Mitsubishi 2010 Fuso FE Owner'S Manual Download | Manualshive

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Foreword

Thank you for purchasing a Mitsubishi Fuso FE, FG Truck.
This Owner’s Manual explains proper vehicle handling, simple maintenance prac-

tices, and the periodic maintenance schedule to ensure that you are able to drive

your vehicle safely and comfortably.
As improper use of the vehicle may result in a breakdown or cause an accident, we

urge you to read this handbook thoroughly before operating the vehicle.
Please keep this manual in the vehicle so it is always available for reference. If you

sell the vehicle, make sure the next owner receives this manual and is aware of its

contents.

© 2009 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

FE_FG.book Page 3 Wednesday, January 14, 2009 7:08 PM

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Summary of Contents for 2010 Fuso FE

Page 1: ...Owner s Manua l Owner s Manual 2010 Model 2010 Model...

Page 2: ...OWNER AND VEHICLE INFORMATION OWNER NAME USER COMPANY NAME MAILING ADDRESS CITY STATE ZIP VEHICLE IDENTIFICATION NUMBER DATE OF DELIVERY WARRANTY START DATE MO DAY YR SELLING DEALER IMPRINT HERE...

Page 3: ......

Page 4: ...ur vehicle safely and comfortably As improper use of the vehicle may result in a breakdown or cause an accident we urge you to read this handbook thoroughly before operating the vehicle Please keep th...

Page 5: ...e following four headings which identify the nature of the instructions and infor mation Q California Proposition 65 Warning DANGER Precautions that should be taken when handling danger ous substances...

Page 6: ...7 Starting and driving 7 1 8 4WD operation FG models 8 1 9 Heating and air conditioning 9 1 10 Interior equipment and accessories 10 1 11 In cold weather 11 1 12 Simple inspection and service 12 1 13...

Page 7: ......

Page 8: ...engine numbers 1 2 Powerline label 1 2 Vehicle identification number VIN 1 3 Maintenance 1 4 Fuels 1 5 Handling of the new vehicle 1 8 Reporting safety defects 1 9 Obtaining service 1 10 1 Recommenda...

Page 9: ...r is indicated on the left side of the crankcase The powerline label located in the position shown indicates the vehicle model chassis number and information relevant to the vehicle s power trans miss...

Page 10: ...lbs Hydraulic C 16 001 to 19 500 lbs Hydraulic Line A FE83D B FE84D C FE85D D FE84DW E FG84D Series wheel base D 2 9 to 3 19 m 9 51 to 10 46 ft E 3 2 to 3 49 m 10 49 to 11 44 ft F 3 5 to 3 79 m 11 48...

Page 11: ...ion and adjustments to compensate for the initial settle ment of various parts When the distance has been reached have your vehicle inspected by an autho rized dealer by showing them this Owner s Manu...

Page 12: ...tain cooperation from a reputable fuel oil supplier Both fuel suppliers and users are responsible for keeping fuel clean 2 Diesel fuel to be used in your engine Use only a ultra low sulfur diesel fuel...

Page 13: ...reduced cetane number CAUTION The lower the cetane number the more likely internal engine damage will occur Do not add antifreeze agents or other sub stances to the fuel They could damage the engine s...

Page 14: ...se To close the cap turn it fully clockwise 113 liter fuel tank FE other than Crew cab models The fuel tank is at the rear of the vehicle To open the fuel tank cap slowly turn it counterclockwise To c...

Page 15: ...At 4 000 km 2 500 miles Engine oil Manual transmission gear oil Transfer gear oil FG Front axle housing gear oil FG Rear axle housing gear oil WARNING When filling the fuel tank using a gun type fuel...

Page 16: ...y open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between...

Page 17: ...ed as follows and in the sequence listed STEP 1 Contact your Nearest Authorized Dealer This is the most direct and expedient way to obtain service Each Authorized Dealer has the ultimate responsibilit...

Page 18: ...You also may correspond with the Customer Ser vice Representative in writing addressed to MITSUBISHI FUSO TRUCK OF AMERICA INC CUSTOMER SERVICE REPRESENTATIVE 2015 CENTER SQUARE RD LOGAN TOWNSHIP NJ 0...

Page 19: ......

Page 20: ...2 1 Locations in cab 2 3 Locations outside cab 2 6 2 Warning labels...

Page 21: ...nform an authorized dealer The warning and caution labels apply only to the vehicle itself not to any equipment mounted on the vehicle For information on cau tion and warning labels that apply to equi...

Page 22: ...Hydraulic brake booster FE85 Hydraulic brake booster FE85 Towing Automatic transmission vehicles Transfer lever FG 113 liter fuel tank FE other than Crew cab models Limited slip differential High exha...

Page 23: ...2 4 Warning labels Fuel DPF indicator lamp Fuse DPF system Parking Automatic transmission vehicles Z19698...

Page 24: ...2 5 Z17778 Engine inspection hatch Crew cab models...

Page 25: ...ab models Pressure cap High current fuse Oil cooler Automatic transmission vehicles Oil cooler Automatic transmission vehicles Battery Engine oil Automatic transmission fluid 113 liter fuel tank FE ot...

Page 26: ...2 7 Z17822 Limited slip differential 125 liter fuel tank 125 liter fuel tank Cab tilt function Vehicles other than Crew cab models Cab tilt function Vehicles other than Crew cab models...

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Page 28: ...3 1 Starter key 3 2 Doors 3 2 Central door locks 3 4 Keyless entry system 3 5 Entering and leaving the vehicle 3 10 Door window glass 3 12 3 Opening and closing...

Page 29: ...ing from behind before opening the doors Driving with a door ajar can be very dan gerous Make sure the doors are com pletely closed before starting Exercise caution when opening a door in strong wind...

Page 30: ...the lock knob down then pull the outer handle and keep it pulled as you close the door NOTE If your vehicle is not a Crew cab model vehicle locking the driver s door using the starter key or lock knob...

Page 31: ...pulling any part other than the door waist bar could damage the door mechanism Vehicles other than Crew cab models When the LOCK side of the switch is pressed both doors are locked When the UNLK side...

Page 32: ...with Part 15 of the FCC Rules Operation is subject to the following two conditions This device may not cause harmful interference This device must accept any interference received including interferen...

Page 33: ...the FCC Rules Operation is subject to the following two conditions This device may not cause harmful interference This device must accept any interference received including interference that may cau...

Page 34: ...emote control switch Point the remote control switch toward the cen ter of the cabin Operate the remote control switch within 3 m 9 8 ft from the center of the cabin Press the LOCK button to lock all...

Page 35: ...tomatically be locked again NOTE The range in which you can operate the remote control varies somewhat depending on the sur roundings such as proximity to a TV tower power station broadcasting station...

Page 36: ...fect the environment For disposal wrap the battery with tape vinyl sheet etc for insulation so that the battery cannot contact other metal objects or be exposed to water Do not expose the inside of th...

Page 37: ...he step If the soles of your shoes are oily or greasy you could slip when climbing down from the vehicle or when operating the brake or clutch pedal Wipe any oil and grease off the soles of your shoes...

Page 38: ...entering or leaving an FG model truck do not place your feet or hands on the fender The fender could suffer damage Also the fender can be dangerously slippery When climbing into and out of the cab su...

Page 39: ...er or any other liquid gets on a window switch it can cause a malfunction Door window glass WARNING Do not allow a child to put its hands or head out of a window The child s head or hands could hit an...

Page 40: ...ndow switches If water or any other liquid gets on a window switch it can cause a fault NOTE If a child is in your vehicle it is important for safety s sake to press the power window lock switch to pr...

