Mitsubishi Fuso FE.FG Series Repair Service Manual 1990-1991
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Fuso FE.FG Series 1990-1991, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi Fuso FE.FG Series 1990-2001 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.
Mitsubishi Fuso FE.FG Series 1990-1991 Service Manual (TWSE8911).pdf
Mitsubishi Fuso FE.FG Series 1992-1995 Service Manual (TWSE9105).pdf
Mitsubishi Fuso FE.FG Series 1995-2001 Service Manual (TWSE9501).pdf
PRODUCT DETAILS:
Total Pages: 5,802 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
FE.FG Series 1990-1991 Fuso Service Manual (TWSE8911 - 1,734 pages).....1
1990-1991 FE/FG Service Manual.....1
Foreword.....2
Manual Layout.....3
Group 00 - 1991 Minor Changes.....5
Group 00 - General.....13
Table of Contents.....14
1. External Views.....15
2. Major Specifications.....17
3. Power Train Table.....22
4. Equipment Model Notation.....22
5. Performance Curves.....23
5.1 Operation Performance Curves.....23
5.2 Engine Performance Curves.....27
6. Servicing Precautions.....28
7. Standard Bolts and Nuts Tightening Torque Table.....32
8. Towing Precautions.....33
9. Vehicle Identification Number.....34
Group 01 - Maintenance Schedule.....35
Table of Contents.....36
1. How to Read the Maintenance Schedule Tables.....37
2. Maintenance Schedule Tables.....38
3. Maintenance Operations.....40
3.1 Replacement of the Oil Filter Element.....40
3.2 Replacement of the Fuel Filter Element.....40
3.3 The Water Separator.....40
3.4 Cleaning the Fuel Feed Pump Gauze Filter.....41
3.5 Bleeding Air from the Fuel Line.....41
3.6 Adjusting V-Belt Tension.....42
3.7 Cleaning and Replacement of the Air Cleaner Element.....43
3.8 Inspecting the Clutch Pedal.....44
3.9 The Tires.....44
3.9.1 Air Pressure.....44
3.9.2 Removing Tires.....44
3.9.3 Putting Tires On.....46
3.9.4 Checking the Wheel Nuts for Looseness.....47
3.9.5 Tire Rotation.....47
3.10 Adjusting the Clearance of the Wheel Brake Shoe (Drum Brake).....48
3.11 Checking for Wear in the Disk Brake Pads.....49
3.12 Adjusting the Clearance of the Parking Brake Shoe.....49
3.13 The Battery.....50
3.13.1 Cleaning the Battery Terminals.....50
3.13.2 Inspecting the Battery.....50
3.14 Fuses.....51
4. Lubrication.....53
4.1 Engine Oil.....54
4.2 Gear Oil for Manual Transmissions.....55
4.3 Transmission Fluid for Automatic Transmissions.....55
4.4 Front Axle <FG Models Only> and Rear Axle Gear Oil.....58
4.5 Transfer Gear Oil <FG Models Only>.....59
4.6 Power Steering Fluid.....59
4.7 Brake Fluid.....62
4.8 Greasing the Various Areas of the Chassis.....65
Group 11 - Engine.....67
Table of Contents.....68
1. Troubleshooting.....69
2. Engine Removal and Installation (Manual Transmission Vehicles).....76
2.1 Service Standards.....76
2.1.1 Tightening Torque Table.....76
2.1.2 Lubricant Table.....76
2.2 Engine and Transmission Removal.....77
2.2.1 Preparations Before Removal.....77
2.2.2 Harness Removal.....79
2.2.3 Vacuum Hose Removal.....83
2.2.4 Removal of Parts Around Engine.....85
2.2.5 Removal of Each Engine Part.....86
2.2.6 Removal of Each Transmission Part.....90
2.2.7 Removing the Engine From the Vehicle.....92
2.2.8 Separating the Engine From the Transmission.....94
2.3 Installation of the Engine and Transmission.....95
2.3.1 Engine and Transmission Installation.....95
2.3.2 Installation the Engine and Transmission in the Vehicle.....96
2.3.3 Installation of Each Transmission Part.....99
2.3.4 Installation of Each Engine Part.....102
2.3.5 Installation of Parts Around the Engine.....105
2.3.6 Vacuum Hose Installation.....107
2.3.7 Harness Installation.....109
2.4 Adjustment After Installation.....113
2.4.1 Procedures After Installation.....113
2.4.2 Adjustment.....115
3. Engine Removal and Installation (Automatic Transmission Vehicles).....116
3.1 Service Standards.....116
3.1.1 Tightening Torque Table.....116
3.2 Engine and Transmission Removal.....116
3.2.1 Preparations Before Removal.....116
3.2.2 Harness Removal.....117
3.2.3 Vacuum Hose Removal.....119
3.2.4 Removal of Parts Around Engine.....119
3.2.5 Removal of Each Engine Part.....119
3.2.6 Removal of Each Transmission Part.....120
3.2.7 Removing the Engine From the Vehicle.....122
3.2.8 Separating the Engine and Transmission.....124
3.3 Installation of the Engine and Transmission.....125
3.3.1 Transmission Installation.....125
3.3.2 Installing the Engine and Transmission in the Vehicle.....126
3.3.3 Installation of Each Transmission Part.....128
3.3.4 Installation of Each Engine Part.....131
3.3.5 Installation of Parts Around the Engine.....131
3.3.6 Vacuum Hose Installation.....131
3.3.7 Harness Installation.....131
3.4 Adjustment After Installation.....134
3.4.1 Operations After Installation.....134
3.4.2 Adjustment.....136
4. Engine Assembly.....137
4.1 Specifications.....137
4.2 Service Standards.....137
4.2.1 Service Standards Table.....137
4.2.2 Tightening Torque Table.....138
4.2.3 Special Tool Table.....138
4.3 Valve Clearance Inspection and Adjustment.....139
4.4 Compression Pressure Measurement.....140
4.5 Oil Pressure Inspection.....142
4.6 Fuel Injection Timing Inspection and Adjustment.....142
4.7 Bleeding the Fuel System.....146
4.8 Inspection and Adjustment of V-Belt Tension.....146
4.8.1 V-Belt Tension Inspection.....146
4.8.2 V-Belt Tension Adjustment.....147
4.9 Turbocharger Boost Pressure Measurement.....149
5. Cylinder Head and Valve Mechanism.....151
5.1 Service Standards.....151
5.1.1 Service Standard Table.....151
5.1.2 Tightening Torque Table.....151
5.1.3 Special Tool Table.....152
5.2 General Description.....153
5.2.1 Cylinder Head.....153
5.2.2 Valve Mechanism.....154
5.3 Removal.....154
5.4 Disassembly.....157
5.4.1 Rocker and Bracket Assembly.....157
5.4.2 Cylinder Head Assembly.....158
5.5 Inspection.....160
5.6 Reassembly.....168
5.6.1 Cylinder Head Assembly.....168
5.6.2 Rocker and Bracket Assembly.....170
5.7 Installation.....172
6. Flywheel and Rear Plate (Manual Transmission Vehicles).....175
6.1 Service Standards.....175
6.1.1 Maintenance Standards Table.....175
6.1.2 Tightening Torque Table.....175
6.1.3 Special Tool Table.....175
6.1.4 Lubricant Table.....175
6.2 General Description.....176
6.3 Removal.....177
6.4 Inspection.....178
6.5 Installation.....179
7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles).....183
7.1 Service Standards.....183
7.1.1 Tightening Torque Table.....183
7.1.2 Special Tool Table.....183
7.1.3 Lubricant Table.....183
7.2 General Description.....184
7.3 Removal.....185
7.4 Inspection.....186
7.5 Installation.....187
8. Timing Gear and Camshaft.....190
8.1 Service Standards.....190
8.1.1 Service Standards Table.....190
8.1.2 Tightening Torque Table.....190
8.1.3 Lubricant Table.....190
8.1.4 Special Tool Table.....190
8.2 General Description.....192
8.3 Removal.....192
8.4 Inspection.....195
8.5 Installation.....199
9. Crankcase and Main Moving Parts.....203
9.1 Service Standards.....203
9.1.1 Service Standards Table.....203
9.1.2 Tightening Torque Table.....204
9.1.3 Sealant Table.....204
9.1.4 Special Tool Table.....204
9.2 General Description.....206
9.2.1 Crankshaft.....206
9.2.2 Connecting Rods.....206
9.2.3 Piston.....206
9.3 Disassembly.....207
9.4 Inspection.....211
9.5 Reassembly.....222
Group 12 - Lubrication.....228
Table of Contents.....229
1. Troubleshooting.....230
2. Lubrication System.....231
2.1 Specifications.....231
2.2 General Description.....231
2.2.1 System Outline.....231
2.2.2 Lubrication of Main Moving Parts.....232
2.2.3 Camshaft Lubrication.....233
2.2.4 Valve Mechanism Lubrication.....233
2.2.5 Timing Gear Lubrication.....233
2.2.6 Camshaft Skew Gear and Oil Pump Gear Lubrication.....234
2.2.7 Turbocharger Lubrication.....234
2.2.8 Injection Pump Assembly Lubrication.....234
2.2.9 Vacuum Pump Lubrication.....234
2.3 Oil Pressure Check.....235
3. Oil Pump, Oil Filter.....236
3.1 Service Standards.....236
3.1.1 Service Standards Table.....236
3.1.2 Tightening Torque Table.....236
3.1.3 Special Tools Table.....236
3.2 General Description.....237
3.2.1 Oil Pump.....237
3.2.2 Oil Filter.....238
3.3 Removal.....238
3.4 Disassembly and Inspection.....239
3.5 Reassembly.....242
3.6 Installation.....244
4. Oil Cooler.....246
4.1 Service Standards.....246
4.1.1 Service Standards Table.....246
4.1.2 Tightening Torque Table.....246
4.2 General Description.....246
4.3 Removal.....247
4.4 Disassembly and Inspection.....249
4.5 Reassembly.....251
4.6 Installation.....253
5. Oil Pan, Oil Strainer.....255
5.1 Service Standards.....255
5.1.1 Tightening Torque Table.....255
5.1.2 Sealant Table.....255
5.2 General Description.....255
5.3 Removal.....255
5.4 Installation.....256
5.5 Post-Installation Inspection.....257
Group 13 - Fuel and Engine Control.....258
Table of Contents.....259
1. Troubleshooting.....260
2. Fuel System.....266
3. Injection Pump Assembly.....267
3.1 Specifications.....267
3.2 Service Standards.....267
3.2.1 Service Standards Table.....267
3.2.2 Tightening Torque Table.....268
3.2.3 Special Tools Table.....269
3.3 General Description.....270
3.3.1 Injection Pump.....270
3.3.2 Governor.....272
3.3.3 Feed Pump.....277
3.3.4 Automatic Timer.....278
3.4 Removal.....279
3.5 Installation.....282
3.6 Post-Installation Adjustment.....284
3.6.1 Bleeding Air From the Fuel System.....284
3.6.2 Fuel Injection Timing Adjustment.....284
3.6.3 Minimum Unloaded Idling Speed and Maximum Speed Adjustment.....285
3.6.4 Idle Up Adjustment <Manual Transmission Equipped Vehicles>.....285
3.6.5 Engine Stop Cable Operational Check.....286
4. Injection Nozzles.....287
4.1 Specifications.....287
4.2 Service Standards.....287
4.2.1 Service Standards Table.....287
4.2.2 Tightening Torque Table.....287
4.3 General Description.....288
4.4 Removal.....288
4.5 Disassembly.....288
4.6 Inspection and Cleaning.....290
4.7 Reassembly.....291
4.8 Testing and Adjustment.....293
4.9 Installation.....294
5. Fuel Filter.....295
5.1 Specifications.....295
5.2 Service Standards.....295
5.2.1 Tightening Torque Table.....295
5.2.2 Special Tools Table.....295
5.3 General Description.....296
5.4 Removal and Inspection.....296
5.5 Installation.....296
6. Water Separator.....298
6.1 Specifications.....298
6.2 Service Standards.....298
6.3 General Description.....298
6.4 Removal.....298
6.5 Disassembly and Inspection.....299
6.6 Reassembly.....300
6.7 Installation.....301
6.8 Draining Water.....301
7. Fuel Tank.....302
7.1 Specifications.....302
7.2 Service Standards.....302
7.3 General Description.....302
7.4 Removal.....303
7.5 Inspection.....304
7.6 Installation.....305
8. Engine Control System.....307
8.1 Specifications.....307
8.2 Service Standards.....308
8.3 General Description.....308
8.4 Removal.....309
8.4.1 Disconnecting the Accelerator Control Cable and Engine Stop Cable from the Engine Side.....310
8.4.2 Removing the Throttle Cable and Accelerator Pedal.....310
8.4.3 Disconnecting the Accelerator Control Cable and Accelerator Lever.....312
8.4.4 Removing the Engine Stop Cable.....313
8.5 Inspection.....315
8.6 Installation.....316
8.6.1 Installating the Engine Stop Cable.....317
8.6.2 Installing the Throttle Cable, Accelerator Lever Assembly, and Accelerator Pedal.....318
8.6.3 Securing the Accelerator Control Cable.....321
8.6.4 Installing the Accelerator Control Cable and the Engine Stop Cable to Engine Side.....321
8.7 Post-Installation Adjustment.....323
8.7.1 Accelerator Pedal Stopper Adjustment.....323
8.7.2 Engine Stop Cable Operation Check.....324
8.7.3 Accelerator Switch (Exhaust Brake Microswitch) Adjustment.....325
Group 14 - Cooling.....326
Table of Contents.....327
1. Troubleshooting.....328
2. Cooling System.....330
2.1 Specifications.....330
2.2 Service Standards.....330
2.3 General Description.....331
2.4 Removal.....332
2.4.1 Radiator Removal.....332
2.4.2 Cooling Fan and Auto Cool Fan Coupling Removal.....334
2.4.3 Water Pump Removal.....335
2.4.4 Thermostat Removal.....336
2.5 Installation.....337
2.5.1 Thermostat Installation.....337
2.5.2 Water Pump Installation.....338
2.5.3 Cooling Fan and Auto Cool Fan Coupling Removal.....338
2.5.4 Radiator Installation.....340
3. Cooling Fan and Auto Cool Fan Coupling.....343
3.1 Service Standards.....343
3.2 General Description.....343
3.2.1 Cooling Fan.....343
3.2.2 Auto Cool Fan Coupling.....343
3.3 Inspection.....344
4. Water Pump.....345
4.1 Service Standards.....345
4.1.1 Service Standards Table.....345
4.1.2 Special Tools Table.....345
4.2 General Description.....345
4.3 Disassembly <4D31T>.....345
4.4 Inspection <4D31T>.....347
4.5 Reassembly <4D31T>.....347
5. Thermostat.....349
5.1 Service Standards.....349
5.2 General Description.....349
5.3 Inspection.....350
6. Radiator.....351
6.1 Service Standards.....351
