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Mitsubishi FUSO FE 2006, Owner'S Manual

The Mitsubishi FUSO FE 2006 Owner's Manual is an essential guide for every owner of this reliable truck. Packed with detailed instructions and helpful diagrams, this manual allows you to understand your vehicle and perform maintenance tasks effectively. Download the free manual from manualshive.com and unleash the full potential of your FUSO FE 2006.

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13-16

Useful advice for emergencies

1 Headlamp bulb replacement

For safety and simplicity, bulb replacement is per-

formed with the headlamp removed. The front and

side turn signal lamp and dummy lamp must be

removed before the headlamp can be removed.

1.1

Headlamp removal and installation

•

Headlamp removal

1. For removal of the headlamp  , first remove the

screw   and rivet  , then move the lamp rub-

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 door, then loosen the screws 

behind the front and side turn signal lamp   and

the screw   behind the dummy lamp   until

they spin freely.

NOTE:

The screws are designed not to come out.

3. Pull out screw   toward you.

CAUTION

Unless the screw is pulled out, the front and

side turn signal lamp and dummy lamp will

catch on it and you will not be able to remove

them.

4. Close the door.

5. Remove the front and side turn signal lamp 

toward the outside of the vehicle, then remove

the connector  .

CAUTION

•

When removing the front and side turn sig-

nal lamp, do not pull it forward (toward the

front of the vehicle) or its tabs could break.

•

Do not open the door with the front and side

turn signal lamp moved outward (but not

completely removed) or the door could hit

and damage it.

Z11264

Z11265

Z11266

Z11267

FEFG.book  Page 16  Thursday, March 10, 2005  7:30 PM

Summary of Contents for FUSO FE 2006

Page 1: ...Owner s Manual Pub No Owner s Manual 2006 Model 2006 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: ...our vehicle safely and com fortably 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 vehi cle make sure the next owner receives this manual and is aware of its contents 2005 Mitsubishi Fuso Truck Bus Co...

Page 5: ...the follow ing four headings which identify the nature of the instructions and information Q California Proposition 65 Warning DANGER Precautions that should be taken when handling dangerous sub stances such as battery fluid in order to prevent a serious injury or death WARNING Precautionary instructions which if not observed could result in serious injury or death CAUTION Precautionary instructio...

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 Useful advice for emergencies 13 1 14 Service data 14 1 15 Maintenance schedule 15 1 16 Alphabetical index 16 1 17 Maintenance record 17 1 Each chapter has a table of contents on its first page ...

Page 7: ......

Page 8: ...d 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 7 Reporting safety defects 1 8 Obtaining service 1 9 1 Recommendation to drivers ...

Page 9: ... on the left frame near the left front wheel 2 Engine number The engine number 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 mission components Chassis and engine numbers Powerline label Z11767 Example FE84DD Vehicle model Chassis number Example 4M50 E...

Page 10: ...e system B 14 001 to 16 000 lbs Hydraulic C 16 001 to 19 500 lbs Hydraulic Line B FE84D C FE85D D FE84 W E FG84D Series wheel base C 2 6 to 2 89 m 8 53 to 9 48 ft 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 G 3 8 to 4 09 m 12 46 to 13 41 ft H 4 1 to 4 39 m 13 45 to 14 40 ft J 4 4 to 4 69 m 14 43 to 15 38 ft Cab chassis type 1 Chassis cab Engine S 4 899 L Diesel turbo charged...

Page 11: ...f various parts When the distance has been reached have your vehicle inspected by an autho rized dealer by showing them this Owner s Manual NOTE The cost of oil lubricants parts and any work that is not included in the new vehicle inspection must be borne by the owner 2 Pre operational check Make a habit of checking your vehicle at the start of every day s operation This will ensure safe and comfo...

Page 12: ...from a reputable fuel oil supplier Both fuel suppliers and users are responsible for keeping fuel clean 2 Danger of fire and explosion by using mixed fuel Fuel containing 5 gasoline has a flash point as low as 0 C 32 F which can lead to a fire or explo sion while the engine is running Fuels Use condition Recommendation Normal operation at temperatures above 12 C 10 F ASTM D 975 Grade Low Sulfur Gr...

