Complete workshop repair service manual with electrical wiring diagrams for Mitsubishi Fuso FK/FM Series MY1986-2001 Trucks. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

Mitsubishi Fuso FK.FM Series 1986-2001 Trucks service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

4,700+ pages, bookmarked, Searchable, Printable, high quality PDF
FK.FM Series 1986-1987 Fuso Service Manual (TWME8514 - 751 pages).pdf
FK.FM Series 1990-1991 Fuso Service Manual (TWME8910 - 904 pages).pdf
FK.FM Series 1992-1995 Fuso Service Manual (TWME9107 - 1,252 pages).pdf
FK.FM Series 1996-2001 Fuso Service Manual (TWME9503 - 1,909 pages).pdf

EXCERPT:
FK.FM Series 1996-2001 Fuso Service Manual (TWME9503 - 1;909 pages)...2
  GR00 GENERAL...2
  GR00 97MC...45
  GR00 98MC...65
  GR00 99MC...92
  GR00 00MC...142
  GR00 01MC...198
  GR01 Maintenance Schedule...253
  GR10 REMOVAL AND ISTALLATION OF ENGINE...297
  GR11 ENGINE...305
  GR12 LUBRICATION...368
  GR13 FUEL AND ENGINE CONTROL...391
  GR13 MC99 FUEL AND ENGINE CONTROL '99 Minor changes...465
  GR14 COOLING...549
  GR15 INTAKE AND EXHAUST...575
  GR21 CLUTCH...607
  GR22A MANUAL TRANSMISSION M060S5,S6,M070S6...665
  GR22A MANUAL TRANSMISSIO UPDATE...750
  GR22B MANUAL TRANSMISION M8S2X5...843
  GR23 AUTOMATIC TRANSMISSION...914
  GR23 AUTOMATIC TRANSMISSION 2001 MODEL YEAR CHANGE...945
  GR25 PROPELLER SHAFT...1024
  GR26 FRONT AXLE...1059
  GR27 REAR AXLE...1094
  GR31 WHEEL AND TIRE...1140
  GR33 FRONT SUSPENSION...1148
  GR34 REAR SUSPENSION...1161
  GR35A BRAKE...1175
  GR35B BRAKE FULL AIR BRAKE...1277
  GR35C ABS '99 MINOR CHANGE...1373
  GR36A PARKING BRAKE...1455
  GR36B Parking Brake...1469
  GR37 STEERING...1483
  GR41 FRAME...1528
  GR42 CAB...1535
  GR54 ELECTRICAL...1608
  GR55A AIR- CONDITIONER...1859
  GR55B Heater...1893
FK.FM Series 1986-1987 Fuso Service Manual (TWME8514 - 751 pages)...1911
  1986-1987 FK/FM Service Manual...1911
    Foreword...1912
      1. Group Classification...1913
      2. Definition of Terms and Unit Used...1914
      3. Notes On Illustrations...1915
    Group 00 - General...1917
      1. Exterior Views...1918
      2. Major Specifications...1919
      3. Power Train Table...1924
      4. Equipment Model Notation...1925
      5. Performance Curves...1926
        5.1 Operation Performance Curves...1926
        5.2 Engine Performance Curves...1930
      6. Servicing Precautions...1931
      7. Vehicle Identification Number...1934
      8. Standard Bolts and Nuts Tightening Torque Table...1936
    Group 01 - Maintenance Schedule...1937
      1. Using the Maintenance Schedule Table...1939
      2. Maintenance Schedule Table...1940
        2.1 Replacement of Oil Filter Element...1946
        2.2 Replacement of the Fuel Filter Element...1946
        2.3 Cleaning of the Fuel Feed Pump Gauze Filter...1947
        2.4 Bleeding of the Fuel System...1947
        2.5 Adjustment of V-Belt Tension...1947
        2.6 Cleaning and Replacement of Air Cleaner Element...1948
          2.6.1 Dry Dust Buildup...1948
          2.6.2 Oil Smoke, Soot, and Oil Black Deposits...1948
          2.6.3 Inspection After Drying...1949
        2.7 Inspection of Clutch Pedal...1949
          2.7.1 Inspection of Pedal Play...1949
          2.7.2 Clearance to Floorboard When Released...1949
          2.7.3 Clutch Operation...1949
        2.8 Servicing of Tires...1950
          2.8.1 Tire Inflation Pressure...1950
          2.8.2 Removal of Tire...1950
          2.8.3 Installation of Tire...1951
          2.8.4 Retightening of Wheel Nuts...1951
          2.8.5 Tire Rotation...1952
        2.9 Servicing of Air Drier...1952
        2.10 Adjustment of Wheel Brake Shoe Clearance...1952
          2.10.1 Adjusting Gear Type [FK415, FK455]...1952
          2.10.2 Adjusting Cam Type [FM555]...1953
        2.11 Adjustment of Parking Brake Shoe Clearance...1954
        2.12 Servicing of Battery...1955
          2.12.1 Cleaning of Battery Terminals...1955
          2.12.2 Inspection of Fluid Level...1955
          2.12.3 Specific Gravity...1956
        2.13 Replacement of Fuses...1956
      3. Lubrication...1958
        3.1 Engine...1959
          3.1.1 Engine Oil Level and Contamination...1959
          3.1.2 Replacement of Engine Oil...1959
        3.2 Clutch...1960
          3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank...1960
          3.2.2 Replacement of Brake Fluid...1961
          3.2.3 Bleeding of Clutch System...1961
        3.3 Transmission...1961
          3.3.1 Inspection of Transmission Gear Oil Level...1961
          3.3.2 Replacement of Transmission Gear Oil...1962
        3.4 Rear Axle...1962
          3.4.1 Inspection of Rear Axle Gear Oil Level...1962
          3.4.2 Replacement of Rear Axle Gear Oil...1962
        3.5 Brakes...1962
          3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank...1962
          3.5.2 Replacement of Brake Fluid...1962
          3.5.3 Bleeding of the Brake System...1963
        3.6 Power Steering...1964
          3.6.1 Inspection of Power Steering Oil Level...1964
          3.6.2 Replacement of Power Steering Oil...1964
          3.6.3 Bleeding of the Power Steering System...1965
        3.7 Lubrication...1965
    Group 11 - Engine...1968
      1. General...1969
        1.1 Engine Proper...1969
        1.2 Air Compressor...1971
      2. Specifications...1971
      3. Service Standards...1972
        3.1 Service Standard Table...1972
        3.2 Tightening Torque Table...1976
        3.3 Sealant, Oil and Grease...1976
      4. Service Procedure...1977
        4.1 Engine Proper...1977
          4.1.1 Measurement of Compression Pressure...1977
          4.1.2 Removal...1978
          4.1.3 Disassembly...1983
          4.1.4 Inspection and Correction...1990
          4.1.5 Reassembly...2006
          4.1.6 Installation...2017
          4.1.7 Adjustment...2018
        4.2 Air Compressor...2019
          4.2.1 Removal...2019
          4.2.2 Disassembly...2020
          4.2.3 Inspection and Correction...2021
          4.2.4 Reassembly...2024
          4.2.5 Installation...2025
      5. Special Tool...2026
      6. Troubleshooting...2030
        6.1 Engine...2030
        6.2 Valve Mechanism...2036
    Group 12 - Lubrication...2039
      1. General...2040
      2. Specifications...2044
      3. Service Standards...2045
        3.1 Service Standard Table...2045
        3.2 Tightening Torque Table...2046
      4. Service Procedure...2046
        4.1 Oil Pump...2047
          4.1.1 Removal...2047
          4.1.2 Disassembly and Inspection...2048
          4.1.3 Reassembly...2050
          4.1.4 Installation...2050
        4.2 Oil Filter, Oil Cooler...2051
          4.2.1 Disassembly and Inspection...2051
        4.3 Regulator Valve, Check Valve [6D14T]...2053
          4.3.1 Regulator Valve...2053
          4.3.2 Check Valve [6D14T]...2053
      5. Special Tool...2054
      6. Troubleshooting...2055
    Group 13 - Fuel...2057
      1. General...2058
        1.1 Fuel System...2058
        1.2 Engine Control...2062
      2. Specifications...2063
      3. Service Standards...2063
        3.1 Service Standard Table...2063
        3.2 Tightening Torque Table...2065
      4. Service Procedure...2066
        4.1 Injection Pump...2066
          4.1.1 Removal...2066
          4.1.2 Disassembly...2067
          4.1.3 Inspection and Correction...2068
          4.1.4 Reassembly...2069
          4.1.5 Test and Adjustment...2070
        4.2 Governor...2075
          4.2.1 Removal and Disassembly...2075
          4.2.2 Inspection and Reassembly...2076
          4.2.3 Adjustment...2078
        4.3 Auto Timer...2083
          4.3.1 Disassembly and Inspection...2083
          4.3.2 Reassembly...2085
          4.3.3 Adjustment...2085
        4.4 Feed Pump...2086
          4.4.1 Disassembly and Reassembly...2086
          4.4.2 Test...2087
        4.5 Injection Nozzle...2087
          4.5.1 Removal...2087
          4.5.2 Disassembly...2087
          4.5.3 Cleaning and Inspection...2088
          4.5.4 Reassembly...2089
          4.5.5 Test and Adjustment...2089
          4.5.6 Installation...2090
        4.6 Fuel Filter...2091
          4.6.1 Disassembly and Reassembly...2091
        4.7 Water Separator...2091
          4.7.1 Disassembly and Reassembly...2091
        4.8 Bleeding the Fuel System...2091
        4.9 Engine Control...2092
          4.9.1 Removal and Installation...2092
          4.9.2 Adjustment...2093
      5. Special Tool...2095
      6. Troubleshooting...2096
    Group 14 - Cooling...2102
      1. General...2103
      2. Specifications...2105
      3. Service Standards...2106
        3.1 Service Standard Table...2106
        3.2 Tightening Torque Table...2106
        3.3 Sealant, Oil and Grease...2106
      4. Service Procedure...2107
        4.1 Auto Cool Fan Coupling...2107
          4.1.1 Removal and Disassembly...2107
          4.1.2 Inspection and Correction...2107
          4.1.3 Reassembly and Installation...2108
        4.2 Water Pump...2108
          4.2.1 Removal...2108
          4.2.2 Disassembly and Inspection...2109
          4.2.3 Reassembly...2111
        4.3 Thermostat...2111
          4.3.1 Removal and Disassembly...2111
          4.3.2 Inspection...2112
        4.4 Radiator...2112
          4.4.1 Removal and Disassembly...2112
          4.4.2 Inspection...2113
          4.4.3 Installation...2114
          4.4.4 Gas Leak Test...2115
        4.5 Reservoir Tank...2115
          4.5.1 Removal and Inspection...2115
        4.6 Cleaning of Cooling System...2116
      5. Special Tool...2117
      6. Troubleshooting...2118
    Group 15 - Intake and Exhaust...2120
      1. General...2121
      2. Specifications...2123
      3. Service Standards...2123
        3.1 Service Standard Table...2123
        3.2 Tightening Torque Table...2123
      4. Service Procedure...2124
        4.1 Turbocharger [6D14T]...2124
          4.1.1 Removal...2124
          4.1.2 Disassembly...2125
          4.1.3 Inspection and Correction...2126
          4.1.4 Reassembly...2128
          4.1.5 Installation...2129
          4.1.6 Adjustment...2129
        4.2 Air Cleaner...2131
          4.2.1 Disassembly and Reassembly...2131
          4.2.2 Inspection and Cleaning...2132
        4.3 Inlet Manifold...2133
        4.4 Exhaust Manifold...2133
        4.5 P.C.V. (Positive Crankcase Ventilation) Valve [6D14T]...2134
      5. Special Tool...2135
      6. Troubleshooting...2136
    Group 16 - Engine Electrical...2139
      1. General...2140
      2. Specifications...2142
      3. Service Standards...2142
        3.1 Service Standard Table...2142
        3.2 Tightening Torque Table...2143
        3.3 Sealant, Oil and Grease...2143
      4. Service Procedure...2144
        4.1 Starter...2144
          4.1.1 Removal...2144
          4.1.2 Disassembly...2144
          4.1.3 Inspection...2145
          4.1.4 Reassembly...2146
        4.2 Alternator...2147
          4.2.1 Removal...2147
          4.2.2 Disassembly...2148
          4.2.3 Inspection...2149
          4.2.4 Reassembly...2149
          4.2.5 Tests...2150
          4.2.6 Installation...2151
        4.3 Glow Plug System...2153
          4.3.1 Removal and Installation...2153
          4.3.2 Inspection...2154
      5. Troubleshooting...2155
    Group 21 - Clutch [C5W33]...2160
      1. General...2161
        1.1 Clutch Control...2161
        1.2 Clutch Proper...2162
      2. Specifications...2162
      3. Service Standards...2163
        3.1 Service Standard Table...2163
        3.2 Tightening Torque Table...2164
      4. Service Procedure...2164
        4.1 Removal...2164
          4.1.1 Removal From Vehicle...2164
        4.2 Clutch Proper...2165
          4.2.1 Disassembly and Inspection...2165
          4.2.2 Reassembly and Adjustment...2167
        4.3 Clutch Pedal...2169
          4.3.1 Diassembly and Inspection...2169
          4.3.2 Reassembly and Adjustment...2169
        4.4 Clutch Master Cylinder...2170
          4.4.1 Disassembly and Inspection...2170
          4.4.2 Reassembly and Adjustment...2170
        4.5 Clutch Power Cylinder...2171
          4.5.1 Disassembly and Inspection...2171
          4.5.2 Reassembly...2171
        4.6 Replacement of Clutch System Fluid...2172
        4.7 Bleeding Clutch System...2172
        4.8 Adjustment of Clutch Control...2173
      5. Special Tool...2174
      6. Troubleshooting...2175
    Group 21 - Clutch [C6W35]...2184
      1. General...2185
        1.1 Clutch Control...2185
        1.2 Clutch Proper...2186
      2. Specifications...2186
      3. Service Standards...2187
        3.1 Service Standard Table...2187
        3.2 Tightening Torque Table...2189
      4. Service Procedure...2190
        4.1 Removal...2190
          4.1.1 Removal from Vehicle...2190
        4.2 Clutch Proper...2191
