Mitsubishi FUSO FH 1997, Service Manual

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Page 9: ...Group 00 General Pub No TWME9502 00 Table of Contents BACK HOME...

Page 10: ...DING SYSTEM 2 POWER TRAIN TABLE 3 CHASSIS NUMBER AND ENGINE NUMBER 3 POWER TRAIN LABEL 4 VEHICLE IDENTIFICATION NUMBER 4 PRECAUTIONS FOR MAINTENANCE OPERATION 6 TABLE OF STANDARD TIGHTENING TORQUES 18...

Page 11: ...33 Disc outer diameter Facing material M Cera metallic Loading capacity of major type tonnage Stands for clutch Transmission M 050 S 5 No of forward speeds Meshing S Synchromesh A Automatic Loading ca...

Page 12: ...NUMBER The serial numbers for chassis and engines are assigned to the respective vehicles and engines in manufacturing sequence every vehicle and engine has its own numbers These numbers are required...

Page 13: ...rake system C 7258 to 8845 kg 16001 to 19500 lbs Air over hydraulic 5 Line C FH211 6 Series Wheelbase C 2 6 to 2 9 m 8 6 to 9 5 ft E 3 2 to 3 5 m 10 5 to 11 5 ft G 3 8 to 4 1 m 12 5 to 13 4 ft H 4 1 t...

Page 14: ...00 5 00 M E M O...

Page 15: ...val or disassembly of the part is necessary Then follow the proce dure specified by this manual 06473 00008 00009 14192 Perform maintenance work at a level area Prepare the following To prevent the se...

Page 16: ...missions and axles When lifting up heavy items using cables pay special attention to the following points Check the mass of the item to be lifted and use a cable capable of lifting that mass 14194 141...

Page 17: ...herwise you might miss detecting the leakage 00013 00014 Prepare replacement part s beforehand Replace oil seals packing O rings and other rubber parts gaskets and split pins with new parts whenever a...

Page 18: ...rings during assembly Use only the specified oil grease etc for lubricant remove the excess immediately after application with a piece of waste etc CAUTION When the specified lubricant fluid and seala...

Page 19: ...stru ments with waterproof material beforehand Cover with vinyl sheet or the like Keep water away from harness wire connectors and sensors If any of them should get wet wipe them off immediately When...

Page 20: ...n the specified value In particular pay close attention to the electronic control unit and sen sors since they are not always fed the battery voltage When using testers or the like for continuity test...

Page 21: ...ing female pins Insert a test probe into a terminal However do not force the probe into the terminal or it will cause a poor contact 02589 PRECAUTIONS FOR MAINTENANCE OPERATION 02587 Connect the test...

Page 22: ...pins even if the connector body is se cured and might cause some pins to fall out Check if the pins have fallen out from the connector by pulling each harness gently 02594 02591 Connector inspection...

Page 23: ...t circuits A Battery B Fuse C Loaded switch D Load E Short circuit 02596 _ _ 0 A E B C D While the engine is running do not remove the battery terminals If the battery terminals are removed at that ti...

Page 24: ...destroyed 04749 Do not short circuit terminal B and terminal L while running the alternator If the terminals are short circuited while the alternator is running the diode trio might be destroyed 0516...

Page 25: ...e elements depending on the actual conditions identified If vibration is suspected as a possible cause inspect individual con nectors as follows to check if the fault will occur Shake the connector ge...

Page 26: ...00 17 00 M E M O...

Page 27: ...5 0 33 to 43 4 5 to 6 0 31 to 50 4 3 to 6 9 M 12 35 to 50 31 to 46 70 to 95 65 to 85 85 to 110 75 to 100 25 to 36 3 4 to 5 0 22 to 34 3 1 to 4 7 51 to 69 7 0 to 9 5 47 to 61 6 5 to 8 5 61 to 80 8 5 to...

Page 28: ...90 100 to 135 14 to 19 87 to 115 12 to 16 180 to 255 25 to 35 160 to 215 22 to 30 M 20 190 to 260 170 to 230 350 to 470 320 to 420 135 to 190 19 to 26 120 to 165 17 to 23 260 to 345 36 to 48 230 to 31...

Page 29: ...ipe diameter 4 76 mm 0 19 in 6 35 mm 0 25 in 8 mm 0 31 in 10 mm 0 39 in 12 mm 0 47 in 15 mm 0 59 in Tightening torque 17 12 1 7 25 19 2 6 39 29 4 0 59 43 6 0 88 65 9 0 98 72 10 0 TABLE OF STANDARD TIG...

Page 30: ...00 21 00 M E M O...

Page 31: ...00 22 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AA AA 1 A AA 2 A AA 2 B AA 3 A AA 3 B AA 4 A AA 4 B AA 6 A...

Page 32: ...00 23 00 Model Number shows number of pins Connection AA 6 B AA 8 A AA10A AA12A AA AB AB 2 A AB 3 A AB 4 A AB 6 A AB 1 A...