Page 41: ...els Turn the window regulator handle to open or close the window Open Close CAUTION The front door window glass lowering limit is near the door waist bar Trying to lower it fur ther could damage the i...

Page 42: ...4 1 Seats 4 2 Seat belts 4 5 Steering wheel 4 8 4 Seat and steering wheel adjustments...

Page 43: ...ly with your arms slightly bent Seats WARNING Adjusting the seat while the vehicle is in motion is dangerous as the seat may move more than you intend Be sure to stop the vehicle and set the parking b...

Page 44: ...back raise reclining lever Lower the armrest to use it Turn the armrest knob to adjust the height of the armrest in its lowered position Up Down 2 Assistant driver s seat Assistant driver s seat Cente...

Page 45: ...d up for access to them When you wish to stow or remove something from these compartments release the hooks at the base of the seat and raise the seat cushion To retain the seat cushion use the retain...

Page 46: ...in the cargo area while the vehicle is in motion Unless seated and properly belted up the risk of injury is greatly increased Seat belts should be worn as low as possi ble over the hips Wearing a sea...

Page 47: ...slip ping off in a collision is reduced Fastening 1 Hold tang and gently extend the belt If the belt locks or is difficult to extend let it retract and pull it gently again 2 Take care that the belt d...

Page 48: ...ildren to stand or kneel on the seats For maximum safety we recommend fitting and using a restraint system that complies with Fed eral Motor Vehicle Safety Standards The use of child and or baby restr...

Page 49: ...d thinner may seri ously affect the strength of the webbing P 12 95 Never attempt to bleach or dye the seat belts as this could weaken them considerably Do not attempt to remove the seat belts or dis...

Page 50: ...4 9 Pull the lock lever then adjust the steering wheel to the height and angle that are most comfortable for you Push the lock lever back in to securely retain the steering wheel Adjust Retain Z14892...

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Page 52: ...Pedals 5 12 Gearshift lever 5 13 Range selector lever 5 14 Overdrive switch 5 17 Parking brake lever 5 17 Combination switch 5 18 Cruise control 5 22 Hazard warning lamp switch 5 27 Rheostat control s...

Page 53: ...itch vehicles other than Crew cab models P 3 4 Oil level check switch P 12 24 Cruise control main switch vehicles with cruise control Range selector lever automatic transmission vehicles Overdrive swi...

Page 54: ...e ACC position for long periods for example for listening to the radio as the battery could be completely dis charged Starter switch WARNING Never turn the starter switch to any position other than th...

Page 55: ...er can be used Audio equip ment radio etc installed and connected in the approved manner can also be used ON The engine is running in this position All electrical circuits are operable START The engin...

Page 56: ...cause unconsciousness or death If you smell exhaust gases inside the cab inspect the exhaust pipe and check whether exhaust gases are leaking through holes or cracks caused by corro sion or damage If...

Page 57: ...using a high capacity battery improves engine startability 1 Pre starting steps 1 Pull parking brake lever to fully apply the parking brake 2 Manual transmission vehicles Place gearshift lever in the...

Page 58: ...es out Automatic transmission vehicles While holding down the brake pedal turn the starter switch to the START position to start the engine Manual transmission vehicles While holding down the clutch p...

Page 59: ...rking brake lever fully to apply the parking brake and block the wheels with chocks thus preventing the vehicle from accidentally moving Performing the cranking is of essential importance in terms of...

Page 60: ...a garage or other closed area When starting the engine or entering or leaving a garage do not run the engine for longer than is nec essary as the accumulation of exhaust gas in closed areas is very d...

Page 61: ...after starting the engine while the engine is still cold you will encounter the following problems In a cold region the extreme coldness of the engine will cause poor ignition of fuel making the engi...

Page 62: ...n the neutral position Automatic transmission vehicles Place the range selector lever in the P posi tion Stopping the engine WARNING Never allow the vehicle to coast with the engine stopped as braking...

Page 63: ...a time before stopping it 4 Turn the starter switch to the ACC position to stop the engine Accelerator pedal Racing the engine also increases fuel consumption Pedals WARNING If you use a floor mat lay...

Page 64: ...horten the service life of the clutch Driving with your foot on the clutch pedal could prevent engine braking and exhaust braking from taking place Depress the clutch pedal fully when changing gear If...

Page 65: ...hanging gear If you do not depress the pedal completely the clutch will slip and the clutch disc will be damaged which could lead to an accident The shift pattern is inscribed on the top of gear shift...

Page 66: ...n authorized dealer 2 Ranges P Used when stationary for example when start ing or warming up the engine The starter key can be removed with the range selector lever in this position R For backing up T...

Page 67: ...owing conditions may occur as a result of this action Note that this control will be terminated when the fluid reaches a suitable temperature Difficulty may be experienced in making auto matic gear ch...

Page 68: ...erature rises Overdrive OFF Overdrive should be switched off when engine brak ing is needed on a downhill road or when driving uphill for a long period In the D range gear shifts are made automaticall...

Page 69: ...ntally drove the vehicle with the parking brake applied the parking brake would wear prematurely and overheat leading to reduced effectiveness and the risk of a fire When parking your vehicle on a slo...

Page 70: ...down activates the headlamp high beams and pull ing it back to the original position reactivates the low beams When the high beams are on indicator lamp lights up 4 Turn signal lamp switch Turn signa...

Page 71: ...icator however is not illu minated Activation and deactivation of exhaust brake Pushing the lever forward activates the exhaust brake While the exhaust brake is activated the indicator lamp stays illu...

Page 72: ...Washer fluid may splash around in some circumstances Do not operate the wipers when the rubber parts of the wiper blades are frozen onto the windshield or otherwise stuck to the wind shield The wiper...

Page 73: ...servoir but none is sprayed when you operate the washer the nozzles may be blocked Clean the nozzles using a piece of thin wire If fluid is still not sprayed when you operate the washer have the vehic...

Page 74: ...SUME Press this side of the switch to change the set speed to a higher speed and to return to the pre viously set speed as well The switch returns automatically to the neutral position after having be...

Page 75: ...pressing the ON side of the main switch to set a desired speed make sure the exhaust brake switch is in the OFF position You will not be able to set the speed if the exhaust brake switch is in the ON...

Page 76: ...ecrease the set speed in cruise con trol mode Continue to press the SET side of the SET RESUME switch The vehicle will decelerate Release the switch when the desired speed is reached The vehicle will...

Page 77: ...atic transmission 6 To reactivate the temporarily deacti vated cruise control To reactivate the cruise control press the RESUME side of the SET RESUME switch The indicator lamp will illuminate again a...

Page 78: ...r When there is a problem with the engine control system the cruise control cannot be used CAUTION The battery may be discharged and the engine impossible to restart if the hazard warning lamps are op...

Page 79: ...nside the van body With the starter switch in the ON position operate the van body dome light switch to turn the van body interior lighting on or off An indicator light comes on in the switch when it...

Page 80: ...be in their outward positions and adjusted so that clear rear views may be obtained through them When turning right or left bear in mind the difference in tracking of the front and rear inner wheels a...

Page 81: ...to its maximum capacity following these types of driving you must manually regenerate it after bringing the vehicle to a stop this is called parked DPF regeneration The following table shows when the...

Page 82: ...op the engine frequently during opera tion The system informs you of such a condition by flashing the indicator lamp to prompt you to manually remove the DPF trapped PM by oxidation The flashing inter...

Page 83: ...ration in a place where there are flammable materials such as dead grass or paper During the parked DPF regeneration all surfaces of and around the exhaust pipe and muffler as well as the exhaust gase...

Page 84: ...e may also operate during the parked DPF regeneration NOTE The parked DPF regeneration sequence does not start under the following conditions The engine coolant temperature is too low Then the engine...