          4.2.1 Disassembly and Inspection...2191
          4.2.2 Reassembly and Adjustment...2193
        4.3 Clutch Pedal...2195
          4.3.1 Disassembly and Inspection...2195
          4.3.2 Reassembly and Adjustment...2195
        4.4 Clutch Master Cylinder...2196
          4.4.1 Disassembly and Inspection...2196
          4.4.2 Reassembly and Adjustment...2196
        4.5 Clutch Booster...2197
          4.5.1 Disassembly and Inspection...2197
          4.5.2 Reassembly and Adjustment...2198
        4.6 Inspection of Clutch Disc Wear...2200
        4.7 Replacement of Clutch System Fluid...2200
        4.8 Bleeding Clutch System...2201
        4.9 Adjustment of Clutch Control...2202
      5. Special Tool...2203
      6. Troubleshooting...2205
    Group 22 - Transmission [M5S5]...2215
      1. General...2216
      2. Specifications...2219
      3. Service Standards...2220
        3.1 Service Standard Table...2220
        3.2 Tightening Torque Table...2222
      4. Service Procedure...2223
        4.1 Key Points for Removal...2223
        4.2 Key Points for Installation...2224
        4.3 Adjustment After Installation...2224
        4.4 Disassembly, Inspection and Reassembly...2224
          4.4.1 Transmission Assembly...2224
          4.4.2 Main Shaft...2228
          4.4.3 Counter Shaft Gear...2232
          4.4.4 Reverse Gear...2234
          4.4.5 Drive Pinion...2236
          4.4.6 Reassembly of Clutch Housing...2236
          4.4.7 Gearshifter, Lower...2237
          4.4.8 Gearshifter, Upper...2241
          4.4.9 Rear Cover...2243
          4.4.10 Speedometer Gears...2245
          4.4.11 Transmission Control...2245
      5. Special Tool...2248
      6. Troubleshooting...2253
    Group 22 - Transmission [M6S5]...2260
      1. General...2261
      2. Specifications...2264
      3. Service Standards...2265
        3.1 Service Standard Table...2265
        3.2 Tightening Torque Table...2267
      4. Service Procedure...2268
        4.1 Key Points for Removal...2268
        4.2 Key Points for Installation...2269
        4.3 Adjustment After Installation...2269
        4.4 Disassembly, Inspection and Reassembly...2269
          4.4.1 Transmission Assembly...2269
          4.4.2 Main Shaft...2273
          4.4.3 Counter Shaft Gear...2277
          4.4.4 Reverse Gear...2279
          4.4.5 Drive Pinion...2281
          4.4.6 Reassembly of Clutch Housing...2281
          4.4.7 Gearshifter, Lower...2282
          4.4.8 Gearshifter, Upper...2286
          4.4.9 Rear Cover...2288
          4.4.10 Speedometer Gears...2290
          4.4.11 Transmission Control...2290
      5. Special Tool...2293
      6. Troubleshooting...2298
    Group 22 - Transmission [M8S2x5]...2305
      1. General...2306
      2. Specifications...2309
        2.1 Transmission Proper...2309
        2.2 Transmission Control...2309
      3. Service Standards...2310
        3.1 Service Standard Table...2310
        3.2 Tightening Torque Table...2313
      4. Service Procedure...2315
        4.1 Key Points for Removal...2315
        4.2 Key Points for Installation...2316
        4.3 Adjustment After Installation...2316
        4.4 Disassembly, Inspection and Reassembly...2316
          4.4.1 Transmission Assembly...2316
          4.4.2 Main Shaft...2320
          4.4.3 Counter Shaft Gear...2324
          4.4.4 Reverse Gear...2327
          4.4.5 Drive Pinion...2328
          4.4.6 Reassembly of Clutch Housing...2329
          4.4.7 Gearshifter, Lower...2329
          4.4.8 Gearshifter, Upper...2333
          4.4.9 Splitter, Upper...2335
          4.4.10 Rear Cover...2337
          4.4.11 Speedometer Gears...2338
          4.4.12 Splitter Case and Gears...2339
          4.4.13 Power Shift...2341
          4.4.14 Splitter Control...2343
          4.4.15 Transmission Control...2345
      5. Special Tool...2348
      6. Troubleshooting...2353
    Group 25 - Propeller Shaft...2362
      1. General...2363
      2. Specifications...2363
      3. Service Standards...2364
        3.1 Service Standard Table...2364
        3.2 Tightening Torque Table...2364
      4. Service Procedure...2365
        4.1 Removal and Installation...2365
        4.2 Disassembly, Inspection and Correction...2366
        4.3 Reassembly...2369
        4.4 Propeller Shaft Dynamic Balance Adjustment Procedures...2372
      5. Special Tool...2374
      6. Troubleshooting...2376
    Group 26 - Front Axle...2378
      1. General...2379
      2. Specifications...2379
      3. Service Standards...2380
        3.1 Service Standard Table...2380
        3.2 Tightening Torque Table...2381
      4. Service Procedure...2382
        4.1 Removal and Installation...2382
        4.2 Wheel Hub and Brake Drum...2383
          4.2.1 Disassembly, Inspection and Correction...2383
          4.2.2 Reassembly...2385
          4.2.3 Adjustment of Bearing Starting Torque...2386
        4.3 Front Axle, Knuckle and Kingpin...2388
          4.3.1 Disassembly, Inspection and Correction...2388
          4.3.2 Measurement of Front Axle Bends...2389
          4.3.3 Measurement of Kingpin Inclination...2390
          4.3.4 Reassembly...2390
        4.4 Adjustment After Installation (Wheel Alignment)...2391
      5. Special Tool...2392
      6. Troubleshooting...2395
    Group 27 - Rear Axle...2398
      1. General...2399
      2. Specifications...2399
      3. Service Standards...2400
        3.1 Service Standard Table...2400
        3.2 Tightening Torque Table...2401
      4. Service Procedure...2402
        4.1 Removal and Installation...2402
        4.2 Wheel Hub and Brake Drum...2403
          4.2.1 Disassembly, Inspection and Correction...2403
          4.2.2 Reassembly...2405
          4.2.3 Adjustment of Bearing Starting Torque...2407
        4.3 Reduction and Differential...2408
          4.3.1 Disassembly, Inspection and Correction...2408
          4.3.2 Reassembly...2412
          4.3.3 Adjustment of Starting Torque of Reduction Pinion Bearing...2415
          4.3.4 Selection of Reduction Pinion Mounting Adjusting Shim...2415
          4.3.5 Adjustment of Differential Case Side Bearing and Reduction Gear...2416
          4.3.6 Reduction Gear Tooth Contact...2417
      5. Special Tool...2420
      6. Troubleshooting...2426
    Group 31 - Wheel and Tire...2429
      1. Specifications...2430
      2. Service Procedure...2430
      3. Service Standards...2431
        3.1 Service Standard Table...2431
        3.2 Tightening Torque Table...2431
      4. Troubleshooting...2431
    Group 33 - Front Suspension...2434
      1. General...2435
      2. Specifications...2435
      3. Service Standards...2436
        3.1 Service Standard Table...2436
        3.2 Tightening Torque Table...2436
      4. Service Procedure...2437
        4.1 Removal and Installation...2437
        4.2 Disassembly, Inspection and Correction...2438
        4.3 Reassembly...2439
      5. Special Tool...2441
      6. Troubleshooting...2442
    Group 34 - Rear Suspension...2444
      1. General...2445
      2. Specifications...2445
      3. Service Standards...2446
        3.1 Service Standard Table...2446
        3.2 Tightening Torque Table...2446
      4. Service Procedure...2447
        4.1 Removal and Installation...2447
        4.2 Disassembly, Inspection and Correction...2448
        4.3 Reassembly...2449
      5. Special Tool...2450
      6. Troubleshooting...2451
    Group 35 - Brake...2453
      1. General...2455
        1.1 Service Brake...2455
        1.2 Parking Brake...2463
        1.3 Exhaust Brake...2464
      2. Specifications...2465
        2.1 Service Brake...2465
        2.2 Parking Brake...2466
        2.3 Exhaust Brake...2466
      3. Service Standards...2467
        3.1 Service Standard Table...2467
          3.1.1 Service Brake...2467
          3.1.2 Parking Brake...2471
          3.1.3 Exhaust Brake...2471
        3.2 Tightening Torque Table...2472
          3.2.1 Service Brake...2472
          3.2.2 Parking Brake...2474
          3.2.3 Exhaust Brake...2474
      4. Service Procedure of Service Brake...2475
        4.1 Brake System Diagram...2475
        4.2 Brake Pedal and Air Brake Valve...2477
          4.2.1 Removal and Installation...2477
          4.2.2 Brake Pedal...2478
          4.2.3 Air Brake Valve...2479
          4.2.4 Inspection and Adjustment After Reassembly...2483
        4.3 Brake Booster...2484
          4.3.1 Brake Booster for FK Series...2484
          4.3.2 Brake Booster for FM Series...2489
          4.3.3 Function Check After Reassembly...2494
        4.4 Air Pressure Governor...2495
          4.4.1 Function Check...2495
          4.4.2 Disassembly, Inspection and Correction...2496
          4.4.3 Reassembly...2497
          4.4.4 Inspection and Adjustment After Reassembly...2497
        4.5 Check Valve...2497
          4.5.1 Disassembly, Inspection and Correction...2497
          4.5.2 Reassembly and Inspection...2498
        4.6 Safety Valve...2498
        4.7 Low Air Pressure Switch...2498
        4.8 Stop Lamp Switch...2498
        4.9 Supply Valve...2499
          4.9.1 Disassembly, Inspection and Correction...2499
          4.9.2 Reassembly and Adjustment...2499
        4.10 Air Drier...2499
          4.10.1 Maintenance and Inspection...2499
          4.10.2 Disassembly, Inspection and Correction...2499
          4.10.3 Reassembly...2501
          4.10.4 Inspection After Installation in Vehicle...2502
          4.10.5 Troubleshooting...2502
        4.11 Wheel Brake...2503
          4.11.1 Removal and Installation...2503
          4.11.2 Disassembly, Inspection and Correction...2503
          4.11.3 Reassembly...2510
          4.11.4 Replacement of Brake Lining and Correction of Brake Drum...2518
        4.12 Inspection and Adjustment After Installation...2518
          4.12.1 Replacement of Brake Fluid and Bleeding of Brake (Oil) System...2518
          4.12.2 Brake Shoe Clearance Adjustment...2520
      5. Service Procedure of Parking Brake...2521
        5.1 Parking Brake Drum Assembly...2521
          5.1.1 Key Points for Removal...2521
        5.2 Parking Brake Proper...2522
        5.3 Parking Brake Control...2526
        5.4 Adjustment After Installation...2527
      6. Service Procedure of Exhaust Brake...2529
        6.1 Exhaust Brake Valve...2529
          6.1.1 Disassembly and Inspection...2529
          6.1.2 Reassembly and Adjustment...2530
        6.2 Control Cylinder...2531
          6.2.1 Disassembly and Inspection...2531
          6.2.2 Reassembly...2531
        6.3 Exhaust Brake Microswitch...2532
      7. Special Tool...2533
        7.1 Service Brake...2533
        7.2 Parking Brake...2534
      8. Troubleshooting...2535
    Group 37 - Steering...2549
      1. General...2550
      2. Specifications...2553
      3. Service Standards...2554
        3.1 Service Standard Table...2554
        3.2 Tightening Torque Table...2555
      4. Service Procedure...2556
        4.1 Removal and Installation of Steering System...2556
          4.1.1 Removal of Starter Switch Wires and Cables...2557
          4.1.2 Removal of Upper and Lower Shaft Assembly...2557
          4.1.3 Removal of Starter Switch...2558
          4.1.4 Installation of Starter Switch...2558
        4.2 Disassembly and Reassembly of Steering Wheel...2558
        4.3 Steering Shaft...2559
          4.3.1 Disassembly, Inspection and Correction...2559
          4.3.2 Reassembly...2559
        4.4 Details of Link and Bracket Section...2560
        4.5 Drag Link...2560
        4.6 Tie Rod...2561
        4.7 Integral Power Steering Booster...2561
          4.7.1 Disassembly, Inspection and Correction...2562
          4.7.2 Reassembly and Adjustment...2564
        4.8 Power Steering Oil Pump...2567
          4.8.1 Disassembly, Inspection and Correction...2567
          4.8.2 Reassembly...2568
          4.8.3 Adjustment...2569
        4.9 Power Steering Oil Tank...2569
          4.9.1 Disassembly...2569
          4.9.2 Reassembly...2570
        4.10 Adjustment After Installation...2570
          4.10.1 Bleeding...2570
          4.10.2 Performance Verification Tests...2571
          4.10.3 Steering Wheel Play...2572
          4.10.4 Adjustment of Steering Angle...2572
      5. Special Tool...2572
      6. Troubleshooting...2573
    Group 41 - Frame...2583
      1. General...2584
      2. Specifications...2584
      3. Service Procedure...2584
        3.1 Frame...2584
        3.2 Rivets...2585
        3.3 Shape of Frame...2586
      4. Troubleshooting...2589
    Group 42 - Cab...2590
      1. General...2591
      2. Specifications...2591
      3. Service Standards...2591
        3.1 Tightening Torque Table...2591
      4. Service Procedure...2592
        4.1 Key Points for Cab Removal and Installation...2592
          4.1.1 Removal...2592
          4.1.2 Installation...2593
        4.2 Doors...2595