Page 33: ...00 24 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AC 2 A AC 4 A AC 3 A AD 1 A AD 2 A AE 2 A AE 3 A AE 5 A AD AE AC 1 A AC...

Page 34: ...00 25 00 Model Number shows number of pins Connection AE 9 A AE11A AE13A AE15A AE16A AE16B AE16C AE17A White Gray Black Green Blue AE 7 A AE...

Page 35: ...00 26 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AG AG20A AH10A AH12A AH18A AH AG16A...

Page 36: ...00 27 00 Model Number shows number of pins Connection AH AH18B AH24A AH26A AH22 AH26A AH22 AH22A AH26A...

Page 37: ...00 28 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AJ 2 A AJ 4 A AJ 8 A AJ10A AJ12A AJ...

Page 38: ...00 29 00 Model Number shows number of pins Connection AJ16A AJ...

Page 39: ...00 30 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AJ20A AK 2 A AK 3 A AK 4 A AK 6 A AJ AK...

Page 40: ...00 31 00 Model Number shows number of pins Connection AK 8 A AK10A AK14A AK18A AK20A AK...

Page 41: ...00 32 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AK20B AK22A AK22B AL 1 A AL 2 A or or or or AK AL...

Page 42: ...00 33 00 Model Number shows number of pins Connection AL 2 B AL 3 A or or AL 3 B AL 3 C AL 3 D or AL 3 E or AL...

Page 43: ...00 34 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AL 4 A or or AL 4 B AL 6 A or or AL 6 B AL 8 A AL 8 B or or AL...

Page 44: ...00 35 00 Model Number shows number of pins Connection AM 2 A AM 2 B AM 2 C AM 4 A AM 4 B AM 6 A AM 6 B AM 8 A AM 8 B AM...

Page 45: ...00 36 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AM10A AN 1 A AN 2 A AN 3 A AN 4 A AN 4 B AN 6 A AN 6 B AN 8 A AM AN...

Page 46: ...00 37 00 Model Number shows number of pins Connection AN 8 B AP 1 A AP 1 B AP 2 A AP 2 B AP 2 C AQ 3 A AQ 3 B AQ13A AN AP AQ...

Page 47: ...00 38 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AQ15A AQ20A AR 2 A AR 2 B AR 2 C AR 2 D AR 2 E AR 2 F AQ AR...

Page 48: ...00 39 00 Model Number shows number of pins Connection AR 3 A AS 1 A AS 2 A AS 2 B AT 4 A AU 6 A AU 8 A AU10A AR AS AT AU...

Page 49: ...00 40 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection AU12A AU13A AU16A AV 1 A AV 2 A AW 1 A AW 1 B AW 2 A AX 4 A AU AV AW AX...

Page 50: ...00 41 00 Model Number shows number of pins Connection AY 2 A AZ 2 A BA 3 A BB 2 A BB 3 A BC 3 A BD 8 A BE 6 A BF12A AY AZ BA BB BC BD BE BF...

Page 51: ...00 42 CONNECTOR CONFIGURATION CHART Model Number shows number of pins Connection BG16A BH 4 A BJ 9 A BL 2 A BM 2 A BM 2 B BM 2 C BG BH BJ BL BM BN 1 A BN...

Page 52: ...BACK HOME...

Page 53: ...98 Minor Change Group 01 Maintenance Schedule Pub No TWME9502 201 Table of Contents BACK HOME...

Page 54: ...ion 01 11 Cleaning and Replacement of Air Cleaner Element 01 13 Inspection of Clutch Pedal Free Play 01 14 Tire 01 14 Inspection of Brake Pedal Free Play 01 20 Inspection of Clearance between Brake Pe...

Page 55: ...eeler gauge Gr 11 5 E Oil filter replacement Every 20000 km Replace element Gr 12 12000 miles Working procedures 3 Remarks 4 Inspection interval Time of inspection and maintenance 2 Pre operation chec...

Page 56: ...separator drain plug to discharge water Gr 13 12 E Removal of water and sediment from Every 24 months Remove fuel tank drain plug and remove water and Gr 13 fuel tank sediment 13 Retightening of fuel...

Page 57: ...39 Tire inflation pressure cracking tread 1 Measure inflation pressure with tire gauge and Gr 31 groove depth abnormal wear etc check that tire tread groove is deep enough 2 Check tire tread and side...

Page 58: ...system 1 Check steering system for looseness and play Gr 37 including hoses and pipes 2 Check power steering hoses and pipes for looseness 65 Wheel alignment Measure toe in camber caster and kingpin...

Page 59: ...her Check if fluid level in washer tank is okay 79 Gauges and pilot lamps function Check function of gauges and pilot lamps Gr 54 80 Switch function Check operation damage and installation of each swi...

Page 60: ...ck that there is no oil leakage from gasket area A Check the oil level and if it is low top it up 1 A 2 06446 0 Lubricant Location Points of application Specified lubricant Quantity 2 Inside oil filte...