Page 85: ...obably indicates a blocked DPF and or failure of the system Park the vehicle in a safe place as soon as possible and proceed to the following 1 Hold the starter switch in the ACC or LOCK position for...

Page 86: ...6 1 Arrangement of instruments and warning lamps 6 2 Speedometer 6 2 Tachometer 6 3 Water temperature gauge 6 3 Fuel gauge 6 4 Warning indicator lamps 6 5 6 Instruments and warning lamps...

Page 87: ...ODO and TRIP each time the trip knob pressed ODO odometer The total distance covered by the vehicle is shown to the nearest mile TRIP tripmeter The distance covered by the vehicle from a selected poi...

Page 88: ...enters the red zone the engine has overheated The warning lamp will illuminate at this time In this event pull off the road as soon as you can safely do so then let the engine cool down by running it...

Page 89: ...13 28 CAUTION Be careful not to allow the engine to run out of fuel Engine stall resulting from an empty tank could cause damage to the fuel injection sys tem NOTE Air will be present in the fuel syst...

Page 90: ...mponent failures and possible dan ger of accident Never drive the vehicle while a red warning lamp is illuminated If any of them light up stop the vehicle as soon as it is safe to do so and make check...

Page 91: ...id pressure on FE85 or parking brake activated 6 9 Charge warning lamp Problem in battery charging system 6 10 Engine oil pressure warning lamp Excessively low engine oil pressure 6 10 Cab lock warnin...

Page 92: ...ion elec tronic control system 6 13 Daytime running light indicator lamp Headlamps low beam illuminated by daytime running light system 5 19 Engine overheating warning lamp Engine overheating 6 14 Cru...

Page 93: ...g lamp Goes off when engine is started Amber Engine control warning lamp Goes off when engine is started Automatic transmission warning lamp Automatic transmission vehicles Goes off a few seconds afte...

Page 94: ...d Should the lamp remain illuminated even after the parking brake lever has been released or light up during driving pull off the road as soon as it is safe to do so and perform the checks below With...

Page 95: ...thorized dealer 4 Engine oil pressure warning lamp The engine oil pressure level warning lamp lights up when the starter switch is turned to the ON posi tion and goes out as soon as the engine is turn...

Page 96: ...authorized dealer 6 Fuel filter warning lamp If this lamp is illuminated water is present in the fuel filter in an amount exceeding the limit Pull off the road as soon as it is safe to do so and drain...

Page 97: ...s Illumination of this lamp may indicate a blocked DPF and or faulty DPF system If this lamp illumi nates during driving stop the vehicle as soon as it is safe to do so and perform the following inspe...

Page 98: ...ve the sys tem repaired by an authorized dealer as soon as possible NOTE Even with the ABS faulty and the warning lamp remaining lit the normal brake system is still func tioning satisfactorily Only t...

Page 99: ...er steps that are necessary following overheating of the engine P 13 8 CAUTION Be sure to stop the engine only after letting it run at a speed slightly above the idling RPM until the coolant cools dow...

Page 100: ...n problems occur in the vehicle s electrical control system If it lights up pull off the road as soon as it is safe to do so Place the starter switch to the ACC or LOCK position for more than 5 second...

Page 101: ......

Page 102: ...or driving 7 3 Tips for improving fuel economy 7 7 Braking 7 8 Antilock braking system ABS 7 9 On uphill and downhill roads 7 11 On rough roads and in bad weather 7 13 Parking 7 14 Vehicles with limit...

Page 103: ...the parking brake is released Fully release the parking brake Set manual transmission vehicles in motion slowly When pulling away avoid racing the engine and suddenly engaging the clutch Sud den star...

Page 104: ...gate the cause P 6 5 If you cannot identify the cause or cannot rectify the problem contact an authorized dealer Avoid making sharp turns and braking hard except in emergencies Doing so during high sp...

Page 105: ...er steering system to mal function Do not try to forcefully turn the steering wheel when the front wheels are stuck against a curb stone or other object Doing so could cause the steering gearbox to fa...

Page 106: ...ad resulting in an accident Operate the radio and other items of equipment in the cab when the vehicle is stationary It is dangerous to operate such items of equipment or use a carphone other than a h...

Page 107: ...would make engine braking and exhaust braking impossible and force you to overuse the service brakes It could also damage the trans mission When the vehicle is driving fast shifting down will be prohi...

Page 108: ...eedle in the 1 500 to 2 000 rpm range With an automatic vehicle fuel consumption can be further minimized by setting the overdrive switch to ON Try to drive at moderate and constant speeds Unnecessary...

Page 109: ...gency Sudden application of the brakes generates a large shock which could cause an accident Sudden braking will wear down tires and could cause malfunc tions in other sections of the vehicle Avoid ov...

Page 110: ...varies with road surface conditions It is always important to maintain sufficient distance from the vehicle ahead regardless of whether your vehicle is equipped with an ABS or not Also the braking di...

Page 111: ...e clutch pedal first and then the brake pedal If cargo is loaded only on the back half of the cargo bed the rear wheel brakes must share an extremely large burden during braking to pre vent the front...

Page 112: ...to make sure that they are functioning well Place the vehicle in the gear used when driving uphill and use engine braking and exhaust brake to help slow the vehicle Never drive downhill at high speed...

Page 113: ...ssion vehicle shifting down will be prohibited by a safety device if the vehicle is driving fast In such cases depress the brake pedal and reduce the vehicle speed WARNING Never coast downhill with th...

Page 114: ...ince it causes the transmission oil to heat up rapidly Drive very slowly on bumpy roads and take care not to allow the undercarriage to bottom out When the diesel particulate filter DPF strikes a rock...

Page 115: ...F the oxidation cata lyst and ceramic filter could be damaged In fog drive carefully at low speeds paying attention to the center line and the vehicle ahead of you When driving in snow or on frozen ro...

Page 116: ...le sleep ing Also you could suffer carbon monox ide poisoning from exhaust gases if the vehicle is parked in a closed space Never leave lighters cans of carbonated drink and spectacles in the cabin wh...

Page 117: ...C position could result in a dead battery Be sure to turn off all lights after parking to prevent drainage of the battery 5 If parking on a slope is unavoidable block the wheels securely with chocks a...

Page 118: ...rfaces excessively depress ing the accelerator pedal during a turn may cause the vehicle to skid and lose balance Keep this in mind for your safety Using tires different in air pressure or outside dia...

Page 119: ...s The vehicle s GVWR front GAWR and rear GAWR are listed on the VIN plate that is located as shown in the illustration NOTE Loading to a weight almost equal to a total of the front and rear GAWRs may...

Page 120: ...prevent cargo from falling strap it down securely and cover it with a tarpaulin Secure the tarpaulin ends neatly so they do not flap WARNING When roping up cargo or covering it with a tarpaulin make s...

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Page 122: ...8 1 Control and indicator lamps for 4WD operation 8 2 Advice on use of the 4WD mode 8 8 Precautions to be taken when selecting the 4WD mode 8 10 8 4WD operation FG models...

Page 123: ...ad pattern Be particu larly careful when fitting snow tires or other winter use tires Use tires that do not differ from each other in terms of the extent of wear Regularly check the tire inflation pre...

Page 124: ...n which the engine power is transmitted to all four wheels Pressing the ON side of this switch selects the 4WD mode whereas pressing the OFF side selects the 2WD mode The indicator lamp lights up when...

Page 125: ...on when the low speed range is selected To change the range from one to the other hold down the clutch pedal with the vehicle stationary and move the lever fully to the LOW range posi tion until the i...

