Circuit....26258
345 - Cab Lamp Circuit....26260
348 - Illumination Lamp Circuit....26262
349 - Identification and Side Marker Lamp Circuit....26263
352 - Van Body Dome Light Circuit....26264
54-04 - Meter Circuit....26265
401 - Meter Cluster Internal Circuit....26266
410 - Tachometer Circuit....26268
412 - Speedometer Circuit....26269
415 - Tachograph Circuit....26270
420 - Fuel Gauge Circuit....26271
425 - Water Temperature Gauge Circuit....26272
54-05 - Indicator and Warning Lamp Circuit....26273
510 - Parking Brake Indicator Circuit....26274
515 - Brake Warning Circuit....26275
536 - Engine Oil Pressure Warning Circuit....26276
537 - Overheating Warning Circuit....26277
550 - Cab Tilt Warning Circuit....26278
554 - Starter Key Removal Reminder Alarm Circuit....26279
566 - Fuel Filter Circuit....26280
54-06 - Cab Side Electrical Circuit....26281
610 - Cigarette Lighter Circuit....26282
612 - Audio Circuit....26283
614 - Wiper and Washer Circuit....26284
616 - Horn Circuit....26285
620 - Heater and Air-conditioner Circuit....26286
622 - Power Window and Central Door Lock Circuit....26291
629 - Mirror Heater Circuit....26292
654 - Keyless Entry Circuit....26293
54-07 - Chassis Side Electrical Circuit....26294
790 - Anti-lock Brake System....26295
54-08 - Engine and Transmission Side Electrical Circuit....26297
810 - Four-Wheel Drive Circuit....26298
850 - Transmission Power Take-off Circuit....26299
873 - DUONIC System Electric Circuit....26300
880 - Common Rail System Electric Circuit....26302
54-09 - Other Circuit....26309
905 - Joint Connector (J/C)....26310
54-10 - Electrical Equipment Installation Positions....26314
Cab Side....26315
A - Switch and Sensor....26315
B - Relay and Electronic Control Unit....26319
C - Meter and Motor....26323
D - Air-conditioner....26325
E - Door....26329
F - Roof....26330
G - Cab....26331
H - Tilt....26332
J - Joints of Main Harness Connectors....26333
P - Others....26337
Engine and Transmission....26339
R - Engine....26339
S - Transmission....26341
Chassis Side....26343
T - Switch and Sensor....26343
U - Fuse, Relay and Electronic Control Unit....26349
V - Magnetic Valve, Motor and Buzzer....26351
W - Joints of Main Harness Connectors....26353
X - Others....26357
54-11 - Inspection of Electrical Equipment....26361
#001 to #179 Switch....26362
#180 to #249 Relay....26367
#250 to #349 Sensor....26368
#350 to #409 Control Unit....26376
#410 to #509 Motor....26377
#510 to #539 Actuator....26380
#560 to #609 Magnetic Valve....26382
#610 to #649 Buzzer, Horn....26383
#650 to #699 Lamp....26384
#750 to #859 Other....26385
#860 Battery....26389
#890 Meter....26392
54-12 - Starter and Alternator....26393
#930 Starter....26394
#940 Alternator....26412
54-13 - On-Vehicle Inspection and Adjustment....26414
#950 Inspection of Alternator....26415
#951 Inspection of Regulator....26416
#960 Headlamp Aiming....26417
#961 Fog Lamp Aiming....26419
54-14 - Connector Configuration Chart....26420
Connector Configuration Chart....26421
Group 54EI - Immobilizer (2014 1/2 to 2016 Model Years)....26520
Index....26521
Structure and Operation....26522
1. Overview....26522
2. Electronic Control System....26523
3. Electronic Control Circuit Diagram....26524
Troubleshooting....26526
1. Inspection Based on Diagnosis Codes....26526
2. Fuso Diagnostics Service Data (Measured Values)....26529
Initial Settings of Immobilizer....26530
1. Connecting the Fuso Diagnostics....26530
2. Selection of the Setting of Immobilizer....26530
3. Various Operations (Initial Key Registration, Additional Key Registration, Secret Key Registration, Key Information Deletion)....26531
4. Additional Starter Key Registration (Up to 6 Keys Can be Registered)....26535
5. New Starter Key Registration After All of Starter Keys Have Been Lost....26536
Inspection of Electrical Parts....26164