Page 13: ...age the engine s fuel injection system If the fuel tank cap and breather air hole become so dirty that the breather gets blocked the fuel tank may deform and the fuel injection system may fail Be sure to clean them regularly 4 Refueling NOTE If you run out of fuel refuel the tank After fueling the fuel system must be primed before the engine can be started P 13 23 WARNING Stop the engine before fu...

Page 14: ...ve the dealer this manual at that time During the initial run in period oil is quickly contam inated Replace the following oils and oil filter ele ments at the time of the new vehicle inspection Fuel tank capacity 125 liters 33 gallons Fuel tank capacity 113 liters 29 8 gallons WARNING When filling the fuel tank using a gun type fuel pump do not continue pumping after the pump automatically stops ...

Page 15: ... National Highway Traffic Safety Administration NHTSA and the Mitsubishi Fuso Truck of America Inc MFTA If NHTSA receives similar complaints it may 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 you your dealer or MFTA To contact NHTSA you may eith...

Page 16: ... expedient way to obtain service Each Authorized Dealer has the ultimate responsibility for providing the services and repairs you may need We recommend that you contact the Service Manager of your nearest Authorized Dealer for assistance In the event that you feel additional assistance is required ask to speak to the General Manager of the Authorized Dealer STEP 2 Contact MFTA After the completio...

Page 17: ......

Page 18: ...2 1 Locations in cab 2 2 Locations outside cab 2 5 2 Warning labels ...

Page 19: ...s 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 equipment mounted on the vehicle please refer to the Owner s Manual supplied by the manufacturer of the equipment The caution and warning labels are located in the cab as shown below Samples of these labels are indicated in this and following pages Locations i...

Page 20: ...2 3 Voltage Transfer lever FG Hydraulic brake booster FE85 Hydraulic brake booster FE85 Towing Automatic transmission vehicles Fuse Z11770 Z12483 Z11694 Z11693 Z11666 Z12564 ...

Page 21: ...2 4 Warning labels Engine inspection hatch Crew cab models Cab tilt function Vehicles other than Crew cab models Z11805 Z10697 ...

Page 22: ...2 5 Locations outside cab Z12496 ...

Page 23: ... Warning labels Engine oil Automatic transmission fluid Battery Pressure cap Oil cooler Automatic transmission vehicles Oil cooler Automatic transmission vehicles Z10084 Z12549 Z08670 Z11680 Z11844 Z11773 ...

Page 24: ...cles other than Crew cab models 125 liter fuel tank 113 liter fuel tank FE other than Crew cab models Air conditioner Cab tilt function Vehicles other than Crew cab models Limited slip differential Z11803 Z11774 Z11678 Z12494 Z13208 Z11804 Z10707 ...

Page 25: ......

Page 26: ...3 1 Starter key 3 2 Doors 3 2 Central door locks 3 4 Entering and leaving the vehicle 3 4 Door window glass 3 6 3 Opening and closing ...

Page 27: ... are com pletely closed before starting Exercise caution when opening a door in strong wind Otherwise the wind could catch the door and suddenly blow it open Exercise caution when opening a door on a downward slope Otherwise the inclina tion of the vehicle could cause the door to suddenly fall open When leaving the vehicle take with you any child who was riding in the cab Never leave a child in th...

Page 28: ...d unlocking the driver s door using the starter key or lock knob unlocks only the driver s door When you leave your vehicle be sure to remove the starter key from the starter switch to prevent theft Be careful not to lock the doors with the starter key inside the vehicle 2 From the inside To close use the door waist bar Close the door completely To lock the driver s door or assistant driver s door...

Page 29: ...ur foot on the wheel or tire since it could easily slip off The step can become slippery in rain or snow Firmly hold the grip while climbing into or down from the vehicle Holding the grip is particularly important when snow has settled and frozen on the 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 ...

Page 30: ... 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 Hold the grip tightly and put your foot fully on the step when entering or leaving the vehicle If you place your hand on the fender put it on the non slip section Z12471 FE FG Rear doors Crew cab models ...

Page 31: ...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 object outside the vehicle and the child could be seriously injured in the event of hard braking WARNING Always make sure that no one has their head or hands out of the window when closing it A body ...