Page 61: ...1882 MAINTENANCE OPERATIONS 94 2 3 71 WARNING Fuel ignites easily Do not get it near flame or heat Wipe up any diesel fuel that has been spilled because it can cause a fire Do not use an unsuitable fi...

Page 62: ...ea Check for fuel leakage Cleaning of Fuel Feed Pump Gauze Filter Tightening torque Unit N m lbf ft kgf m Location Parts to be tightened Tightening torque Remarks 2 Eye bolt 25 to 29 18 to 22 2 5 to 3...

Page 63: ...ckwise and pull it up so the top protrudes Loosen air vent plug 2 of the fuel filter and move the top part of priming pump 1 up and down Move priming pump 1 up and down repeatedly until air bubbles ar...

Page 64: ...the V belts Remember that too much tension can damage the V belts and bearings Do not grease V belts This causes them to slip which reduce service life 0 Special tools Location Tool name and shape Pa...

Page 65: ...sting bolt P After adjustment tighten the bolts N P securely CAUTION Bear in mind that excessive tension of V belts 2 might damage the belts and bearings that engage with the V belts Be sure to replac...

Page 66: ...e the air cleaner element NOTE If the dust on air cleaner element 2 is wet due to oil smoke or soot replace the air cleaner regardless of the scheduled replace ment interval Cleaning Blow compressed a...

Page 67: ...be certain that it is not difficult to shift the vehicle into first and reverse gears Gradually release clutch pedal 1 to set the vehicle in motion Check to be sure there is no slippage and that the c...

Page 68: ...where the tread groove has worn away WARNING If the depth of the tread grooves is not adequate the tires will slip on wet roads and present a hazard Such tires are also extremely dangerous because th...

Page 69: ...ck both the tire to be removed and the tire diagonally oppo site to it so that they will not rotate when you are removing the tire Loosen wheel nuts 2 slightly The wheel nuts for right tires C have ri...

Page 70: ...nuts 4 jack the vehicle up and mount on outer tire 3 then tighten outer wheel nuts 2 Even if only outside tire 3 is to be changed do not mount it until inner wheel nuts 4 have been fastened at the spe...

Page 71: ...er tightening the wheel nuts can damage them 14214 Checking the wheel nuts for looseness The wheel nuts should be checked for looseness every 10000 km 6000 miles All nuts should be tightened at the sp...

Page 72: ...er shown below When the tread patterns for all tires are identical 02358 02359 When the tread patterns are different for the front and rear tires CAUTION Always adjust air pressure after running in ne...

Page 73: ...490 N 110 lbf 50 kgf when the engine is idling to check if clearance A between the brake pedal and the floor panel conforms to the standard value If the measured value deviates from the standard valu...

Page 74: ...ydrogen gas is generated by the battery be sure to obey the following warnings Do not short circuit the and terminals on the battery Keep sparks and lit cigarettes away from the battery Do not wear me...

Page 75: ...attery NOTE The specific gravity of the battery electrolyte depends on the liquid temperature Use the following formula to convert the actual value to the value were the temperature 20 C 68 F S20 68 S...

Page 76: ...5 Quick charge Amount of discharge Ah 5 hour rating capacity Ah 100 Use the graph shown on the left to calculate the amount of discharge Use diluted sulfuric acid made up of sulfuric acid and refined...

Page 77: ...use box CAUTION If a fuse blows make sure you identify and remedy the cause then replace the fuse Make sure that you replace the fuse with one having the same rating Make sure that you remove the term...

Page 78: ...o FH1 Fuse box F1 to F4 50 A FH2 Fuse box F5 to F8 F11 40 A FH3 Brake booster Hydraulic booster 50 A FH4 Starter switch Terminal B 50 A FH5 Glow relay 50 A FH6 Alternator 120 A FH7 Fuse box F31 to F34...

Page 79: ...ace the fluid at the first 10000 km 6000 miles inspection 7 Axle housing gear oil level Gear oil Gr 27 Axle housing gear oil replacement API classification GL 5 Below 40 C 104 F SAE 90 Over 40 C 104 F...

Page 80: ...level is low top it up Tilt the cab 02196 02176 Replenishment Clean the area surrounding oil filler cap 2 and prevent dust from entering through the filler Remove oil filler cap 2 and top up with eng...

Page 81: ...ugh the filler Remove oil filler cap 2 Remove oil pan drain plug 3 and drain the oil At the same time replace the oil filter After reinstalling drain plug 3 slowly add engine oil through the oil fille...

Page 82: ...system to swell resulting in faulty clutch operation as well as ineffective braking and brake drag ging Do not allow foreign particles or water to become mixed into the brake fluid when refilling bec...

Page 83: ...2 when air is bled completely Depress clutch pedal 4 several times again then keep it depressed at its fullest extent With clutch pedal 4 depressed loosen air bleeder 2 to drain brake fluid containing...