6.1.1 Service Standards Table.....351
6.1.2 Tightening Torque Table.....351
6.2 General Description.....351
6.2.1 Radiator.....351
6.2.2 Radiator Cap.....352
6.2.3 Radiator Shroud.....352
6.2.4 Condenser Tank.....353
6.3 Inspection and Cleaning.....353
6.3.1 Radiator Cleaning.....353
6.3.2 Radiator Inspection.....353
6.3.3 Radiator Cap Inspection.....354
6.3.4 Radiator (Cooling System) Cleaning.....354
6.3.5 Gas Leak Test.....357
6.3.6 Cooling System Air Bleeding.....357
Group 15 - Intake and Exhaust.....358
Table of Contents.....359
1. Troubleshooting.....360
2. Intake System.....362
2.1 Specifications.....362
2.2 Service Standards.....362
2.2.1 Service Standards Table.....362
2.2.2 Tightening Torque Table.....362
2.3 General Description.....363
2.4 Removal.....365
2.5 Disassembly.....368
2.5.1 Air Cleaner Disassembly.....368
2.5.2 Removing the Intake Shutter.....370
2.6 Inspection and Cleaning.....370
2.7 Reassembly.....371
2.7.1 Actuator Installation.....371
2.7.2 Air Cleaner Reassembly.....372
2.8 Installation.....374
2.9 Post-Installation Adjustment.....376
3. Exhaust System.....377
3.1 Service Standards.....377
3.1.1 Tightening Torque Table.....377
3.2 General Description.....377
3.3 Removal.....378
3.4 Installation.....383
4. Turbocharger.....389
4.1 Specifications.....389
4.2 Service Standards.....389
4.2.1 Service Standards Table.....389
4.2.2 Tightening Torque Table.....389
4.2.3 Lubricants Table.....390
4.3 General Description.....390
4.4 Removal.....392
4.5 Disassembly.....396
4.6 Inspection and Cleaning.....400
4.6.1 Cleaning .....400
4.6.2 Inspection.....401
4.7 Reassembly.....403
4.8 Installation.....410
4.9 Post-Installation Inspection.....412
5. Intercooler <4D31T2>.....413
5.1 Specifications.....413
5.2 Service Standards.....413
5.3 Outline.....413
5.4 Removal.....413
5.5 Inspection and Cleaning.....414
5.6 Installation.....414
Group 16 - Engine Electrical.....415
Table of Contents.....416
1. Troubleshooting.....417
2. Electrical System.....422
2.1 Specifications.....422
2.2 General Description.....423
2.2.1 The Starting Device.....426
2.2.2 Charger.....433
3. Starter.....434
3.1 Service Standards.....434
3.1.1 Service Standards Table.....434
3.1.2 Special Tools Table.....434
3.1.3 Lubrication Table.....434
3.2 General Description.....435
3.3 Removal.....436
3.4 Disassembly.....438
3.5 Inspection.....442
3.6 Reassembly.....450
3.7 Testing.....455
3.8 Installation.....457
4. 75A Alternator.....458
4.1 Service Standards.....458
4.1.1 Service Standards Table.....458
4.1.2 Tightening Torque Table.....458
4.1.3 Lubrication Table.....458
4.2 General Description.....459
4.3 Removal.....462
4.4 Disassembly.....463
4.5 Inspection.....466
4.6 Reassembly.....471
4.7 Testing.....475
4.7.1 Handling Precautions.....475
4.7.2 Performance Testing.....476
4.7.3 Regulator Inspection.....477
4.8 Installation.....477
5. 80A Alternator.....479
5.1 Service Standards.....479
5.1.1 Service Standards Table.....479
5.1.2 Tightening Torque Table.....479
5.1.3 Lubrication Table.....479
5.2 General Description.....480
5.3 Removal.....483
5.4 Disassembly.....484
5.5 Inspection.....486
5.6 Reassembly.....491
5.7 Testing.....494
5.7.1 Handling Precautions.....494
5.7.2 Performance Testing.....495
5.7.3 Regulator Inspection.....496
5.8 Installation.....496
6. Vacuum Pump.....498
6.1 Service Standards.....498
6.2 General Description.....498
6.3 Removal.....499
6.4 Disassembly.....499
6.5 Inspection.....500
6.6 Reassembly.....501
6.7 Testing.....502
7. Glow System.....503
7.1 Service Standards.....503
7.1.1 Service Standards Table.....503
7.1.2 Special Tools Table.....503
7.1.3 Tightening Torque Table.....503
7.2 General Description.....504
7.3 Removal.....506
7.4 Inspection.....507
7.4.1 Glow Plug Inspection.....507
7.4.2 Glow Control Inspection.....507
7.4.3 Water Temperature Gauge Unit Inspection.....508
7.5 Installation.....508
8. Idle Up System.....510
8.1 Service Standards.....510
8.2 General Description.....510
8.3 Removal.....511
8.4 Inspection.....511
8.5 Installation.....512
8.6 Adjustment.....512
Group 21 - Clutch.....513
Table of Contents.....514
1. Troubleshooting.....515
2. Clutch Proper.....524
2.1 Specifications.....524
2.2 Service Standards.....524
2.2.1 Service Standards Table.....524
2.2.2 Tightening Torque Table.....524
2.2.3 Special Tools Table.....525
2.3 General Description.....526
2.4 Removal.....527
2.4.1 Before Removal.....527
2.4.2 Removal.....528
2.5 Inspection and Adjustment.....529
2.5.1 Inspection.....529
2.5.2 Adjustment.....532
2.6 Installation.....532
2.7 Post-Installation Adjustment.....533
3. Clutch Control.....534
3.1 Specifications.....534
3.2 Service Standards.....534
3.2.1 Service Standards Table.....534
3.2.2 Tightening Torque Table.....535
3.2.3 Special Tools Table.....535
3.3 General Description.....536
3.4 Clutch Hose and Clutch Tube.....537
3.4.1 Removal.....537
3.4.2 Inspection.....538
3.4.3 Installation.....539
3.5 Clutch Pedal.....540
3.5.1 Removal.....540
3.5.2 Disassembly.....541
3.5.3 Inspection.....542
3.5.4 Reassembly.....544
3.5.5 Installation.....545
3.5.6 Post-Installation Adjustment.....546
3.6 Clutch Master Cylinder.....547
3.6.1 Disassembly.....547
3.6.2 Inspection.....548
3.6.3 Reassembly.....548
3.7 Clutch Power Cylinder.....549
3.7.1 Removal.....549
3.7.2 Disassembly.....550
3.7.3 Inspection.....551
3.7.4 Reassembly.....552
3.7.5 Installation.....553
3.8 Clutch Housing Assembly.....553
3.8.1 Removal.....553
3.8.2 Disassembly.....554
3.8.3 Reassembly.....556
3.8.4 Installation.....557
3.9 Fluid Change of Clutch System.....558
3.10 Bleeding the Clutch System.....560
3.11 Post-Installation Adjustment.....561
3.12 Clutch Adjustment.....562
Group 22 - Manual Transmission.....564
Table of Contents.....565
1. Troubleshooting.....566
2. Removing the Transmission.....571
2.1 Service Standards.....571
2.2 Preliminary Operations.....571
2.3 Removal.....572
2.4 Installation.....575
3. Transmission Assembly.....578
3.1 Specifications.....578
3.2 Service Standards.....578
3.2.1 Service Standards Table.....578
3.2.2 Tightening Torque Table.....578
3.2.3 Special Tools Table.....579
3.3 General Description.....581
3.4 Removal.....583
3.4.1 Clutch Housing Assembly.....583
3.4.2 Gear Shift, Upper and Lower.....583
3.4.3 Rear Cover.....583
3.4.4 Transmission.....583
3.5 Installation.....587
3.5.1 Transmission.....587
3.5.2 Rear Cover.....590
3.5.3 Gear Shift, Upper and Lower.....590
3.5.4 Clutch Housing Assembly.....591
4. Main Shaft Assembly.....592
4.1 Service Standards.....592
4.1.1 Service Standards Table.....592
4.1.2 Special Tools Table.....592
4.2 Preliminary Inspection.....593
4.3 Disassembly.....594
4.4 Inspection.....598
4.5 Reassembly.....599
5. Reverse Gear.....604
5.1 Service Standards.....604
5.2 Inspection and Replacement.....604
6. Gear Shift, Lower.....605
6.1 Service Standards.....605
6.1.1 Service Standards Table.....605
6.1.2 Tightening Torque Table.....605
6.2 Disassembly.....606
6.3 Inspection.....608
6.4 Reassembly.....609
7. Gear Shift, Upper.....611
7.1 Service Standards.....611
7.1.1 Service Standards Table.....611
7.1.2 Tightening Torque Table.....611
7.2 Disassembly.....611
7.3 Inspection.....612
7.4 Reassembly.....613
8. Rear Cover.....615
8.1 Service Standards.....615
8.1.1 Service Standards Table.....615
8.1.2 Tightening Torque Table.....615
8.1.3 Special Tools Table.....615
8.2 Disassembly.....616
8.3 Inspection.....618
8.4 Reassembly.....618
9. Transmission Control.....620
9.1 Service Standards.....620
9.2 General Description.....620
9.3 Preliminary Operations.....621
9.4 Removal.....621
9.5 Inspection, Repair, and Replacement.....622
9.6 Installation.....623
9.7 Cross-Shaft Assembly.....625
9.7.1 Disassembly.....625
9.7.2 Inspection.....625
9.7.3 Reassembly.....626
9.8 Control Rod Assembly.....627
9.8.1 Disassembly.....627
9.8.2 Inspection.....627
9.8.3 Reassembly.....628
9.9 Set Board Assembly.....629
9.9.1 Disassembly.....629
9.9.2 Inspection.....630
9.9.3 Reassembly.....631
9.10 Post-Installation Adjustment.....632
Group 23A - Automatic Transmission <M2A3>.....633
Table of Contents.....634
1. Troubleshooting.....635
2. Transmission Assembly.....641
2.1 Specifications.....641
2.2 Service Standards.....641
2.3 General Description.....642
2.4 Maintenance and Inspection.....642
2.4.1 Preliminary Operations.....642
2.4.2 Fluid Level Inspection.....643
2.4.3 Fluid Replacement.....643
2.4.4 Neutral Start and Backup Lamp Switch Inspection.....645
2.5 Adjustment.....645
2.5.1 Preliminary Operations.....645
2.5.2 Kick-Down Band Adjustment.....645
2.5.3 Low-Reverse Band Adjustment.....646
2.6 Removing the Transmission.....647
2.6.1 Preliminary Operations.....647
2.6.2 Removal.....648
2.6.3 Installation.....652
2.7 Oil Seal Replacement.....657
2.7.1 Front Oil Seal Replacement.....657
2.7.2 Rear Oil Seal Replacement.....658
2.8 Removing the Speedometer Pinion.....659
3. Transmission Control.....662
3.1 Service Standards.....662
3.2 General Description.....662
3.3 Range Selector.....663
3.3.1 Preliminary Operations.....663
3.3.2 Removal.....663
3.3.3 Inspection.....664
3.3.4 Installation.....664
3.4 Selector Cable.....665
3.4.1 Preliminary Operations.....665
3.4.2 Removal.....665
3.4.3 Inspection.....666
3.4.4 Installation.....666
3.4.5 Follow-Up Inspection.....667
3.5 Throttle Cable.....667
3.5.1 Removal.....667
3.5.2 Inspection.....668
3.5.3 Installation.....668
3.5.4 Follow-Up Inspection.....669
4. Oil Cooler.....670
4.1 Service Standards.....670
4.2 General Description.....670
4.3 Removal, Inspection.....671
Group 23B - Automatic Transmission (Body Unit) <M2A3>.....672
Table of Contents.....673
1. Specifications.....674
2. Service Standards.....675
3. General Description.....676
3.1 Hydraulic Control System.....677
3.2 Operating Instructions.....677
4. Diagnosis and Test.....679
4.1 Diagnosis - General.....679
4.2 Hydraulic Pressure Tests.....682
4.3 Converter Stall Test.....683
4.4 Clutch and Servo Air Pressure Tests.....684
4.5 Fluid Leakage - Transmission Converter Housing Area.....685
4.6 Diagnosis Chart.....690
5. Hydraulic Control Pressure Adjustments.....691
5.1 Line Pressure.....691
5.2 Throttle Pressure.....691
6. Service In Vehicle.....692
6.1 Neutral Start and Back-Up Lamp Switch.....692
6.2 Governor and Parking Gear.....692
6.3 Parking Lock Components.....693
6.4 Valve Body and Accumulator Piston Removal.....693
6.5 Valve Body Disassembly.....694
6.6 Valve Body Reassembly.....699
6.7 Valve Body and Accumulator Piston Installation.....700
6.8 Aluminum Thread Repair.....700
7. Service Out of Vehicle.....701
7.1 Disassembly-Subassembly Removal.....701
7.2 Recondition Subassemblies.....703
7.2.1 Oil Pump and Reaction Shaft Support.....703
7.2.2 Front Clutch.....706
7.2.3 Rear Clutch.....708
7.2.4 Planetary Gear Train.....710
7.2.5 Overrunning Clutch.....711
7.2.6 Kickdown Servo and Band.....713
7.2.7 Low-Reverse Servo and Band.....713
7.3 Assembly-Subassembly Installation.....713
Group 23C - Automatic Transmission <M030A4>.....717
Table of Contents.....718
1. Troubleshooting.....719
2. Specifications.....723
3. Service Standards.....724
3.1 Service Standards Table.....724
3.2 Tightening Torque Table.....725
4. Special Tools.....726
5. Specifications.....727
5.1 Control Mechanisms.....730
5.1.1 Line Pressure Control.....731
5.1.2 Gear Shift Control.....732
5.1.3 Lockup Control.....733
5.1.4 Overrun Clutch Control.....734
5.1.5 Shift Pattern Selector Control.....735
5.1.6 Self Diagnosis Function.....736
5.1.7 Fail Safe Functions.....737
5.2 Electronic Control Devices.....739
5.2.1 Control Unit.....739
5.2.2 Accelerator Sensor.....739
5.2.3 Idle Switch (Accelerator Switch.....740
5.2.4 Vehicle Speed Sensor 2.....740
5.2.5 Vehicle Speed Sensor 1.....740
5.2.6 Fluid Temperature Sensor.....740
5.2.7 Shift Solenoids A and B.....741
5.2.8 Line Pressure Solenoid and Lockup Solenoid.....741
5.2.9 Overrun Clutch Solenoid.....741
5.2.10 Engine Speed Sensor.....741
5.2.11 Dropping Register.....741
5.2.12 Power Mode Switch.....742
5.3 Hydraulic Pressure Control Device.....743
5.4 Gear Shift Mechanism.....745
5.4.1 Reverse Clutch (Multi-Plate Clutch).....747
5.4.2 High Clutch (Multi-Plate Clutch).....748
5.4.3 Brake Band.....749
5.4.4 Forward Clutch (Multi-Plate Clutch).....750
5.4.5 Low and Reverse Brake (Multi-Plate Clutch).....751
5.4.6 Planetary Gear.....752
5.4.7 Forward One Way Clutch.....752
5.4.8 Low One Way Clutch.....753
5.4.9 Torque Transmission Path.....753
5.5 Torque Converter (With Lock up).....760
5.6 Oil Pump (Variable Capacity Vane Pump).....761
6. Service Standards.....763
6.1 Maintenance and Inspection.....763
6.1.1 ATF Inspection.....763
6.1.2 ATF Replacement.....764
6.2 Transmission Removal and Installation.....765
6.2.1 Tasks Prior to Removal.....765