Page 32: ... sake to press the power window lock switch to pre vent the child from opening or closing the assistant driver s window 3 Window regulator handle Crew cab models 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 internal mechanism WARNING When a child is ...

Page 33: ......

Page 34: ...4 1 Seats 4 2 Seat belts 4 4 Steering wheel 4 7 4 Seat and steering wheel adjustments ...

Page 35: ...bly 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 brake before performing any adjustment of the seat After you have adjusted the seat gently move or rock the seat to ensure that it is locked in the desired position When adjusting the seat keep your h...

Page 36: ...ard to adjust the seatback angle as desired After adjusting the seatback angle or returning the seatback to its original position after tipping it forward gently rock the seatback to make sure it is locked in place It is possible to tip the seatback fully forward With the lever pulled grasp the seatback at the top and tip it forward 3 Rear seat Crew cab models Storage compartments are located unde...

Page 37: ...ss should be adjusted automati cally If there is any looseness lift the shoulder belt gently and the mechanism will take up the slack With the belt properly tightened the risk of it slip ping off in a collision is reduced Seat belts WARNING Passengers must never be in the cargo area while the vehicle is in motion Unless seated and properly belted up the risk of injury is greatly increased Seat bel...

Page 38: ...damage or injury hold it while the belt retracts 3 Adjust the tang stopper to locate the tang in an easy to reach position and prevent it from slipping 2 Lap belt Fastening 1 Take care that the belt does not become twisted Insert the tang into the buckle until you hear a click 2 Pull on the tang to confirm that it is locked in 3 Adjust the belt so it is low across your hips 4 To adjust the belt s ...

Page 39: ... an accident pregnant women should consult a doctor about the use of seat belts before riding in the vehicle A pregnant woman should wear her seat belt as low as possible across the hips not across her abdo men 5 Seat belt care Periodically check the action of the mechanical parts such as the buckles tangs and emer gency locking retractor ELR units Check also for any damage that could stop the sea...

Page 40: ... securely retain the steering wheel Adjust Retain Steering wheel WARNING After every adjustment try to move the steering wheel back and forth to make sure that it is securely locked Unless the lever returns to its original position the steering wheel may move while the vehicle is in motion and cause an accident Make adjustments with the vehicle station ary Adjusting the steering wheel while drivin...

Page 41: ......

Page 42: ...rming up the engine 5 10 Stopping the engine 5 12 Pedals 5 13 Gearshift lever 5 14 Range selector lever 5 15 Overdrive switch 5 17 Parking brake lever 5 17 Combination switch 5 18 Hazard warning lamp switch 5 22 Rheostat control switch 5 22 Van body dome light switch 5 22 Rearview mirrors 5 23 Mirror heater switch 5 23 5 Switches and controls ...

Page 43: ...itch passing dimmer switch turn sig nal switch Front drive switch FG P 8 3 Oil level check switch P 12 19 Central door lock switch vehicles other than Crew cab models P 3 4 Warm up switch Range selector lever Overdrive switch Shift lock release knob Rheostat control switch Van body dome light switch vehicles other than Crew cab models Transfer lever FG P 8 3 Mirror heater switch option Arrangement...

Page 44: ...bat tery Avoid using the 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 the ON position while driving the vehicle Turning the starter switch to the ACC position would be dangerous because the engine would stop and the following problems would occur Th...

Page 45: ...tion All electrical circuits are operable START The engine is turned over and started in this position Once the engine is running release the key and the switch will automatically return to the ON position NOTE Turn the key only after inserting it fully in the starter switch If you are unable to turn the key gently turn the steering wheel clockwise and counterclockwise as you turn the key To warm ...

Page 46: ...the engine may become exces sively noisy Make sure the idling speed is correct NOTE If the engine speed is raised by the engine idling control volume with the Warm up switch set to the ON position a black smoke may be produced Before turning ON the Warm up switch be sure to set the engine idling control volume to the AUTO position Automatic control The engine is warmed up with the speed being auto...

Page 47: ... ide CO which if breathed can 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 exhaust gases are leak ing have the exhaust pipe inspected by an authorized dealer If exhaust gases that have leaked from the exhaust pipe come into the cab ventilate the...