Page 126: ...eeling hubs on both front wheels are in the LOCK position P 8 7 2 Press the front drive switch either at the ON side 4WD or OFF side 2WD when the vehi cle is either in motion or stationary Mode range...

Page 127: ...g from 4WD mode to 2WD mode the system may remain in 4WD mode even after the indicator lamp has gone out If this happens release the accelerator pedal and depress it again lightly The switching will t...

Page 128: ...when the 4WD vehicle is running in the two wheel drive mode with the engine power transmitted only to the rear wheels the front wheels are always connected to the power train differential propeller s...

Page 129: ...riate to do so after checking sand or mud conditions Start out slowly Drive at low speeds keeping the speed as constant as possible Avoid quick acceleration sudden braking and sharp turn as they can c...

Page 130: ...ageous features it is not designed for driving in water If it is absolutely necessary to drive in water select the 4WD LOW setting and drive as described below to get out of water in the shortest poss...

Page 131: ...not imply any abnormal condition exists If you experience this condition either straighten steering wheel or switch to the 2WD mode 1 If you have driven in water by necessity Immediately check engine...

Page 132: ...9 1 Front air outlets 9 2 Air conditioner 9 3 Heater 9 8 Outside air inlets 9 12 9 Heating and air conditioning...

Page 133: ...irection Adjust the left right airflow direction from each outlet as desired by moving the knob to the left or right Adjust the up down airflow direction from each outlet as desired by pressing the to...

Page 134: ...automatically restart functioning normally as soon as the engine compartment temperature drops to a normal temperature following the ter mination of the DPF regeneration In some vehicles a fast idling...

Page 135: ...air and introduction of outside air When recirculation is selected the indicator lamp in the switch comes on Outside air Use this setting when driving in normal condi tions Recirculation Use this set...

Page 136: ...conditioner switch once more stops the air conditioner 1 5 Mode selector dial Use the mode selector dial to select outlets as desired For airflow toward the upper body Place the mode selector dial in...

Page 137: ...and the rest of the air is directed toward the windshield 2 With the dial in the position air is directed equally toward the feet and windshield For airflow toward the windshield Place the mode select...

Page 138: ...t the maximum fan speed and use the temperature adjustment dial to select the maximum temperature 2 4 To ventilate the cab Press the air selector switch to select outside air and place the mode select...

Page 139: ...clogged air filter may cause a poor air condi tioning performance and blower motor malfunction P 12 87 NOTE The heater uses the heat produced by the engine coolant Warm air is therefore not available...

Page 140: ...ondi tions Recirculation Use this setting when the outside air is dirty Using this setting when parking enables you to prevent dust from entering the cab CAUTION Using the recirculation setting for a...

Page 141: ...the feet Place the mode selector dial in the position For airflow toward the feet and toward the windshield 1 With the dial in the position most air is directed toward the feet and the rest of the ai...

Page 142: ...ool airflow toward the head and warm airflow toward the feet Place the mode selector dial in the position or in the position 2 3 To defog the windshield Place the mode selector dial in the position If...

Page 143: ...malfunction of the blower motor P 12 86 Make sure the outside air inlets are not cov ered or otherwise obstructed Remove any object that is covering or otherwise obstructing them Unless the inlets are...

Page 144: ...10 1 Cigarette lighter 10 2 Ashtrays 10 3 Coat hooks 10 4 Sun visors 10 4 Interior lamp 10 4 Small article compartments 10 5 Using the radio 10 8 Accessories 10 8 10 Interior equipment and accessories...

Page 145: ...fire Do not allow a child to touch the cigarette lighter The child could get burned Do not touch the metallic parts of the ciga rette lighter You could get burned Never use a cigarette lighter from an...

Page 146: ...then hold down the spring and push the ashtray into place Ashtrays WARNING Be sure to put out cigarettes and match sticks before putting them in the ashtrays Close ashtrays completely Put only cigare...

Page 147: ...back of the driver s sun visor The interior lamp s can be used with the starter switch in any position CAUTION Leaving an interior lamp illuminated for a long time with the engine not running can drai...

Page 148: ...comes on when a door is opened and goes off when the door is closed OFF position The lamp is off regardless of the door positions Small article compartments WARNING Always close the glove compartment...

Page 149: ...use the console and tray to hold items that are prone to rolling while the vehi cle is moving Such items could create a haz ard by impeding driving Vertical compartment Hook Vehicles other than Crew c...

Page 150: ...ed to hold express way tickets and similar items Pocket The pocket may be used as a radio or other audio equipment mounting space WARNING The contents in a cup or can held in the cup holder may spill...

Page 151: ...e when tilting the cab See an authorized dealer if you are considering adding accessories to your vehicle Your vehicle contains electronic devices Even though these are protected against interference...

Page 152: ...11 1 Coolant 11 2 Engine oil 11 2 Fuels 11 3 Other recommendations for cold weather operation 11 3 Installing tire chains 11 4 11 In cold weather...

Page 153: ...DIESEL LONGLIFE COOLANT or equivalent to the recommended concentration P 12 48 CAUTION Never mix FUSO DIESEL LONGLIFE COOLANT with other brands of anti freeze or anti corro sion additives since these...

Page 154: ...the manufacturer s instructions CAUTION Do not use engine coolant or antifreeze since these would damage the vehicle s paint Occasionally check the undercarriage and fender wells and if necessary rem...

Page 155: ...is not being used Vehicles other than FG models On FG models tire chains cannot be used on both front and rear wheels Make sure that tire chains are installed properly so that they do not become loose...

Page 156: ...e slack in the inside chain by pulling cross chains for the inside tire outward NOTE Pull the hook section outward to the possible maxi mum extent 3 Temporarily connect hook of outside chain as shown...

Page 157: ...ten extra chain links with a metal wire to pre vent them from hitting against other vehicle parts 8 Fit spring band Attach the hooks of spring band on the chain at even intervals with the hook ends fa...

Page 158: ...nt 12 56 Range selector lever check 12 59 Steering wheel check 12 60 Service brakes check 12 62 Parking brake check and adjustment 12 64 Clutch check 12 65 Tires check 12 66 Tire replacement 12 69 Whe...

Page 159: ...pipe or other engine related parts until they have cooled down Do not loosen the engine pressure cap while the engine is hot Wait for the engine to cool down then grip the cap with a cloth and turn i...

Page 160: ...terminal of the battery CAUTION Replace filters and filter elements regularly Blocked or damaged filters and elements can reduce the engine s power and impair its operation Always use genuine parts fo...

Page 161: ...bottom of the seat cush ion 4 Attach the retaining hook to the grip beside the assistant driver s seat to hold the seat in place To cover the opening 1 Remove the retaining hook from the grip while su...

Page 162: ...eak the windshield or other equipment Take out or safety stow all loose items before tilting the cab Any objects on the roof must be removed Close both doors completely Tilting the cab WARNING Before...

Page 163: ...g it quickly with great force could damage the cab tilt mecha nism 1 Pull lever A With lever A still pulled pull up lever B Keep lever A pulled until the lever B has been fully raised CAUTION Lever B...

Page 164: ...lever to prevent the cab from dropping Do not raise the cab holding lever B or lever C Failure to observe this precaution can lead to the cab tilt mechanism being damaged or to incomplete locking when...

Page 165: ...ges with the latch WARNING When you have unlocked the cab stay immediately move your hands away from the lock lever The cab stay will tip toward the rear of the vehicle so your hands could otherwise g...

Page 166: ...le and contact your authorized dealer 1 Confirm that the latch is fully engaged with the pin Also confirm that lever B does not move when it is pulled 2 Confirm that the cab does not rise up when leve...

Page 167: ...below at the start of each day s operation in order to ensure safe and comfortable driving If you find anything unusual which you are unable to repair yourself you should have this cor rected at an au...