          4.2.1 Removal of Doors...2595
          4.2.2 Door Installation Adjustment...2596
          4.2.3 Door Trim...2597
          4.2.4 Door Locking System...2598
          4.2.5 Parts Related to Glass...2599
        4.3 Seats...2601
          4.3.1 Seats...2601
          4.3.2 Seat Belts...2601
        4.4 Floor Mat...2602
        4.5 Overhead Console...2603
        4.6 Trims...2604
        4.7 Instrument Panel...2606
        4.8 Windshield Glass and Rear Window Glass...2606
          4.8.1 Removal...2606
          4.8.2 Installation...2607
        4.9 Rearview Mirrors...2608
        4.10 Removal of Front Panel and Related Parts...2609
      5. Troubleshooting...2611
    Group 54 - Chassis Electrical...2619
      1. General...2620
      2. Specifications...2620
        2.1 Electrical...2620
        2.2 Meter and Gauge...2621
        2.3 Lighting...2622
        2.4 Exhaust Brake...2623
        2.5 Wiper and Washer...2623
        2.6 Accessory...2624
      3. Service Procedure...2624
        3.1 Aiming of Headlamps...2624
        3.2 Warning and Indicator Lamps...2626
      4. Troubleshooting...2628
    Group 55 - Heater...2650
      1. General...2651
      2. Specifications...2651
      3. Service Procedure...2652
        3.1 Removal and Installation...2652
        3.2 Cleaning of Air Filter...2652
        3.3 Heater Control Adjustment Procedures...2653
      4. Troubleshooting...2655
    Wiring Diagram...2657
    Alphabetical Index...2659
FK.FM Series 1990-1991 Fuso Service Manual (TWME8910 - 904 pages)...2662
  1990-1991 FK/FM Service Manual...2662
    Foreword...2663
    Compilation of this Manual...2664
      1. Group Classification...2664
      2. Definitions of Terms and Units Used...2665
      3. Notes On Illustrations...2666
    Group 00 - General...2667
      Table of Contents...2668
      1. Exterior Views...2669
      2. Major Specifications...2671
      3. Power Train Table...2678
      4. Equipment Model Notation...2679
      5. Performance Curves...2680
        5.1 Operation Performance Curves...2680
        5.2 Engine Performance Curves...2688
      6. Servicing Precautions...2689
      7. Standard Bolts and Nuts Tightening Torque Table...2694
      8. Towing Precautions...2695
      9. Chassis and Engine Numbers...2695
      10. Vehicle Identification Number...2696
    Group 01 - Maintenance Schedule...2697
      Table of Contents...2698
      1. Using Maintenance Schedule Table...2699
      2. Maintenance Schedule...2700
        2.1 Replacement of Oil Filter Element...2706
        2.2 Replacement of Fuel Filter Element...2706
        2.3 Cleaning of Fuel Feed Pump Gauze Filter...2707
        2.4 Bleeding of Fuel System...2707
        2.5 Adjustment of V-Belt Tension...2707
        2.6 Cleaning and Replacement of Air Cleaner Element...2708
          2.6.1 Dry Dust Buildup...2708
        2.7 Inspection of Clutch Pedal...2709
          2.7.1 Inspection of Pedal Play...2709
          2.7.2 Clearance to Floorboard When Released...2709
          2.7.3 Clutch Operation...2709
        2.8 Servicing of Tires...2710
          2.8.1 Tire Inflation Pressures...2710
          2.8.2 Removal of Tire...2710
          2.8.3 Installation of Tire...2711
          2.8.4 Retightening of Wheel Nuts...2711
          2.8.5 Tire Rotation...2712
        2.9 Servicing of Air Drier...2712
        2.10 Adjustment of Wheel Brake Shoe Clearance...2713
          2.10.1 Air Over Hydraulic Brake <FK415, FK455>...2713
          2.10.2 Full Air Brake <FM Series>...2713
        2.11 Adjustment of Parking Brake Shoe Clearance <FK415, FK455>...2715
        2.12 Servicing of Battery...2715
          2.12.1 Cleaning of Battery Terminals...2716
          2.12.2 Inspection of Fluid Level...2716
          2.12.3 Specific Gravity...2716
        2.13 Replacement of Fuses...2717
      3. Lubrication...2719
        3.1 Engine...2720
          3.1.1 Engine Oil Level and Contamination...2720
          3.1.2 Replacement of Engine Oil...2721
        3.2 Clutch...2722
          3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank...2722
          3.2.2 Replacement of Brake Fluid...2722
          3.2.3 Bleeding of Clutch System...2722
        3.3 Transmission...2723
          3.3.1 Inspection of Transmission Gear Oil Level...2723
          3.3.2 Replacement of Transmission Gear Oil...2723
        3.4 Rear Axle...2723
          3.4.1 Inspection of Rear Axle Gear Oil Level...2723
          3.4.2 Replacement of Rear Axle Gear Oil...2723
        3.5 Brake <FK415, FK455>...2724
          3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank...2724
          3.5.2 Replacement of Brake Fluid...2724
          3.5.3 Bleeding of Brake System...2724
        3.6 Power Steering...2725
          3.6.1 Inspection of Power Steering Fluid Level...2725
          3.6.2 Replacement of Power Steering Fluid...2726
          3.6.3 Bleeding of Power Steering System...2726
        3.7 Chassis Parts...2727
    Group 11 - Engine...2728
      Table of Contents...2729
      1. Troubleshooting...2730
      2. Specifications...2732
      3. Service Standards...2733
        3.1 Service Standards Table...2733
        3.2 Tightening Torque Table...2736
      4. Special Tools...2737
      5. General...2742
      6. Service Procedure...2745
        6.1 Removal and Installation of Engine and Transmission...2745
        6.2 Engine Proper...2750
          6.2.1 Measurement of Compression Pressure...2750
          6.2.2 Cylinder Head and Valve Mechanism...2751
          6.2.3 Flywheel, Timing Gear, and Camshaft...2764
          6.2.4 Crankcase and Main Moving Parts...2774
          6.2.5 Adjustment...2791
    Group 12 - Lubrication...2792
      Table of Contents...2793
      1. Troubleshooting...2794
      2. Specifications...2794
      3. Service Standards...2795
        3.1 Service Standards Table...2795
        3.2 Tightening Torque Table...2795
      4. Special Tools...2796
      5. General...2796
      6. Service Procedure...2802
        6.1 Oil Pump...2802
          6.1.1 Removal and Installation...2802
          6.1.2 Disassembly and Inspection...2803
          6.1.3 Reassembly...2805
        6.2 Oil Filter and Oil Cooler...2805
          6.2.1 Removal and Installation...2805
          6.2.2 Disassembly, Inspection, and Reassembly of Oil Filter...2806
          6.2.3 Disassembly, Inspection, and Reassembly of Oil Cooler...2806
        6.3 Regulator Valve...2807
        6.4 Check Valve...2807
    Group 13 - Fuel and Engine Control...2808
      Table of Contents...2809
      1. Troubleshooting...2810
      2. Specifications...2814
      3. Service Standards...2815
        3.1 Service Standards Table...2815
        3.2 Tightening Torque Table...2815
      4. Special Tools...2816
      5. General...2817
        5.1 Fuel System...2817
        5.2 Engine Control...2821
      6. Service Procedure...2822
        6.1 Injection Pump Assembly...2822
          6.1.1 Removal and Installation...2822
          6.1.2 Inspection and Adjustment of Fuel Injection Timing...2823
        6.2 Feed Pump...2825
          6.2.1 Disassembly, Inspection, and Reassembly...2825
          6.2.2 Test...2825
        6.3 Injection Nozzle...2826
          6.3.1 Removal and Installation...2826
          6.3.2 Disassembly...2826
          6.3.3 Cleaning and Inspection...2826
          6.3.4 Reassembly...2827
          6.3.5 Test and Adjustment...2827
        6.4 Fuel Filter...2829
        6.5 Water Separator...2829
        6.6 Bleeding the Fuel System...2830
        6.7 Engine Control...2831
          6.7.1 Removal and Installation...2831
          6.7.2 Adjustment...2831
        6.8 Fuel Tank and Fuel Gauge Unit...2833
    Group 14 - Cooling...2834
      Table of Contents...2835
      1. Troubleshooting...2836
      2. Specifications...2837
      3. Service Standards...2837
        3.1 Service Standards Table...2837
        3.2 Tightening Torque Table...2838
      4. Special Tools...2838
      5. General...2839
      6. Service Procedure...2843
        6.1 Removal and Installation of Cooling System...2843
        6.2 Water Pump...2846
          6.2.1 Disassembly and Inspection...2846
          6.2.2 Reassembly...2848
        6.3 Inspection of Thermostat...2849
        6.4 Inspection of Auto Cool Fan Coupling...2849
        6.5 Inspection of Radiator...2850
        6.6 Inspection and Adjustment of V-Belt Tension...2851
        6.7 Cleaning of Cooling System...2851
        6.8 Gas Leak Test...2853
        6.9 Bleeding Cooling System...2853
    Group 15 - Intake and Exhaust...2854
      Table of Contents...2855
      1. Troubleshooting...2856
      2. Specifications...2857
      3. Service Standards...2857
        3.1 Service Standards Table...2857
        3.2 Tightening Torque Table...2858
      4. Special Tools...2858
      5. General...2858
      6. Service Procedure...2864
        6.1 Removal, Installation, and Inspection of Intake System...2864
        6.2 Air Cleaner...2865
          6.2.1 Disassembly and Reassembly...2865
          6.2.2 Inspection and Cleaning...2865
        6.3 Removal, Installation, and Inspection of Exhaust System...2867
        6.4 Turbocharger...2868
          6.4.1 Removal and Installation...2868
          6.4.2 Disassembly...2870
          6.4.3 Cleaning and Inspection...2873
          6.4.4 Reassembly...2876
          6.4.5 Measurement of Turbocharger Boost Pressure...2882
        6.5 Intercooler <6D16T2>...2884
          6.5.1 Removal and Installation...2884
          6.5.2 Inspection...2884
    Group 16 - Engine Electrical...2885
      Table of Contents...2886
      1. Troubleshooting...2887
      2. Specifications...2888
      3. Service Standards...2889
        3.1 Service Standards Table...2889
        3.2 Tightening Torque Table...2890
      4. Special Tools...2890
      5. General...2891
        5.1 Starter...2891
        5.2 Alternator...2894
        5.3 Glow System...2897
      6. Service Procedure...2899
        6.1 Starter...2899
          6.1.1 Removal and Installation...2899
          6.1.2 Disassembly...2899
          6.1.3 Inspection...2902
          6.1.4 Reassembly...2909
          6.1.5 Inspection and Adjustment After Reassembly...2911
        6.2 Alternator...2912
          6.2.1 Removal and Installation...2912
          6.2.2 Disassembly...2913
          6.2.3 Inspection...2915
          6.2.4 Reassembly...2919
          6.2.5 Inspection and Adjustment After Installation...2920
        6.3 Glow System...2923
          6.3.1 Removal and Installation of Glow Plug...2923
          6.3.2 Inspection...2923
    Group 21 - Clutch...2926
      Table of Contents...2927
      1. Troubleshooting...2928
      2. Specifications...2931
      3. Service Standards...2932
        3.1 Service Standards Table...2932
        3.2 Tightening Torque Table...2934
      4. Special Tools...2935
      5. General...2937
        5.1 Clutch Proper...2937
        5.2 Clutch Control...2938
          5.2.1 Clutch Master Cylinder...2939
          5.2.2 Clutch Booster...2940
      6. Service Procedure...2942
        6.1 Clutch...2942
          6.1.1 Removal and Installation...2942
          6.1.2 Disassembly and Inspection...2944
          6.1.3 Reassembly...2949
        6.2 Clutch Pedal...2952
          6.2.1 Removal and Installation...2952
          6.2.2 Disassembly and Inspection...2953
          6.2.3 Reassembly and Adjustment...2955
        6.3 Clutch Master Cylinder...2957
          6.3.1 Disassembly and Inspection...2957
          6.3.2 Reassembly...2958
        6.4 Power Cylinder...2958
          6.4.1 Removal and Installation...2958
          6.4.2 Disassembly and Inspection...2959
          6.4.3 Reassembly...2959
        6.5 Clutch Booster (Vehicles With M8S2x5)...2960
          6.5.1 Removal and Installation...2960
          6.5.2 Disassembly and Inspection...2960
          6.5.3 Reassembly...2963
          6.5.4 Performance Test...2965
          6.5.5 On-the-Vehicle Functional Check...2965
        6.6 Clutch Housing...2967
          6.6.1 Disassembly...2967
          6.6.2 Reassembly...2968
        6.7 Replacement of Brake Fluid in Clutch System...2970
        6.8 Bleeding the Clutch System...2970
        6.9 Adjustment of Clutch Pedal...2972
        6.10 Lubrication of Drive Pinion Splines...2973
    Group 22A - Manual Transmission (M5S5, M6S5)...2974
      Table of Contents...2975
      1. Troubleshooting...2976
      2. Specifications...2977
      3. Service Standards...2978
        3.1 Service Standards Table...2978
        3.2 Tightening Torque Table...2980
      4. Special Tools...2981
      5. General...2984
      6. Service Procedure...2986
        6.1 Removal and Installation of Transmission...2986
          6.1.1 Key Points for Removal...2986
          6.1.2 Key Points for Installation...2988