Page 84: ...diately after the vehicle stopped so take care not to burn yourself Inspection and replenishment Remove inspection plug 1 and check whether the oil level is up to the edge of the entrance If the level...

Page 85: ...cking to it Reinsert the dipstick then pull it out again and check the fluid level If the fluid level is inspected right after the engine is started and the fluid temperature is still low approximatel...

Page 86: ...rature has been reached before draining the fluid NOTE The fluid will drain faster if the engine is first run to raise the fluid temperature The fluid cannot be drained from the hydraulic circuit the...

Page 87: ...ediately after supplying fluid because of the fluid adhering to the interior of dipstick guide 2 If this is the case check the fluid level several times at intervals Be careful not to supply too much...

Page 88: ...urself Remove inspection plug 1 check the oil level and make sure it is up to the edge of the entrance If the oil level is low add oil through the inspection plug hole until the level comes up to the...

Page 89: ...If it is below the MIN level remove filler cap 2 from power steering oil tank 1 then supply the specified fluid until the level has come up to the MAX level Do not fill above the MAX level CAUTION If...

Page 90: ...l at such time does not need to be operated If there is an abnormal noise air is still in the system Turn the steering wheel several times next depress the brake pedal several times to raise the fluid...

Page 91: ...not add different quality fluid or mineral oil gas oil engine oil gear oil automatic transmission fluid etc to the clutch system because this will cause the rubber parts of the clutch system and brake...

Page 92: ...pection and replenishment Inspect the level of the brake fluid in fluid tank 1 It should fall between the MAX and MIN levels If it is below the MIN level remove the cap from fluid tank 1 then supply t...

Page 93: ...er 2 at specified torque as soon as brake fluid flowing out is free of air bubbles Adjust brake shoe clearance when you have finished air bleeding Check that brake fluid comes up to level MAX of fluid...

Page 94: ...01 41 01 M E M O...

Page 95: ...rear left and right 4 points 3Rear spring pin front left and right 2 points 4Rear spring pin rear left and right 4 points 5Steering shaft 6Kingpin bearing left and right 4 points 7Universal joint of p...

Page 96: ...01 43 01 Door hinge 01518...

Page 97: ...Table of Contents BACK HOME...

Page 98: ...lter 9 Bleeding of Air from Fuel Line 10 Adjustment of V Belt Tension 11 Cleaning and Replacement of Air Cleaner Element 13 Inspection of Clutch Pedal Free Play 14 Tire 14 Inspection of Brake Lining T...

Page 99: ...eeler gauge Gr 11 5 E Oil filter replacement Every 20000 km Replace element Gr 12 12000 miles Working procedures 3 Remarks 4 Inspection interval Time of inspection and maintenance 2 Pre operation chec...

Page 100: ...separator drain plug to discharge water Gr 13 12 E Removal of water and sediment from Every 24 months Remove fuel tank drain plug and remove water and Gr 13 fuel tank sediment 13 Retightening of fuel...

Page 101: ...ge Check disc wheel for corrosion deformation and cracks Gr 31 39 Tire inflation pressure cracking tread 1 Measure inflation pressure with tire gauge and Gr 31 groove depth abnormal wear etc check tha...

Page 102: ...ent necessary 63 Brake booster packing cup and rubber Every 12 months Check brake booster packing cup and rubber parts Gr 35 parts replacement replace if necessary 64 Brake hose replacement Every 12 m...

Page 103: ...als for Gr 54 wiring and connections looseness and corrosion 84 Battery electrolyte level and specific Every 20000 km 1 Check electrolyte level Gr 54 gravity 12000 miles 2 Measure electrolyte specific...

Page 104: ...w oil filter 2 into oil cooler body 1 until gasket area A sits on the body From this position tighten further by rotating by three quarters of a turn After installation run the engine and check that t...

Page 105: ...MAINTENANCE OPERATIONS 94 2 3 71 WARNING Fuel ignites easily Do not get it near flame or heat Wipe up any gas oil that has been spilled because it can cause a fire Do not use an unsuitable filter beca...

Page 106: ...rea Check for fuel leakage Cleaning of Fuel Feed Pump Gauze Filter Tightening torque Unit N m lbf ft kgf m Location Parts to be tightened Tightening torque Remarks 2 Eye bolt 25 to 29 18 to 22 2 5 to...

Page 107: ...and pull it up so the top protrudes Loosen air vent plug 2 of the fuel filter and move the top part of priming pump 1 up and down Move priming pump 1 up and down repeatedly until air bubbles are no lo...

Page 108: ...the V belts Remember that too much tension can damage the V belts and bearings Do not grease V belts This causes them to slip which reduce service life 0 Special tools Location Tool name and shape Pa...

Page 109: ...sting bolt P After adjustment tighten the bolts N P securely CAUTION Bear in mind that excessive tension of V belts 2 might damage the belts and bearings that engage with the V belts Be sure to replac...