6.2.2 Removal.....765
6.2.3 Installation.....767
6.2.4 Inspection and Adjustment After Installation.....769
6.3 Oil Seal Replacement.....770
6.4 Inhibitor Switch.....771
6.4.1 Removal and Installation.....771
6.4.2 Inspection and Adjustment.....772
6.5 Accelerator Sensor Inspection.....773
6.6 Automatic Transmission Control System Inspection.....775
6.6.1 Inspection Preparation Tasks.....775
6.6.2 Sensor Switch and Harness Inspection.....776
6.6.3 Automatic Transmission Control Unit Inspection.....777
6.6.4 Post-Inspection Tasks.....777
6.7 Cause of Failure and Prevention.....778
6.7.1 Causes of Automatic Transmission Failure.....778
6.7.2 Self Diagnosis Function.....778
6.7.3 Load Test.....788
6.7.4 Line Pressure Test.....788
6.7.5 Stall Test.....790
6.7.6 Fluid Leakage.....790
6.8 Removal and Installation of Oil Cooler.....791
Group 24 - Transfer.....792
Table of Contents.....793
1. Troubleshooting.....794
2. Removing the Transfer.....796
2.1 Service Standards.....796
2.1.1 Tightening Torque Table.....796
2.1.2 Special Tool Chart.....796
2.2 Removal.....797
2.3 Installation.....800
3. Transfer Main Body.....804
3.1 Specifications.....804
3.2 Service Standards.....804
3.2.1 Service Standards Table.....804
3.2.2 Tightening Torque Table.....805
3.2.3 Special Tools.....805
3.3 Specifications.....807
3.4 Disassembly.....808
3.5 Inspection.....815
3.6 Reassembly.....817
4. Transfer Control.....826
4.1 Specifications.....826
4.2 Service Standards.....826
4.2.1 Service Standards Table.....826
4.2.2 Tightening Torque Table.....826
4.3 Specifications.....827
4.4 Removal.....827
4.5 Installation.....829
4.6 Adjustment After Removal.....830
4.7 Disassembly.....831
4.8 Inspection.....834
4.9 Reassembly.....835
Group 25 - Propeller Shaft.....839
Table of Contents.....840
1. Troubleshooting.....841
2. Front Propeller Shaft <Single Joint>.....843
2.1 Specifications.....843
2.2 Service Standards.....843
2.2.1 Service Standards Table.....843
2.2.2 Tightening Torque Table.....843
2.2.3 Special Tools Table.....844
2.3 General Description.....844
2.4 Removal.....845
2.5 Disassembly.....847
2.6 Inspection.....849
2.7 Reassembly.....851
2.8 Installation.....853
3. Rear Propeller Shaft <Two Joints>.....855
3.1 Specifications.....855
3.2 Service Standards.....855
3.2.1 Service Standards Table.....855
3.2.2 Tightening Torque Table.....855
3.2.3 Special Tools Table.....855
3.3 General Description.....857
3.4 Removal.....858
3.5 Disassembly.....860
3.6 Inspection.....863
3.7 Reassembly.....865
3.8 Installation.....869
4. Double Cardin Propeller Shaft.....870
4.1 Specifications.....870
4.2 Service Standards.....870
4.2.1 Service Standards Table.....870
4.2.2 Tightening Torque Table.....870
4.2.3 Special Tools Table.....871
4.3 General Description.....871
4.4 Removal.....872
4.5 Disassembly.....874
4.6 Inspection.....876
4.7 Reassembly.....877
4.8 Installation.....880
Group 26A - Front Axle <FE>.....881
Table of Contents.....882
1. Troubleshooting.....883
2. Front Axle Assembly.....886
2.1 Specifications.....886
2.2 Service Standards.....886
2.2.1 Tightening Torque Table.....886
2.3 General Description.....887
2.4 Removal.....887
2.5 Installation.....888
2.6 Post-Installation Adjusting.....888
3. Wheel Hub and Rotor.....892
3.1 Service Standards.....892
3.1.1 Service Standards Table.....892
3.1.2 Tightening Torque Table.....892
3.1.3 Special Tools Table.....893
3.2 Disassembly.....894
3.3 Inspection.....897
3.4 Reassembly.....899
4. Front Axle Center and Knuckle.....902
4.1 Service Standards.....902
4.1.1 Service Standards Table.....902
4.1.2 Tightening Torque Table.....902
4.1.3 Special Tools Table.....903
4.2 Removal.....903
4.3 Disassembly.....904
4.4 Inspection.....907
4.5 Reassembly.....909
4.6 Installation.....911
Group 26B - Front Axle <FG>.....912
Table of Contents.....913
1. Troubleshooting.....914
2. Front Axle Assembly.....922
2.1 Specifications.....922
2.2 Service Standards.....922
2.2.1 Tightening Torque Table.....922
2.2.2 Special Tools Table.....922
2.3 General Description.....923
2.4 Removal.....925
2.5 Installation.....926
2.6 Post-Installation Adjusting.....926
3. Wheel Hub and Brake Drum.....931
3.1 Service Standards.....931
3.1.1 Service Standards Table.....931
3.1.2 Tightening Torque Table.....931
3.1.3 Special Tools Table.....931
3.2 Disassembly.....933
3.3 Inspection.....938
3.4 Reassembly.....940
4. Axle, Knuckle, and Drive Shaft.....945
4.1 Service Standards.....945
4.1.1 Service Standards Table.....945
4.1.2 Tightening Torque Table.....945
4.1.3 Special Tools Table.....945
4.2 Disassembly.....947
4.3 Inspection and Adjusting.....950
4.4 Reassembly.....951
5. Reduction and Differential.....955
5.1 Service Standards.....955
5.1.1 Service Standards Table.....955
5.1.2 Tightening Torque Table.....955
5.1.3 Special Tools Table.....956
5.2 Removal.....960
5.3 Preliminary Inspection.....961
5.4 Disassembly.....963
5.5 Inspection.....966
5.6 Reassembly.....968
5.7 Installation.....973
Group 27 - Rear Axle.....974
Table of Contents.....975
1. Troubleshooting.....976
2. Rear Axle Assembly.....980
2.1 Specifications.....980
2.2 Service Standards.....980
2.2.1 Service Standards Table.....980
2.2.2 Tightening Torque Table.....980
2.3 General Description.....981
2.4 Removal.....982
2.5 Disassembly.....983
2.6 Inspection.....983
2.7 Reassembly.....985
2.8 Installation.....985
3. Wheel Hub and Brake Drum.....987
3.1 Service Standards.....987
3.1.1 Service Standards Table.....987
3.1.2 Tightening Torque Table.....987
3.1.3 Special Tools Table.....988
3.2 Disassembly.....990
3.3 Inspection.....993
3.4 Reassembly.....995
4. Reduction and Differential.....999
4.1 Service Standards.....999
4.1.1 Service Standards Table.....999
4.1.2 Tightening Torque Table.....999
4.1.3 Specials Tools Table.....1000
4.2 Removal.....1004
4.3 Preliminary Inspection.....1006
4.4 Disassembly.....1008
4.5 Inspection.....1012
4.6 Reassembly.....1014
4.7 Installation.....1020
Group 31 - Wheels and Tires.....1022
Table of Contents.....1023
1. Troubleshooting.....1024
2. Wheels and Tires.....1026
2.1 Specifications.....1026
2.2 Service Standards.....1026
2.2.1 Service Standards Table.....1026
2.2.2 Tightening Torque Table.....1026
2.3 General Description.....1026
2.4 Removal.....1027
2.4.1 Preliminary Operation.....1027
2.4.2 Removal.....1029
2.4.3 Front Tires.....1029
2.4.4 Rear Tires.....1030
2.4.5 Inspection of Wheel Bolt and Nut.....1031
2.5 Disassembly and Inspection.....1031
2.6 Reassembly.....1034
2.7 Post-Assembly Inspection and Adjustment.....1035
2.8 Installation.....1036
Group 33 - Front Suspension.....1038
Table of Contents.....1039
1. Troubleshooting.....1040
2. Front Suspension Assembly.....1042
2.1 Service Standards.....1042
2.2 General Description.....1042
2.3 Removal.....1043
2.4 Inspection.....1046
2.5 Installation.....1047
3. Leaf Springs.....1051
3.1 Specifications.....1051
3.2 Service Standards.....1051
3.3 General Description.....1051
3.4 Pre-Disassembly Inspection.....1051
3.5 Disassembly.....1052
3.6 Inspection.....1053
3.7 Reassembly.....1053
4. Shock Absorbers.....1055
4.1 Specifications.....1055
4.2 General Description.....1055
4.3 Disassembly.....1055
4.4 Inspection.....1056
5. Stabilizer <FE Series Only.....1057
5.1 General Description.....1057
5.2 Pre-Disassembly Inspection.....1057
5.3 Disassembly.....1057
5.4 Inspection.....1058
5.5 Reassembly.....1058
Group 34 - Rear Suspension.....1059
Table of Contents.....1060
1. Troubleshooting.....1061
2. Rear Suspension Assembly.....1063
2.1 Service Standards.....1063
2.1.1 Service Standards Table.....1063
2.1.2 Tightening Torque Table.....1063
2.1.3 Special Tools Table.....1064
2.2 General Description.....1065
2.3 Removal.....1065
2.4 Inspection.....1068
2.5 Installation.....1069
3. Leaf Springs.....1073
3.1 Specifications.....1073
3.2 Service Standards.....1073
3.3 General Description.....1073
3.4 Pre-Disassembly Inspection.....1074
3.5 Disassembly.....1074
3.6 Inspection.....1075
3.7 Reassembly.....1075
4. Shock Absorbers.....1076
4.1 Specifications.....1076
4.2 General Description.....1076
4.3 Disassembly.....1076
4.4 Inspection.....1076
5. Stabilizer <FE Series Only>.....1077
5.1 General Description.....1077
5.2 Pre-Disassembly Inspection.....1077
5.3 Disassembly.....1077
5.4 Inspection.....1078
5.5 Reassembly.....1078
Group 35 - Brake.....1079
Table of Contents.....1080
1. Troubleshooting.....1081
2. Brake System.....1092
2.1 Service Standards.....1092
2.1.1 Tightening Torque Table.....1092
2.2 General Description.....1092
2.3 Bleeding of Air From the Brake System.....1093
2.3.1 Front Brake System.....1094
2.3.2 Rear Brake System.....1097
2.3.3 Bypass Valve System.....1099
2.4 Replacing of Brake Fluid.....1102
2.4.1 Draining the Brake Fluid.....1102
2.4.2 Changing Front Brake System Brake Fluid.....1105
2.4.3 Changing Rear Brake System Brake Fluid.....1107
2.4.4 Changing the Brake Fluid of the Bypass Valve System.....1108
2.4.5 Bleeding of Brake System.....1109
3. Brake Piping.....1110
3.1 Service Standards.....1110
3.1.1 Tightening Torque Table.....1110
3.2 Inspection Before Removal.....1110
3.3 Draining Out Brake Fluid.....1111
3.4 Removal.....1112
3.5 Inspection.....1115
3.6 Installation.....1116
4. Vacuum Tank.....1122
4.1 Service Standards.....1122
4.1.1 Service Standards.....1122
4.2 Vacuum Switch.....1122
4.2.1 Inspection.....1122
4.2.2 Removal.....1122
4.2.3 Installation.....1123
4.3 Vacuum Tank.....1123
4.3.1 Removal.....1123
4.3.2 Inspection.....1124
4.3.3 Installation.....1124
5. Brake Pedal.....1126
5.1 Service Standards.....1126
5.1.1 Service Standards Table.....1126
5.1.2 Tightening Torque Table.....1126
5.2 Brake Fluid Tank.....1127
5.2.1 Inspection Before Removal.....1127
5.2.2 Removal.....1128
5.2.3 Inspection.....1132
5.2.4 Installation.....1133
5.3 Brake Pedal.....1137
5.3.1 Removal.....1138
5.3.2 Disassembly.....1147
5.3.3 Inspection.....1149
5.3.4 Assembly.....1150
5.3.5 Installation.....1151
5.3.6 Positioning Brake Pedal.....1160
5.3.7 Brake Pedal Play.....1160
5.3.8 Distance Between Brake Pedal and Floor Board.....1160
5.3.9 Adjustment of Stop Lamp Switch.....1161
6. Brake Booster (Master Vac).....1162
6.1 Specifications.....1162
6.2 Service Standards.....1162
6.2.1 Tightening Torque Table.....1162
6.2.2 Special Tools Table.....1162
6.3 General Description.....1165
6.4 Removal.....1166
6.5 Disassembly.....1167
6.6 Inspection.....1172
6.7 Reassembly.....1174
6.8 Installation.....1181
6.9 Adjustment After Installation.....1181
6.10 Inspection and Installation.....1181
7. Brake Master Cylinder.....1184
7.1 Specifications.....1184
7.2 Service Standards.....1184
7.2.1 Service Standards Table.....1184
7.2.2 Tightening Torque Table.....1184
7.3 General Description.....1185
7.4 Removal.....1186
7.5 Disassembly.....1190
7.6 Inspection.....1192
7.7 Reassembly.....1193
7.8 Installation.....1197
8. Proportioning Valve.....1200
8.1 Specifications.....1200
8.2 Service Standards.....1200
8.2.1 Service Standards Table.....1200
8.2.2 Tightening Torque Table.....1200
8.2.3 Special Tools Table.....1201
8.3 General Description.....1202
8.3.1 Valve Unit.....1202
8.3.2 Sensor.....1203
8.4 Removal.....1203
8.5 Disassembly.....1205
8.6 Inspection.....1210
8.7 Reassembly.....1211
8.8 Installation.....1215
8.9 Adjustment After Installation and Functional Test.....1216
9. Bypass Valve.....1220
9.1 General Description.....1220
9.2 Functional Inspection.....1220
9.3 Removal.....1222
9.4 Installation.....1222
10. Front Disc Brake <FE Series>.....1224
10.1 Specifications.....1224
10.2 Service Standards.....1224
10.2.1 Service Standards Table.....1224
10.2.2 Tightening Torque Table.....1224
10.2.3 Special Tools.....1225
10.3 General Description.....1225
10.4 Replacing the Pads.....1226
10.5 Removal.....1228
10.6 Disassembly.....1230
10.7 Inspection.....1231
10.8 Reassembly.....1233
10.9 Installation.....1235
10.10 Measure Dragging Torque (Tangential Force).....1236
11. Front Drum Brake <FG Series>.....1237
11.1 Specifications.....1237
11.2 Service Standards.....1237
11.2.1 Service Standards Table.....1237
11.2.2 Tightening Torque Table.....1237
11.3 Outline.....1238
11.4 Removal.....1238
11.5 Disassembly.....1240
11.6 Inspection.....1242
11.7 Reassembly.....1244
11.8 Wheel Cylinder.....1247
11.8.1 Disassembly.....1247
11.8.2 Inspection.....1248
11.8.3 Reassembly.....1248
11.9 Installation.....1251
11.10 Shoe Clearance Adjustment.....1252
12. Rear Drum Brake.....1254
12.1 Specifications.....1254
12.2 Service Standards.....1254
12.2.1 Service Standards Table.....1254
12.2.2 Tightening Torque Table.....1254
12.3 General Description.....1255
12.4 Removal.....1256
12.5 Disassembly.....1258
12.6 Inspection.....1260
12.7 Reassembly.....1262
12.8 Wheel Cylinder <FE Series>.....1265