          6.1.3 Inspection and Adjustment After Installation...2988
        6.2 Transmission Assembly...2989
          6.2.1 Disassembly...2989
          6.2.2 Reassembly...2990
        6.3 Transmission...2990
          6.3.1 Inspection Before Disassembly...2990
          6.3.2 Disassembly and Inspection...2992
          6.3.3 Reassembly...2995
        6.4 Main Shaft...2998
          6.4.1 Disassembly and Inspection...2998
          6.4.2 Reassembly...3002
        6.5 Counter Shaft...3004
          6.5.1 Disassembly...3004
          6.5.2 Reassembly...3005
        6.6 Lower Gear Shifter...3006
          6.6.1 Disassembly and Inspection...3006
          6.6.2 Reassembly...3008
        6.7 Upper Gear Shifter...3009
          6.7.1 Disassembly and Inspection...3009
          6.7.2 Reassembly...3010
        6.8 Rear Cover...3012
          6.8.1 Disassembly and Inspection...3012
          6.8.2 Reassembly...3014
        6.9 Transmission Control...3016
          6.9.1 Disassembly and Inspection...3016
          6.9.2 Reassembly...3017
          6.9.3 Adjustment After Installation...3018
    Group 22B - Manual Transmission (M8S5, M8S2x5)...3019
      Table of Contents...3020
      1. Troubleshooting...3021
      2. Specifications...3022
        2.1 Transmission Proper...3022
        2.2 Transmission Control...3023
      3. Service Standards...3023
        3.1 Service Standards Table...3023
        3.2 Tightening Torque Table...3025
      4. Special Tools...3026
      5. General...3031
      6. Service Procedure...3033
        6.1 Removal and Installation of Transmission...3033
          6.1.1 Key Points for Removal...3033
          6.1.2 Key Points for Installation...3034
          6.1.3 Inspection and Adjustment After Installation...3034
        6.2 Transmission Assembly...3035
          6.2.1 Disassembly...3035
          6.2.2 Reassembly...3036
        6.3 Transmission...3037
          6.3.1 Inspection Before Disassembly...3037
          6.3.2 Disassembly and Inspection...3038
          6.3.3 Reassembly...3040
        6.4 Main Shaft...3044
          6.4.1 Disassembly and Inspection...3044
          6.4.2 Reassembly...3047
        6.5 Counter Shaft...3049
          6.5.1 Disassembly...3049
          6.5.2 Reassembly...3050
        6.6 Lower Gear Shifter...3051
          6.6.1 Disassembly and Inspection...3051
          6.6.2 Reassembly...3053
        6.7 Upper Gear Shifter...3054
          6.7.1 Disassembly and Inspection...3054
          6.7.2 Reassembly...3055
        6.8 Upper Splitter <M8S2x5 Only>...3057
          6.8.1 Disassembly...3057
          6.8.2 Reassembly...3057
        6.9 Rear Cover...3058
          6.9.1 Disassembly and Inspection...3058
          6.9.2 Reassembly...3059
        6.10 Splitter Case and Gear <M8S2x5 Only>...3060
          6.10.1 Inspection Before Disassembly...3060
          6.10.2 Disassembly and Inspection...3061
          6.10.3 Reassembly...3063
        6.11 Power Shift...3065
          6.11.1 Disassembly and Inspection...3065
          6.11.2 Reassembly...3066
        6.12 Splitter Control <M8S2x5 Only>...3067
          6.12.1 Splitter Air Piping...3067
          6.12.2 Power Cylinder...3067
        6.13 Transmission Control...3069
          6.13.1 Disassembly and Inspection...3069
          6.13.2 Reassembly...3070
          6.13.3 Adjustment After Installation...3071
    Group 23 - Automatic Transmission...3072
      Table of Contents...3073
      1. Troubleshooting...3074
      2. Specification...3076
      3. Service Standards...3076
        3.1 Service Standards Table...3076
        3.2 Tightening Torque Table...3077
      4. Special Tools...3078
      5. General...3079
        5.1 Automatic Transmission Control...3079
        5.2 Oil Cooler...3080
      6. Service Procedure...3081
        6.1 Removal and Installation of Automatic Transmission...3081
          6.1.1 Removal...3081
          6.1.2 Installation...3083
        6.2 Oil Seal and Speedometer Worm...3085
          6.2.1 Removal and Installation...3085
          6.2.2 Replacement of Front Oil Seal...3086
          6.2.3 Replacement of Rear Oil Seal...3086
          6.2.4 Replacement of Speedometer Worm...3086
        6.3 Automatic Transmission Control System...3088
          6.3.1 Removal and Installation...3088
          6.3.2 Inspection After Installation...3089
        6.4 Oil Cooler...3090
          6.4.1 Removal and Installation...3090
        6.5 Oil Filter...3090
          6.5.1 Removal and Installation...3090
        6.6 Replacement of Oil and Oil Filter...3091
    Group 25 - Propeller Shaft...3093
      Table of Contents...3094
      1. Troubleshooting...3095
      2. Specifications...3096
      3. Service Standards...3096
        3.1 Service Standards Table...3096
        3.2 Tightening Torque Table...3096
      4. Special Tools...3097
      5. General...3098
      6. Service Procedure...3099
        6.1 Removal and Installation...3099
        6.2 Front Propeller Shaft...3100
          6.2.1 Disassembly and Inspection...3100
          6.2.2 Reassembly...3104
        6.3 Rear Propeller Shaft...3107
          6.3.1 Disassembly and Inspection...3107
          6.3.2 Reassembly...3109
        6.4 Adjustment After Reassembly...3111
    Group 26 - Front Axle...3113
      Table of Contents...3114
      1. Troubleshooting...3115
      2. Specifications...3116
      3. Service Standards...3117
        3.1 Service Standards Table...3117
        3.2 Tightening Torque Table...3118
      4. Special Tools...3119
      5. General...3122
      6. Service Procedure...3123
        6.1 Removal and Installation...3123
        6.2 Wheel Hub and Brake Drum...3124
          6.2.1 Disassembly, Inspection, and Corrections...3124
          6.2.2 Reassembly...3126
        6.3 Front Axle, Knuckle, and Kingpin...3130
          6.3.1 Disassembly and Inspection...3130
          6.3.2 Reassembly...3133
        6.4 Inspection and Adjustment After Installation...3136
    Group 27 - Rear Axle...3140
      Table of Contents...3141
      1. Troubleshooting...3142
      2. Specifications...3143
      3. Service Standards...3144
        3.1 Service Standards Table...3144
        3.2 Tightening Torque Table...3145
      4. Special Tools...3146
      5. General...3151
      6. Service Procedure...3152
        6.1 Removal and Installation...3152
        6.2 Wheel Hub and Brake Drum...3153
          6.2.1 Disassembly, Inspection, and Corrections...3153
          6.2.2 Reassembly...3155
        6.3 Reduction and Differential...3160
          6.3.1 Removal...3160
          6.3.2 Inspection Before Disassembly...3160
          6.3.3 Disassembly and Inspection...3162
          6.3.4 Reassembly...3165
    Group 31 - Wheel and Tire...3174
      Table of Contents...3175
      1. Troubleshooting...3176
      2. Specifications...3176
      3. Service Standards...3177
        3.1 Service Standards Table...3177
        3.2 Tightening Torque Table...3177
      4. General...3177
      5. Service Procedure...3178
        5.1 Removal...3178
        5.2 Disassembly and Reassembly...3180
          5.2.1 Tire With Tube...3180
          5.2.2 Tubeless Tire...3185
        5.3 Inspection and Correction...3188
        5.4 Installation...3191
    Group 33 - Front Suspension...3193
      Table of Contents...3194
      1. Troubleshooting...3195
      2. Specifications...3195
      3. Service Standards...3196
        3.1 Service Standards Table...3196
        3.2 Tightening Torque Table...3196
      4. Special Tools...3197
      5. General...3197
      6. Service Procedure...3198
        6.1 Removal and Installation...3198
        6.2 Disassembly, Inspection, and Correction...3199
        6.3 Installation...3202
    Group 34 - Rear Suspension...3204
      Table of Contents...3205
      1. Troubleshooting...3206
      2. Specifications...3206
      3. Service Standards...3207
        3.1 Service Standards Table...3207
        3.2 Tightening Torque Table...3207
      4. Special Tools...3208
      5. General...3209
      6. Service Procedure...3210
        6.1 Removal and Installation...3210
        6.2 Disassembly, Inspection, and Correction...3212
        6.3 Installation...3215
    Group 35A - Brake (Air Over Hydraulic Brake)...3217
      Table of Contents...3218
      1. Troubleshooting...3219
      2. Specifications...3222
        2.1 Service Brake...3222
        2.2 Wheel Brake...3223
        2.3 Exhaust Brake...3223
      3. Service Standards...3223
        3.1 Service Standards Table...3223
          3.1.1 Service Brake...3223
          3.1.2 Wheel Brake...3226
          3.1.3 Exhaust...3226
        3.2 Tightening Torque Table...3227
          3.2.1 Service Brake...3227
          3.2.2 Wheel Brake...3228
          3.2.3 Exhaust Brake...3228
      4. Special Tools...3229
      5. General...3233
        5.1 Service Brake...3233
        5.2 Air Compressor...3234
        5.3 Air Drier...3235
        5.4 Dual Brake Valve...3237
        5.5 Brake Booster (Airmaster)...3239
        5.6 Air Pressure Governor...3241
        5.7 Exhaust Brake System...3242
      6. Service Procedure...3243
        6.1 Brake System Diagram...3243
        6.2 Service Brake Equipment...3244
          6.2.1 Air Compressor...3244
          6.2.2 Air Drier...3251
          6.2.3 Brake Pedal and Dual Brake Valve...3254
          6.2.4 Brake Booster (Airmaster)...3261
          6.2.5 Air Pressure Governor...3267
          6.2.6 Check Valve...3270
          6.2.7 Supply Valve...3271
          6.2.8 Safety Valve...3272
          6.2.9 Low Air Pressure Switch...3272
          6.2.10 Stop Lamp Switch...3272
        6.3 Wheel Brake...3273
          6.3.1 Front Wheel Brake...3273
          6.3.2 Front Wheel Cylinder...3276
          6.3.3 Rear Wheel Brake...3277
          6.3.4 Rear Wheel Cylinder...3280
        6.4 Inspection and Adjustment After Installation...3281
          6.4.1 Shoe Clearance Adjustment...3281
          6.4.2 Replacement of Brake Fluid and Bleeding of Brake System...3282
        6.5 Exhaust Brake...3283
          6.5.1 Exhaust Brake Unit...3283
          6.5.2 Control Cylinder...3286
          6.5.3 Exhaust Brake Control...3287
          6.5.4 Adjustment and Inspection After Installation...3288
    Group 35B - Brake (Full Air Brake)...3289
      Table of Contents...3290
      1. Troubleshooting...3291
      2. Specifications...3293
        2.1 Service Brake...3293
        2.2 Wheel Brake...3294
        2.3 Exhaust Brake...3294
      3. Service Standards...3295
        3.1 Service Standards Table...3295
          3.1.1 Service Brake...3295
          3.1.2 Wheel Brake...3297
          3.1.3 Exhaust Brake...3298
        3.2 Tightening Torque Table...3298
          3.2.1 Service Brake...3298
          3.2.2 Wheel Brake...3300
          3.2.3 Exhaust Brake...3300
      4. Special Tools...3301
      5. General...3303
        5.1 Service Brake...3303
        5.2 Air Compressor...3304
        5.3 Air Drier...3305
        5.4 Dual Brake Valve...3307
        5.5 Air Pressure Governor...3309
        5.6 Exhaust Brake System...3310
      6. Service Procedure...3311
        6.1 Brake System Diagram...3311
        6.2 Service Brake Equipment...3312
          6.2.1 Air Compressor...3312
          6.2.2 Air Drier...3318
          6.2.3 Brake Pedal and Dual Brake Valve...3322
          6.2.4 Air Pressure Governor...3329
          6.2.5 Check Valve...3331
          6.2.6 Supply Valve...3332
          6.2.7 Safety Valve...3333
          6.2.8 Low Air Pressure Switch...3333
          6.2.9 Stop Lamp Switch...3334
          6.2.10 Relay Valve...3334
          6.2.11 Quick Release Valve...3336
          6.2.12 Double Check Valve...3337
          6.2.13 Air Check Valve...3338
        6.3 Wheel Brake...3338
          6.3.1 Front Wheel Brake...3338
          6.3.2 Front Brake Chamber...3342
          6.3.3 Rear Wheel Brake...3343
          6.3.4 Rear Brake Chamber...3347
        6.4 Inspection and Adjustment After Installation...3349
          6.4.1 Adjustment of Brake Shoe Clearance...3349
        6.5 Exhaust Brake...3351
          6.5.1 Exhaust Brake Unit...3351
          6.5.2 Control Cylinder...3354
          6.5.3 Exhaust Brake Control...3355
          6.5.4 Adjustment and Inspection After Installation...3356
    Group 36A - Parking Brake (Center Parking Brake)...3357
      Table of Contents...3358
      1. Troubleshooting...3359
      2. Specifications...3359
      3. Service Standards...3360
        3.1 Service Standards Table...3360
        3.2 Tightening Torque Table...3360
      4. Special Tools...3360
      5. General...3361
      6. Service Procedure...3362
        6.1 Parking Brake...3362
          6.1.1 Removal and Installation...3362
          6.1.2 Disassembly and Inspection...3362
          6.1.3 Reassembly...3363
        6.2 Parking Brake Control...3364