Page 48: ...e On a vehicle that has not been operated for a week or more or after replacement of engine oil or engine oil filter element be sure to crank the engine before starting it If the indicator lamp does not illuminate in cold weather the fuse for the preheating circuit may have blown and should be inspected P 13 13 If the indicator lamp flashes the preheating circuit is malfunctioning Have it inspecte...

Page 49: ...sition only when absolutely necessary for example if the engine stops while the vehicle is on a level crossing 2 Starting procedure 1 Turn the starter switch to the ON position 2 Check whether the indicator lamp illumi nates or not If the indicator lamp does not illuminate hold down the clutch pedal and turn the starter switch to the START position to start the engine Do not depress the accelerato...

Page 50: ...l the parking 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 protecting the turbo charger 1 Pull the parking brake lever to fully apply the parking brake 2 Manual transmission vehicles Place gearshift lever in the neutral position Automatic transmission...

Page 51: ...g to the pro cedures described here Warming up the engine WARNING Do not warm up the engine in 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 dangerous Exhaust emissions contain carbon monox ide CO which if breathed can cause unconsciousness or deat...

Page 52: ...engine will be abnormally noisy Be sure to return the idling speed to the appropriate value With the engine idling control volume turned to the automatic control position the engine s idling speed is adjusted automatically To make the engine warm up more quickly take the following steps 1 After the engine starts turn ON the warm up switch The indicator lamp will illumi nate the engine speed will s...

Page 53: ...le for more than 3 minutes before stopping it When the vehicle is in motion engine parts become extremely hot This is particularly true during uphill or high speed driving Therefore let the engine cool down sufficiently by allowing it to idle for a time before stopping it Stopping the engine WARNING Never allow the vehicle to coast with the engine stopped as braking may be danger ously sluggish an...

Page 54: ... it goes off approximately three seconds later the disc brake pads are normal Use the brake pedal correctly P 7 7 Pedals WARNING If you use a floor mat lay it correctly and make sure it is suitable for the size of the vehicle It is dangerous for a floor mat to cover the accelerator pedal or for floor mats to be laid in multiple layers since the acceler ator pedal may be prevented from returning wh...

Page 55: ...o the reverse gear or vice versa should be done only after the vehicle has come to a complete stop When backing up always double check to make sure that there is nothing in your path When the gearshift lever is in the neutral position never keep your hand on the lever as a forward or backward pressure resulting from this practice could cause malfunction of the transmission When shifting fully depr...

Page 56: ...the starter switch is in the LOCK posi tion or ACC position If the range selector lever cannot be moved out of the P position even with the starter switch in the ON position and the brake pedal depressed move the range selector lever while pushing the shift lock release knob This problem can be caused by an electrical fault so have an inspection carried out by an authorized dealer 2 Ranges P Used ...

Page 57: ...trol is implemented to accelerate warming up of the transmission when the weather is cold and the temperature of the transmission fluid is low and the following 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 changes If the fluid temperature is extremely l...

Page 58: ...perature 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 automatically between the 1st and 4th gears NOTE Even with the overdrive switch in the OFF posi tion the 5th and 6th gears will automatically be selected if there is any risk of the engine overrev ving Overdrive...

Page 59: ...he 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 slope block the wheels with chocks for added safety 1 Arrangement of switches Lighting switch Passing dimmer switch Turn signal switch Exhaust brake switch Manual transmission vehicles Wiper and washer switch 2 Lighti...

Page 60: ...l position reactivates the low beams When the high beams are on indicator lamp lights up 4 Turn signal lamp switch Turn signal Moving the lever forward or backward activates the corresponding turn signal causing it to flash At the same time the corresponding indicator lamp or flashes When the steering wheel is returned to the neutral position after a right or left turn the switch automat ically mo...

Page 61: ...y will be returned when the original conditions have been restored The accelerator pedal is depressed The gearshift lever is positioned in neutral for 10 seconds or longer The ABS is operating Automatic transmission vehicles The exhaust brake activates if the accelerator pedal is released while the vehicle is in motion The indicator lamp illuminates when the exhaust brake is functioning The exhaus...

Page 62: ...e windshield may get scratched Operating the washer continuously for more than 20 seconds or when there is no fluid in the reservoir could burn out the washer motor Rotating the grip at the end of the lever activates the windshield wipers in one of the following three modes INT Wipers operate intermittently at 3 to 5 sec ond intervals LO Wipers operate at a slow speed HI Wipers operate at a rapid ...