12.8.1 Disassembly.....1265
12.8.2 Inspection.....1266
12.8.3 Reassembly.....1266
12.9 Wheel Cylinder <FG Series>.....1270
12.9.1 Disassembly.....1270
12.9.2 Inspection.....1271
12.9.3 Reassembly.....1272
12.10 Installation.....1275
12.11 Adjusting Shoe Clearance.....1275
13. Exhaust Brake System.....1278
13.1 Specifications.....1278
13.2 Service Standards.....1278
13.2.1 Service Standards Table.....1278
13.2.2 Tightening Torque Table.....1279
13.3 General Description.....1280
13.4 Removal.....1284
13.5 Disassembly.....1287
13.6 Inspection.....1288
13.7 Reassembly.....1290
13.8 Installation.....1292
13.9 Inspection After Installation.....1295
Group 36 - Parking Brake.....1296
Table of Contents.....1297
1. Troubleshooting.....1298
2. Parking Brake Control.....1300
2.1 Specifications.....1300
2.2 Service Standards.....1300
2.2.1 Service Standards Table.....1300
2.2.2 Tightening Torque Table.....1300
2.3 General Description.....1301
2.4 Removal.....1301
2.4.1 Preliminary Operations.....1301
2.4.2 Parking Brake Lever Assembly.....1302
2.4.3 Parking Brake Cable.....1303
2.4.4 Inspection.....1303
2.5 Disassembly and Inspection.....1304
2.5.1 Disassembly.....1304
2.5.2 Inspection.....1305
2.6 Assembly and Repair.....1306
2.7 Installation.....1307
2.7.1 Parking Brake Lever Assembly.....1307
2.7.2 Parking Brake Cable.....1308
2.8 Post-Installation Adjustments.....1309
3. Parking Brake Drum and Brake Shoe.....1311
3.1 Specifications.....1311
3.2 Service Standards.....1311
3.2.1 Service Standards Table.....1311
3.2.2 Tightening Torque Table.....1311
3.2.3 Special Tools Table.....1312
3.3 General Description.....1312
3.4 Removal.....1313
3.4.1 Preliminary Operations.....1313
3.4.2 Removal.....1313
3.5 Disassembly and Inspection.....1315
3.5.1 Disassembly.....1315
3.5.2 Inspection.....1316
3.6 Reassembly.....1318
3.7 Installation.....1319
Group 37 - Steering.....1321
Table of Contents.....1322
1. Troubleshooting.....1323
2. Steering System.....1336
2.1 Service Standards.....1336
2.1.1 Service Standards Table.....1336
2.1.2 Tightening Torque Table.....1336
2.2 General Description.....1337
2.2.1 Steering System.....1337
2.2.2 Power Steering System.....1337
2.3 Oil Pump V-Belt Inspection and Adjustment.....1338
2.4 Power Steering Oil Change.....1341
2.5 Performance Verification Tests.....1347
2.6 Overall Power Steering Inspection.....1351
3. Steering Wheel and Shaft.....1354
3.1 Specifications.....1354
3.2 Service Standards.....1354
3.2.1 Tightening Torque Table.....1354
3.3 General Description.....1355
3.4 Removal.....1355
3.5 Disassembly.....1361
3.6 Assembly.....1364
3.7 Installation.....1367
3.8 Post-Installation Inspection.....1372
4. Steering Linkage.....1373
4.1 Service Standards.....1373
4.1.1 Service Standards Table.....1373
4.1.2 Tightening Torque Table.....1373
4.2 General Description.....1374
4.3 Drag Link.....1375
4.3.1 Removal.....1375
4.3.2 Installation.....1377
4.3.3 Greasing.....1381
4.4 Tie Rods.....1381
4.4.1 Removal.....1381
4.4.2 Disassembly.....1383
4.4.3 Inspection.....1384
4.4.4 Assembly.....1384
4.4.5 Installation.....1386
4.4.6 Greasing.....1387
4.5 Post-Installation Inspection and Adjustment.....1387
5. Power Steering Booster.....1388
5.1 Specifications.....1388
5.2 Service Standards.....1388
5.2.1 Service Standards Table.....1388
5.2.2 Tightening Torque Table.....1389
5.2.3 Special Tools Table.....1389
5.3 General Description.....1391
5.3.1 Structure.....1391
5.3.2 Operation.....1392
5.4 Removal.....1395
5.5 Pre-Disassembly Work and Inspection.....1396
5.6 Disassembly.....1398
5.7 Inspection.....1404
5.8 Assembly.....1407
5.9 Post-Assembly Work and Inspection.....1414
5.10 Installation.....1415
5.11 Post-Installation Inspection.....1417
6. Power Steering Oil Pump.....1418
6.1 Specifications.....1418
6.2 Service Standards.....1418
6.2.1 Service Standards Table.....1418
6.2.2 Tightening Torque Table.....1419
6.2.3 Special Tools Table.....1419
6.3 General Description.....1420
6.4 Removal.....1423
6.5 Disassembly.....1425
6.6 Inspection.....1430
6.7 Assembly.....1434
6.8 Installation.....1438
6.9 Post-Installation Inspection and Adjustment.....1439
Group 41 - Frame.....1440
Table of Contents.....1441
1. Frame Assembly.....1442
1.1 Specifications.....1442
1.2 General Description.....1442
1.3 Inspection and Repair.....1443
1.3.1 Frame.....1443
1.3.2 Rivets.....1445
1.3.3 Nuts and Bolts.....1446
1.4 Frame Shape.....1446
Group 42 - Cab.....1449
Table of Contents.....1450
1. Troubleshooting.....1451
2. Cab.....1457
2.1 Specifications.....1457
2.2 Service Standards.....1457
2.3 General Description.....1458
2.4 Cab Tilting Method.....1458
2.5 Removal.....1460
2.5.1 Operations Before Removal.....1460
2.5.2 Operations Inside the Cab.....1462
2.5.3 Operations in Front of the Cab.....1464
2.5.4 Cab Tilting Operations.....1466
2.5.5 Lifting the Cab.....1469
2.6 Installing the Cab.....1470
2.6.1 Lifting the Cab.....1470
2.6.2 Operations for Tilting the Cab.....1471
2.6.3 Operations in Front of the Cab.....1474
2.6.4 Operations Inside the Cab.....1477
2.6.5 Operations After Installation.....1478
3. Cab Mounting.....1479
3.1 Specifications.....1479
3.2 Service Standards.....1479
3.3 General Description.....1480
3.3.1 Cab Mounting.....1480
3.3.2 Cab Hinge.....1480
3.3.3 Cab Stay.....1481
3.3.4 Cab Tilt Link.....1481
3.4 Removal.....1482
3.4.1 Operations Before Removal.....1482
3.4.2 Removing the Cab Tilt Link.....1482
3.4.3 Removing the Rear Cab Mounting.....1483
3.4.4 Removing the Cab Hinge.....1484
3.5 Installation.....1485
3.5.1 Cab Hinge Installation.....1485
3.5.2 Rear Cab Mounting Installation.....1487
3.5.3 Cab Tilt Link Installation.....1489
3.5.4 Operations After Installation.....1490
4. Front Windshield Glass and Rear Window Glass.....1491
4.1 Specifications.....1491
4.2 Service Standards.....1491
4.3 Removal.....1491
4.3.1 Operations Before Removal.....1491
4.3.2 Removal Operations.....1492
4.4 Installation.....1493
4.4.1 Installation Operations.....1493
4.4.2 Operations After Installation.....1494
5. Door Assembly.....1495
5.1 Specifications.....1495
5.2 Service Standards.....1495
5.3 General Description.....1496
5.4 Removal.....1497
5.4.1 Operations Before Removal.....1497
5.4.2 Removing the Door Trim.....1497
5.4.3 Removing the Front Door Window Glass.....1498
5.4.4 Removing the Front Door Window Regulator.....1500
5.4.5 Removing the Front Door Locking System.....1500
5.4.6 Removing the Outside Mirror Stay Assembly.....1501
5.4.7 Removing the Front Door Panel.....1502
5.5 Installation.....1502
5.5.1 Front Door Panel Installation.....1503
5.5.2 Outside Mirror Stay Assembly Installation.....1504
5.5.3 Front Door Locking System Installation.....1505
5.5.4 Inspection and Adjustment After Installing the Front Door Locking System.....1506
5.5.5 Front Door Window Regulator Installation.....1506
5.5.6 Front Door Window Glass Installation.....1507
5.5.7 Door Trim Installation.....1509
6. Seat and Seat Belts.....1511
6.1 Specifications.....1511
6.2 Service Standards.....1511
6.3 Removal.....1512
6.3.1 Removing the Driver's Seat.....1512
6.3.2 Removing the Floor Console.....1512
6.3.3 Removing the Passenger Seat.....1513
6.3.4 Removing the Seat Belts.....1514
6.4 Installation.....1515
6.4.1 Seat Belt Installation.....1515
6.4.2 Driver's Seat Installation.....1516
6.4.3 Passenger Seat Installation.....1516
6.4.4 Floor Console Installation.....1517
7. Trim.....1518
7.1 Full Trim <Vehicles Mounting the 4D31T2 Engine>.....1518
7.1.1 Removal.....1518
7.1.2 Installation.....1521
7.2 Semi Trim <Vehicles Mounting the 4D31T2 Engine>.....1524
7.2.1 Removal.....1524
7.2.2 Installation.....1525
8. Floor Mats.....1526
8.1 Removal.....1526
8.2 Installation.....1526
9. Instrument Panel.....1528
9.1 Service Standards.....1528
9.2 Removal.....1528
9.3 Installation.....1541
10. Front Panel and Fender.....1554
10.1 Service Standards.....1554
10.2 Removal.....1554
10.3 Installation.....1559
11. Silencer.....1565
11.1 Service Standards.....1565
11.2 Removal.....1565
11.3 Installation.....1566
Group 54 - Chassis Electrical.....1569
Table of Contents.....1570
1. Troubleshooting.....1571
2. Chassis Electrical System.....1586
2.1 Specifications.....1586
2.2 General Description.....1586
2.3 Wiring Harness.....1587
2.4 Central Ground Connections.....1591
3. Battery.....1592
3.1 Specifications.....1592
3.2 General Description.....1592
3.3 Inspection.....1593
4. Fuses and Relays.....1595
4.1 Specifications.....1595
4.2 General Description.....1597
4.3 Installation Locations.....1597
4.4 Inspection.....1597
5. Fusible Link.....1599
5.1 Specifications.....1599
5.2 General Description.....1599
5.3 Installation Locations.....1599
5.4 Inspection.....1599
6. Starting System.....1600
6.1 Specifications.....1600
6.2 General Description.....1600
6.3 Installation Locations.....1601
6.4 Inspection.....1601
7. Column Switches.....1603
7.1 Specifications.....1603
7.2 General Description.....1603
7.3 Installation Locations.....1604
7.4 Inspection.....1604
8. Lighting System.....1606
8.1 Specifications.....1606
8.2 Wiring Diagram.....1606
8.3 General Description.....1608
8.4 Installation Locations.....1611
8.5 Inspection.....1614
9. Meters and Gauges.....1616
9.1 Specifications.....1616
9.2 Wiring Diagram.....1617
9.3 General Description.....1618
9.4 Installation Locations.....1618
9.5 Inspection.....1620
10. Indicators and Warning Lamps.....1622
10.1 Specifications.....1622
10.2 Wiring Diagram.....1622
10.3 General Description.....1625
10.4 Installation Locations.....1627
10.5 Inspection.....1629
11. Exhaust Brake System.....1632
11.1 Specifications.....1632
11.2 Wiring Diagram.....1632
11.3 General Description.....1633
11.4 Installation Locations.....1634
11.5 Inspection.....1635
12. Wiper and Washer.....1636
12.1 Specifications.....1636
12.2 Wiring Diagram.....1637
12.3 Installation Locations.....1638
12.4 Inspection.....1638
13. Sub-Starting System.....1640
13.1 Specifications.....1640
13.2 Wiring Diagram.....1640
13.3 General Description.....1641
13.4 Installation Locations.....1642
13.5 Inspection.....1642
14. Horn.....1644
14.1 Specifications.....1644
14.2 Wiring Diagram.....1644
14.3 Installation Locations.....1644
14.4 Inspection.....1644
15. Radio, Speakers, and Antenna.....1645
15.1 Specifications.....1645
15.2 Wiring Diagram.....1645
15.3 Installation Locations.....1645
16. Cigarette Lighter.....1649
16.1 Specifications.....1649
16.2 Wiring Diagram.....1649
16.3 General Description.....1649
16.4 Installation Locations.....1649
16.5 Inspection.....1649
17. Heater and Air Conditioner.....1650
17.1 Specifications.....1650
17.2 General Description.....1650
17.3 Installation Locations.....1650
17.4 Inspection.....1651
Group 55A - Air Conditioner.....1652
Table of Contents.....1653
1. Specifications.....1654
2. Outlines of Refrigeration System.....1655
2.1 Air System.....1655
2.2 Refrigerating Cycle.....1655
2.3 Electrical System.....1656
3. Construction.....1657
3.1 Engine Compartment.....1657
3.2 Cab.....1657
3.3 Control System.....1658
3.4 Compressor and Magnetic Clutch.....1661
3.4.1 Compressor.....1661
3.4.2 Check Valve.....1662
3.4.3 Magnetic Clutch.....1662
3.5 Condenser.....1662
3.6 Receiver Drier.....1663
3.7 Cooling Unit.....1663
3.8 Expansion Valve.....1663
3.9 High Pressure Switch.....1664
3.10 Power Relay.....1664
3.11 A/C Switch.....1664
3.12 Thermo Sensor.....1664
4. Troubleshooting.....1665
4.1 General Precautions.....1665
4.2 Trouble, Cause, and Remedy.....1666
4.3 Inspection Procedures.....1668
4.3.1 A/C Switch.....1668
4.3.2 High Pressure Switch.....1668
4.3.3 Thermo Sensor.....1669
4.3.4 Magnetic Clutch.....1669
4.3.5 Refrigerant Charge.....1669
4.3.6 Receiver Drier Assembly.....1670
4.3.7 Belt Tension.....1670
4.3.8 Expansion Valve.....1653
4.3.9 Compressor.....1670
4.3.10 Air Inclusion in Refrigerant Circuit.....1671
4.3.11 Moisture Inclusion in Refrigerant Circuit.....1671
5. Removal and Installation.....1672
5.1 Precaution for Removal and Installation.....1672
5.2 Removal.....1672
5.2.1 Inside the Engine Compartment.....1672
5.2.2 Inside the Cab.....1673
5.3 Installation.....1676
6. Treatment After Installation.....1677
6.1 Check and Adjustment.....1677
6.2 Leak Test.....1677
6.2.1 Test Point.....1677
6.2.2 Test Procedure.....1677
6.3 Evacuation.....1678
6.4 Gas Charge.....1679
6.5 Checking the Refrigerant Level.....1679
6.6 Performance Test.....1680
6.6.1 Preparation.....1680
6.6.2 Stationary Performace Test.....1680
7. Cooling Unit.....1681
7.1 Components.....1681
7.2 Cautions in Disassembling.....1682
7.3 Disassembling.....1682
8. Maintenance.....1683
9. Compressor.....1684
9.1 Disassembling the Clutch.....1684
9.2 Reassembly the Clutch.....1685
9.3 Diassembling the Shaft Seal.....1686
9.4 Reassembly the Shaft Seal.....1687