          6.2.1 Removal and Installation...3364
          6.2.2 Parking Brake Lever...3365
        6.3 Adjustment...3366
    Group 36B - Parking Brake (Wheel Parking Brake)...3367
      Table of Contents...3368
      1. Troubleshooting...3369
      2. Service Standards...3369
        2.1 Service Standards Table...3369
        2.2 Tightening Torque Table...3369
      3. General...3370
        3.1 Parking Brake System...3370
        3.2 Parking Brake Control Valve...3370
        3.3 Spring Brake Valve...3371
      4. Service Procedure...3373
        4.1 Parking Brake Control Valve...3373
          4.1.1 Disassembly...3373
          4.1.2 Reassembly...3374
          4.1.3 Inspection After Reassembly...3374
        4.2 Spring Brake Valve...3375
          4.2.1 Disassembly...3375
          4.2.2 Reassembly...3376
          4.2.3 Inspection After Reassembly...3376
    Group 37 - Steering...3378
      Table of Contents...3379
      1. Troubleshooting...3380
      2. Specifications...3384
      3. Service Standards...3385
        3.1 Service Standards Table...3385
        3.2 Tightening Torque Table...3386
      4. Special Tools...3387
      5. General...3392
      6. Service Procedure...3395
        6.1 Removal and Installation...3395
        6.2 Steering Shaft...3396
          6.2.1 Removal...3396
          6.2.2 Installation...3397
          6.2.3 Disassembly, Inspection, and Correction...3398
          6.2.4 Reassembly...3399
        6.3 Link and Bracket Section...3400
          6.3.1 Disassembly...3400
          6.3.2 Reassembly...3401
        6.4 Drag Link...3402
        6.5 Tie Rod...3403
        6.6 Integral Power Steering Booster...3404
          6.6.1 Disassembly, Inspection, and Correction...3404
          6.6.2 Reassembly and Adjustment...3408
        6.7 Power Steering Oil Pump...3414
          6.7.1 Removal...3414
          6.7.2 Installation...3414
          6.7.3 Disassembly, Inspection, and Correction...3414
          6.7.4 Reassembly...3416
          6.7.5 Adjustment...3418
        6.8 Power Steering Oil Tank...3418
          6.8.1 Disassembly...3418
          6.8.2 Reassembly...3418
        6.9 Adjustment After Installation...3419
          6.9.1 Bleeding...3419
          6.9.2 Performance Verification Tests...3419
          6.9.3 Steering Wheel Play...3420
          6.9.4 Adjustment of Steering Angle...3420
    Group 41 - Frame...3421
      Table of Contents...3422
      1. General...3423
      2. Service Procedure...3423
        2.1 Inspection and Repair...3423
          2.1.1 Frame...3423
          2.1.2 Rivets...3426
    Group 42 - Cab...3427
      Table of Contents...3428
      1. Troubleshooting...3429
      2. Specifications...3431
      3. Service Procedures...3431
        3.1 Service Standards Table...3431
        3.2 Tightening Torque Table...3431
      4. General...3432
        4.1 Cab Proper...3432
        4.2 Cab Mounting...3433
          4.2.1 Front Cab Mounting...3433
          4.2.2 Rear Cab Mounting...3433
        4.3 Cab Tilt System...3433
      5. Service Procedure...3434
        5.1 Removal...3434
          5.1.1 Key Points for Removal...3434
          5.1.2 Key Points for Installation...3436
          5.1.3 Inspection and Adjustment After Installation...3437
        5.2 Cab Mounting...3438
          5.2.1 Front Cab Mounting...3438
          5.2.2 Cab Stay...3440
          5.2.3 Rear Cab Mounting...3441
          5.2.4 Cab Tilt Link...3443
        5.3 Doors...3446
          5.3.1 Removal of Doors...3446
          5.3.2 Door Installation Adjustment...3446
          5.3.3 Front Door Assembly...3448
        5.4 Interior Parts...3452
          5.4.1 Seats and Center Console...3452
          5.4.2 Seat Belts...3453
          5.4.3 Floor Mat...3455
          5.4.4 Overhead Console...3456
          5.4.5 Trim and Headlining...3457
          5.4.6 Instrument Panel...3459
        5.5 Window Glass...3463
          5.5.1 Removal...3463
          5.5.2 Installation...3463
        5.6 Exterior Parts...3465
          5.6.1 Front Panel, Fender, and Allied Parts...3465
          5.6.2 Rear View Mirrors...3467
    Group 54 - Chassis Electrical...3468
      Table of Contents...3469
      1. Troubleshooting...3470
      2. Specifications...3476
      3. Service Standards...3478
      4. General...3480
      5. Service Procedure...3481
        5.1 Battery...3481
          5.1.1 General Description...3481
          5.1.2 Inspection...3481
        5.2 Fuses...3483
          5.2.1 General Description...3483
          5.2.2 Inspection...3484
        5.3 Fusible Link...3485
          5.3.1 General Description...3485
          5.3.2 Inspection...3485
        5.4 Starter Switch and Cold Starter Switch...3486
          5.4.1 General Description...3486
          5.4.2 Inspection...3487
        5.5 Sub-Starter System...3488
          5.5.1 General Description...3488
          5.5.2 Inspection...3488
        5.6 Combination Switch...3489
          5.6.1 General Description...3489
          5.6.2 Inspection...3490
        5.7 Lighting System...3491
          5.7.1 General Description...3491
          5.7.2 Inspection...3492
          5.7.3 Inspection and Adjustment After Installation...3493
        5.8 Meter System...3494
          5.8.1 General Description...3494
          5.8.2 Inspection...3495
        5.9 Indicators and Warning Lamps...3500
          5.9.1 General Description...3500
          5.9.2 Inspection...3502
        5.10 Wiper and Washer System...3506
          5.10.1 General Description...3506
          5.10.2 Inspection...3507
          5.10.3 Inspection and Adjustment After Installation...3510
        5.11 Horn...3511
          5.11.1 General Description...3511
          5.11.2 Inspection...3511
        5.12 Back-Up Buzzer...3512
          5.12.1 General Description...3512
          5.12.2 Inspection...3512
        5.13 Radio and Cassette Stereo...3512
          5.13.1 Mounting Position...3512
          5.13.2 AM/FM Radio...3513
          5.13.3 AM/FM Radio and Cassette Stereo...3513
          5.13.4 Troubleshooting...3514
        5.14 Cigarette Lighter...3515
          5.14.1 General Description...3515
          5.14.2 Inspection...3515
      Wiring Diagram - FK <Manual Transmission>...3517
      Wiring Diagram - FK <Automatic Transmission>...3518
      Wiring Diagram - FM...3519
    Group 55A - Air Conditioner...3520
      Table of Contents...3521
      1. Specifications...3522
      2. Outlines of Refrigeration System...3523
        2.1 Air System...3523
        2.2 Refrigerating Cycle...3523
        2.3 Electrical System...3524
      3. Construction...3525
        3.1 Engine Compartment...3525
        3.2 Cab...3525
        3.3 Control System...3526
        3.4 Compressor and Magnetic Clutch...3528
          3.4.1 Compressor...3528
          3.4.2 Check Valve...3529
          3.4.3 Magnetic Clutch...3529
        3.5 Condenser...3529
        3.6 Receiver Drier...3529
        3.7 Cooling Unit...3530
        3.8 Expansion Valve...3530
        3.9 A/C Switch...3530
        3.10 Thermo Sensor...3531
        3.11 Power Relay...3531
        3.12 Dual Pressure Switch...3531
      4. Troubleshooting...3532
        4.1 General Precautions...3532
        4.2 Trouble, Cause, and Remedy...3533
        4.3 Inspection Procedures...3535
          4.3.1 A/C Switch...3535
          4.3.2 Dual Pressure Switch...3535
          4.3.3 Thermo Sensor...3536
          4.3.4 Magnetic Clutch...3536
          4.3.5 Refrigerant Charge...3536
          4.3.6 Receiver Drier Assembly...3537
          4.3.7 Belt Tension...3537
          4.3.8 Expansion Valve...3537
          4.3.9 Compressor...3538
          4.3.10 Air Inclusion in Refrigerant Circuit...3538
          4.3.11 Moisture Inclusion in Refrigerant Circuit...3538
      5. Removal and Installation...3539
        5.1 Precaution for Removal and Installation...3539
        5.2 Removal...3539
          5.2.1 Inside the Engine Compartment...3539
          5.2.2 Inside the Cab...3540
        5.3 Installation...3541
      6. Treatment After Installation...3542
        6.1 Check and Adjustment...3542
        6.2 Leak Test...3542
          6.2.1 Test Point...3542
          6.2.2 Test Procedure...3542
        6.3 Evacuation...3543
        6.4 Gas Charge...3544
        6.5 Checking the Refrigerant Level...3544
        6.6 Performance Test...3545
          6.6.1 Preparation...3545
          6.6.2 Stationary Performance Test...3545
      7. Cooling Unit...3546
        7.1 Components...3546
        7.2 Cautions in Disassembling...3547
        7.3 Disassembling...3547
      8. Maintenance...3548
      9. Compressor...3549
        9.1 Disassembling the Clutch...3549
        9.2 Reassembly the Clutch...3550
        9.3 Disassembling the Shaft Seal...3551
        9.4 Reassembly the Shaft Seal...3552
        9.5 Special Tool Figure...3554
    Group 55B - Heater...3557
      Table of Contents...3558
      1. Troubleshooting...3559
      2. Specifications...3560
      3. General...3560
        3.1 Ventilation System...3560
        3.2 Heater...3561
      4. Service Procedure...3562
        4.1 Removal and Installation...3562
        4.2 Cleaning of Air Filter...3563
        4.3 Heater Control Adjustment Procedure...3564
FK.FM Series 1992-1995 Fuso Service Manual (TWME9107 - 1;252 pages)...3566
  92-95 FK/FM Service Manual...3566
    Compilation of This Manual...3567
    Group 00 - General...3570
      Group 00 - General [Supplement]...3571
        Table of Contents...3572
        Summary of Modifications...3573
        Group 01 - Maintenance Schedule...3575
        Group 35A - Brake (Air Over Hydraulic Brake)...3578
        Group 35B - Brake (Full Air Brake)...3590
      '95 Model Changes...3600
      '94 Minor Change...3632
        Table of Contents...3633
        1. Differences of 1994 Model from 1993 Model...3634
        2. Details of Change Due to Running Change Made on 1993 Model...3635
      '93 Minor Change...3639
        Table of Contents...3640
        1. FK457 (Vehicles with M6S6)...3641
          1.1 Major Specifications...3641
          1.2 Power Train Table...3645
          1.3 Operation Performance Curves...3646
        2. Differences of 1993 Model from 1992 Model...3648
      Group 00 - General...3650
        Table of Contents...3651
        1. Exterior Views...3652
        2. Major Specifications...3654
        3. Power Train Table...3661
        4. Equipment Model Notation...3662
        5. Peformance Curves...3663
          5.1 Operation Performance Curves...3663
          5.2 Engine Performance Curve...3673
        6. Servicing Precautions...3673
        7. Standard Bolts and Nuts Tightening Torque Table...3679
        8. Towing Precautions...3680
        9. Chassis and Engine Numbers...3680
        10. Vehicle Identification Number...3681
    Group 01 - Maintenance Schedule...3682
      Table of Contents...3683
      1. Using the Maintenance Schedule Table...3684
      2. Maintenance Schedule...3685
        2.1 Replacement of Oil Filter Element...3691
        2.2 Replacement of Fuel Filter Element...3691
        2.3 Cleaning of Fuel Feed Pump Gauze Filter...3692
        2.4 Bleeding of Fuel System...3692
        2.5 Adjustment of V-Belt Tension...3692
        2.6 Cleaning and Replacement of Air Cleaner Element...3693
        2.7 Inspection of Clutch Pedal...3694
          2.7.1 Inspection of Pedal Play...3694
          2.7.2 Clearance to Floorboard When Released...3694
          2.7.3 Clutch Operation...3694
        2.8 Servicing of Tires...3695
          2.8.1 Tire Inflation Pressures...3695
          2.8.2 Removal of Tire...3695
          2.8.3 Installation of Tire...3696
          2.8.4 Retightening of Wheel Nuts...3696
          2.8.5 Tire Rotation...3697
        2.9 Servicing of Air Drier...3697
        2.10 Adjustment of Wheel Brake Shoe Clearance...3698
          2.10.1 Air Over Hydraulic Brake <FK Series>...3698
          2.10.2 Full Air Brake <FM Series>...3698
        2.11 Adjustment of Parking Brake Shoe Clearance <FK Series>...3700
        2.12 Servicing of Battery...3700
          2.12.1 Cleaning of Battery Terminals...3701
          2.12.2 Inspection of Fluid Level...3701
          2.12.3 Specific Gravity...3701
        2.13 Replacement of Fuses...3702
      3. Lubrication...3704
        3.1 Engine...3705
          3.1.1 Engine Oil Level and Contamination...3705
          3.1.2 Replacement of Engine Oil...3706
        3.2 Clutch...3707
          3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank...3707
          3.2.2 Replacement of Brake Fluid...3707
          3.2.3 Bleeding of Clutch System...3708
        3.3 Transmission...3708
          3.3.1 Inspection of Transmission Gear Oil Level...3708
          3.3.2 Replacement of Transmission Gear Oil...3709
        3.4 Rear Axle...3709
          3.4.1 Inspection of Rear Axle Gear Oil Level...3709