Page 168: ...he point midway between the pulleys Check also that the belt is not nicked or other wise damaged P 12 57 Engine oil level Check that there is sufficient engine oil using the oil level gauge or oil lev...

Page 169: ...r operates smoothly and clicks at each range position P position through 2 position Check if the shift indicator lamp in the meter clus ter indicates the selected range Set the range selector lever to...

Page 170: ...r P 12 62 Clutch pedal free play Manual transmission vehicles With your hand depress the clutch pedal and make sure that it has 0 2 to 4 mm 0 0079 to 0 16 in of free play P 12 65 Brake fluid level Che...

Page 171: ...ess than 20 mm 0 79 in P 12 60 Horn operation Press the horn button to check that the horn is working properly Windshield wiper and washer operation Check the washer for proper fluid spray direc tion...

Page 172: ...peration Check that gauges warning lamps and indi cators are working properly P 6 2 Rearview mirrors Seated in the driver s seat adjust the angles for clear views of the sides and rear Make sure the m...

Page 173: ...12 16 Simple inspection and service 3 While walking around the vehicle Seat belts Confirm that the seat belt buckles function correctly when fastening and unfastening Z11943 Z17516...

Page 174: ...sure tread groove depth foreign objects in grooves cracks and uneven wear P 12 66 Suspension springs Check for broken springs and tilt of vehicle body toward either side License plate and reflector c...

Page 175: ...e UPPER and LOWER level lines marked on the sides of the battery case P 12 82 Steering wheel operation Check that the steering wheel does not vibrate or pull to one side and that it is not unduely hea...

Page 176: ...below 23 C 10 F For details refer to an authorized dealer CAUTION Apply and replace lubricants regularly Use of lubricants beyond their designed service life could cause bearings or other compo nents...

Page 177: ...12 20 Simple inspection and service Greasing intervals Every 10 000 km 6 000 miles Z12034 FE Z12506 FG...

Page 178: ...Li soap Rear spring pin front 2 points each on both sides Rear spring pin rear 4 points each on both sides King pin bearing 4 points in total on both sides Z09225 Z09227 Z16543 Grease nipple Dust plu...

Page 179: ...le of the slip joint Propeller shaft double cardan joint FG NOTE The number of greasing points on the propeller shaft differs from model to model 2 Door hinge 4 points in total on both sides 8 points...

Page 180: ...other oils may contain substances that cause the ceramic filter inside the DPF to be loaded with particulate matter PM prematurely to the capacity and thus shorten the effectively functioning period o...

Page 181: ...evel The quantity of engine oil may increase due to the fuel that may have mixed with it when the DPF trapped PM is removed by oxidation This does not indicate any abnormality For the same reason the...

Page 182: ...ring inspection Checking 1 Remove oil level gauge and wipe off oil with a cloth 2 Fully insert the oil level gauge in the crankcase and gently draw it out 3 The oil level marked on the oil level gauge...

Page 183: ...ap and add oil as neces sary 3 Make sure that the oil level is correct If the oil level is checked immediately after adding the reading may be lower than the actual level because all added oil may hav...

Page 184: ...t for more than 10 minutes and check the oil level using the oil level gauge 7 Crank the engine with the starter switch then start the engine P 5 8 8 Let the engine idle allowing oil to circulate thro...

Page 185: ...riod should be performed at the first 4 000 km 2 500 miles Recommended oil Gear oil API classification GL 3 SAE80 general GL 3 SAE90 warm region GL 4 SAE90 tropical region Engine oil API Classificatio...

Page 186: ...ace a container under the drain plug 2 Remove inspection plug and drain plug to let the oil flow out NOTE Oil removal is quicker if performed not so long after the vehicle has been stopped and while t...

Page 187: ...ction plug 3 Automatic transmission fluid Recommended fluid Automatic transmission fluid Exxon Mobil Mobil ATF3309 or equivalent Have the automatic transmission oil changed by an authorized dealer Tig...

Page 188: ...the cab On the Crew cab models open the inspec tion cover in the rear floor mat Release the lock then open the hatch CAUTION The inspection hatch may remain at high tem peratures for a certain period...

Page 189: ...Check that the oil surface reaches the open ing of the inspection plug hole by putting your finger straightly into it If insufficient add the oil from the inspection plug hole up to the opening Put y...

Page 190: ...er one minute has passed and check that the oil is filled up to the opening of the hole 4 Install the inspection plug 5 Axle housing gear oil The first axle housing gear oil replacement during the run...

Page 191: ...On vehicles with a limited slip differential fill the differential with Genuine Gear Oil Part No 8149630EX GL 5 SAE90 Quantity required These oil quantities are given only as guidelines Be sure to che...

Page 192: ...er the vehicle has been stopped and while the oil is still warm 2 Install the drain plug The drain plug on the front axle is fitted with a magnet Wipe off any metal particles sticking to the magnet be...

Page 193: ...by an authorized dealer Recommended fluid Brake fluid SAE J1703 FMVSS No 116 DOT3 NOTE With a manual transmission vehicle the brake fluid serves also as clutch fluid Inspection intervals At the time o...

Page 194: ...oil to mix with the brake fluid When mixed with the brake fluid even very small in amounts such oils will cause the rubber parts of the brake system to swell and could cause brakes to become slug gish...

Page 195: ...clean the surfaces around cap of reservoir tank open cap and add the rec ommended brake fluid up to the MAX line 2 Close the cap firmly CAUTION Be careful not to exceed the MAX line when adding brake...

Page 196: ...adding fluid Vehicles other than Crew cab model 1 Make sure the parking brake is securely applied 2 Manual transmission vehicles Place gearshift lever in the neutral position Automatic transmission v...

Page 197: ...tch CAUTION In certain cases the inspection hatch may remain at high temperatures for a certain period of time after the engine has been stopped In order to prevent burns avoid touching this hatch or...

Page 198: ...ding more fluid than specified Insufficient oil can make the steering heavy or noisy and can damage power steering components 1 Oil filter replacement CAUTION Oil filter element must not be cleaned an...

Page 199: ...t of engine oil to gasket on the mounting surface of the filter element assembly Turn the assembly in the direction of the arrow until the gasket touches the sealing surface of the filter head From th...

Page 200: ...out Leaking fuel could cause a fire or explosion Use only the fuel filter specified for your vehicle Use of other filters could cause fuel to leak and cause a fire or explosion When replacing the fuel...

Page 201: ...ing the special tool available from an authorized dealer by turning it in the direction of the arrow Drain the fuel from the filter case 8 Remove the element and the sensor from the filter case 9 Repl...

Page 202: ...lter at the specified cleaning intervals Unnecessary frequent cleaning can damage the element allowing dust and other foreign matter to be drawn into the engine NOTE Even if the cleaning interval has...

Page 203: ...ats of the filter paper CAUTION Keep the air pressure under 685 kPa 100 psi 7 kgf cm2 to prevent the element from being damaged Do not strike the element or hit it against another object If the elemen...

Page 204: ...ws 1 Prepare a receiver for water 2 Disconnect the connector on the sensor then turn the sensor in the direction of the arrow to loosen it the water will flow from the pipe at the end of the sensor Op...

Page 205: ...dlig coolant be sure to use FUSO DIESEL LONGLIFE COOLANT or an equivalent Using any coolant other than FUSO DIESEL LONGLIFE COOLANT or an equivalent could cause corrosion and dam age to the radiator T...

Page 206: ...he properties shown in the fol lowing table Do no use hard water from wells and rivers as it is liable to form scales and cause corro sion 3 Using coolant additive To prevent the cooling system freezi...