9.5 Special Tool Figure.....1689
Group 55B - Heater.....1692
Table of Contents.....1693
1. Troubleshooting.....1694
2. Heater.....1698
2.1 Specifications.....1698
2.2 General Descriptions.....1698
2.3 Wiring Diagram.....1701
2.4 Pre-Removal Inspection.....1702
2.4.1 Heater Switch Inspection.....1702
2.4.2 Mode Selector Lever Inspection.....1702
2.4.3 Temperature Control Lever Inspection.....1705
2.4.4 Air Selector Lever Inspection.....1705
2.4.5 Side Ventilator Inspection.....1706
2.5 Removal.....1707
2.6 Disassembly.....1714
2.7 Reassembly.....1715
2.8 Installation.....1717
2.9 Post-Installation Adjustments.....1723
2.10 Water Hoses.....1723
2.10.1 Inspection.....1723
2.10.2 Removal.....1724
2.10.3 Connection.....1725
3. Ventilation.....1727
3.1 Removal.....1727
3.2 Installation.....1730
3.3 Post-Installation Adjustment.....1733
FE.FG Series 1992-1995 Fuso Service Manual (TWSE9105 - 1,801 pages).....1735
1992-1995 FE/FG Service Manual.....1735
Foreword.....1735
Group 00 - General.....1738
1995 Model Changes.....1739
Outline of the '95 Model Change.....1741
Group 00 - General.....1742
(1) Change of Model.....1742
(2) Change of Engine Stamp Mark Position.....1742
Group 11 - Engine.....1742
(3) Tension of Air Conditioner Belt.....1742
(4) Change of Piston.....1742
(5) Change of Connecting Rod.....1743
(6) Change of Front Oil Seal.....1743
(7) Change of Camshaft.....1744
(8) Change of Camshaft Bushing.....1744
(9) Change of Timing Gear Case Sealer.....1744
(10) Change of Tappet.....1745
Group 12 - Lubrication.....1745
(11) Change of Oil Pump.....1745
(12) Change of Oil Filter.....1745
Group 13 - Fuel and Engine Control.....1746
(13) Change of Injection Pump.....1746
(14) Addition of Inspection Procedure Using the Pre-Stroke Type Injection Pump System MUT.....1746
Group 15 - Intake and Exhaust.....1747
(15) Employment of Catalyst Converter.....1747
(16) Change of Exhaust Manifold.....1747
(17) Change of Front Pipe.....1748
Group 16 - Engine Electrical.....1748
(18) Change of Alternator.....1748
(19) Change of Vacuum Pump.....1749
Group 22 - Manual Transmission.....1749
(20) Change of Special Tool for Main Shaft Removal and Installation.....1749
(21) Change of Shift Fork and Jaw Set.....1750
(22) Change of Speed Meter Gear.....1750
Group 23 - Automatic Transmission.....1751
(23) Change of Manual Lever Attaching Nut.....1751
(24) Change of Oil Cooler Piping.....1751
(25) Change of Oil Temperature.....1752
Group 35 - Brake.....1752
(26) Modification of Exhaust Brake Circuit Diagram.....1752
Group 36 - Parking Brake.....1752
(27) Change of Parking Brake Lever.....1752
Group 37 - Steering.....1752
(28) Change of Power Steering Oil Pump Gear Attaching Nut.....1752
(29) Change of Power Steering Oil Pump.....1753
Group 42 - Cab and Body.....1753
(30) Change of Outside Mirror Stay.....1753
Group 55 - Heater and Air Conditioner.....1753
(31) Change of Air Conditioner Compressor.....1753
1994 Minor Change.....1811
Table of Contents.....1812
1. Differences of 1994 Model From 1993 Model.....1813
2. Change Due to Running Change Made on 1993 Model.....1814
1993 Minor Change.....1815
1. Differences of 1993 Model From 1992 Model.....1817
2. Electrical Wiring Diagram.....1834
Group 00 - General.....1836
Table of Contents.....1837
1. External Views.....1838
2. Major Specifications.....1840
3. Power Train Table.....1845
4. Equipment Model Notation.....1845
5. Performance Curves.....1846
5.1 Operation Performance Curves.....1846
5.2 Engine Performance Curves.....1848
6. Servicing Precautions.....1849
7. Standard Bolts and Nuts Tightening Torque Table.....1855
8. Towing Precautions.....1856
9. Chassis and Engine Numbers.....1856
10. Vehicle Identification Number.....1857
Group 01 - Maintenance Schedule.....1858
Table of Contents.....1859
1. How To Read the Maintenance Schedule Tables.....1860
2. Maintenance Schedule Tables.....1861
3. Maintenance Operations.....1863
3.1 Replacement of the Engine Oil Filter Element.....1863
3.2 Replacement of the Fuel Filter Element.....1863
3.3 Water Separator Condensation Drain.....1864
3.4 Cleaning the Fuel Feed Pump Gauze Filter.....1864
3.5 Bleeding Air From the Fuel Line.....1864
3.6 Adjusting V-Belt Tension.....1865
3.7 Cleaning and Replacement of the Air Cleaner Element.....1866
3.8 Inspecting the Clutch Pedal.....1867
3.9 The Tires.....1867
3.9.1 Air Pressure.....1867
3.9.2 Removing Tires.....1867
3.9.3 Putting Tires On.....1869
3.9.4 Checking the Wheel Nuts for Looseness.....1870
3.9.5 Tire Rotation.....1870
3.10 Adjusting the Clearance of the Wheel Brake Shoe (FG Model Only).....1871
3.11 Checking for Wear in the Disk Brake Pads (FE Model Only).....1872
3.12 Adjusting the Clearance of the Parking Brake Shoe.....1872
3.13 The Battery.....1873
3.13.1 Cleaning the Battery Terminals.....1873
3.13.2 Inspecting the Battery.....1873
3.14 Fuses.....1874
4. Lubrication.....1876
4.1 Engine Oil.....1877
4.2 Gear Oil for Manual Transmissions.....1878
4.3 Transmission Fluid for Automatic Transmissions.....1878
4.4 Front Axle <FG Model Only> and Rear Axle Gear Oil.....1880
4.5 Transfer Gear Oil <FG Model Only>.....1880
4.6 Power Steering Fluid.....1881
4.7 Brake Fluid.....1883
4.8 Greasing the Various Areas of the Chassis.....1886
Group 11 - Engine.....1888
Table of Contents.....1889
1. Troubleshooting.....1890
2. Engine Removal and Installation (Manual Transmission Vehicles).....1897
2.1 Service Standards.....1897
2.1.1 Tightening Torque Table.....1897
2.1.2 Lubricant Table.....1897
2.2 Engine and Transmission Removal.....1898
2.2.1 Preparations Before Removal.....1898
2.2.2 Harness Removal.....1900
2.2.3 Vacuum Hose Removal.....1904
2.2.4 Removal of Parts Around Engine.....1905
2.2.5 Removal of Each Engine Parts.....1907
2.2.6 Removal of Each Transmission Parts.....1911
2.2.7 Removing the Engine From the Vehicle.....1913
2.2.8 Separating the Engine From the Transmission.....1915
2.3 Installation of the Engine and Transmission.....1916
2.3.1 Engine and Transmission Installation.....1916
2.3.2 Installation the Engine and Transmission in the Vehicle.....1917
2.3.3 Installation of Each Transmission Part.....1920
2.3.4 Installation of Each Engine Part.....1923
2.3.5 Installation of Parts Around the Engine.....1927
2.3.6 Vacuum Hose Installation.....1929
2.3.7 Harness Installation.....1930
2.4 Adjustment After Installation.....1934
2.4.1 Operations After Installation.....1934
2.4.2 Adjustment.....1936
3. Engine Removal and Installation (Automatic Transmission Vehicles).....1937
3.1 Service Standards.....1937
3.1.1 Tightening Torque Table.....1937
3.2 Engine and Transmission Removal.....1937
3.2.1 Preparations Before Removal.....1937
3.2.2 Harness Removal.....1938
3.2.3 Vacuum Hose Removal.....1940
3.2.4 Removal of Parts Around Engine.....1940
3.2.5 Removal of Each Engine Part.....1940
3.2.6 Removal of Each Transmission Part.....1941
3.2.7 Removing the Engine From the Vehicle.....1943
3.2.8 Separating the Engine and Transmission.....1945
3.3 Installation of the Engine and Transmission.....1946
3.3.1 Transmission Installation.....1946
3.3.2 Installing the Engine and Transmission in the Vehicle.....1947
3.3.3 Installation of Each Transmission Part.....1949
3.3.4 Installation of Each Engine Part.....1951
3.3.5 Installation of Parts Around the Engine.....1951
3.3.6 Vacuum Hose Installation.....1951
3.3.7 Harness Installation.....1951
3.4 Adjustment After Installation.....1954
3.4.1 Operations After Installation.....1954
3.4.2 Adjustment.....1956
4. Engine Assembly.....1957
4.1 Specifications.....1957
4.2 Service Standards.....1957
4.2.1 Service Standards Table.....1957
4.2.2 Tightening Torque Table.....1958
4.2.3 Special Tools Table.....1958
4.3 Valve Clearance Inspection and Adjustment.....1959
4.4 Compression Pressure Measurement.....1960
4.5 Oil Pressure Inspection.....1962
4.6 Fuel Injection Timing Inspection and Adjustment.....1963
4.7 Bleeding the Fuel System.....1966
4.8 Inspection and Adjustment of V-Belt Tension.....1967
4.8.1 V-Belt Tension Inspection.....1967
4.8.2 V-Belt Tension Adjustment.....1967
4.9 Turbocharger Boost Pressure Measurement.....1968
5. Cylinder Head and Valve Mechanism.....1970
5.1 Service Standards.....1970
5.1.1 Service Standards Table.....1970
5.1.2 Tightening Torque Table.....1970
5.1.3 Special Tools Table.....1971
5.2 General Description.....1972
5.2.1 Cylinder Head.....1972
5.2.2 Valve Mechanism.....1973
5.3 Removal.....1973
5.4 Disassembly.....1976
5.4.1 Rocker and Bracket Assembly.....1976
5.4.2 Cylinder Head Assembly.....1977
5.5 Inspection.....1979
5.6 Reassembly.....1987
5.6.1 Cylinder Head Assembly.....1987
5.6.2 Rocker and Bracket Assembly.....1989
5.7 Installation.....1991
6. Flywheel and Rear Plate (Manual Transmission Vehicles).....1994
6.1 Service Standards.....1994
6.1.1 Service Standards Table.....1994
6.1.2 Tightening Torque Table.....1994
6.1.3 Special Tools Table.....1994
6.1.4 Lubricant Table.....1994
6.2 General Description.....1995
6.3 Disassembly.....1996
6.4 Inspection.....1997
6.5 Reassembly.....1998
7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles).....2002
7.1 Service Standards.....2002
7.1.1 Tightening Torque Table.....2002
7.1.2 Special Tools Table.....2002
7.1.3 Lubricant Table.....2002
7.2 General Description.....2003
7.3 Disassembly.....2004
7.4 Inspection.....2005
7.5 Reassembly.....2006
8. Timing Gear and Camshaft.....2009
8.1 Service Standards.....2009
8.1.1 Service Standards Table.....2009
8.1.2 Tightening Torque Table.....2009
8.1.3 Lubricant Table.....2009
8.1.4 Special Tools Table.....2009
8.2 General Description.....2011
8.3 Disassembly.....2011
8.4 Inspection.....2014
8.5 Reassembly.....2018
9. Crankcase and Main Moving Parts.....2021
9.1 Service Standards.....2021
9.1.1 Service Standards Table.....2021
9.1.2 Tightening Torque Table.....2022
9.1.3 Sealant Table.....2022
9.1.4 Special Tools Table.....2022
9.2 General Description.....2024
9.2.1 Crankshaft.....2024
9.2.2 Connecting Rod.....2024
9.2.3 Piston.....2024
9.3 Disassembly.....2025
9.4 Inspection.....2029
9.5 Reassembly.....2040
Group 12 - Lubrication.....2047
Table of Contents.....2048
1. Troubleshooting.....2049
2. Lubrication System.....2050
2.1 Specifications.....2050
2.2 General Description.....2051
2.2.1 System Outline.....2051
2.2.2 Lubrication of Main Moving Parts.....2052
2.2.3 Camshaft Lubrication.....2052
2.2.4 Valve Mechanism Lubrication.....2052
2.2.5 Timing Gear Lubrication.....2053
2.2.6 Turbocharger Lubrication.....2053
2.2.7 Injection Pump Assembly Lubrication.....2053
2.2.8 Vacuum Pump Lubrication.....2054
2.3 Oil Pressure Check.....2054
3. Oil Pan and Oil Strainer.....2055
3.1 Service Standards.....2055
3.1.1 Tightening Torque Table.....2055
3.1.2 Sealant Table.....2055
3.2 General Description.....2055
3.3 Removal.....2055
3.4 Installation.....2056
3.5 Post-Installation Inspection.....2057
4. Oil Pump.....2058
4.1 Service Standards.....2058
4.1.1 Service Standards Table.....2058
4.2 General Description.....2058
4.3 Removal.....2058
4.4 Disassembly and Inspection.....2059
4.5 Reassembly.....2061
4.6 Installation.....2062
5. Oil Cooler and Oil Filter.....2063
5.1 Service Standards.....2063
5.1.1 Service Standards Table.....2063
5.1.2 Tightening Torque Table.....2063
5.1.3 Special Tools Table.....2063
5.2 General Description.....2064
5.3 Removal.....2065
5.4 Disassembly and Inspection.....2066
5.5 Reassembly.....2067
5.6 Installation.....2068
Group 13 - Fuel and Engine Control.....2069
Table of Contents.....2070
1. Troubleshooting.....2071
2. Fuel System.....2077
3. Pre-Stroke Control Injection Pump System.....2078
3.1 Specifications.....2078
3.2 Service Standards.....2079
3.2.1 Service Standards Table.....2079
3.2.2 Tightening Torque Table.....2080
3.2.3 Special Tools Table.....2080
3.3 General Description.....2081
3.3.1 Pre-Stroke Control Injection Pump System.....2081
3.3.2 Control Unit.....2084
3.3.3 Sensors.....2085
3.3.4 Injection Pump Unit.....2086
3.3.5 Governor.....2088
3.3.6 Feed Pump.....2093
3.4 Service Procedure.....2094
3.4.1 System Inspection.....2097
3.4.2 Removing Injection Pump Assembly.....2121
3.4.3 Installing Injection Pump Assembly.....2123
3.4.4 Bleeding Air From the Fuel System.....2125
3.4.5 Fuel Injection Timing Adjustment.....2125
3.4.6 Minimum Unloaded Idling Speed and Maximum Speed Adjustment.....2125
3.4.7 Idle Up Adjustment <Manual Transmission Equipped Vehicles>.....2126
3.4.8 Engine Stop Cable Operational Check.....2126
4. Injection Nozzles.....2127
4.1 Specifications.....2127
4.2 Service Standards.....2127
4.2.1 Service Standards Table.....2127
4.2.2 Tightening Torque Table.....2127
4.3 General Description.....2128
4.4 Removal.....2128
4.5 Disassembly.....2128
4.6 Inspection and Cleaning.....2130
4.7 Reassembly.....2131