          3.4.2 Replacement of Rear Axle Gear Oil...3709
        3.5 Brake <FK Series>...3709
          3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank...3709
          3.5.2 Replacement of Brake Fluid...3709
          3.5.3 Bleeding of Brake System...3710
        3.6 Power Steering...3711
          3.6.1 Inspection of Power Steering Fluid Level...3711
          3.6.2 Replacement of Power Steering Fluid...3711
          3.6.3 Bleeding of Power Steering System...3712
        3.7 Chassis Parts...3712
    Group 11 - Engine...3714
      Table of Contents...3715
      1. Troubleshooting...3716
      2. Specifications...3718
      3. Service Standards...3719
        3.1 Service Standards Table...3719
        3.2 Tightening Torque Table...3722
      4. Special Tools...3723
      5. General...3728
      6. Service Procedure...3731
        6.1 Removal and Installation of Engine and Transmission...3731
        6.2 Engine Proper...3736
          6.2.1 Measurement of Compression Pressure...3736
          6.2.2 Cylinder Head and Valve Mechanism...3737
          6.2.3 Flywheel, Timing Gear and Camshaft...3749
          6.2.4 Crankcase and Main Moving Parts...3761
          6.2.5 Adjustment...3777
    Group 12 - Lubrication...3778
      Table of Contents...3779
      1. Troubleshooting...3780
      2. Specifications...3780
      3. Service Standards...3781
        3.1 Service Standards Table...3781
        3.2 Tightening Torque Table...3781
      4. Special Tools...3782
      5. General...3782
      6. Service Procedure...3788
        6.1 Oil Pump...3788
          6.1.1 Removal and Installation...3788
          6.1.2 Disassembly and Inspection...3790
          6.1.3 Reassembly...3792
        6.2 Oil Cooler...3792
          6.2.1 Removal and Installation...3792
          6.2.2 Disassembly and Inspection...3793
        6.3 Oil Filter...3794
    Group 13 - Fuel and Engine Control...3795
      Group 13 - Fuel and Engine Control...3796
        Table of Contents...3797
        1. Troubleshooting...3798
        2. Specifications...3802
        3. Service Standards...3803
          3.1 Service Standards Table...3803
          3.2 Tightening Torque Table...3803
        4. Special Tools...3804
        5. General...3805
          5.1 Fuel System...3805
          5.2 Engine Control...3810
        6. Service Procedure...3811
          6.1 Injection Pump Assembly...3811
            6.1.1 Removal and Installation...3811
            6.1.2 Inspection and Adjustment of Fuel Injection Timing...3814
            6.1.3 Cleaning of Fuel Feed Pump Gauze Filter...3815
          6.2 Injection Nozzle...3815
            6.2.1 Removal and Installation...3815
            6.2.2 Disassembly...3815
            6.2.3 Cleaning and Inspection...3816
            6.2.4 Reassembly...3817
            6.2.5 Test and Adjustment...3817
          6.3 Fuel Filter...3818
          6.4 Water Separator...3819
          6.5 Bleeding the Fuel System...3819
          6.6 Engine Control...3820
            6.6.1 Removal and Installation...3820
            6.6.2 Inspection and Adjustment...3820
          6.7 Fuel Tank and Fuel Gauge Unit...3822
      Group 13A - Fuel and Engine Control <for 1995 Model>...3823
        Table of Contents...3824
        1. Troubleshooting...3825
        2. Specifications...3828
        3. Service Standards...3829
          3.1 Service Standards Table...3829
          3.2 Tightening Torque Table...3830
        4. Special Tools...3831
        5. General...3832
          5.1 Fuel System...3832
          5.2 Prestroke Control Type Injection Pump System...3837
          5.3 Engine Control...3844
        6. Service Procedure...3845
          6.1 Injection Pump Assembly...3845
            6.1.1 Removal and Installation...3845
            6.1.2 Inspection and Adjustment of Fuel Injection Timing...3849
            6.1.3 Cleaning of Fuel Feed Pump Gauze Filter...3849
            6.1.4 Adjustment of No-Load Minimum and Maximum Speeds...3850
          6.2 Inspection of Prestroke Control Type Injection Pump System...3851
            6.2.1 Troubleshooting Procedures...3851
            6.2.2 Inspection Items by Multi-Use Tester (MUT)...3855
            6.2.3 Inspection on the Basis of DIAG Code...3856
            6.2.4 Other Inspections...3870
            6.2.5 Inspection of Transient Malfunctions...3874
          6.3 Injection Nozzle...3875
            6.3.1 Removal and Installation...3875
            6.3.2 Disassembly...3875
            6.3.3 Cleaning and Inspection...3875
            6.3.4 Reassembly...3876
            6.3.5 Test and Adjustment...3877
          6.4 Fuel Filter...3878
          6.5 Water Separator...3878
          6.6 Bleeding the Fuel System...3879
          6.7 Engine Control...3880
            6.7.1 Removal and Installation...3880
            6.7.2 Inspection and Adjustment...3882
          6.8 Fuel Tank and Fuel Gauge Unit...3883
    Group 14 - Cooling...3884
      Table of Contents...3885
      1. Troubleshooting...3886
      2. Specifications...3887
      3. Service Standards...3887
        3.1 Service Standards Table...3887
        3.2 Tightening Torque Table...3888
      4. Special Tool...3888
      5. General...3889
      6. Service Procedure...3893
        6.1 Removal and Installation of Cooling System...3893
        6.2 Water Pump...3896
          6.2.1 Disassembly and Inspection...3896
          6.2.2 Reassembly...3898
        6.3 Inspection of Thermostat...3899
        6.4 Inspection of Auto-Cool Fan Coupling...3900
        6.5 Inspection of Radiator...3900
        6.6 Inspection and Adjustment of V-Belt Tension...3901
        6.7 Cleaning of Cooling System...3901
        6.8 Gas Leak Test...3904
        6.9 Bleeding Cooling System...3904
    Group 15 - Intake and Exhaust...3905
      Table of Contents...3906
      1. Troubleshooting...3907
      2. Specifications...3908
      3. Service Standards...3908
        3.1 Service Standards Table...3908
        3.2 Tightening Torque Table...3909
      4. Special Tools...3909
      5. General...3910
      6. Service Procedure...3915
        6.1 Removal, Installation and Inspection of Intake System...3915
        6.2 Air Cleaner...3916
          6.2.1 Disassembly and Reassembly...3916
          6.2.2 Inspection and Cleaning...3916
        6.3 Removal, Installation and Inspection of Exhaust System...3918
        6.4 Turbocharger...3919
          6.4.1 Removal and Installation...3919
          6.4.2 Disassembly...3920
          6.4.3 Cleaning and Inspection...3923
          6.4.4 Reassembly...3926
          6.4.5 Measurement of Turbocharger Boost Pressure...3932
        6.5 Intercooler...3934
          6.5.1 Removal and Installation...3934
          6.5.2 Inspection...3934
    Group 16 - Engine Electrical...3935
      Table of Contents...3936
      1. Troubleshooting...3937
      2. Specifications...3938
      3. Service Standards...3939
        3.1 Service Standards Table...3939
        3.2 Tightening Torque Table...3940
      4. General...3941
        4.1 Starter...3942
        4.2 Alternator...3947
        4.3 Glow System...3950
      5. Service Procedure...3953
        5.1 Starter...3953
          5.1.1 Removal and Installation...3953
          5.1.2 Disassembly...3953
          5.1.3 Inspection...3956
          5.1.4 Reassembly...3963
          5.1.5 Inspection and Adjustment After Reassembly...3965
        5.2 Alternator...3966
          5.2.1 Removal and Installation...3966
          5.2.2 Disassembly...3967
          5.2.3 Inspection...3969
          5.2.4 Reassembly...3973
          5.2.5 Inspection and Adjustment After Installation...3974
        5.3 Glow System...3977
          5.3.1 Removal and Installation...3977
          5.3.2 Inspection...3977
    Group 21 - Clutch...3981
      Table of Contents...3982
      1. Troubleshooting...3983
      2. Specifications...3986
      3. Service Standards...3987
        3.1 Service Standards Table...3987
        3.2 Tightening Torque Table...3989
      4. Special Tools...3990
      5. General...3992
        5.1 Clutch Proper...3992
        5.2 Clutch Control...3993
          5.2.1 Clutch Master Cylinder...3994
          5.2.2 Clutch Booster...3995
      6. Service Procedure...3997
        6.1 Clutch...3997
          6.1.1 Removal and Installation...3997
          6.1.2 Disassembly and Inspection...3999
          6.1.3 Reassembly and Adjustment...4003
        6.2 Clutch Pedal...4005
          6.2.1 Removal and Installation...4005
          6.2.2 Disassembly and Inspection...4006
          6.2.3 Reassembly and Adjustment...4009
        6.3 Clutch Master Cylinder...4011
          6.3.1 Disassembly and Inspection...4011
          6.3.2 Reassembly...4013
        6.4 Power Cylinder...4013
          6.4.1 Removal and Installation...4013
          6.4.2 Disassembly and Inspection...4014
          6.4.3 Reassembly...4014
        6.5 Clutch Booster (Vehicles with M8S2x5)...4015
          6.5.1 Removal and Installation...4015
          6.5.2 Disassembly and Inspection...4015
          6.5.3 Reassembly...4018
          6.5.4 Performance Test...4020
          6.5.5 On-the-Vehicle Functional Check...4020
        6.6 Clutch Housing...4022
          6.6.1 Disassembly...4022
          6.6.2 Reassembly...4023
        6.7 Replacement of Brake Fluid in Clutch System...4025
        6.8 Bleeding the Clutch System...4025
        6.9 Adjustment of Clutch Pedal...4027
        6.10 Lubrication of Drive Pinion Splines...4028
    Group 22 - Manual Transmission...4029
      Group 22A - Manual Transmission (M5S5, M6S5)...4030
        Table of Contents...4031
        1. Troubleshooting...4032
        2. Specifications...4033
        3. Service Standards...4034
          3.1 Service Standards Table...4034
          3.2 Tightening Torque Table...4036
        4. Special Tools...4037
        5. General...4040
        6. Service Procedure...4042
          6.1 Removal and Installation of Transmission...4042
            6.1.1 Key Points for Removal...4042
            6.1.2 Key Points for Installation...4044
            6.1.3 Inspection and Adjustment After Installation...4044
          6.2 Transmission Assembly...4045
            6.2.1 Disassembly...4045
            6.2.2 Reassembly...4046
          6.3 Transmission...4047
            6.3.1 Inspection Before Disassembly...4047
            6.3.2 Disassembly and Inspection...4048
            6.3.3 Reassembly...4051
          6.4 Main Shaft...4055
            6.4.1 Disassembly and Inspection...4055
            6.4.2 Reassembly...4059
          6.5 Counter Shaft...4061
            6.5.1 Disassembly...4061
            6.5.2 Reassembly...4062
          6.6 Lower Gear Shifter...4063
            6.6.1 Disassembly and Inspection...4063
            6.6.2 Reassembly...4065
          6.7 Upper Gear Shifter...4066
            6.7.1 Disassembly and Inspection...4066
            6.7.2 Reassembly...4067
          6.8 Rear Cover...4069
            6.8.1 Disassembly and Inspection...4069
            6.8.2 Reassembly...4071
          6.9 Transmission Control...4073
            6.9.1 Disassembly and Inspection...4073
            6.9.2 Reassembly...4074
            6.9.3 Adjustment After Installation...4075
          6.10 Transmission PTO Control <Option>...4076
            6.10.1 Transmission PTO Control Circuit...4076
            6.10.2 Inspection...4076
      Group 22B - Manual Transmission (M8S5, M8S2x5)...4078
        Table of Contents...4079
        1. Troubleshooting...4080
        2. Specifications...4081
          2.1 Transmission Proper...4081
          2.2 Transmission Control...4082
        3. Service Standards...4082
          3.1 Service Standards Table...4082
          3.2 Tightening Torque Table...4085
        4. Special Tools...4086
        5. General...4091
        6. Service Procedure...4093
          6.1 Removal and Installation of Transmission...4093
            6.1.1 Key Points for Removal...4093
            6.1.2 Key Points for Installation...4094
            6.1.3 Inspection and Adjustment After Installation...4095
          6.2 Transmission Assembly...4096
            6.2.1 Disassembly...4096
            6.2.2 Reassembly...4097
          6.3 Transmission...4098
            6.3.1 Inspection Before Disassembly...4098
            6.3.2 Disassembly and Inspection...4100
            6.3.3 Reassembly...4106
          6.4 Main Shaft...4112
            6.4.1 Disassembly and Inspection...4112
            6.4.2 Reassembly...4115
          6.5 Counter Shaft...4118
            6.5.1 Disassembly...4118
            6.5.2 Reassembly...4119
          6.6 Lower Gear Shifter...4120
            6.6.1 Disassembly and Inspection...4120
            6.6.2 Reassembly...4122
          6.7 Upper Gear Shifter...4123
            6.7.1 Disassembly and Inspection...4123