Page 110: ...e the air cleaner element NOTE If the dust on air cleaner element 2 is wet due to oil smoke or soot replace the air cleaner regardless of the scheduled replace ment interval Cleaning Blow compressed a...

Page 111: ...eck to be certain that it is not difficult to shift the vehicle into first and reverse gears Gradually release clutch pedal 1 to set the vehicle in motion Check to be sure there is no slippage and tha...

Page 112: ...where the tread groove has worn away WARNING If the depth of the tread grooves is not adequate the tires will slip on wet roads and present a hazard Such tires are also extremely dangerous because th...

Page 113: ...ck both the tire to be removed and the tire diagonally oppo site to it so that they will not rotate when you are removing the tire Loosen wheel nuts 2 slightly The wheel nuts for right tires C have ri...

Page 114: ...nuts 4 jack the vehicle up and mount on outer tire 3 then tighten outer wheel nuts 2 Even if only outside tire 3 is to be changed do not mount it until inner wheel nuts 4 have been fastened at the spe...

Page 115: ...er tightening the wheel nuts can damage them 14214 Checking the wheel nuts for looseness The wheel nuts should be checked for looseness every 10000 km 6000 miles All nuts should be tightened at the sp...

Page 116: ...er shown below When the tread patterns for all tires are identical 02358 02359 When the tread patterns are different for the front and rear tires CAUTION Always adjust air pressure after running in ne...

Page 117: ...lammable hydrogen gas is generated by the battery be sure to obey the following warnings Do not short circuit the and terminals on the battery Keep sparks and lit cigarettes away from the battery Do n...

Page 118: ...E The specific gravity of the battery electrolyte depends on the liquid temperature Use the following formula to convert the actual value to the value were the temperature 20 C 68 F S20 68 St 0 0007 t...

Page 119: ...e Amount of discharge Ah 5 hour rating capacity Ah 100 Use the graph shown on the left to calculate the amount of discharge Use diluted sulfuric acid made up of sulfuric acid and refined or distilled...

Page 120: ...01 23 01 M E M O...

Page 121: ...use box CAUTION If a fuse blows make sure you identify and remedy the cause then replace the fuse Make sure that you replace the fuse with one having the same rating Make sure that you remove the term...

Page 122: ...e box F1 to F4 50 A FH2 Fuse box F5 to F8 50 A FH3 Fuse box F9 to F12 40 A FH4 Starter switch Terminal B 40 A FH5 Glow relay 50 A FH6 Alternator 120 A FH7 Fuse box F31 to F34 40 A Fuse Main load Capac...

Page 123: ...e housing gear oil replacement API classification GL 5 Below 40 C 104 F SAE 90 Over 40 C 104 F SAE 140 Use SAE 140 when operating vehicle at high load such as continuous ascent on slopes and when the...

Page 124: ...level is low top it up Tilt the cab 02196 02176 Replenishment Clean the area surrounding oil filler cap 2 and prevent dust from entering through the filler Remove oil filler cap 2 and top up with eng...

Page 125: ...ugh the filler Remove oil filler cap 2 Remove oil pan drain plug 3 and drain the oil At the same time replace the oil filter After reinstalling drain plug 3 slowly add engine oil through the oil fille...

Page 126: ...ubber parts of the clutch system to swell resulting in faulty clutch operation Do not allow foreign particles or water to become mixed into the brake fluid when refilling because this will cause fault...

Page 127: ...depress clutch pedal 4 continuously Keep depressing clutch pedal 4 and tighten air bleeder 2 when air is bled completely Depress clutch pedal 4 several times again then keep it depressed at its fulle...

Page 128: ...y after the vehicle stopped so take care not to burn yourself Inspection and replenishment Remove inspection plug 1 and check whether the oil level is up to the edge of the entrance If the level is lo...

Page 129: ...to it Reinsert the dipstick then pull it out again and check the fluid level If the fluid level is inspected right after the engine is started and the fluid temperature is still low approximately 15...

Page 130: ...void scalds wait until a safe temperature has been reached before draining the fluid NOTE The fluid will drain faster if the engine is first run to raise the fluid temperature The fluid cannot be drai...

Page 131: ...ediately after supplying fluid because of the fluid adhering to the interior of dipstick guide 2 If this is the case check the fluid level several times at intervals Be careful not to supply too much...

Page 132: ...urself Remove inspection plug 1 check the oil level and make sure it is up to the edge of the entrance If the oil level is low add oil through the inspection plug hole until the level comes up to the...

Page 133: ...etween the end and F on the dipstick If the level is low add fluid After inspection install filler cap 2 by turning it clockwise WARNING Close filter cap 2 firmly otherwise power steering fluid will l...

Page 134: ...ht repeatedly When the fluid level has dropped add fluid to maintain the fluid level within range A Repeat these steps until the fluid level does not drop If there is an abnormal noise air is still in...