4.8 Testing and Adjustment.....2133
4.9 Installation.....2134
5. Fuel Filter.....2135
5.1 Specifications.....2135
5.2 Service Standards.....2135
5.2.1 Tightening Torque Table.....2135
5.2.2 Special Tools Table.....2135
5.3 General Description.....2136
5.4 Removal and Inspection.....2136
5.5 Installation.....2136
6. Water Separator.....2138
6.1 Specifications.....2138
6.2 Service Standards.....2138
6.3 General Description.....2138
6.4 Removal.....2138
6.5 Disassembly and Inspection.....2139
6.6 Reassembly.....2139
6.7 Installation.....2140
6.8 Draining Water.....2140
7. Fuel Tank.....2141
7.1 Specifications.....2141
7.2 Service Standards.....2141
7.3 General Description.....2141
7.4 Removal.....2142
7.5 Inspection.....2143
7.6 Installation.....2144
8. Engine Control System.....2146
8.1 Specifications.....2146
8.2 Service Standards.....2147
8.3 General Description.....2147
8.4 Removal.....2148
8.4.1 Disconnecting the Accelerator Control Cable and Engine Stop Cable From the Engine Side.....2149
8.4.2 Removing the Throttle Cable and Accelerator Pedal.....2149
8.4.3 Disconnecting the Accelerator Control Cable and Accelerator Lever.....2151
8.4.4 Removing the Engine Stop Cable.....2152
8.5 Inspection.....2154
8.6 Installation.....2155
8.6.1 Installing the Engine Stop Cable.....2156
8.6.2 Installing the Throttle Cable, Accelerator Lever Assembly and Accelerator Pedal.....2157
8.6.3 Securing the Accelerator Control Cable.....2160
8.6.4 Installing the Accelerator Control Cable and the Engine Stop Cable to Engine Side.....2160
8.7 Post-Installation Adjustment.....2162
8.7.1 Accelerator Pedal Stopper Adjustment.....2162
8.7.2 Engine Stop Cable Operation Check.....2163
8.7.3 Accelerator Switch (Exhaust Brake Microswitch) Adjustment.....2163
Group 14 - Cooling.....2165
Table of Contents.....2166
1. Troubleshooting.....2167
2. Cooling System.....2169
2.1 Specifications.....2169
2.2 Service Standards.....2169
2.3 General Description.....2170
2.4 Removal.....2170
2.4.1 Radiator Removal.....2170
2.4.2 Cooling Fan and Auto-Cool Fan Coupling Removal.....2172
2.4.3 Water Pump Removal.....2173
2.4.4 Thermostat Removal.....2174
2.5 Installation.....2175
2.5.1 Thermostat Installation.....2175
2.5.2 Water Pump Installation.....2176
2.5.3 Cooling Fan and Auto-Cool Fan Coupling Installation.....2177
2.5.4 Radiator Installation.....2178
3. Cooling Fan and Auto-Cool Fan Coupling.....2180
3.1 General Description.....2180
3.1.1 Cooling Fan.....2180
3.1.2 Auto-Cool Fan Coupling.....2180
3.2 Removal.....2181
3.3 Inspection.....2181
3.4 Installation.....2182
4. Water Pump.....2183
4.1 General Description.....2183
5. Thermostat.....2184
5.1 Service Standards.....2184
5.2 General Description.....2184
5.3 Inspection.....2185
6. Radiator.....2186
6.1 Service Standards.....2186
6.1.1 Service Standards Table.....2186
6.1.2 Tightening Torque Table.....2186
6.2 General Description.....2186
6.2.1 Radiator.....2186
6.2.2 Pressure Cap.....2187
6.2.3 Radiator Shroud.....2187
6.2.4 Condenser Tank.....2188
6.3 Inspection and Cleaning.....2188
6.3.1 Radiator Cleaning.....2188
6.3.2 Radiator Inspection.....2188
6.3.3 Pressure Cap Inspection.....2189
6.3.4 Radiator (Cooling System) Cleaning.....2189
6.3.5 Cooling System Air Bleeding.....2192
6.3.6 Gas Leak Test.....2192
Group 15 - Intake and Exhaust.....2193
Table of Contents.....2194
1. Troubleshooting.....2195
2. Intake System.....2197
2.1 Specifications.....2197
2.2 Service Standards.....2197
2.2.1 Service Standards Table.....2197
2.2.2 Tightening Torque Table.....2197
2.3 General Description.....2198
2.4 Removal.....2199
2.5 Disassembly.....2201
2.5.1 Air Cleaner Disassembly.....2201
2.5.2 Removing the Intake Shutter.....2201
2.6 Inspection and Cleaning.....2202
2.7 Reassembly.....2203
2.7.1 Actuator Installation.....2203
2.7.2 Air Cleaner Reassembly.....2203
2.8 Installation.....2203
2.9 Post-Installation Adjustment.....2205
3. Exhaust System.....2206
3.1 Service Standards.....2206
3.1.1 Tightening Torque Table.....2206
3.2 General Description.....2206
3.3 Removal.....2207
3.4 Installation.....2212
4. Turbocharger.....2218
4.1 Sepcifications.....2218
4.2 Service Standards.....2218
4.2.1 Service Standards Table.....2218
4.2.2 Tightening Torque Table.....2218
4.2.3 Lubricants Table.....2219
4.3 General Description.....2219
4.4 Removal.....2220
4.5 Disassembly.....2224
4.6 Inspection and Cleaning.....2228
4.6.1 Cleaning.....2228
4.6.2 Inspection.....2229
4.7 Reassembly.....2231
4.8 Installation.....2238
4.9 Post-Installation Inspection.....2240
5. Intercooler.....2241
5.1 Specifications.....2241
5.2 Service Standard.....2241
5.2.1 Service Standards Table.....2241
5.2.2 Tightening Torque Table.....2241
5.3 Outline.....2242
5.4 Removal.....2242
5.5 Inspection and Cleaning.....2243
5.6 Installation.....2244
Group 16 - Engine Electrical.....2245
Table of Contents.....2246
1. Troubleshooting.....2247
2. Electrical System.....2252
2.1 Specifications.....2252
2.2 General Description.....2253
2.2.1 Starting System.....2255
2.2.2 Charging System.....2259
3. Starter.....2260
3.1 Service Standards.....2260
3.1.1 Service Standards Table.....2260
3.1.2 Lubrication Table.....2260
3.2 General Description.....2261
3.3 Removal.....2262
3.4 Disassembly.....2264
3.5 Inspection.....2268
3.6 Reassembly.....2276
3.7 Testing.....2281
3.8 Installation.....2283
4. Alternator.....2284
4.1 Service Standards.....2284
4.1.1 Service Standards Table.....2284
4.1.2 Tightening Torque Table.....2284
4.1.3 Lubrication Table.....2284
4.2 General Description.....2285
4.3 Removal.....2288
4.4 Disassembly.....2289
4.5 Inspection.....2291
4.6 Reassembly.....2296
4.7 Testing.....2299
4.7.1 Handling Precautions.....2299
4.7.2 Performance Testing.....2300
4.7.3 Regulator Inspection.....2301
4.8 Installation.....2302
5. Vacuum Pump.....2304
5.1 Service Standards.....2304
5.2 General Description.....2304
5.3 Removal.....2305
5.4 Disassembly.....2305
5.5 Inspection.....2306
5.6 Reassembly.....2307
5.7 Testing.....2308
6. Glow Plug System.....2309
6.1 Service Standards.....2309
6.1.1 Service Standards Table.....2309
6.1.2 Special Tools Table.....2309
6.1.3 Tightening Torque Table.....2309
6.2 General Description.....2310
6.3 Removal.....2312
6.4 Inspection.....2313
6.4.1 Glow Plug Inspection.....2313
6.4.2 Glow Controller Inspection.....2313
6.4.3 Water Temperature Gauge Unit Inspection.....2314
6.5 Installation.....2314
7. Idle Up System and Warning System.....2316
7.1 Service Standards.....2316
7.1.1 Service Standards Table.....2316
7.1.2 Tightening Torque Table.....2316
7.1.3 Lubrication Table.....2316
7.2 General Description.....2317
7.3 Removal.....2318
7.4 Inspection.....2318
7.5 Installation.....2320
7.6 Adjustment.....2321
Group 21 - Clutch.....2322
Table of Contents.....2323
1. Troubleshooting.....2324
2. Clutch Proper.....2333
2.1 Specifications.....2333
2.2 Service Standards.....2333
2.2.1 Service Standards Table.....2333
2.2.2 Tightening Torque Table.....2333
2.2.3 Special Tools Table.....2334
2.3 General Description.....2335
2.4 Removal.....2336
2.4.1 Before Removal.....2336
2.4.2 Removal.....2337
2.5 Inspection and Adjustment.....2338
2.5.1 Inspection.....2338
2.5.2 Adjustment.....2341
2.6 Installation.....2341
2.7 Post-Installation Adjustment.....2342
3. Clutch Control.....2343
3.1 Specifications.....2343
3.2 Service Standards.....2343
3.2.1 Service Standards Table.....2343
3.2.2 Tightening Torque Table.....2344
3.2.3 Special Tools Table.....2344
3.3 General Description.....2345
3.4 Clutch Hose and Clutch Tube.....2346
3.4.1 Removal.....2346
3.4.2 Inspection.....2347
3.4.3 Installation.....2348
3.5 Clutch Pedal.....2349
3.5.1 Removal.....2349
3.5.2 Disassembly.....2350
3.5.3 Inspection.....2351
3.5.4 Reassembly.....2353
3.5.5 Installation.....2354
3.5.6 Post-Installation Adjustment.....2355
3.6 Clutch Master Cylinder.....2356
3.6.1 Disassembly.....2356
3.6.2 Inspection.....2357
3.6.3 Reassembly.....2357
3.7 Clutch Power Cylinder.....2358
3.7.1 Removal.....2358
3.7.2 Disassembly.....2359
3.7.3 Inspection.....2360
3.7.4 Reassembly.....2361
3.7.5 Installation.....2362
3.8 Clutch Housing Assembly.....2362
3.8.1 Removal.....2362
3.8.2 Disassembly.....2363
3.8.3 Reassembly.....2365
3.8.4 Installation.....2366
3.9 Fluid Change of Clutch System.....2367
3.10 Bleeding the Clutch System.....2369
3.11 Post-Installation Adjustment.....2370
3.12 Clutch Adjustment.....2371
Group 22 - Manual Transmission.....2373
Table of Contents.....2374
1. Troubleshooting.....2375
2. Removing the Transmission.....2380
2.1 Service Standards.....2380
2.2 Preliminary Operations.....2380
2.3 Removal.....2381
2.4 Installation.....2384
3. Transmission Assembly.....2387
3.1 Specifications.....2387
3.2 Service Standards.....2387
3.2.1 Service Standards Table.....2387
3.2.2 Tightening Torque Table.....2387
3.2.3 Special Tools Table.....2388
3.3 General Description.....2390
3.4 Removal.....2393
3.4.1 Clutch Housing Assembly.....2393
3.4.2 Gear Shift, Upper and Lower.....2393
3.4.3 Rear Cover.....2393
3.4.4 Transmission.....2393
3.5 Installation.....2397
3.5.1 Transmission.....2397
3.5.2 Rear Cover.....2400
3.5.3 Gear Shift, Upper and Lower.....2400
3.5.4 Clutch Housing Assembly.....2401
4. Main Shaft Assembly.....2402
4.1 Service Standards.....2402
4.1.1 Service Standards Table.....2402
4.1.2 Special Tools Table.....2402
4.2 Preliminary Inspection.....2403
4.3 Disassembly.....2404
4.4 Inspection.....2408
4.5 Reassembly.....2410
5. Gear Shift, Lower.....2415
5.1 Service Standards.....2415
5.1.1 Service Standards Table.....2415
5.1.2 Tightening Torque Table.....2415
5.2 Disassembly.....2416
5.3 Inspection.....2418
5.4 Reassembly.....2420
6. Gear Shift, Upper.....2422
6.1 Service Standards.....2422
6.1.1 Service Standards Table.....2422
6.1.2 Tightening Torque Table.....2422
6.2 Disassembly.....2422
6.3 Inspection.....2423
6.4 Reassembly.....2424
7. Rear Cover.....2427
7.1 Service Standards.....2427
7.1.1 Service Standards Table.....2427
7.1.2 Tightening Torque Table.....2427
7.1.3 Special Tools Table.....2427
7.2 Disassembly.....2428
7.3 Inspection.....2430
7.4 Reassembly.....2430
8. Transmission Control.....2433
8.1 Service Standards.....2433
8.2 General Description.....2434
8.3 Preliminary Operations.....2434
8.4 Removal.....2435
8.5 Inspection, Repair and Replacement.....2436
8.6 Installation.....2437
8.7 Cross-Shaft Assembly.....2441
8.7.1 Disassembly.....2441
8.7.2 Inspection.....2441
8.7.3 Reassembly.....2442
8.8 Select Lever Assembly.....2443
8.8.1 Disassembly.....2443
8.8.2 Inspection and Replacement.....2443
8.8.3 Reassembly.....2443
8.9 Shift Lever Assembly.....2444
8.9.1 Disassembly.....2444
8.9.2 Inspection and Replacement.....2444
8.9.3 Reassembly.....2445
8.10 NO.1 Cross Lever Assembly.....2446
8.10.1 Disassembly.....2446
8.10.2 Inspection.....2447
8.10.3 Reassembly.....2447
8.11 Lever Complete.....2449
8.11.1 Disassembly.....2449
8.11.2 Inspection.....2449
8.11.3 Reassembly.....2450
8.12 Change Lever Complete.....2451
8.12.1 Disassembly.....2451
8.12.2 Inspection.....2452
8.12.3 Reassembly.....2452
8.13 Post-Installation Adjustment.....2454
Group 23 - Automatic Transmission.....2455
Table of Contents.....2456
1. Troubleshooting.....2457
2. Specifications.....2461
3. Service Standards.....2462
3.1 Service Standards Table.....2462
3.2 Tightening Torque Table.....2463
4. Special Tools.....2464
5. Specifications.....2465
5.1 Control Mechanisms.....2468
5.1.1 Line Pressure Control.....2469
5.1.2 Gear Shift Control.....2470
5.1.3 Lockup Control.....2471
5.1.4 Overrun Clutch Control.....2472
5.1.5 Shift Pattern Selector Control.....2473
5.1.6 Self Diagnosis Function.....2474
5.1.7 Fail Safe Functions.....2475
5.2 Electronic Control Devices.....2477
5.2.1 Control Unit.....2477
5.2.2 Accelerator Sensor.....2477
5.2.3 Idle Switch (Accelerator Switch).....2478
5.2.4 Vehicle Speed Sensor 2.....2478
5.2.5 Vehicle Speed Sensor 1.....2478
5.2.6 Fluid Temperature Sensor.....2478
5.2.7 Shift Solenoids A and B.....2479
5.2.8 Line Pressure Solenoid and Lock Up Solenoid.....2479
5.2.9 Overrun Clutch Solenoid.....2479
5.2.10 Engine Speed Sensor.....2479
5.2.11 Dropping Register.....2479
5.2.12 Power Mode Switch.....2480
5.3 Hydraulic Pressure Control Device.....2481
5.4 Gear Shift Mechanism.....2483
5.4.1 Reverse Clutch (Multi-Plate Clutch).....2485
5.4.2 HIGH Clutch (Multi-Plate Clutch).....2486
5.4.3 Brake Band.....2487
5.4.4 Forward Clutch (Multi-Plate Clutch) Overrun Clutch (Multi-Plate Clutch).....2488
5.4.5 Low and Reverse Brake (Multi-Plate Clutch).....2489
5.4.6 Planetary Gear.....2490
5.4.7 Forward One Way Clutch.....2490
5.4.8 Low One Way Clutch.....2491
5.4.9 Torque Transmission Path.....2491
5.5 Torque Converter (With Lock Up).....2498
5.6 Oil Pump (Variable Capacity Vane Pump).....2499