Page 63: ...th the meter cluster lamps on press and hold either side of the switch to set the lamps to your desired brightness then release the switch NOTE The lamps can be brightened and dimmed only within a fixed range Pressing the rheostat control switch after the lamps have brightened or dimmed to the limit will have no effect Vehicles other than Crew cab models This switch operates the lighting inside th...

Page 64: ...erwise the battery may become drained making it impossible to start the engine Rearview mirrors WARNING During normal driving the mirrors must 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 and use the rearview mirrors to confirm safety behind you ...

Page 65: ......

Page 66: ...6 1 Arrangement of instruments and warning lamps 6 2 Speedometer 6 2 Tachometer 6 2 Water temperature gauge 6 3 Fuel gauge 6 4 Warning indicator lamps 6 5 6 Instruments and warning lamps ...

Page 67: ... tripmeter The distance covered by the vehicle from a selected point to its present location is shown to the nearest 0 1 mile The tripmeter has two indications TRIP A and TRIP B which can be set and displayed indepen dently of each other To zero the current indication press the trip knob for approximately 1 second or longer The indication will return to 0 0 The tachometer indicates engine speed in...

Page 68: ...e road as soon as you can safely do so then let the engine cool down by running it at a speed slightly higher than its idling speed If the vehicle has an air conditioner switch it off When the gauge needle comes down to approxi mately the center of the scale stop the engine and perform the checks and corrective steps described on this reference page P 13 7 CAUTION Be sure to stop the engine only a...

Page 69: ...till remaining in the fuel tank F Full E Empty When the needle approaches the E mark refuel as soon as possible If the vehicle completely runs out of fuel air must be bled out of the fuel system P 13 23 Fuel gauge Manual transmission vehicles Automatic transmission vehicles Z12504 ...

Page 70: ...omponent 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 checks for locating the cause If necessary have your vehicle repaired by an authorized dealer NOTE The red warning lamps may also come on if the engine is started when the battery s performance has decrea...

Page 71: ...12 8 LOW range indicator lamp FG Transfer LOW range gear selected 8 3 Automatic transmission fluid tempera ture warning lamp Automatic transmission vehicles Automatic transmission fluid excessively hot 6 10 Fuel filter warning lamp Excessive water in fuel filter 6 10 Disc brake warning lamp Disc brake pad worn 6 10 Green Engine oil level warning lamp Engine oil level normal 12 19 Amber Engine oil ...

Page 72: ...gine is started Engine oil pressure warning lamp Goes off when engine is started Red Engine control warning lamp Goes off when engine is started Amber Engine control warning lamp Automatic transmission warning lamp Automatic transmission vehicles Goes off a few seconds after starter switch is turned to ON position Automatic transmission fluid temperature warning lamp Automatic transmission vehicle...

Page 73: ...n after it has gone out the vacuum system is defective and must be repaired Call an autho rized dealer 2 Brake warning lamp This lamp lights up when the parking brake lever is pulled when the brake fluid level drops below the safe limit or when the power steering fluid pressure is too low on FE85 When the power steering fluid pressure is too low on FE85 illumination of the lamp is accompanied by s...

Page 74: ...Also check belt ten sion P 12 46 2 Check for a blown high current fuse in the bat tery charging circuit If blown replace with a new one P 13 12 3 If both the above checks have turned out nor mal the problem is probably in the battery charging system Call an authorized dealer 4 Engine oil pressure warning lamp The engine oil pressure level warning lamp lights up when the starter switch is turned to...

Page 75: ...e checked by an 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 the fuel filter of water P 12 38 If the warning lamp does not go out or lights up fre quently have the vehicle checked by an authorized dealer CAUTION Never continue driving with the ...

Page 76: ...your vehicle inspected at an authorized dealer in the earliest opportunity 9 ABS warning lamp This lamp comes on when the starter key is turned to ON It should go out a few seconds later If the lamp comes on again this indicates there is a mal function in the antilock braking system ABS Should this lamp illuminate during driving stop the vehicle in a safe place and perform the following inspection...