            6.7.2 Reassembly...4124
          6.8 Upper Splitter <M8S2x5 Only>...4126
            6.8.1 Disassembly...4126
            6.8.2 Reassembly...4126
          6.9 Rear Cover <M8S2x5 Only>...4127
            6.9.1 Disassembly and Inspection...4127
            6.9.2 Reassembly...4128
          6.10 Extension Housing <M8S6 Only>...4130
            6.10.1 Disassembly and Inspection...4130
            6.10.2 Reassembly...4131
          6.11 Splitter Case and Gear <M8S2x5 Only>...4132
            6.11.1 Inspection Before Disassembly...4132
            6.11.2 Disassembly and Inspection...4133
            6.11.3 Reassembly...4135
          6.12 Power Shift...4137
            6.12.1 Disassembly and Inspection...4137
            6.12.2 Reassembly...4138
          6.13 Splitter Control <M8S2x5 Only>...4139
            6.13.1 Splitter Air Piping...4139
            6.13.2 Power Cylinder...4140
          6.14 Transmission Control...4141
            6.14.1 Disassembly and Inspection...4141
            6.14.2 Reassembly...4142
            6.14.3 Adjustment After Installation...4143
          6.15 Transmission PTO Control <Option>...4144
            6.15.1 Transmission PTO Control Circuit...4144
            6.15.2 Inspection...4144
      Group 22C - Manual Transmission (M6S6)...4146
        Table of Contents...4147
        1. Troubleshooting...4148
        2. Specifications...4149
        3. Service Standards...4150
          3.1 Service Standards Table...4150
          3.2 Tightening Torque Table...4152
        4. Special Tools...4154
        5. General...4157
        6. Service Procedure...4159
          6.1 Removal and Installation of Transmission...4159
            6.1.1 Key Points for Removal...4159
            6.1.2 Key Points for Installation...4161
            6.1.3 Inspection and Adjustment After Installation...4161
          6.2 Transmission Assembly...4162
            6.2.1 Disassembly...4162
            6.2.2 Reassembly...4163
          6.3 Transmission...4164
            6.3.1 Inspection Before Disassembly...4164
            6.3.2 Disassembly and Inspection...4165
            6.3.3 Reassembly...4170
          6.4 Main Shaft...4176
            6.4.1 Disassembly and Inspection...4176
            6.4.2 Reassembly...4180
          6.5 Counter Shaft...4182
            6.5.1 Disassembly...4182
            6.5.2 Reassembly...4183
          6.6 Lower Gear Shifter...4184
            6.6.1 Disassembly and Inspection...4184
            6.6.2 Reassembly...4186
          6.7 Upper Gear Shifter...4187
            6.7.1 Disassembly and Inspection...4187
            6.7.2 Reassembly...4188
          6.8 Extension Housing...4190
            6.8.1 Disassembly and Inspection...4190
            6.8.2 Reassembly...4191
          6.9 Transmission Control...4193
            6.9.1 Disassembly and Inspection...4193
            6.9.2 Reassembly...4194
            6.9.3 Adjustment After Installation...4196
    Group 23 - Automatic Transmission...4197
      Table of Contents...4198
      1. Troubleshooting...4199
      2. Specifications...4201
      3. Service Standards...4201
        3.1 Service Standards Table...4201
        3.2 Tightening Torque Table...4202
      4. Special Tools...4203
      5. General...4204
        5.1 Automatic Transmission Control...4204
        5.2 Oil Cooler...4205
      6. Service Procedure...4206
        6.1 Removal and Installation of Automatic Transmission...4206
          6.1.1 Removal...4206
          6.1.2 Installation...4209
        6.2 Oil Seal and Speedometer Worm...4211
          6.2.1 Removal and Installation...4211
          6.2.2 Replacement of Front Oil Seal...4212
          6.2.3 Replacement of Rear Oil Seal...4212
          6.2.4 Replacement of Speedometer Worm...4212
        6.3 Automatic Transmission Control System...4214
          6.3.1 Removal and Installation...4214
          6.3.2 Inspection After Installation...4215
        6.4 Oil Cooler...4216
          6.4.1 Removal and Installation...4216
          6.4.2 Inspection...4217
        6.5 Oil Filter...4218
          6.5.1 Removal and Installation...4218
        6.6 Replacement of Fluid and Oil Filter...4219
    Group 25 - Propeller Shaft...4222
      Table of Contents...4223
      1. Troubleshooting...4224
      2. Specifications...4225
      3. Service Standards...4225
        3.1 Service Standards Table...4225
        3.2 Tightening Torque Table...4225
      4. Special Tools...4226
      5. General...4227
      6. Service Procedure...4228
        6.1 Removal and Installation...4228
        6.2 Front Propeller Shaft...4229
          6.2.1 Disassembly and Inspection...4229
          6.2.2 Reassembly...4233
        6.3 Rear Propeller Shaft...4236
          6.3.1 Disassembly and Inspection...4236
          6.3.2 Reassembly...4238
        6.4 Adjustment After Reassembly...4240
    Group 26 - Front Axle...4242
      Table of Contents...4243
      1. Troubleshooting...4244
      2. Specifications...4245
      3. Service Standards...4246
        3.1 Service Standards Table...4246
        3.2 Tightening Torque Table...4247
      4. Special Tools...4248
      5. General...4251
      6. Service Procedure...4252
        6.1 Removal and Installation...4252
        6.2 Wheel Hub and Brake Drum...4253
          6.2.1 Disassembly, Inspection and Corrections...4253
          6.2.2 Reassembly...4255
        6.3 Front Axle, Knuckle and Kingpin...4259
          6.3.1 Disassembly and Inspection...4259
          6.3.2 Reassembly...4262
        6.4 Inspection and Adjustment After Installation...4266
    Group 27 - Rear Axle...4270
      Table of Contents...4271
      1. Troubleshooting...4272
      2. Specifications...4273
      3. Service Standards...4274
        3.1 Service Standards Table...4274
        3.2 Tightening Torque Table...4275
      4. Special Tools...4276
      5. General...4282
      6. Service Procedure...4283
        6.1 Removal and Installation...4283
        6.2 Wheel Hub and Brake Drum...4284
          6.2.1 Disassembly, Inspection and Corrections...4284
          6.2.2 Reassembly...4286
        6.3 Reduction and Differential...4291
          6.3.1 Removal...4291
          6.3.2 Inspection Before Disassembly...4291
          6.3.3 Disassembly and Inspection...4293
          6.3.4 Reassembly...4297
    Group 31 - Wheel and Tire...4307
      Table of Contents...4308
      1. Troubleshooting...4309
      2. Specifications...4309
      3. Service Standards...4310
        3.1 Service Standards Table...4310
        3.2 Tightening Torque Table...4310
      4. General...4310
      5. Service Procedure...4311
        5.1 Removal...4311
        5.2 Disassembly and Procedure...4313
          5.2.1 Tubeless Tire...4313
        5.3 Inspection and Correction...4316
        5.4 Installation...4319
    Group 33 - Front Suspension...4321
      Table of Contents...4322
      1. Troubleshooting...4323
      2. Specifications...4323
      3. Service Standards...4324
        3.1 Service Standards Table...4324
        3.2 Tightening Torque Table...4324
      4. Special Tools...4325
      5. General...4325
      6. Service Procedure...4326
        6.1 Removal and Installation...4326
        6.2 Disassembly, Inspection and Correction...4327
        6.3 Installation...4331
    Group 34 - Rear Suspension...4333
      Table of Contents...4334
      1. Troubleshooting...4335
      2. Specifications...4335
      3. Service Standards...4336
        3.1 Service Standards Table...4336
        3.2 Tightening Torque Table...4336
      4. Special Tools...4337
      5. General...4338
      6. Service Procedure...4339
        6.1 Removal and Installation...4339
        6.2 Disassembly, Inspection and Correction...4341
        6.3 Installation...4344
    Group 35 - Brake...4346
      Group 35A - Brake (Air Over Hydraulic Brake)...4347
        Table of Contents...4348
        1. Troubleshooting...4349
        2. Specifications...4352
          2.1 Service Brake...4352
          2.2 Wheel Brake...4353
          2.3 Exhaust Brake...4353
        3. Service Standards...4353
          3.1 Service Standards Table...4353
            3.1.1 Service Brake...4353
            3.1.2 Wheel Brake...4356
            3.1.3 Exhaust Brake...4356
          3.2 Tightening Torque Table...4357
            3.2.1 Service Brake...4357
            3.2.2 Wheel Brake...4358
            3.2.3 Exhaust Brake...4358
        4. Special Tools...4359
        5. General...4360
          5.1 Service Brake...4360
          5.2 Air Compressor...4361
          5.3 Air Dryer...4362
          5.4 Dual Brake Valve...4364
          5.5 Brake Booster (Airmaster)...4370
          5.6 Air Pressure Governor...4373
          5.7 Exhaust Brake System...4374
        6. Service Procedure...4375
          6.1 Brake System Diagram...4375
          6.2 Service Brake Equipment...4376
            6.2.1 Air Compressor...4376
            6.2.2 Air Dryer...4383
            6.2.3 Brake Pedal and Dual Brake Valve...4386
            6.2.4 Brake Booster (Airmaster)...4394
            6.2.5 Air Pressure Governor...4402
            6.2.6 Check Valve...4405
            6.2.7 Supply Valve...4406
            6.2.8 Safety Valve...4407
            6.2.9 Brake Fluid Tank...4408
          6.3 Wheel Brake...4409
            6.3.1 Front Wheel Brake...4409
            6.3.2 Front Wheel Cylinder...4414
            6.3.3 Rear Wheel Brake...4415
            6.3.4 Rear Wheel Cylinder...4419
          6.4 Inspection and Adjustment After Installation...4420
            6.4.1 Shoe Clearance Adjustment...4420
            6.4.2 Replacement of Brake Fluid and Bleeding of Brake System...4421
          6.5 Exhaust Brake...4423
            6.5.1 Exhaust Brake Unit...4423
            6.5.2 Control Cylinder...4426
            6.5.3 Exhaust Brake Control <Except A/T Vehicles>...4427
            6.5.4 Adjustment and Inspection After Installation <Except A/T Vehicles>...4428
      Group 35B - Brake (Full Air Brake)...4429
        Table of Contents...4430
        1. Troubleshooting...4431
        2. Specifications...4433
          2.1 Service Brake...4433
          2.2 Wheel Brake...4434
          2.3 Exhaust Brake...4434
        3. Service Standards...4435
          3.1 Service Standards Table...4435
            3.1.1 Service Brake...4435
            3.1.2 Wheel Brake...4437
            3.1.3 Exhaust Brake...4438
          3.2 Tightening Torque Table...4438
            3.2.1 Service Brake...4438
            3.2.2 Wheel Brake...4440
            3.2.3 Exhaust Brake...4440
        4. Special Tools...4441
        5. General...4442
          5.1 Service Brake...4442
          5.2 Air Compressor...4443
          5.3 Air Dryer...4444
          5.4 Dual Brake Valve...4445
          5.5 Air Pressure Governor...4451
          5.6 Exhaust Brake System...4452
        6. Service Procedure...4454
          6.1 Brake System Diagram...4454
          6.2 Service Brake Equipment...4455
            6.2.1 Air Compressor...4455
            6.2.2 Air Dryer...4461
            6.2.3 Brake Pedal and Dual Brake Valve...4465
            6.2.4 Air Pressure Governor...4472
            6.2.5 Check Valve...4474
            6.2.6 Supply Valve...4475
            6.2.7 Safety Valve...4476
            6.2.8 Relay Valve...4477
            6.2.9 Quick Release Valve...4479
            6.2.10 Double Check Valve...4480
            6.2.11 Air Check Valve...4481
          6.3 Wheel Brake...4481
            6.3.1 Front Wheel Brake...4481
            6.3.2 Front Brake Chamber...4487
            6.3.3 Rear Wheel Brake...4488
            6.3.4 Rear Brake Chamber...4494
          6.4 Inspection and Adjustment After Installation...4496
            6.4.1 Adjustment of Brake Shoe Clearance...4496
          6.5 Exhaust Brake...4498
            6.5.1 Exhaust Brake Unit...4498
            6.5.2 Control Cylinder...4501
            6.5.3 Exhaust Brake Control...4502
            6.5.4 Adjustment and Inspection After Installation...4503
    Group 36 - Parking Brake...4504
      Group 36A - Parking Brake (Center Parking Brake)...4505
        Table of Contents...4506
        1. Troubleshooting...4507
        2. Specifications...4507
        3. Service Standards...4508
          3.1 Service Standards Table...4508
          3.2 Tightening Torque Table...4508
        4. Special Tools...4508
        5. General...4509
        6. Service Procedure...4510
          6.1 Parking Brake...4510
            6.1.1 Removal and Installation...4510
            6.1.2 Disassembly and Inspection...4510
            6.1.3 Reassembly...4511
          6.2 Parking Brake Control...4512
            6.2.1 Removal and Installation...4512
            6.2.2 Parking Brake Lever...4513
          6.3 Adjustment...4514
      Group 36B - Parking Brake (Wheel Parking Brake)...4515
        Table of Contents...4516
        1. Troubleshooting...4517