Page 135: ...different quality fluid or mineral oil gas oil engine oil gear oil automatic transmission fluid etc to the brake system because this will cause the rubber parts of the brake system to swell resulting...

Page 136: ...plied brake fluid check whether the diaphragm is assembled as illustrated 4 Slide ring 5 Ring cover A Correct condition of diaphragm when brake fluid is being supplied B Condition when diaphragm is ex...

Page 137: ...Air bleeding 04867 04903 A 0 2 1 2 0 A Start the engine and let it idle until brake fluid replacement is completed Attach one end of 0 vinyl hose to front or rear airmaster 1 Then attach one end of an...

Page 138: ...der 2 at specified torque as soon as brake fluid flowing out is free of air bubbles Adjust brake shoe clearance when you have finished air bleeding Check that brake fluid comes up to lebel H of the fl...

Page 139: ...rear left and right 4 points 3Rear spring pin front left and right 2 points 4Rear spring pin rear left and right 4 points 5Steering shaft 6Kingpin bearing left and right 4 points 7Universal joint of p...

Page 140: ...01 43 01 Door hinge 01518...

Page 141: ...Group 10 Removal and Installation of Engine Pub No TWME9502 10 Table of Contents BACK HOME...

Page 142: ...AND INSTALLATION OF ENGINE REMOVAL AND INSTALLATION OF ENGINE Charge and Discharge of Engine Coolant Removal and Installation of Hoses 2 Removal and Installation of Engine Related Parts 4 Removal and...

Page 143: ...10 2 REMOVAL AND INSTALLATION OF ENGINE Charge and Discharge of Engine Coolant Removal and Installation of Hoses 13258 13257 9 8 7 6 1 5 2 3 4 A 14 15 11 12 13 13259 13260 10...

Page 144: ...them and secure them at a higher level than the fuel tank to prevent fuel from flowing out of them Otherwise a fire might be caused You must make sure that the engine coolant is cold before draining i...

Page 145: ...10 4 13262 13261 Removal and Installation of Engine Related Parts REMOVAL AND INSTALLATION OF ENGINE 1 23 22 21 20 19 6 8 7 14 15 16 17 18 5 4 3 9 10 12 11 13 2...

Page 146: ...Chassis harness 17 Engine stop cable Gr 13 18 Accelerator control cable Gr 13 19 Cooler compressor Gr 55A 20 Harness Chassis harness 21 Harness Ground 22 Air intake hose Gr 15 23 Front pipe Gr 15 NOTE...

Page 147: ...ATION OF ENGINE Removal sequence 1 Bolt 2 Nut 3 Engine assembly WARNING When you lift engine assembly 3 you must use lifting gear that is strong enough to lift the mass of the engine approximately 550...

Page 148: ...lift the engine using crane C until the lifting gear becomes taut Make sure that wiring and hoses are disconnected 13263 13264 Lower engine assembly 3 slowly so that it does not hit the frame or cab W...

Page 149: ...Group 11 Engine Pub No TWME9502 11 Table of Contents BACK HOME...

Page 150: ...NG 6 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE Inspection of Engine Compression 7 Inspection and Adjustment of Valve Clearance 9 CYLINDER HEAD AND VALVE MECHANISM 10 TIMING GEAR 24 CAMSHAFT 28 PIST...

Page 151: ...diesel Combustion chamber type Direct injection type Valve mechanism Overhead valve OHV type Maximum output HP rpm 175 2900 SAE Gross Maximum torque lbs ft rpm 325 2000 SAE Gross Bore stroke mm in 104...

Page 152: ...1 Rocker arm 2 Valve spring 3 Camshaft 4 Cylinder sleeve 5 Cylinder head 6 Flywheel 7 Crankshaft 8 Exhaust valve 9 Piston 10 Connecting rod 11 Timing gear 12 Tappet 13 Inlet valve 14 Push rod A Direct...

Page 153: ...rod bolt 5 Upper connecting rod bearing 6 Lower connecting rod bearing A Alignment mark B Mass mark A B C D E F G STRUCTURE AND OPERATION Connecting Rod Piston 03141 1 3 A 5 6 4 B 2 14204 A Stamped m...

Page 154: ...ar 4 Oil pump gear 5 Idler gear 6 Idler shaft 7 Idler bushing 8 Bolt 9 Thrust plate 10 Power steering oil pump gear A Oil hole Alignment marks 1 2 3 are punch marked on each timing gear to ensure prop...

Page 155: ...Gr 13 Air cleaner mesh clogged Gr 15 Muffler clogged Gr 15 Pipe and hose installation faulty Ancillary equipment injection pump alternator etc or installation faulty Gr 13 Gr 54 V belt loose or damag...

Page 156: ...he engine It is strongly recommended that this item is inspected periodi cally and that you record the history of deterioration in engine perform ance as this will help you to diagnose causes of futur...