Page 77: ...er the table below 11 Engine overheating warning lamp This lamp illuminates if the engine overheats With the engine overheated the needle in the coolant temperature gauge is in the red zone Promptly stop the vehicle then run the engine at a speed slightly higher than the idling speed until the coolant has cooled down Also take other steps that are necessary following overheating of the engine P 13...

Page 78: ... for driving 7 3 Tips for improving fuel economy 7 6 Braking 7 7 Antilock braking system ABS 7 7 On uphill and downhill roads 7 9 On rough roads and in bad weather 7 11 Parking 7 12 Vehicles with limited slip differential 7 13 Loading cargo 7 15 7 Starting and driving ...

Page 79: ...suddenly engaging the clutch Sud den starts place undue strain on the vehicle and should be avoided Also avoid slipping the clutch for extended periods since this can dam age it In an automatic transmission vehicle depress the brake pedal and move the range selector lever out of the P position The range selector lever cannot be moved unless the brake pedal is depressed If the engine s idling speed...

Page 80: ...cle to tip over If you notice a strange noise vibration or smell or if steering or braking feels unusual pull the vehicle off the road as soon as it is safe to do so and check for the source of the trouble If you cannot determine the cause of the problem and or cannot rectify it contact the nearest autho rized dealer When driving on narrow streets or when making a turn keep in mind that the tracki...

Page 81: ... grip on the steering wheel and gradually reduce your speed Stop the vehicle in the nearest safe place Do not brake sharply Braking sharply would be dangerous because the steering wheel would be pulled to one side with great force When driving at high speeds in the rain it some times happens that the tires ride on a film of water and lose contact with the road surface This is known as hydroplaning...

Page 82: ...her than the recommended maximum RPM Overrevving the engine could lead to an engine failure 2 When driving an automatic transmis sion vehicle For normal driving select the D range and use the overdrive switch depending on conditions P 5 17 It is possible to pull away using the range selec tor lever in the same way as a manual gearshift lever starting in 2 then upshifting through 3 to D Do not push...

Page 83: ... 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 acceleration and deceleration causes fuel waste In a manual transmission vehicle do not keep the exhaust brake switch in the activation posi tion at all times Frequent use of the exhaust brake reduces fuel econo...

Page 84: ...ons and precautions to ensure safe driving with your ABS equipped vehi cle Braking WARNING When warning lamps and or light up immediately stop the vehicle and perform necessary checks P 6 6 Using the exhaust brake on a wet frozen snow covered or otherwise slippery road surface when the vehicle is lightly loaded or not loaded can cause the tires to slip on the road surface resulting in a skid Do no...

Page 85: ...sound of motor operation may be heard These indicate the ABS is operating nor mally and do not indicate any abnormal condi tion Keep fully depressing the brake pedal When the ABS starts functioning after sudden braking the steering wheel may be pulled slightly to one side because of braking power distribution control made by the system Espe cially in a condition where the traction is different bet...

Page 86: ... brakes and exhaust brake in advance 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 speeds If your vehicle is equipped with an automatic transmission leaving the range selector lever in the D position will result in insufficient engine braking causing t...

Page 87: ...poor braking Fading refers to the condition in which the brake linings or brake pads overheat to the point where friction is significantly reduced This also results in poor braking First decelerate the engine sufficiently before downshifting Downshifting more than two gears at a time or downshifting at a high engine speed could cause the engine to overrev Decelerate as a rule to roughly 2 000 rpm ...

Page 88: ...d the exhaust brake together with the wheel brakes to decelerate Note however that sudden engine braking can cause a skid Drive at a speed at which you can stay comfortably in control of the vehicle When the vehicle is driven through puddles or washed with water braking performance can be reduced by water entering the brake drums or splashed over the brake discs In this event drive slowly with lig...

Page 89: ...t immediately after the vehi cle has been driven Do not park the vehi cle in any place where there is dry grass waste paper or other flammable material Always stop the engine before sleeping in the cabin You could otherwise cause an accident by unintentionally moving the accelerator pedal or shift lever while sleep ing Also you could suffer carbon monox ide poisoning from exhaust gases if the vehi...