        2. Service Standards...4517
          2.1 Service Standards Table...4517
          2.2 Tightening Torque Table...4517
        3. General...4518
          3.1 Parking Brake System...4518
          3.2 Parking Brake Control Valve...4518
          3.3 Spring Brake Valve...4519
        4. Service Procedure...4521
          4.1 Parking Brake Control Valve...4521
            4.1.1 Disassembly...4521
            4.1.2 Reassembly...4522
            4.1.3 Inspection After Reassembly...4522
          4.2 Spring Brake Valve...4523
            4.2.1 Disassembly...4523
            4.2.2 Reassembly...4524
            4.2.3 Inspection After Reassembly...4524
    Group 37 - Steering...4526
      Table of Contents...4527
      1. Troubleshooting...4528
      2. Specifications...4532
      3. Service Standards...4533
        3.1 Service Standards Table...4533
        3.2 Tightening Torque Table...4534
      4. Special Tools...4535
      5. General...4539
      6. Service Procedure...4542
        6.1 Removal and Installation...4542
        6.2 Steering Shaft...4543
          6.2.1 Removal...4543
          6.2.2 Installation...4544
          6.2.3 Disassembly, Inspection and Correction...4545
          6.2.4 Reassembly...4546
        6.3 Link and Bracket Section...4547
          6.3.1 Disassembly...4547
          6.3.2 Reassembly...4548
        6.4 Drag Link...4549
        6.5 Tie Rod...4550
        6.6 Integral Power Steering Booster...4551
          6.6.1 Disassembly, Inspection and Correction...4551
          6.6.2 Reassembly and Adjustment...4555
        6.7 Power Steering Oil Pump...4561
          6.7.1 Removal...4561
          6.7.2 Installation...4562
          6.7.3 Disassembly, Inspection and Correction...4562
          6.7.4 Reassembly...4564
          6.7.5 Adjustment...4566
        6.8 Power Steering Oil Tank...4566
          6.8.1 Disassembly...4566
          6.8.2 Reassembly...4566
        6.9 Adjustment After Installlation...4567
          6.9.1 Bleeding...4567
          6.9.2 Performance Verification Tests...4567
          6.9.3 Steering Wheel Play...4568
          6.9.4 Adjustment of Steering Angle...4568
    Group 41 - Frame...4569
      Table of Contents...4570
      1. General...4571
      2. Service Procedure...4571
        2.1 Inspection and Repair...4571
          2.1.1 Frame...4571
          2.1.2 Rivets...4574
          2.1.3 Bolts and Nuts...4574
    Group 42 - Cab...4575
      Table of Contents...4576
      1. Troubleshooting...4577
      2. Specifications...4579
      3. Service Standards...4579
        3.1 Service Standards Table...4579
        3.2 Tightening Torque Table...4579
      4. General...4580
        4.1 Cab Proper...4580
        4.2 Cab Mounting...4581
          4.2.1 Front Cab Mounting...4581
          4.2.2 Rear Cab Mounting...4581
        4.3 Cab Tilt System...4581
      5. Service Procedure...4582
        5.1 Removal...4582
          5.1.1 Key Points for Removal...4582
          5.1.2 Key Points for Installation...4584
          5.1.3 Inspection and Adjustment After Installation...4585
        5.2 Cab Mounting...4586
          5.2.1 Front Cab Mounting...4586
          5.2.2 Cab Stay...4588
          5.2.3 Rear Cab Mounting...4589
          5.2.4 Cab Tilt Link...4591
        5.3 Doors...4594
          5.3.1 Removal of Doors...4594
          5.3.2 Doors Installation Adjustment...4594
          5.3.3 Front Door Assembly...4596
        5.4 Interior Parts...4600
          5.4.1 Seats and Center Console...4600
          5.4.2 Air Suspension...4601
          5.4.3 Seat Belts (3-Point Type Seat Belts with ELR)...4603
          5.4.4 Floor Mat...4605
          5.4.5 Overhead Console...4606
          5.4.6 Trim and Headlining...4607
          5.4.7 Instrument Panel...4609
        5.5 Window Glass...4613
          5.5.1 Removal...4613
          5.5.2 Installation...4613
        5.6 Exterior Parts...4615
          5.6.1 Front Panel, Fender and Allied Parts...4615
          5.6.2 Rear View Mirrors...4617
    Group 54 - Electrical...4618
      Table of Contents...4619
      1. Troubleshooting...4620
      2. Specifications...4626
      3. Service Standards...4628
      4. General...4631
      5. Service Procedure...4634
        5.1 Battery...4634
          5.1.1 General Description...4634
          5.1.2 Inspection...4634
        5.2 Fuses...4636
          5.2.1 General Description...4636
          5.2.2 Inspection...4637
        5.3 Fusible Link...4639
          5.3.1 General Description...4639
          5.3.2 Inspection...4639
        5.4 Starter Switch and Cold Start Switch...4640
          5.4.1 General Description...4640
          5.4.2 Inspection...4641
        5.5 Sub-Starter System...4642
          5.5.1 General Description...4642
          5.5.2 Inspection...4642
        5.6 Combination Switch...4643
          5.6.1 General Description...4643
          5.6.2 Inspection...4644
        5.7 Lighting System...4645
          5.7.1 General Description...4645
          5.7.2 Inspection...4649
          5.7.3 Inspection and Adjustment After Installation...4653
        5.8 Meter System...4654
          5.8.1 General Description...4654
          5.8.2 Inspection...4655
        5.9 Indicators and Warning Lamps...4659
          5.9.1 General Description...4659
          5.9.2 Inspection...4662
        5.10 Wiper and Washer System...4666
          5.10.1 General Description...4666
          5.10.2 Inspection...4667
          5.10.3 Inspection and Adjustment After Installation...4670
        5.11 Horn...4672
          5.11.1 General Description...4672
          5.11.2 Inspection...4672
        5.12 Back Buzzer...4673
          5.12.1 General Description...4673
          5.12.2 Inspection...4673
        5.13 Radio and Cassette Stereo <Option>...4673
          5.13.1 Mounting Position...4673
          5.13.2 AM/FM Radio and AM/FM Radio With Cassette Stereo...4674
          5.13.3 Troubleshooting...4675
        5.14 Cigarette Lighter...4676
          5.14.1 General Description...4676
          5.14.2 Inspection...4676
    Group 55A - Air Conditioner...4678
      Group 55A (9107) - Air Conditioner...4679
        Foreword/Table of Contents...4680
        1. Specifications...4681
        2. Outlines of Refrigeration System...4682
          2.1 Air System...4682
          2.2 Refrigerating Cycle...4682
          2.3 Electrical System...4683
        3. Construction...4684
          3.1 Engine Room...4684
          3.2 Cabin Room...4684
          3.3 Control System...4685
          3.4 Compressor and Magnetic Clutch...4687
            3.4.1 Compressor...4687
            3.4.2 Check Valve...4688
            3.4.3 Magnetic Clutch...4688
          3.5 Condenser...4688
          3.6 Receiver Drier...4688
          3.7 Cooling Unit...4689
          3.8 Expansion Valve...4689
          3.9 Dual Pressure Switch...4690
          3.10 Power Relay...4690
          3.11 A/C Switch...4690
          3.12 Fin Thermo...4690
        4. Troubleshooting...4691
          4.1 General...4691
          4.2 Trouble Cause and Remedy...4692
          4.3 Inspection Procedures...4694
            4.3.1 A/C Switch...4694
            4.3.2 Dual Pressure Switch...4694
            4.3.3 Fin Thermo...4695
            4.3.4 Magnetic Clutch...4695
            4.3.5 Refrigerant Charge...4695
            4.3.6 Receiver Drier Assembly...4696
            4.3.7 Belting Tension...4696
            4.3.8 Expansion Valve...4696
            4.3.9 Compressor...4697
            4.3.10 Air Inclusion in Ref. Circuit...4697
            4.3.11 Moisture Inclusion in Ref. Circuit...4697
        5. Removal and Installation...4698
          5.1 Precautions for Removal and Installation...4698
          5.2 Removal...4698
            5.2.1 Inside the Engine Room...4698
            5.2.2 Cabin Room...4699
        6. Treatment After Installation...4701
          6.1 Check and Adjustment...4701
          6.2 Leak Test...4701
            6.2.1 Test Points...4701
            6.2.2 Test Procedure...4701
          6.4 System Charging...4702
            6.4.1 Installation of Charge Equipment...4703
            6.4.2 Charging System...4703
            6.4.3 Charging With Small Cans...4704
            6.4.5 Correcting Low Refrigerant Level...4705
            6.4.6 Discharging System...4705
          6.5 Checking the Refrigerant Level...4705
          6.6 Performance Test...4706
            6.6.1 Preparation...4706
            6.6.2 Stationary Performance Test...4706
        7. Compressor...4707
          7.1 Compressor...4707
          7.2 Disassembly and Reassembly Precautions...4708
            7.2.1 Disassembly Precautions...4708
            7.2.2 Reassembly Precautions...4708
            7.2.3 Tools and Instruments...4708
          7.3 Precautions at Disassembly...4709
          7.4 Maintenance and Check...4717
            7.4.1 Inspection Standards...4717
            7.4.2 Consumable Parts...4718
          7.5 Assembly Procedure...4721
            7.5.1 Tightening Torque...4721
            7.5.2 Assembly Procedure...4722
          7.6 Special Tool Figure...4731
        8. Cooling Unit...4741
          8.1 Components...4741
          8.2 Cautions in Disassembling...4742
          8.3 Disassembling...4742
        9. Maintenance...4743
      Group 55A (9403) - Air Conditioner...4744
        Table of Contents...4745
        1. Specifications...4746
        2. Outlines of Refrigeration System...4747
          2.1 Air System...4747
          2.2 Refrigerating Cycle...4747
          2.3 Electrical System...4748
        3. Construction...4749
          3.1 Engine Room...4749
          3.2 Cabin Room...4749
          3.3 Control System...4750
          3.4 Compressor and Magnetic Clutch...4752
            3.4.1 Compressor...4752
            3.4.2 Check Valve...4753
            3.4.3 Magnetic Clutch...4753
          3.5 Condenser...4753
          3.6 Receiver Assembly...4753
          3.7 Cooling Unit Assembly...4754
          3.8 Expansion Valve...4754
          3.9 Relief Valve...4754
          3.10 Dual Pressure Switch...4755
          3.11 Power Relay...4755
          3.12 A/C Switch...4755
          3.13 Fin Thermo...4755
        4. Troubleshooting...4756
          4.1 General Procedure...4756
          4.2 Trouble Cause and Remedy...4757
          4.3 Inspection Procedures...4759
            4.3.1 A/C Switch...4759
            4.3.2 Dual Pressure Switch...4759
            4.3.3 Fin Thermo...4760
            4.3.4 Magnetic Clutch...4760
            4.3.5 Refrigerant Charge...4760
            4.3.6 Receiver Assembly...4761
            4.3.7 Belting Tension...4761
            4.3.8 Expansion Valve...4761
            4.3.9 Compressor...4762
            4.3.10 Air Inclusion in Ref. Circuit...4762
            4.3.11 Moisture Inclusion in Ref. Circuit...4762
        5. Removal and Installation...4763
          5.1 Precautions for Removal and Installation...4763
          5.2 Removal...4763
            5.2.1 Inside the Engine Room...4763
            5.2.2 Cabin Room...4764
        6. Treatment After Installation...4766
          6.1 Check and Adjustment...4766
          6.2 Leak Test...4766
            6.2.1 Test Points...4766
            6.2.2 Test Procedure...4766
          6.3 System Charging...4767
            6.3.1 Evacuation...4768
            6.3.2 Evacuate the System...4768
            6.3.3 Removal of Charge Equipment...4770
            6.3.4 Discharging System...4770
          6.4 Checking the Refrigerant Level...4770
          6.5 Performance Test...4771
            6.5.1 Preparation...4771
            6.5.2 Stationary Performance Test...4771
        7. Compressor...4772
          7.1 Component of Compressor...4772
          7.2 Disassembly and Reassembly Precautions...4773
            7.2.1 Disassembly Precautions...4773
            7.2.2 Reassembly Precautions...4773
            7.2.3 Tools and Instruments...4773
          7.3 Precautions at Disassembly...4774
          7.4 Maintenance and Check...4782
            7.4.1 Inspection Standards...4782
            7.4.2 Consumable Parts...4783
          7.5 Assembly Procedure...4786
            7.5.1 Tightening Torque...4786
            7.5.2 Assembly Procedure...4787
            9.5 Special Tool Figure...4796
        8. Cooling Unit...4806
          8.1 Components...4806
          8.2 Cautions in Disassembling...4807
          8.3 Disassembling...4807
        9. Maintenance...4808
    Group 55B - Heater...4809
      Table of Contents...4810
      1. Troubleshooting...4811
      2. Specifications...4812
      3. General...4812
        3.1 Ventilation System...4812
        3.2 Heater...4813
      4. Service Procedure...4814
        4.1 Removal and Installation...4814
        4.2 Cleaning of Air Filter...4815
        4.3 Heater Control Adjustment Procedures...4816