6. Service Standards.....2501
6.1 Maintenance and Inspection.....2501
6.1.1 ATF Inspection.....2501
6.1.2 ATF Replacement.....2502
6.2 Transmission Removal and Installation.....2503
6.2.1 Tasks Prior To Removal.....2503
6.2.2 Removal.....2503
6.2.3 Installation.....2505
6.2.4 Inspection and Adjustment After Installation.....2507
6.3 Removal and Installation of Transmission PTO.....2508
6.4 Oil Seal Replacement.....2508
6.5 Inhibitor Switch.....2510
6.5.1 Removal and Installation.....2510
6.5.2 Inspection and Adjustment.....2511
6.6 Accelerator Sensor Inspection.....2512
6.7 Automatic Transmission Control System Inspection.....2514
6.7.1 Inspection Preparation Tasks.....2514
6.7.2 Sensor Switch and Harness Inspection.....2515
6.7.3 Automatic Transmission Control Unit Inspection.....2516
6.7.4 Post Inspection Tasks.....2516
6.8 Causes of Failure and Prevention.....2517
6.8.1 Causes of Automatic Transmission Failure.....2517
6.8.2 Self Diagnosis Function.....2517
6.8.3 Load Test.....2527
6.8.4 Line Pressure Test.....2527
6.8.5 Stall Test.....2529
6.8.6 Fluid Leakage.....2529
6.9 Oil Cooler.....2530
6.9.1 Service Standards.....2530
6.9.2 General Description.....2530
6.9.3 Oil Cooler Fan System.....2531
6.9.4 Removal and Installation.....2532
6.9.5 Inspection.....2533
Group 24 - Transfer.....2534
Table of Contents.....2535
1. Troubleshooting.....2536
2. Removing the Transfer.....2538
2.1 Service Standards.....2538
2.1.1 Tightening Torque Table.....2538
2.1.2 Special Tool Table.....2538
2.2 Removal.....2539
2.3 Installation.....2542
3. Transfer Main Body.....2546
3.1 Specifications.....2546
3.2 Service Standards.....2546
3.2.1 Service Standards Table.....2546
3.2.2 Tightening Torque Table.....2547
3.2.3 Special Tools Table.....2547
3.3 General Description.....2549
3.4 Disassembly.....2550
3.5 Inspection and Replacement.....2557
3.6 Reassembly.....2559
4. Transfer Control.....2569
4.1 Specifications.....2569
4.2 Service Standards.....2569
4.2.1 Service Standards Table.....2569
4.2.2 Tightening Torque Table.....2569
4.3 General Description.....2570
4.4 Removal.....2570
4.5 Installation.....2572
4.6 Adjustment After Installation.....2573
4.7 Disassembly.....2574
4.8 Inspection.....2577
4.9 Reassembly.....2578
Group 25 - Propeller Shaft.....2582
Table of Contents.....2583
1. Troubleshooting.....2584
2. Rear Propeller Shaft.....2586
2.1 Specifications.....2586
2.2 Service Standards.....2586
2.2.1 Service Standards Table.....2586
2.2.2 Tightening Torque Table.....2586
2.2.3 Special Tools Table.....2587
2.3 General Description.....2587
2.4 Removal.....2588
2.5 Disassembly.....2590
2.6 Inspection.....2592
2.7 Reassembly.....2594
2.8 Installation.....2596
3. Front, Rear Propeller Shaft <Two Joints>.....2598
3.1 Specifications.....2598
3.2 Service Standards.....2598
3.2.1 Service Standards Table.....2598
3.2.2 Tightening Torque Table.....2598
3.2.3 Special Tools Table.....2599
3.3 General Description.....2600
3.4 Removal.....2601
3.5 Disassembly.....2603
3.6 Inspection.....2606
3.7 Reassembly.....2608
3.8 Installation.....2612
4. Double Cardin Propeller Shaft.....2613
4.1 Specifications.....2613
4.2 Service Standards.....2613
4.2.1 Service Standards Table.....2613
4.2.2 Tightening Torque Table.....2613
4.2.3 Special Tools Table.....2614
4.3 General Description.....2614
4.4 Removal.....2615
4.5 Disassembly.....2617
4.6 Inspection.....2619
4.7 Reassembly.....2620
4.8 Installation.....2623
Group 26 - Front Axle.....2624
Group 26A - Front Axle <FE>.....2625
Table of Contents.....2626
1. Troubleshooting.....2627
2. Front Axle Assembly.....2630
2.1 Specifications.....2630
2.2 Service Standards.....2630
2.2.1 Tightening Torque Table.....2630
2.3 General Description.....2631
2.4 Removal.....2631
2.5 Installation.....2632
2.6 Post-Installation Adjustment.....2632
3. Wheel Hub and Rotor.....2636
3.1 Service Standards.....2636
3.1.1 Service Standards Table.....2636
3.1.2 Tightening Torque Table.....2636
3.1.3 Special Tools Table.....2637
3.2 Disassembly.....2638
3.3 Inspection.....2641
3.4 Reassembly.....2643
4. Front Axle Center and Knuckle.....2646
4.1 Service Standards.....2646
4.1.1 Service Standards Table.....2646
4.1.2 Tightening Torque Table.....2646
4.1.3 Special Tools Table.....2647
4.2 Removal.....2647
4.3 Disassembly.....2648
4.4 Inspection.....2651
4.5 Reassembly.....2653
4.6 Installation.....2655
Group 26B - Front Axle <FG>.....2656
Table of Contents.....2657
1. Troubleshooting.....2658
2. Front Axle Assembly.....2666
2.1 Specifications.....2666
2.2 Service Standards.....2666
2.2.1 Tightening Torque Table.....2666
2.2.2 Special Tools Table.....2666
2.3 General Description.....2667
2.4 Removal.....2669
2.5 Installation.....2670
2.6 Post-Installation Adjustment.....2670
3. Wheel Hub and Brake Drum.....2675
3.1 Service Standards.....2675
3.1.1 Service Standards Table.....2675
3.1.2 Tightening Torque Table.....2675
3.1.3 Special Tools Table.....2675
3.2 Disassembly.....2677
3.3 Inspection.....2682
3.4 Reassembly.....2684
4. Axle, Knuckle and Drive Shaft.....2689
4.1 Service Standards.....2689
4.1.1 Service Standards Table.....2689
4.1.2 Tightening Torque Table.....2689
4.1.3 Special Tools Table.....2689
4.2 Disassembly.....2691
4.3 Inspection and Adjustment.....2694
4.4 Reassembly.....2695
5. Reduction and Differential.....2699
5.1 Service Standards.....2699
5.1.1 Service Standards Table.....2699
5.1.2 Tightening Torque Table.....2699
5.1.3 Special Tools Table.....2700
5.2 Removal.....2704
5.3 Preliminary Inspection.....2705
5.4 Disassembly.....2707
5.5 Inspection.....2710
5.6 Reassembly.....2712
5.7 Installation.....2717
Group 27 - Rear Axle.....2718
Table of Contents.....2719
1. Troubleshooting.....2720
2. Rear Axle Assembly.....2724
2.1 Specifications.....2724
2.2 Service Standards.....2724
2.2.1 Service Standards Table.....2724
2.2.2 Tightening Torque Table.....2724
2.3 General Description.....2725
2.4 Removal.....2726
2.5 Disassembly.....2727
2.6 Inspection.....2727
2.7 Reassembly.....2729
2.8 Installation.....2729
3. Wheel Hub and Brake Drum.....2731
3.1 Service Standards.....2731
3.1.1 Service Standards Table.....2731
3.1.2 Tightening Torque Table.....2731
3.1.3 Special Tools Table.....2732
3.2 Disassembly.....2734
3.3 Inspection.....2737
3.4 Reassembly.....2739
4. Reduction and Differential.....2743
4.1 Service Standards.....2743
4.1.1 Service Standards Table.....2743
4.1.2 Tightening Torque Table.....2743
4.1.3 Special Tools Table.....2744
4.2 Removal.....2747
4.3 Preliminary Inspection.....2749
4.4 Disassembly.....2751
4.5 Inspection.....2755
4.6 Reassembly.....2760
4.7 Installation.....2768
Group 31 - Wheels and Tires.....2770
Table of Contents.....2771
1. Troubleshooting.....2772
2. Wheels and Tires.....2774
2.1 Specifications.....2774
2.2 Service Standards.....2774
2.2.1 Service Standards Table.....2774
2.2.2 Tightening Torque Table.....2774
2.3 General Description.....2774
2.4 Removal.....2775
2.4.1 Preliminary Operation.....2775
2.4.2 Removal.....2777
2.4.3 Front Tires.....2777
2.4.4 Rear Tires.....2778
2.4.5 Inspection of Wheel Bolt and Nut.....2779
2.5 Disassembly and Inspection.....2779
2.6 Reassembly.....2782
2.7 Post-Assembly Inspection and Adjustment.....2783
2.8 Installation.....2784
Group 33 - Front Suspension.....2787
Table of Contents.....2788
1. Troubleshooting.....2789
2. Front Suspension Assembly.....2791
2.1 Service Standards.....2791
2.2 General Description.....2791
2.3 Removal.....2792
2.4 Inspection.....2795
2.5 Installation.....2796
3. Leaf Springs.....2800
3.1 Specifications.....2800
3.2 Service Standards.....2800
3.3 General Description.....2800
3.4 Pre-Disassembly Inspection.....2800
3.5 Disassembly.....2801
3.6 Inspection.....2802
3.7 Reassembly.....2802
4. Shock Absorbers.....2804
4.1 Specifications.....2804
4.2 General Description.....2804
4.3 Disassembly.....2804
4.4 Inspection.....2805
5. Stabilizer <FE Series Only>.....2806
5.1 General Description.....2806
5.2 Pre-Disassembly Inspection.....2806
5.3 Disassembly.....2806
5.4 Inspection.....2807
5.5 Reassembly.....2807
Group 34 - Rear Suspension.....2808
Table of Contents.....2809
1. Troubleshooting.....2810
2. Rear Suspension Assembly.....2812
2.1 Service Standards.....2812
2.1.1 Service Standard Table.....2812
2.1.2 Tightening Torque Table.....2812
2.1.3 Special Tools Table.....2813
2.2 General Description.....2814
2.3 Removal.....2814
2.4 Inspection.....2817
2.5 Installation.....2818
3. Leaf Springs.....2822
3.1 Specifications.....2822
3.2 Service Standards.....2822
3.3 General Description.....2822
3.4 Pre-Disassembly Inspection.....2823
3.5 Disassembly.....2823
3.6 Inspection.....2824
3.7 Reassembly.....2824
4. Shock Absorbers.....2825
4.1 Specifications.....2825
4.2 General Description.....2825
4.3 Disassembly.....2825
4.4 Inspection.....2825
5. Stabilizer <FE Series Only>.....2826
5.1 General Description.....2826
5.2 Pre-Disassembly Inspection.....2826
5.3 Disassembly.....2826
5.4 Inspection.....2827
5.5 Reassembly.....2827
Group 35 - Brake.....2828
Table of Contents.....2829
1. Troubleshooting.....2830
2. Brake System.....2841
2.1 Specifications.....2841
2.2 Service Standards.....2841
2.2.1 Tightening Torque Table.....2841
2.3 General Description.....2841
2.4 Bleeding of Air From the Brake System.....2842
2.4.1 Front Brake System.....2843
2.4.2 Rear Brake System.....2846
2.4.3 Bypass Valve System.....2848
2.5 Replacing of Brake Fluid.....2851
2.5.1 Draining the Brake Fluid.....2851
2.5.2 Changing Front Brake System Brake Fluid.....2854
2.5.3 Changing Rear Brake System Brake Fluid.....2856
2.5.4 Changing the Brake Fluid of the Bypass Valve System.....2857
2.5.5 Bleeding of Brake System.....2858
3. Brake Piping.....2859
3.1 Service Standards.....2859
3.1.1 Tightening Torque Table.....2859
3.2 Inspection Before Removal.....2859
3.3 Draining Out Brake Fluid.....2860
3.4 Removal.....2861
3.5 Inspection.....2864
3.6 Installation.....2865
4. Vacuum Tank.....2871
4.1 Service Standards.....2871
4.1.1 Service Standards Table.....2871
4.2 Vacuum Switch.....2871
4.2.1 Inspection.....2871
4.2.2 Removal.....2871
4.2.3 Installation.....2872
4.3 Vacuum Tank.....2872
4.3.1 Removal.....2872
4.3.2 Inspection.....2873
4.3.3 Installation.....2873
5. Brake Pedal.....2875
5.1 Service Standard.....2875
5.1.1 Service Standards Table.....2875
5.1.2 Tightening Torque Table.....2875
5.2 Brake Fluid Tank.....2876
5.2.1 Inspection Before Removal.....2876
5.2.2 Removal.....2877
5.2.3 Inspection.....2881
5.2.4 Installation.....2882
5.3 Brake Pedal.....2886
5.3.1 Removal.....2887
5.3.2 Disassembly.....2896
5.3.3 Inspection.....2898
5.3.4 Assembly.....2899
5.3.5 Installation.....2900
5.3.6 Positioning Brake Pedal.....2909
5.3.7 Brake Pedal Play.....2909
5.3.8 Distance Between Brake Pedal and Floor Board.....2909
5.3.9 Adjustment of Stop Lamp Switch.....2910
6. Brake Booster (Master Vac).....2911
6.1 Specifications.....2911
6.2 Service Standards.....2911
6.2.1 Tightening Torque Table.....2911
6.2.2 Special Tools Table.....2911
6.3 General Description.....2913
6.4 Removal.....2914
6.5 Disassembly.....2915
6.6 Inspection.....2921
6.7 Reassembly.....2923
6.8 Installation.....2930
6.9 Adjustments After Installation.....2930
6.10 Inspection After Installation.....2930
7. Brake Master Cylinder.....2933
7.1 Specifications.....2933
7.2 Service Standards.....2933
7.2.1 Service Standards Table.....2933
7.2.2 Tightening Torque Table.....2933
7.3 General Description.....2934
7.4 Removal.....2935
7.5 Disassembly.....2939
7.6 Inspection.....2941
7.7 Reassembly.....2942
7.8 Installation.....2946
8. Proportioning Valve.....2949
8.1 Specifications.....2949
8.2 Service Standards.....2949
8.2.1 Service Standards Table.....2949
8.2.2 Tightening Torque Table.....2949
8.3 General Description.....2950
8.3.1 Valve Unit.....2950
8.3.2 Sensor.....2951
8.4 Removal.....2951
8.5 Disassembly.....2953
8.6 Inspection.....2959
8.7 Reassembly.....2960
8.8 Installation.....2964
8.9 Adjustment After Installation and Functional Test.....2965
9. Bypass Valve.....2969
9.1 General Description.....2969
9.2 Functional Inspection.....2969
9.3 Removal.....2971
9.4 Installation.....2971
10. Front Disc Brake <FE Series>.....2973
10.1 Specifications.....2973
10.2 Service Standards.....2973
10.2.1 Service Standards Table.....2973
10.2.2 Tightening Torque Table.....2973
10.2.3 Special Tools.....2974
10.3 General Description.....2974
10.4 Replacing the Pads.....2975
10.5 Removal.....2977
10.6 Disassembly.....2979
10.7 Inspection.....2980
10.8 Reassembly.....2982
10.9 Installation.....2984
10.10 Measure Dragging Torque (Tangential Force).....2985
11. Front Drum Brake <FG Series>.....2986
11.1 Specifications.....2986
11.2 Service Standards.....2986
11.2.1 Service Standards Table.....2986