Installed Locations of Parts....26164
Electric Circuit Diagram....26164
Group 54EM - Meter Cluster (2014 1/2 to 2016 Model Years)....26537
Index....26538
Specifications....26539
Structure and Operation....26541
1. Overview....26541
2. Electronic Control System....26542
3. Electronic Control Unit Circuit Diagram....26552
Troubleshooting....26553
1. Inspection Based on Diagnosis Codes....26553
2. Fuso Diagnostics Service Data (Actual Values)....26555
3. Fuso Diagnotics Actuator Test (Actuations)....26555
4. Coding Data in Electronic Control Unit....26555
5. Electronic Control Unit Input/Output Table....26556
Inspection of Electrical Parts....26164
Installed Locations of Parts....26164
Electric Circuit Diagram....26164
Group 54ES - Signal Detect and Actuation Modules (2014 1/2 to 2016 Model Years)....26557
Index....26558
Structure and Operation....26559
1. Overview....26559
2. Electronic Control System....26561
3. Electronic Control Unit Circuit Diagram....26569
4. Diagnosis Code Occurrence Condition Range (Lost of Output Current Threshold Values)....26578
Troubleshooting....26581
1. Inspection Based on Diagnosis Codes....26581
2. Fuso Diagnostics Service Data (Actual Values)....26608
3. Fuso Diagnostics Actuator Test (Actuations)....26618
4. Coding Data in Electronic Control Unit....26618
5. Electronic Control Unit Input/Output Table....26619
6. Confirmation Items Before Replacing the Signal Detect and Actuation Module....26621
7. Symptoms and Inspection Procedures When Warning Lamp (Red or Amber) Illuminates....26624
Inspection of Relays in Signal Detect and Actuation Module....26627
Inspection of Electrical Parts....26164
Installed Locations of Parts....26164
Electric Circuit Diagram....26164
Group 55 - Heater, Air-conditioner, and Ventilation....26628
Index....26629
Specifications....26630
Structure and Operation....26631
1. Heater....26631
2. Air Conditioner....26632
3. Compressor....26633
4. Air Duct....26636
5. Heater Control....26637
6. Rear Heater Crew Cab....26641
Troubleshooting....26642
On-Vehicle Inspection and Adjustment....26646
1. Operation Check of Air-Conditioner....26646
2. Recovery of Refrigerant....26650
3. Recharging the System with Refrigerant....26651
Connecting Air-Conditioner Piping....26653
Compressor....26654
Condenser, Receiver....26655
Heater Control Manual Air-Conditioner....26657
Air Duct....26661
Heater and Cooling Unit, Blower....26662
Rear Heater Crew Cab....26663
Group 55E - Full Automatic Air-conditioner....26664
Group 55E - Full Automatic Air-conditioner (2012 to 2014 Model Years)....26665
Index....26666
Specifications....26667
Structure and Operation....26669
1. Overview....26669
2. Electronic Control System....26670
3. Electronic Control Unit Schematic Diagram....26672
Troubleshooting....26673
1. Inspection According to Diagnosis Code (Trouble Codes)....26673
2. Fuso Diagnostics Service Data (Measured Values)....26679
3. Actuator Test (Control) Using Fuso Diagnostics....26681
4. Electronic Control Unit Input/Output Table....26683
Inspection of Electrical Parts....26685
Installed Locations of Parts....26691
Electrical Circuit Diagram....26709
Group 55E - Full Automatic Air-conditioner (2014 1/2 to 2016 Model Years)....26711
Index....26712
Specifications....26628
Structure and Operation....26713
1. Overview....26713
2. Electronic Control System....26714
3. Electronic Control Unit Schematic Diagram....26716
Troubleshooting....26717
1. Inspection Based on Diagnosis Codes....26717
2. Fuso Diagnostics Service Data (Actual Values)....26723
3. Fuso Diagnostics Actuator Test (Actuations)....26726
4. Electronic Control Unit Input/Output Table....26728
Inspection of Electrical Parts....26164
Installed Locations of Parts....26164
Electrical Circuit Diagram....26164
Mitsubishi FUSO Canter / Rosa / Fighter Repair Service Manual 1996-2016