Page 207: ...HES IMMEDIATELY FLUSH FUSO LONGLIFE COOLANT WITH WATER AND SOAP DO NOT USE FUSO DIESEL LONGLIFE COOLANT IN A CLOSED OR POORLY VENTILATED SPACE SHOULD YOU INHALE A LARGE AMOUNT OF GAS OF FUSO DIESEL LO...

Page 208: ...E COOL ANT according to the lowest temperature at which your vehicle is to be operated FUSO DIESEL LONGLIFE COOLANT concentra tion in volume percentage NOTE Vehicles are shipped with a 50 concentratio...

Page 209: ...ly low and quickly drops again when coolant has been added coolant may be leaking from the cooling system Have the vehicle inspected by your nearest authorized dealer 5 Adding coolant CAUTION Coolant...

Page 210: ...it in a folded piece of thick cloth and opening it slowly WARNING Do not replace the coolant immediately after operating the vehicle since the engine radiator coolant and other items will be extremely...

Page 211: ...Open engine drain plug and radiator drain cock to drain the coolant Also drain the coolant in reservoir tank NOTE By connecting an appropriate hose of 12 mm 0 47 in inside diameter commercially avail...

Page 212: ...icle uncover the engine inspection opening 10 Pour coolant FUSO DIESEL LONGLIFE COOLANT plus soft water up to the top of the pressure cap opening Pour the coolant slowly to prevent air from mixing wit...

Page 213: ...the intercooler or front of the radiator core is plugged with mud or dust cooling efficiency will be reduced leading to rust Clean the radiator core at regular intervals P 12 96 An excessively loose o...

Page 214: ...mately 98 N 22 lbs 10 kgf force at the point midway between the pulleys and measure the amount of deflec tion 3 If the deflection is not as specified below the tension of the belt must be adjusted 4 A...

Page 215: ...ce the vehicle was new or since the belt was replaced whichever is more recent The driving distance or time period over the which the belt can still be used is about half of that over which the belt h...

Page 216: ...2 Loosen the tensioner pulley mounting nut approximately half a turn by using a 22 mm 7 8 in offset wrench 3 Turn adjusting bolt to obtain proper belt ten sion Turning the bolt clockwise increases the...

Page 217: ...rious accident 1 Steering wheel play NOTE Be sure to check the steering wheel play both with the engine running and with the engine turned off 1 Make sure the parking brake is securely applied 2 If yo...

Page 218: ...er that is used for steering wheel adjustment is securely locked 3 Steering wheel operation 1 While driving slowly make sure that the steering wheel does not shake and the vehicle does not pull to one...

Page 219: ...uum 5 Measure the distance over which the brake pedal moves when the center of the pedal pad is pressed with light finger force to the point where resistance is felt brake pedal play Check whether the...

Page 220: ...s are detected 3 Braking performance Perform braking tests in a safe place After check ing that warning lamp or is not illumi nated drive the vehicle at a low speed to make sure that braking power is...

Page 221: ...osition 2 Braking performance Stop the vehicle on a dry downgrade set the park ing brake and check to see if the parking brake can hold the vehicle If an appropriate downgrade is not available drive t...

Page 222: ...ent is necessary Have any necessary adjustment made by an authorized dealer 2 Clutch operation 1 Confirm that the parking brake has been prop erly applied 2 Start the engine and run it at idling speed...

Page 223: ...ng an air gauge Properly inflated Excessively inflated Insufficiently inflated If the tires appear incorrectly inflated make any air pressure adjustments necessary before driv ing Standard inflation p...

Page 224: ...oper ation The increases in pressure are not abnor mal they occur because the air in the tires expands as the tires get hot while the vehicle is moving Do not release air from the tires at this time T...

Page 225: ...ires ride up on and slide over a film of water caus ing the driver to lose control of both steering and braking 3 Checking for cracks damage and objects embedded in tread Check both the tread and the...

Page 226: ...l not block traffic and acti vate your hazard warning lamps to flash and use a red or white flag or cloth to give warning to passing vehicles Have all passengers get out of the vehicle Remove any heav...

Page 227: ...king points FE Bottom surface of the leaf spring at the rear of tie rod FG Jack support under the front axle 2 2 Rear axle jacking point FE Bottom surface of the axle housing beside leaf spring U bolt...

Page 228: ...ed with R and have right hand threads Those on the left hand wheel are marked with L and have left hand threads WARNING After raising the vehicle slightly confirm that the jack is securely in position...

Page 229: ...and nuts Spherical surface of wheel nuts Disc wheel mounting surface Disc wheel mating surface Wheel nut contact surface on disc wheel Disc wheel inside surface Guide sections on hub WARNING Fit the s...

Page 230: ...e dirty the nuts will become loose during vehicle operation If wheel bolt or nut threads are damaged or the disc wheel is cracked or otherwise damaged replace the wheel with a new genuine part A damag...

Page 231: ...eel and aluminum wheels 3 Lower the vehicle gently until the tire makes contact with the ground 4 Tighten the wheel nuts in the order shown in the illustration repeating the tightening cycle 2 to 3 ti...

Page 232: ...torque WARNING Fit the socket wrench securely on the wheel nut If fitted improperly the wrench will slip off the nut and could cause injury Do not jump or jerk on the wrench handle when tightening th...

Page 233: ...up somewhat during the early stages of driving due to wear in Therefore it is necessary to retighten the wheel nuts to the specified torque after driving 50 to 100 km 30 to 60 miles Thereafter retight...

Page 234: ...ghten the loosened outer wheel nuts to the specified torque 2nd process Perform the above steps through for the remaining outer wheel nuts and inner wheel nuts WARNING A loose wheel nut could cause pa...

Page 235: ...fe as much as possible rotate the tires at regular intervals Use a tire of the same type on a single axle If different type tires are mounted on an axle the vehicle tends to pull to one side during br...

Page 236: ...uts loosen up somewhat during the early stages of driv ing due to wear in Therefore it is neces sary to retighten the wheel nuts to the specified torque after driving 50 to 100 km 30 to 60 miles There...

Page 237: ...he wiper arms back into position or operate the wipers without wiper blades as this could scratch the windshield 2 Replacing blade rubber only 1 Raise the wiper arm Pinch both sides indicated by arrow...

Page 238: ...op of the check window 3 Close the cap tightly after refilling CAUTION Substituting soapy water for washer fluid could result in clogged washer nozzles or spots on painted surfaces Operating the washe...

Page 239: ...evel should be checked as follows 1 If the battery fluid level is below the LOWER LEVEL line remove the 6 vent plugs and add distilled water via the vent plug holes until the battery fluid level is be...

Page 240: ...xtended period remove the battery 3 Cleaning the terminals Use warm water and sodium bicarbonate baking soda to remove any white powder caused by corro sion If a terminal is seriously corroded remove...

Page 241: ...ve the battery support then remove the battery 4 Install the battery by performing these steps in reverse After installing the battery make sure it is securely retained WARNING When disconnecting the...

Page 242: ...collected PM is removed by combus tion during the DPF regeneration process the ashes resulting from the combustion continue to accumulate inside the filter unless removed manu ally In order to maintai...

Page 243: ...u observe condition and the air condi tioner cools the cab poorly have the air condi tioner inspected by an authorized dealer CAUTION Running the air conditioner without refriger ant will damage the a...

Page 244: ...tioning and even malfunction of the blower motor CAUTION Clean the air filters at shorter intervals if your vehicle is used frequently in dusty areas 1 Outside air filter Disassembly is necessary befo...

Page 245: ...l and the bottom of the lower panel 2 Release the tabs on the lower panel and lower center panel then remove the lower panel 3 Remove the screw that retains the bottom of the tray 4 Open the glove com...