Page 90: ...t drainage of the battery 5 If parking on a slope is unavoidable block the wheels securely with chocks and take any other necessary measures to prevent the vehicle from moving Standard on FG The limited slip differential performs a special func tion in addition to the ordinary differential function which is needed when the vehicle is in a turn When one wheel begins to spin on a slippery surface th...

Page 91: ...nd lose balance Keep this in mind for your safety Using tires different in air pressure or outside diameter between the right and left wheels may result in pulling the vehicle to one side during acceleration or uneven wear of tires Check the tires regularly to make sure the right and left ones are inflated to the same pressure and not different in outside diameter Distribute the load weight evenly...

Page 92: ...NOTE Loading to a weight almost equal to a total of the front and rear GAWRs may exceed the GVWR For example a vehicle with a GVWR of 12 000 lbs 5 445 kg has a front GAWR of 4 850 lbs 2 200 kg and a rear GAWR of 8 600 lbs 3 900 kg Added together the GAWRs total 13 450 lbs 6 100 kg thus exceeding the GVWR Be sure neither the GAWRs nor GVWR are exceeded Loading cargo WARNING Overloading the vehicle ...

Page 93: ...deck To 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 sure that neither the rope nor the end of the tarpaulin hang down between the cab and the cargo deck as a loosely hanging rope or tarpaulin could catch fire from the engine heat When spreading ...

Page 94: ...8 1 Control and indicator lamps for 4WD operation 8 2 Advice on use of the 4WD mode 8 6 Precautions to be taken when selecting the 4WD mode 8 8 8 4WD operation FG models ...

Page 95: ...r winter use tires Use tires that do not differ from each other in terms of the extent of wear Regularly check the tire inflation pressures and keep them adjusted to the specified val ues When tire replacement is necessary replace all of the tires at the same time Use genuine wheels Do not change the wheel size To ensure that the tires wear evenly rotate the tires every 10 000 km 6 000 miles For t...

Page 96: ...t either the high speed range or the low speed range of the transfer gear With the vehicle stationary and the clutch pedal depressed hold down the lever button and move the lever to the high speed range position to select the high speed range or to the low speed range position to select the low speed range The indicator lamp comes on when the low speed range is selected To change the range from on...

Page 97: ... range setting cannot be switched from 4WD LOW to 2WD HIGH The 4WD HIGH setting must be selected before such switching can take place If it is difficult to switch from 2WD mode to 4WD mode and vice versa release the accelerator pedal and then depress it again lightly This will facilitate the switching During switching from 4WD mode to 2WD mode the system may remain in 4WD mode even after the indic...

Page 98: ...without pressing the button NOTE If the HIGH LOW lever cannot be moved even with the button pressed release and re depress the clutch pedal You will then be able to operate the lever If the vehicle refuses to move even with the indicator lamp come on or gone off after operat ing the HIGH LOW lever release and re depress the clutch pedal and then perform the lever operation again CAUTION When 2WD m...

Page 99: ...selected ensure that the free wheeling hubs on both front wheels are set in the LOCK positions Should either or both of them be in the FREE position four wheel driving is not possible When you select the 4WD mode to drive on off road terrain sandy or muddy ground or snow laden or frozen roads take sufficient care to avoid inappro priate operation 1 Driving on snow covered or frozen roads Select ei...

Page 100: ...slip Quick braking can slip the wheels and result in a loss of vehicle control Check road conditions before descending Avoid gear shifting or clutch operation when descending a hill Select the best gear in advance and maintain the gear until the end of the descent 5 Crossing a river Even a 4WD vehicle is not fully water resistant Do not drive in water for more than several minutes and limit drivin...

Page 101: ... circles of different radiuses and is a phe nomenon limited to 4WD vehicles It does 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 transmission trans fer and differential oil If the oil looks milky it is contaminated with water Be sure to replace ...

Page 102: ...9 1 Front air outlets 9 2 Heater 9 3 Air conditioner 9 7 Outside air inlets 9 12 9 Heating and air conditioning ...

Page 103: ...direction 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 top or bottom of the outlet Front air outlets Z11960 Z11961 ...

Page 104: ...g more effective 1 Using the controls Mode selector dial Fan speed dial Temperature adjustment dial Air selector switch 1 1 Fan speed dial The fan speed dial allows you to adjust the fan speed in four steps Turn the dial in the direction of arrow to increase the fan speed and in the direc tion of arrow to reduce it 1 2 Temperature adjustment dial Turn the dial in the direction of arrow to increase...