Page 157: ...e mounting hole at high temperature Mount gasket 3 and 0 compression gauge adaptor in injection nozzle mounting hole A and fasten them with nozzle bridge 4 then mount compression gauge C Measure engin...

Page 158: ...th the following tabulated sequence of each valve 06205 A 2 Piston No 1 2 3 4 5 6 Valve In Ex In Ex In Ex In Ex In Ex In Ex arrangement take haust take haust take haust take haust take haust take haus...

Page 159: ...n Kinds Quantity 4 Thread area of cylinder head bolt Engine oil As required 6 Both ends of push rod Engine oil As required 9 External periphery of tappet Engine oil As required 1 A A 3 5 12408 6 4 2 S...

Page 160: ...1948 6 6Push rod deflection If the measured value is higher than the limit replace push rod 6 03321 12410 First loosen cylinder head bolts 4 in the numbered order as illustrated then remove them A B 4...

Page 161: ...as follows Tightened simultaneously with rocker and bracket assembly 01991 12758 Turn 0 socket wrench holder D counterclockwise and keep the spring in the wrench compressed E Socket F Rod G Rod for co...

Page 162: ...asket 8 onto crankcase in the direction as illustrated CAUTION Be sure to measure the amount of protrusion whenever a piston or connecting rod is replaced since replacement changes the amount of protr...

Page 163: ...mit Remedy Basic diameter in 4 9 Clearance between rocker bushing and rocker shaft 19 0 06 to 0 11 0 2 0 0079 Replace 0 75 0 0024 to 0 0043 Lubricant Location Points of application Kinds Quantity 4 In...

Page 164: ...ation of rocker shaft When installing rocker shaft 9 bring oil passage hole for lubrication A to front side B C Fixing hole of the set bolt 4 9 C C A B 9 Press fitting Align oil hole A of rocker bushi...

Page 165: ...zle tip gasket 15 O ring 16 Injection nozzle Gr 13 17 Inlet valve guide 18 Exhaust valve guide 19 Inlet valve seat 20 Exhaust valve seat 21 Water director 22 Stud 23 Cylinder head Non reusable parts C...

Page 166: ...Outer diameter of stem 8 93 to 8 94 0 3515 to 0 3519 8 85 0 348 Replace Valve recess from the cylinder 0 75 to 1 25 0 030 to 0 049 1 7 0 067 Inspect head bottom surface each part Valve margin 1 5 0 0...

Page 167: ...of valve and valve guide Valve guide remover MH061066 Removal of valve guide 17 18 Valve guide installer MH061998 Press fitting of valve guide A MH061067 B MH061275 19 20 Inlet Press fitting of valve...

Page 168: ...stem seal Apply engine oil to lip A of valve stem seal 6 Tap down 0 valve stem seal installer until it hits cylinder head 23 45 Installation of outer and inner valve springs Install outer springs 4 a...

Page 169: ...lap valve 7 8 and valve seats 19 20 after grinding P11 21 78MNValve and valve guide Inspection When the clearance is higher than the limit replace the faulty parts Installation Tap down valve guides...

Page 170: ...urface A of valves 7 8 with valve seats 19 20 CAUTION Take care not to smear stems B of valves 7 8 with the compound NOTE Start with medium grit compound 120 to 150 grit and for finish ing up use fine...

Page 171: ...another light abrasion using 400 grit emery paper placed between the cutter and the seat Adjust the seat width A of valves 7 8 using 15 or 75 cutter to make seat width conform to the standard value C...

Page 172: ...ad 23 08400 12439 03262 Immerse valve seats 19 20 in liquid nitrogen and cool them substan tially Press fit into the cylinder head using 1 caulking tool body and 2 caulking rings inlet and exhaust CAU...

Page 173: ...sequence Follow the disassembly sequence in reverse 12 Idler gear assembly 13 Idler gear bushing 14 Idler gear 15 Idler gear shaft 16 Clamp 17 Oil hose Gr 37 18 Bolt 19 Oil hose Gr 37 20 O ring 21 Pow...

Page 174: ...039 Replace idler shaft 1 77 0 0012 to 0 0024 0 Special tools Unit mm in Location Tool name and shape Part No Application 2 Cone puller MH062496 Removal of taper cone 13 Idler gear bushing puller MH06...

Page 175: ...Installation of timing gear case Apply sealant A to the mounting surface of timing gear case 9 evenly without break After applying sealant within three minutes mount to the front plate CAUTION Be sure...

Page 176: ...e A Chamfered side 03538 03539 Idler gear bushing Removal A Press 13 0 A 11 10 A A IK Idler gear bushing and idler shaft Inspection If the clearance is higher than the limit replace the faulty parts 1...

Page 177: ...End play of camshaft 0 05 to 0 22 0 0020 to 0 0087 0 3 0 012 Inspect 8 Camshaft Difference between Inlet 7 195 0 05 0 28 0 0020 6 70 0 26 long and short diameters Exhaust 7 321 0 05 0 29 0 0020 6 82...

