---===SME_1005_00008_0001.djvu===--- SERVICE MANUAL 2008 Model FOREWORD This Service Manual contains maintenance and repair methods for the Mitsubishi Fuso Truck FE Series. Read this manual carefully as an aid in providing cor- rect, efficient maintenance. Please note that the infor- mation and specifications contained within this manual may change without notice. This is due to product modifications and continued vehicle improvements that are made throughout the model years. Should you encounter any discrepancy in the information provid- ed, please do not hesitate to contact your nearest DaimlerChrysler Vehiculos Comerciales Mexico dealer or DaimlerChrysler Vehiculos Comerciales Mexico S.A. de C.V. MAY 2007 GROUP INDEX GENERAL .............................................. 00 MAINTENANCE SCHEDULE ................. 01 ENGINE................................................... 11 LUBRICATION ........................................ 12 FUEL AND ENGINE CONTROL............. 13A ELECTRONICALLY CONTROLLED FUEL SYSTEM ....................................... 13E COOLING................................................ 14 INTAKE AND EXHAUST ........................ 15 EMISSION CONTROL ............................ 17 CLUTCH.................................................. 21 MANUAL TRANSMISSION .................... 22 PROPELLER SHAFT ............................. 25 FRONT AXLE ......................................... 26 REAR AXLE............................................ 27 WHEEL AND TIRE ................................. 31 FRONT SUSPENSION ........................... 33 REAR SUSPENSION.............................. 34 BRAKE.................................................... 35A ANTI-LOCK BRAKE SYSTEM (ABS) .... 35E PARKING BRAKE .................................. 36 STEERING .............................................. 37 BUMPER AND FRAME .......................... 41 CAB......................................................... 42 DOOR...................................................... 43 EXTERIOR .............................................. 51 INTERIOR ............................................... 52 ELECTRICAL.......................................... 54 HEATER, AIR-CONDITIONER AND VENTILATION ................................ 55 ---===SME_1005_00008_0001.djvu===--- SERVICE MANUAL 2008 Model FOREWORD This Service Manual contains maintenance and repair methods for the Mitsubishi Fuso Truck FE Series. Read this manual carefully as an aid in providing cor- rect, efficient maintenance. Please note that the infor- mation and specifications contained within this manual may change without notice. This is due to product modifications and continued vehicle improvements that are made throughout the model years. Should you encounter any discrepancy in the information provid- ed, please do not hesitate to contact your nearest DaimlerChrysler Vehiculos Comerciales Mexico dealer or DaimlerChrysler Vehiculos Comerciales Mexico S.A. de C.V. MAY 2007 GROUP INDEX GENERAL .............................................. 00 MAINTENANCE SCHEDULE ................. 01 ENGINE................................................... 11 LUBRICATION ........................................ 12 FUEL AND ENGINE CONTROL............. 13A ELECTRONICALLY CONTROLLED FUEL SYSTEM ....................................... 13E COOLING................................................ 14 INTAKE AND EXHAUST ........................ 15 EMISSION CONTROL ............................ 17 CLUTCH.................................................. 21 MANUAL TRANSMISSION .................... 22 PROPELLER SHAFT ............................. 25 FRONT AXLE ......................................... 26 REAR AXLE............................................ 27 WHEEL AND TIRE ................................. 31 FRONT SUSPENSION ........................... 33 REAR SUSPENSION.............................. 34 BRAKE.................................................... 35A ANTI-LOCK BRAKE SYSTEM (ABS) .... 35E PARKING BRAKE .................................. 36 STEERING .............................................. 37 BUMPER AND FRAME .......................... 41 CAB......................................................... 42 DOOR...................................................... 43 EXTERIOR .............................................. 51 INTERIOR ............................................... 52 ELECTRICAL.......................................... 54 HEATER, AIR-CONDITIONER AND VENTILATION ................................ 55 ---===SME_1005_00008_0002.djvu===--- General Group 00 Pub.No.TWSE0704-00 ---===SME_1005_00008_0003.djvu===--- 00-1 INDEX EQUIPMENT TYPE CODES LIST ...................................................... 00-2 POWER TRAIN TABLE ...................................................................... 00-3 HOW TO READ THIS MANUAL ........................................................ 00-4 CHASSIS NUMBER, ENGINE NUMBER, POWER TRAIN LABEL ..................................................................... 00-8 VEHICLE IDENTIFICATION NUMBER ............................................. 00-9 PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-10 JACKING UP THE VEHICLE .......................................................... 00-22 DIAGNOSIS CODES 1. Diagnosis Codes ........................................................................ 00-24 2. Using Multi-Use Tester .............................................................. 