Page 246: ...ply rubbing compound to glass since it leaves scratches 1 2 Washing You must wash the vehicle whenever it has experi enced any of the following Been driven on coastal roads Cleaning your vehicle WARNI...

Page 247: ...h the cab tilted avoid allowing water to enter the engine through the air intake port When washing the engine compartment and underside of the chassis be careful not to expose the starter alternator c...

Page 248: ...h pressure cleaner toward the steering shaft the dust covers on the steering sys tem or the dust covers on the front axle for a long time at close range Doing so could cause a malfunction When steppin...

Page 249: ...vehicle s paintwork is cooler than human body tem perature 1 4 Dirt caked on paintwork The following contaminants can cause corrosion discoloration or staining of the vehicle if not washed off calcium...

Page 250: ...an leave marks or stains and should be cleaned off as soon as possible Clean the interior of the vehicle with a sponge or soft cloth Remove stubborn dirt with a soft brush Use the appropriate cleaning...

Page 251: ...this method to remove marks resulting from tomato ketchup black coffee egg fruit fruit juice milk cold drinks wine vomit urine and blood 1 Wipe off the smudge then wipe the area again with a damp spo...

Page 252: ...the following method 1 Hold the hooked end of stopper with pliers and pull the stopper toward the front of the vehi cle while twisting the hooked end through approximately 15 degrees to disengage the...

Page 253: ...ged with dust or mud the engine performance may be affected Clean it from time to time by using a soft brush or something also appropriate CAUTION The intercooler could be damaged if a bristle brush o...

Page 254: ...has burned out 13 17 When braking is sluggish 13 25 If the engine stalls while the vehicle is in motion 13 26 If a tire goes flat while the vehicle is in motion 13 26 When the battery has run down 13...

Page 255: ...of the speci fied amperage 13 9 Battery has run down Charge or replace the battery 13 27 Battery cable is disconnected loose or corroded Remove corrosion and connect the cable correctly 12 83 Connecti...

Page 256: ...tarter switch is malfunctioning Have an authorized dealer perform necessary inspection Possible cause Remedy Ref page The DPF system is malfunctioning Have an authorized dealer perform necessary inspe...

Page 257: ...ne 12 23 There is too much oil Adjust the quantity to the proper level 12 23 There is an oil leak Check the oil circuit and retighten connections as necessary Engine oil replacement intervals are too...

Page 258: ...rized dealer perform necessary inspection There is air in the brake fluid Have an authorized dealer perform necessary inspection Possible cause Remedy Ref page Brake fluid is insufficient Add brake fl...

Page 259: ...en the wheel nuts to specifica tion 12 72 Tires are not uniformly inflated Inflate tires properly 12 66 Tires wear unevenly Replace tires 12 69 Tires are damaged Replace tires 12 69 Wheels are not bal...

Page 260: ...uld be dangerous Wherever possible drive out of the tunnel before stopping the vehicle Be sure to block the wheels with chocks after stopping the vehicle as mechanical failure may render the parking b...

Page 261: ...e enters the red zone the engine has overheated Stop the vehicle in a safe place and allow the engine to cool by using the accelerator pedal to run the engine at a speed slightly higher than the idlin...

Page 262: ...until it reaches the FULL line Refit the cap securely after adding coolant 5 Check that there is no dirt stuck to the front of the radiator 6 If coolant leaks or the engine repeatedly over heats the c...

Page 263: ...ing the high current fuse box cover be sure to retain it with the clamps while press ing it straight downward Pushing the cover toward the inside of the vehicle with excessive force could break it 1 3...

Page 264: ...ized dealer perform neces sary inspection Use care not to splash water on or around the fuse box cover Should water be splashed over the fuse box cover check the inside of the fuse box for water Any d...

Page 265: ...gnal lamps B4 10A Auxiliary power supply circuit directly connected to battery B5 10A Audio system B6 10A Interior lamps B7 30A Power window driver s B8 30A Power window assistant driver s B9 20A Engi...

Page 266: ...30 30A Air conditioner blower fan heater blower fan B33 10A Van body dome light B34 20A Automatic transmission fluid cooler fan B36 20A Engine drive unit M1 10A Backup lamps M2 10A Meter cluster M3 15...

Page 267: ...5A Automatic transmission troubleshooting diagnosis 5A ABS troubleshooting diagnosis 10A ABS troubleshooting memory clear 5A MVCU troubleshooting diagnosis 10A MVCU troubleshooting memory clear 5A Eng...

Page 268: ...stall the cover place it on the box and press it straight downward Align the holes of the clips with the protrusions While still pressing the cover downward retain it with the clamps The amperage and...

Page 269: ...cuit FH1 60A yellow Fuse box S1 A1 A5 M1 M12 FH2 60A yellow Fuse box B1 B12 FH3 40A green Fuse box B13 B16 FH7 40A green ABS motor FH8 40A green ABS valve FH12 60A yellow Hydraulic brakes booster BATT...

Page 270: ...ire could result if a fuse of incorrect amperage is used When a lamp has burned out WARNING Use a lamp of the specified voltage and wattage shown in the following table If a wrong lamp is used an exce...

Page 271: ...If such a substance gets on a plastic lens immedi ately wipe it off or rinse it off with water Burnt bulbs should be replaced as soon as possible NOTE In rainy weather and when the vehicle is washed...

Page 272: ...uble filament 12V 21 5W P21 5W 2 Rear turn signal lamp 12V 21W P21W 2 Backup lamp 12V 21W P21W 2 License plate lamp 12V 7 5W A12V7 5W 1 License plate lamp Crew cab or FG models 12V 8W 2 Clearance and...

Page 273: ...b ber under the headlamp toward the centerline of the vehicle and release it from the tabs CAUTION When removing the lamp rubber do not pull it with excessive force or the tabs could break 2 Open the...

Page 274: ...could hit and damage it 6 Remove the screw at the bottom of the dummy lamp then remove the lamp toward the outside of the vehicle 7 Remove the headlamp s bolts and connectors CAUTION Do not turn the b...

Page 275: ...s on the headlamp into the holes and fit the headlamp in place 2 Fit the headlamp s bolts and connectors 3 Pull out the screw in the vehicle 4 Insert the stud pin on the dummy lamp into the grommet ho...

Page 276: ...ould hit the lamp and damage it Do not tighten the screws too tightly or the mounting could get damaged 9 Fit the lamp rubber under the headlamp onto the tabs by moving it toward the outside of the ve...

Page 277: ...ing is dirty clean it 2 Front and side turn signal lamp bulb replacement 1 Open the door 2 Turn the socket in the direction of arrow to remove it 3 Press the bulb and turn it in the direction of arrow...

Page 278: ...cking is cor rectly positioned If the packing is incorrectly installed or twisted water can enter the lamp and shorten its life If the packing is dirty clean it 5 Uniformly tighten the screws that ret...

Page 279: ...the brakes The power steering system then becomes inop erative making steering extremely difficult Additional force must be used when turning the steering wheel Avoid sudden braking Hold the steering...

Page 280: ...y low fluid level it would deteriorate rapidly and could overheat or explode Be careful not to connect the booster cables in the wrong sequence Sparks are often produced when you connect the booster c...

Page 281: ...a dead battery let it draw a charge for several minutes from the vehicle from which you are receiving the boost before attempting to turn over the engine 6 After the engine of the vehicle with the dea...

Page 282: ...NOTE Alternatively connect a hose of 8 mm 0 31 in inside diameter commercially available to the pipe portion of the air vent plug in order to prevent fuel from splashing Use a transparent hose so you...