11.2.2 Tightening Torque Table.....2986
11.3 Outline.....2987
11.4 Removal.....2987
11.5 Disassembly.....2989
11.6 Inspection.....2991
11.7 Reassembly.....2993
11.8 Wheel Cylinder.....2996
11.8.1 Disassembly.....2996
11.8.2 Inspection.....2997
11.8.3 Reassembly.....2997
11.9 Installation.....3000
11.10 Shoe Clearance Adjustment.....3001
12. Rear Drum Brake.....3003
12.1 Specifications.....3003
12.2 Service Standards.....3003
12.2.1 Service Standards Table.....3003
12.2.2 Tightening Torque Table.....3003
12.3 General Description.....3004
12.4 Removal.....3005
12.5 Disassembly.....3007
12.6 Inspection.....3009
12.7 Reassembly.....3011
12.8 Wheel Cylinder <FE Series>.....3014
12.8.1 Disassembly.....3014
12.8.2 Inspection.....3015
12.8.3 Reassembly.....3015
12.9 Wheel Cylinder <FG Series>.....3019
12.9.1 Disassembly.....3019
12.9.2 Inspection.....3020
12.9.3 Reassembly.....3021
12.10 Installation.....3024
12.11 Adjusting Shoe Clearance.....3024
13. Exhaust Brake System.....3027
13.1 Specifications.....3027
13.2 Service Standards.....3027
13.2.1 Service Standards Table.....3027
13.2.2 Tightening Torque Table.....3028
13.3 General Description.....3029
13.4 Removal.....3033
13.5 Disassembly.....3036
13.6 Inspection.....3037
13.7 Reassembly.....3039
13.8 Installation.....3041
13.9 Inspection After Installation.....3044
Group 36 - Parking Brake.....3045
Table of Contents.....3046
1. Troubleshooting.....3047
2. Parking Brake Control.....3049
2.1 Specifications.....3049
2.2 Service Standards.....3049
2.2.1 Service Standards Table.....3049
2.2.2 Tightening Torque Table.....3049
2.3 General Description.....3050
2.4 Removal.....3050
2.4.1 Preliminary Operations.....3050
2.4.2 Parking Brake Lever Assembly.....3051
2.4.3 Parking Brake Cable.....3052
2.4.4 Inspection.....3052
2.5 Disassembly and Inspection.....3053
2.5.1 Disassembly.....3053
2.5.2 Inspection.....3054
2.6 Assembly and Repair.....3055
2.7 Installation.....3056
2.7.1 Parking Brake Lever Assembly.....3056
2.7.2 Parking Brake Cable.....3057
2.8 Post-Installation Adjustments.....3058
3. Parking Brake Drum and Brake Shoe.....3060
3.1 Specifications.....3060
3.2 Service Standards.....3060
3.2.1 Service Standards Table.....3060
3.2.2 Tightening Torque Table.....3060
3.2.3 Special Tools Table.....3061
3.3 General Description.....3061
3.4 Removal.....3062
3.4.1 Preliminary Operations.....3062
3.4.2 Removal.....3062
3.5 Disassembly and Inspection.....3064
3.5.1 Disassembly.....3064
3.5.2 Inspection.....3065
3.6 Reassembly.....3067
3.7 Installation.....3068
Group 37 - Steering.....3070
Table of Contents.....3071
1. Troubleshooting.....3072
2. Steering System.....3085
2.1 Service Standards.....3085
2.1.1 Service Standards Table.....3085
2.1.2 Tightening Torque Table.....3085
2.2 General Description.....3086
2.2.1 Steering System.....3086
2.2.2 Power Steering System.....3086
2.3 Power Steering Oil Change.....3087
2.4 Performance Verification Tests.....3093
2.5 Overall Power Steering Inspection.....3097
3. Steering Wheel and Shaft.....3100
3.1 Specifications.....3100
3.2 Service Standards.....3100
3.2.1 Tightening Torque Table.....3100
3.3 General Description.....3101
3.4 Removal.....3101
3.5 Disassembly.....3107
3.6 Assembly.....3110
3.7 Installation.....3113
3.8 Post-Installation Inspection.....3118
4. Steering Linkage.....3119
4.1 Service Standards.....3119
4.1.1 Service Standards Table.....3119
4.1.2 Tightening Torque Table.....3119
4.2 General Description.....3120
4.3 Drag Link.....3121
4.3.1 Removal.....3121
4.3.2 Installation.....3123
4.3.3 Greasing.....3127
4.4 Tie Rod.....3127
4.4.1 Removal.....3127
4.4.2 Disassembly.....3129
4.4.3 Inspection.....3130
4.4.4 Assembly.....3130
4.4.5 Installation.....3132
4.4.6 Greasing.....3133
4.5 Post-Installation Inspection and Adjustment.....3133
5. Power Steering Booster.....3134
5.1 Specifications.....3134
5.2 Service Standards.....3134
5.2.1 Service Standards Table.....3134
5.2.2 Tightening Torque Table.....3135
5.2.3 Special Tools Table.....3135
5.3 General Description.....3137
5.3.1 Structure.....3137
5.3.2 Operation.....3138
5.4 Removal.....3141
5.5 Pre-Disassembly Work and Inspection.....3142
5.6 Disassembly.....3144
5.7 Inspection.....3150
5.8 Assembly.....3153
5.9 Post-Assembly Work and Inspection.....3160
5.10 Installation.....3161
5.11 Post-Installation Inspection.....3163
6. Power Steering Oil Pump.....3164
6.1 Specifications.....3164
6.2 Service Standards.....3164
6.2.1 Service Standards Table.....3164
6.2.2 Tightening Torque Table.....3165
6.3 General Description.....3165
6.4 Removal.....3169
6.5 Disassembly.....3170
6.6 Inspection.....3174
6.7 Assembly.....3179
6.8 Installation.....3184
6.9 Post-Installation Inspection and Adjustment.....3184
Group 41 - Frame.....3185
Table of Contents.....3186
1. Frame Assembly.....3187
1.1 Specifications.....3187
1.2 General Description.....3187
1.3 Inspection and Repair.....3188
1.3.1 Frame.....3188
1.3.2 Rivets.....3190
1.3.3 Nuts and Bolts.....3191
1.4 Frame Shape.....3191
Group 42 - Cab.....3194
Table of Contents.....3195
1. Troubleshooting.....3196
2. Cab.....3202
2.1 Specifications.....3202
2.2 Service Standards.....3202
2.3 General Description.....3203
2.4 Cab Tilting Method.....3203
2.5 Removal.....3205
2.5.1 Operations Before Removal.....3205
2.5.2 Operations Inside the Cab.....3207
2.5.3 Operations In Front of the Cab.....3209
2.5.4 Cab Tilting Operations.....3211
2.5.5 Lifting the Cab.....3214
2.6 Installing the Cab.....3215
2.6.1 Lifting the Cab.....3215
2.6.2 Operations for Tilting the Cab.....3216
2.6.3 Operations In Front of the Cab.....3220
2.6.4 Operations Inside the Cab.....3223
2.6.5 Operations After Installation.....3224
3. Cab Mounting.....3225
3.1 Specifications.....3225
3.2 Service Standards.....3225
3.3 General Description.....3226
3.3.1 Cab Mounting.....3226
3.3.2 Cab Hinge.....3226
3.3.3 Cab Stay.....3227
3.3.4 Cab Tilt Link.....3227
3.4 Removal.....3228
3.4.1 Operations Before Removal.....3228
3.4.2 Removing the Cab Tilt Link.....3228
3.4.3 Removing the Rear Cab Mounting.....3229
3.4.4 Removing the Cab Hinge.....3232
3.5 Installation.....3233
3.5.1 Cab Hinge Installation.....3233
3.5.2 Rear Cab Mounting Installation.....3234
3.5.3 Cab Tilt Link Installation.....3238
3.5.4 Operations After Installation.....3240
4. Front Windshield Glass and Rear Window Glass.....3241
4.1 Specifications.....3241
4.2 Service Standards.....3241
4.3 Removal.....3241
4.3.1 Operations Before Removal.....3241
4.3.2 Removal Operations.....3242
4.4 Installation.....3242
4.4.1 Installation Operations.....3242
4.4.2 Operations After Installation.....3243
5. Door Assembly.....3245
5.1 Specifications.....3245
5.2 Service Standards.....3245
5.3 General Description.....3246
5.4 Removal.....3247
5.4.1 Operations Before Removal.....3247
5.4.2 Removing the Door Trim.....3247
5.4.3 Removing the Front Door Window Glass.....3248
5.4.4 Removing the Front Door Window Regulator.....3250
5.4.5 Removing the Front Door Locking System.....3251
5.4.6 Removing the Outside Mirror Stay Assembly.....3252
5.4.7 Removing the Front Door Panel.....3252
5.5 Installation.....3252
5.5.1 Front Door Panel Installation.....3253
5.5.2 Outside Mirror Stay Assembly Installation.....3254
5.5.3 Front Door Locking System Installation.....3255
5.5.4 Inspection and Adjustment After Installing the Front Door Locking System.....3256
5.5.5 Front Door Window Regulator Installation.....3256
5.5.6 Front Door Window Glass Installation.....3257
5.5.7 Door Trim Installation.....3259
6. Seat and Seat Belts.....3261
6.1 Specifications.....3261
6.2 Service Standards.....3261
6.3 Removal.....3262
6.3.1 Removing the Driver's Seat.....3262
6.3.2 Removing the Passenger Seat.....3263
6.3.3 Removing the Seat Belts.....3264
6.4 Inspection.....3266
6.4.1 Seat Belt Installation.....3266
6.4.2 Driver's Seat Installation.....3267
6.4.3 Passenger Seat Installation.....3267
7. Trim.....3269
7.1 Service Standards.....3269
7.2 Removal.....3269
7.3 Installation.....3272
8. Floor Mats.....3275
8.1 Removal.....3275
8.2 Installation.....3275
9. Instrument Panel.....3277
9.1 Service Standards.....3277
9.2 Removal.....3277
9.3 Installation.....3289
10. Cab and Associated Parts.....3302
10.1 Service Standards.....3302
10.2 Removal.....3302
10.3 Installation.....3309
11. Silencer.....3316
11.1 Service Standards.....3316
11.2 Removal.....3316
11.3 Installation.....3318
Group 54 - Chassis Electrical.....3320
Table of Contents.....3321
1. Troubleshooting.....3322
2. Chassis Electrical System.....3339
2.1 Specifications.....3339
2.2 General Description.....3339
2.3 Wiring Harness.....3340
2.4 Central Ground Connections.....3344
3. Battery.....3345
3.1 Specifications.....3345
3.2 General Description.....3345
3.3 Inspection.....3346
4. Fuses and Relays.....3348
4.1 Specifications.....3348
4.2 Service Standards.....3349
4.3 General Description.....3349
4.4 Installation Locations.....3350
4.5 Inspection.....3352
5. Fusible Link.....3355
5.1 Specifications.....3355
5.2 General Description.....3355
5.3 Installation Locations.....3355
5.4 Inspection.....3355
6. Starting System.....3356
6.1 Specifications.....3356
6.2 General Description.....3356
6.3 Installation Locations.....3357
6.4 Inspection.....3357
7. Column Switches.....3359
7.1 Specifications.....3359
7.2 General Description.....3359
7.3 Installation Locations.....3360
7.4 Inspection.....3360
8. Lighting System.....3362
8.1 Specifications.....3362
8.2 Wiring Diagram.....3363
8.3 General Description.....3370
8.4 Installation Locations.....3373
8.5 Inspection.....3376
9. Meters and Gauges.....3379
9.1 Specifications.....3379
9.2 Service Standards.....3380
9.3 Wiring Diagram.....3381
9.4 General Description.....3382
9.5 Installation Locations.....3382
9.6 Inspection.....3386
10. Indicators and Warning Lamps.....3389
10.1 Specifications.....3389
10.2 Service Standards.....3389
10.3 Wiring Diagram.....3390
10.4 General Description.....3394
10.5 Installation Locations.....3397
10.6 Inspection.....3399
11. Exhaust Brake System.....3402
11.1 Specifications.....3402
11.2 Wiring Diagram.....3402
11.3 General Description.....3404
11.4 Installation Locations.....3404
11.5 Inspection.....3405
12. Wipers and Washer.....3406
12.1 Specifications.....3406
12.2 Wiring Diagram.....3407
12.3 Installation Locations.....3408
12.4 Inspection.....3408
13. Sub-Starting System.....3410
13.1 Specifications.....3410
13.2 Wiring Diagram.....3410
13.3 General Description.....3411
13.4 Installation Locations.....3411
13.5 Inspection.....3412
14. Horn.....3413
14.1 Specifications.....3413
14.2 Wiring Diagram.....3413
14.3 Installation Locations.....3413
14.4 Inspection.....3413
15. Radio (Option), Cassette Stereo (Option), Speakers and Antenna.....3414
15.1 Specifications.....3414
15.2 General Description.....3415
15.3 Installation Locations.....3416
15.4 Inspection.....3416
16. Cigarette Lighter.....3418
16.1 Specifications.....3418
16.2 Wiring Diagram.....3418
16.3 General Description.....3418
16.4 Installation Locations.....3418
16.5 Inspection.....3418
Group 55A - Air Conditioner.....3419
Group 55A (9401) - Air Conditioner.....3419
Foreword/Table of Contents.....3420
1. Specifications.....3421
2. Outlines of Refrigeration System.....3422
3. Construction.....3424
4. Troubleshooting.....3432
5. Removal and Installation.....3439
6. Treatment After Installation.....3444
7. Cooling Unit.....3450
8. Maintenance.....3452
9. Compressor.....3453
Group 55A (9105) - Air Conditioner.....3456
Table of Contents.....3457
1. Specifications.....3458
2. Outlines of Refrigeration System.....3459
3. Construction.....3461
4. Troubleshooting.....3469
5. Removal and Installation.....3476
6. Treatment After Installation.....3481
7. Cooling Unit.....3487
8. Maintenance.....3489
9. Compressor.....3490
Group 55B - Heater.....3493
Table of Contents.....3494
1. Troubleshooting.....3495
2. Heater.....3499
2.1 Specifications.....3499
2.2 Service Standards.....3499
2.3 General Description.....3499
2.4 Wiring Diagram.....3502
2.5 Pre-Removal Inspection.....3503
2.5.1 Heater Switch Inspection.....3503
2.5.2 Mode Selector Lever Inspection.....3503
2.5.3 Temperature Control Lever Inspection.....3506
2.5.4 Air Selector Lever Inspection.....3506
2.5.5 Side Ventilator Inspection.....3507
2.6 Removal.....3508
2.7 Disassembly.....3515
2.8 Reassembly.....3516
2.9 Installation.....3518
2.10 Post-Installation Adjustments.....3524
2.11 Water Hoses.....3524
2.11.1 Inspection.....3524
2.11.2 Removal.....3525
2.11.3 Connection.....3526
3. Ventilation.....3528
3.1 Service Standards.....3528
3.2 Removal.....3528
3.3 Installation.....3531
3.4 Post-Installation Adjustments.....3534
FE.FG Series 1995-2001 Fuso Service Manual (TWSE9501).....3536
Mitsubishi Fuso FE.FG Series Repair Service Manual 1990-1991