00-24 3. Use of Blinking Warning (Indicator) Lamp for Diagnosis Code ................................................................... 00-26 TABLE OF STANDARD TIGHTENING TORQUES.......................... 00-29 ---===SME_1005_00008_0004.djvu===--- 00-2 Component Name plate marking Code description Engine 4M50T7 4 M 5 0 T 7 Power version number Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4) Clutch C5W33 C 5 W 33 Disc outside diameter Facing material (W: Woven) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the clutch Transmission M036S5W M 036 S 5 W Variation (W: With directly-mounted transfer) Forward speeds Type of mesh (S: Synchromesh) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the transmission Propeller shaft P3 P 3 Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the propeller shaft Front axle F350T F 350 T Vehicle type (T: Truck) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the front axle Rear axle R035T R 03 5 T Vehicle type (T: Truck) Order of development within same series Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the rear axle Reduction and differential D035H D 03 5 H Tooth profile (H: Hypoid gear) Order of development within same series Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the reduction & differential EQUIPMENT TYPE CODES LIST ---===SME_1005_00008_0005.djvu===--- 00 00-3 Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Reduction & differential FE84DDZSLU3A 4M50T7 C5W33 M036S5 P3 R035T D035H FE84DEZSLU3A 4M50T7 C5W33 M036S5 P3 R035T D035H FE84DGZSLU3A 4M50T7 C5W33 M036S5 P3 R035T D035H FE84DHZSLU3A 4M50T7 C5W33 M036S5 P3 R035T D035H POWER TRAIN TABLE ---===SME_1005_00008_0006.djvu===--- 00-4 This manual consists of the following parts: Specifications Structure and Operation Troubleshooting On-vehicle Inspection and Adjustment Service procedures On-vehicle Inspection and Adjustment Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedure Procedures for servicing components and parts off the vehicle are described centering on key points in their re- moval, installation, disassembly, reassembly, inspection, etc. Inspection Check items subject to acceptance or otherwise on the basis of service standards are all given. Some routine visual checks and cleaning of some reused parts are not described but must be always included in actual service work. Caution This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: Terms and Units Front and rear The forward running direction of the vehicle is the front and the reversing direction is the rear. Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. DANGER Precautions that should be taken in handing potentially dangerous substances such as battery fluid and coolant additives. WARNING Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION Precautionary instructions, which, if not observed, could result in damage to or de- struction of equipment or parts. NOTE Suggestions or supplementary information for more efficient use of equipment or a better understandings. HOW TO READ THIS MANUAL ---===SME_1005_00008_0007.djvu===--- 00 00-5 Tightening torque Values are directly specified for out-of-standard tightening torques for bolts and nuts. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.) When the item is to be tightened in a wet state, "wet" is indicated. Where there is no indication, read it as dry. Units Tightening torques and other parameters are given in SI* units with imperial unit and metric units added in brackets {}. *SI: Le Système International d'Unités Unit SI unit {imperial unit, metric unit} Conversion factor Force N {lbs, kgf} 9.80665 N {2.2046 lbs, 1 kgf} Moment of force N·m {ft.lbs, kgf·m} 9.80665 N·m {7.2329 ft.lbs, 1 kgf·m} Pressure Positive pressure kPa {psi, kgf/cm 2 } 98.0665 kPa {14.22 psi, 1 kgf/cm 2 } Vacuum pressure kPa {in.Hg, mmHg} 0.133322 kPa {0.03937 in.Hg, 1 mmHg} Volume J {BTU, kcal} 4186.05 J {3.96825BTU, 1 kcal} Heat quantity W {BTU/h, kcal/h} 1.16279W {3.96825BTU/h, 1 kcal/h} Unit SI unit {imperial unit} Conversion factor Length mm {in.} 1 mm {0.03937 in.} m {ft.} 1 m {3.2808 ft.} km {mile} 1 km {0.6214 mile} Mass kg {lb} 1 kg {2.2046 lb} g {oz} 1 g {0.035274 oz} Temperature (in degree Celsius) °C{°F} 1°C {(1°C 1.8 + 32)° F} Velocity km/h {mph} 1 km/h {0.6214 mph} m/s {ft/s} 1 m/s {3.281 ft/s} Volume L {qts}, L {gal} 1 L {1.05336 qts}, 1 L {0.2642 gal} cm 3 {cu.in.} 1cm 3 {0.061023 cu.in.} Area m 2 {in 2 },m 2 {ft 2 }1 m 2 {1.550 10 3 in 2 },1m 2 {1.076 10 ft 2 } Example: 390 N·m {290 ft.lbs, 40 kgf·m} Metric unit SI unit Imperial unit Example: 30 mm {1.18 in.} SI unit Imperial unit ---===SME_1005_00008_0008.djvu===--- 00-6 Symbol Denotation Application Remarks Tightening torque Parts not tightened to standard torques (standard torques specified where neces- sary for servicing) Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are speci- fied. Locating pin Parts to be positioned for installation Non-reusable parts Parts not to be reused Lubricant and/or sealant Parts to be coated with lubricant or sealant for assembly or installation Necessary lubricant and/or sealant, quantity re- quired, etc. are specified in table. Special tool Parts for which special tools are required for service operation Tool name/shape and part number are shown in table. *a Associated part Parts associated with those removed/disas- sembled for servicing HOW TO READ THIS MANUAL ---===SME_1005_00008_0009.djvu===---