Page 283: ...ront bumper when raising the front wheels attach an L shaped pro tection plate Attach the towing chain securely to the front axle CAUTION Do not attach the chain to the bumper since the bumper would b...

Page 284: ...sand mud or snow free it by driving forward and backward P 7 13 If this method is not successful free the vehicle by towing it as described below CAUTION Use the towing method described in this sectio...

Page 285: ...r towing hook that is located behind the left hand side rail 3 For the sake of safety the angle formed by the tow rope when hooked up should be limited to the range indicated in the illustration Do no...

Page 286: ...ce either vehicle s engine 7 When the towed vehicle becomes free promptly stop it each vehicle by applying the brake pedal To make the rope or wire rope easy to remove from the towing hooks let it bec...

Page 287: ......

Page 288: ...14 1 Recommended lubricants hydraulic fluids and quantities 14 2 Service data 14 4 14 Service data...

Page 289: ...quantities Item Quantity Engine Oil pan FE Approx 7 7 4 FG Approx 8 8 5 Oil filter Approx 1 1 1 Manual transmission 5 speed Approx 3 6 3 8 6 speed Approx 4 4 4 6 Automatic transmission Total quantity...

Page 290: ...low 40 C 104 F 90 Above 40 C 104 F 140 or 85W 140 Limited slip differential vehicles with limited slip differ ential Gear oil for limited slip differential API GL 5 Genuine Gear Oil Part No 8149630EX...

Page 291: ...pedal pad 0 2 to 4 mm 0 0079 to 0 16 in Brake pedal play at center of pedal pad 0 1 to 3 mm 0 0039 to 0 12 in Fully depressed brake pedal to floor clearance 20 mm 0 79 in or more Parking brake lever...

Page 292: ...15 1 Maintenance schedule 15 2 Lubrication schedule 15 7 15 Maintenance schedule...

Page 293: ...ssion items Noise control items Item Time of inspection and maintenance Working procedures Ref page Pre operational checks New vehicle at 4 000 km 2 500 miles Inspection interval Every 10 000 km 6 000...

Page 294: ...ent Every 5 000 km 3 000 miles Clean air cleaner element by blowing clean com pressed air 12 45 Air cleaner element replace ment R Replace air cleaner element 12 45 Exhaust system I Inspect the exhaus...

Page 295: ...ub bearing I Check wheel hub bearing for play Wheel hub bear ing hub seals replacement R When wheel hub bearing grease is replaced also replace the wheel hub bearing hub seals Wheel and tire I I Check...

Page 296: ...Disc brake pad and disc I Check disc brake pad and disc for damage and wear Brake lining I Check lining for wear through inspection hole Brake drum I Disassemble and check drum for wear crack and dama...

Page 297: ...rm air blows properly onto the windshield 9 3 9 8 Rearview mirrors I Seated in the driver s seat adjust the angles for clear views of the sides and rear Make sure the mirrors are clean License plate a...

Page 298: ...d indicators are working properly 6 2 Battery I Check the battery fluid level 12 82 Item Time of inspection and maintenance Reference page Pre operational checks New vehicle at 4 000 km 2 500 miles In...

Page 299: ...lacement R Front axle birfield joint grease replacement FG R Front axle kingpin bearing grease replacement FG R Front axle steering knuckle grease replacement FG R Brake fluid level I 12 38 Brake and...

Page 300: ...ins L Lubrication of door hinge L 12 22 Lubrication of anchor hook Vehicles other than Crew cab models L 12 22 Item Time of inspection and maintenance Reference page Pre operational checks New vehicle...

Page 301: ......

Page 302: ...16 1 16 Alphabetical index...

Page 303: ...Engine number 1 2 Engine oil 11 2 12 23 Engine overheats 13 8 Entering and leaving the vehicle 3 10 Exhaust brake 5 20 Free wheeling hub 8 7 Front air outlets 9 2 Front drive switch 8 3 Fuel filter 1...

Page 304: ...Seat belts 4 5 Seats 4 2 Service data 14 4 Small article compartments 10 5 Speedometer 6 2 Starter key 3 2 Starter switch 5 3 Starting the engine 5 5 Steering wheel 4 8 Stopping the engine 5 11 Sun vi...

Page 305: ......

Page 306: ...17 MAINTENANCE RECORD NOTE The symbols and prefixed to some check items stand for Exhaust Emission Control item and Noise Control item respectively 17 1...

Page 307: ......

Page 308: ...miles Lubrication Engine oil replacement Manual transmission oil replacement Transfer gear oil replacement FG Rear axle housing gear oil replacement Front axle housing gear oil replacement FG Inspecti...

Page 309: ......

Page 310: ...l level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of...

Page 311: ...4 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 312: ...ation of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehic...

Page 313: ...6 Suspension system Spring U bolt nuts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 314: ...using gear oil replacement FG Wheel hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease...

Page 315: ...orque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake li...

Page 316: ...oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication...

Page 317: ...axle Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system...

Page 318: ...ent or 12 months Lubrication of propeller shaft center bear ing Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication o...

Page 319: ...sal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys...

Page 320: ...FG Wheel hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease replacement FG Power steer...

Page 321: ...rque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking s...

Page 322: ...il level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication o...

Page 323: ...16 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 324: ...r oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubricatio...

Page 325: ...axle Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system...

Page 326: ...ousing gear oil replacement FG Wheel hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease...

Page 327: ...orque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake li...

Page 328: ...ement or 12 months Lubrication of propeller shaft center bear ing Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication...

Page 329: ...shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc b...

Page 330: ...oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication...

Page 331: ...24 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 332: ...ement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease replacement FG Power steering fluid level Lubrication of univ...

Page 333: ...joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake p...

Page 334: ...il level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication o...

Page 335: ...28 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 336: ...ation of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehic...

Page 337: ...30 Suspension system Spring U bolt nuts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 338: ...grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease replacement FG Brake and clutch fluid replacemen...

Page 339: ...e performance of range selector lever or 6 months Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel hub bearing Wheel hub bearing hub...

Page 340: ...ar oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubricati...

Page 341: ...axle Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system...

Page 342: ...oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication...

Page 343: ...36 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 344: ...nt FG Wheel hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease replacement FG Power ste...

Page 345: ...eller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retighten...

Page 346: ...oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication...

Page 347: ...40 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 348: ...ement Power steering fluid replacement or 12 months Lubrication of propeller shaft center bear ing Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear...

Page 349: ...wear Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Brakin...

Page 350: ...housing gear oil replacement FG Wheel hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grea...

Page 351: ...orque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake li...

Page 352: ...ication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Veh...

Page 353: ...46 Suspension system Spring U bolt nuts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 354: ...oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication...

Page 355: ...48 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 356: ...cement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease replacement FG Power steering fluid level Lubrication of uni...

Page 357: ...joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake p...

Page 358: ...r 12 months Lubrication of center bearing Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubricatio...

Page 359: ...sal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys...

Page 360: ...ication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Veh...

Page 361: ...54 Suspension system Spring U bolt nuts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 362: ...housing gear oil replacement FG Wheel hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grea...

Page 363: ...orque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake li...

Page 364: ...ear oil level FG Power steering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubricat...

Page 365: ...axle Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system...

Page 366: ...teering fluid level Lubrication of universal joints slip joint Lubrication of double cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubric...

Page 367: ...60 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake sys tem parts Steering system Steering system...

Page 368: ...placement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replace ment FG Front axle steering knuckle grease replacement FG Brake and clutch fluid replacement Power s...

Page 369: ...isc wear Operate performance of range selector lever or 6 months Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel hub bearing Wheel...

Page 370: ...Pub No MH996028 Owner s Manua l 2010 Model...

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