Page 178: ...by undoing bolts 1 through the holes in camshaft gear 5 CAUTION Be careful not to damage the camshaft bushings when you remove camshaft assembly 2 12651 1 5 2 0 Special tools Unit mm in Location Tool...

Page 179: ...camshaft gear 5 with the alignment mark on the idler gear P11 CAMSHAFT 12652 2 03547 5Camshaft gear Removal Never remove camshaft gear 5 by striking hitting or hammering it Installation Install camsha...

Page 180: ...ated because the cam is tapered B Long diameter C Short diameter D Front of the engine 8to FHI Camshaft and camshaft bushing Inspection If the clearance is greater than the limit replace the faulty pa...

Page 181: ...231 12 F E 0 Press in until surface D of No 4 camshaft bushing 12 is flush with chamfered part E of crankcase F Front of the engine Align oil hole C of No 4 camshaft bushing 12 in the direction as ill...

Page 182: ...and press in until camshaft bushing surface P is flush with crankcase surface Q F Front of the engine 06227 0 F P M N F Q 12698 GInstallation of sealing cap Press fit sealing cap 11 into crankcase to...

Page 183: ...2 Lower connecting rod bearing 3 Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly P11 42 6 Cylinder sleeve 12702 1 Crankshaft P11 52 2 Crankcase P11 52 3 Oil pan...

Page 184: ...028 to 0 0043 replace with oversizes 6 Cylinder sleeve Inner 104 to 104 03 4 094 to 4 095 104 25 4 10 Adjust or diameter replace with Circular 0 01 0 00039 or less oversizes accuracy Cylindrical 0 03...

Page 185: ...procedure Inspection before disassembly 1 Extent of piston protrusion from the upper surface of crankcase 2 NOTE Always inspect the extent of piston protrusion because it af fects the engine performan...

Page 186: ...g Inspection CAUTION Do not forcibly open or expand connecting rod bearings 2 4 When either upper or lower connecting rod bearings 2 4 needs replacing replace as a set 03381 4 2 B A A 06358 1 Expansio...

Page 187: ...ine using the following procedure D Front of the engine 03384 11651 03386 Match the inner diameter of 1 piston guide clamp to the outer diameter of the piston skirt by turning adjusting bolt E of 2 pi...

Page 188: ...ersized piston A In the direction of the crankshaft axis B At right angles to the crankshaft axis If the clearance between piston 5 and cylinder sleeve 6 deviates from the standard value even when the...

Page 189: ...rities such as defects or insufficient interfer ence correct them by boring NOTE Pull out cylinder sleeve 6 of all cylinders and bore the sleeve holes perfectly round when you bore the sleeve holes of...

Page 190: ...sufficient Prepare cylinder sleeve 6 which is 0 5 mm 0 020 in oversize in diameter Hone crankcase 2 making the clearance between the outer diam eter of cylinder sleeve 6 and the sleeve hole of crankca...

Page 191: ...connecting rod 0 05 0 0020 Repair or replace 5 to 7 Deviation of piston ring 1st compression ring 0 3 to 0 45 0 012 to 0 018 1 5 0 059 Replace fitted position 2nd compression ring 0 4 to 0 55 0 016 to...

Page 192: ...ushing puller kit A Base B Bracket C Puller D Collar E Plate F Collar G Nut Pulling out Remove upper connecting rod bearing from the big end of connecting rod 4 Place connecting rod 4 on base A and fi...

Page 193: ...iston pin and connecting rod and piston Disassembly Drift out piston pin 2 using a rod When removal of piston pin 2 is difficult warm piston 8 using a piston heater or hot water Installation Apply eng...

Page 194: ...tortion B of connecting rod 4 If the measured value is higher than the limit repair or replace the connect ing rod C Connecting rod aligner Measuring instrument NOTE When making measurements by mounti...

Page 195: ...slit Install piston rings 5 to 7 into the crankcase cylinder sleeve using the head of piston 8 to level the piston ring Measure the clearance of the piston ring split while keeping them level and stat...

Page 196: ...y parts Measure using feeler gauge F by pressing 1st compression ring 5 against piston 8 with straight edge G NOTE Measurement has to be conducted around the whole periphery of piston 8 after removing...

Page 197: ...ission Manual transmission Service standards Unit mm in Location Maintenance item Standard value Limit Remedy 7 Height from bolt mounting surface 20 0 787 19 0 748 Correct to friction surface or repla...

Page 198: ...st then begin the inspection 03350 7 8 03349 2 Height of friction surfaces If the measured value is lower than the limit repair or replace flywheel assembly 7 A Height from bolt mounting surface to fr...

Page 199: ...ting of rear oil seal Apply engine oil to lip area A of rear oil seal 11 Install rear oil seal 11 in flywheel housing 12 in the direction as illustrated Apply sealant C along line B on rear oil seal 1...

Page 200: ...11 51 11 M E M O...