Page 105: ...les you to prevent dust from entering the cab CAUTION Using the recirculation setting for a long time will cause air to become stale If this happens switch to the outside air setting NOTE Select outside air when driving in normal condi tions Using the recirculation setting for a long period when humidity is high makes the windows prone to fogging 1 4 Mode selector dial Use the mode selector dial t...

Page 106: ...hield 1 With the dial in the position most air is directed toward the feet 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 selector dial in the position Z11964 Z11965 Z11966 Z11967 ...

Page 107: ...lace the mode selector dial in the position If you wish to defog the windshield quickly use the fan speed dial to select 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 selector dial in the position 3 Cleaning the air filter Clean the air filter every 6 mo...

Page 108: ...ot increase automatically when the air conditioner is used the vehicle is not fitted with a fast idling device Therefore the engine con trol knob must be used to raise the engine s idling speed to a speed slightly higher than the normal idling speed when the air conditioner is used A fast idling device can be fitted by the nearest authorized dealer 1 Using the controls Mode selector dial Fan speed...

Page 109: ...etween recirculation of inside 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 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 long ti...

Page 110: ...elector dial to select outlets as desired For airflow toward the upper body Place the mode selector dial in the position For airflow toward the upper body and toward the feet Place the mode selector dial in the position For airflow toward 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 ...

Page 111: ...ector dial in the position or in the position 2 2 For cool 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 you wish to defog the windshield quickly use the fan speed dial to select the maximum fan speed and use the temperature adjustment dial to selec...

Page 112: ...e air conditioner so it gives maximum cooling performance place the fan speed dial in the position and the temperature adjustment dial in the position Observe the receiver s inspection window through the grille Check for the presence of bubbles The refrigerant is sufficient if no bubbles are visible through the glass when the air conditioner is being operated If bubbles are visible the amount of r...

Page 113: ...ning system Be sure to use only the HFC 134a NOTE Do not release refrigerant into the atmosphere When necessary because of servicing or scrapping of the vehicle consult the nearest authorized dealer in order to have the refrigerant properly removed 4 Cleaning the air filter Clean the air filter every 6 months A dust clogged air filter may cause a poor air condi tioning performance and blower motor...

Page 114: ...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 7 Accessories 10 8 10 Interior equipment and accessories ...

Page 115: ...ed in the socket could cause a fire Do not leave your vehicle with the ciga rette lighter pushed in Doing so could result in a 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 another vehicle Your vehicle s cigarette lighter is designed for a 12 V pow...

Page 116: ...e 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 cigarette stubs and matchsticks in the ashtray Empty the ashtray before it becomes full completely as too many stubs crammed into the ashtray could catch fire Do not throw cigarette ends out of the win dow...

Page 117: ... 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 drain the battery to such an extent that the engine cannot be started Always turn off the lamps before you leave the vehicle 1 Interior lamp 1 1 Other than Crew cab models ON position The lamp is illumin...

Page 118: ...cal items are located below the glove compartment and tray Do not splash water on the glove compartment and tray and do not put wet objects in them Do not 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 Small article compartments WARNING Always close the glove compartment before operating the vehicl...

Page 119: ...ed Seatback trays Vehicles other than Crew cab models The assistant driver s seat and center seat each have a seatback tray Each tray can be used with the relevant seatback folded forward Glove compartment Glove compartment Tray WARNING The contents in a cup or can held in the cup holder may spill during movement of the vehicle Be careful of scalding if they contain hot beverages A fusebox is loca...

Page 120: ...ing space The radio optional can be used with the starter switch in the ON position or ACC position CAUTION Using the radio for an extended period without the engine running could drain the battery Extend the antenna before using the radio Retract the antenna when it is likely to cause an obstruction for example when tilting the cab Using the radio Z11989 Z12007 ...

Page 121: ...ough these are protected against interference from electromagnetic emissions you should refer to an authorized dealer before fitting equip ment that emits strong signals such as mobile telephones Accessories WARNING To avoid the risk of overheating fire or faulty operation have electrical accessories con nected by an authorized dealer Never con nect them yourself Z00020 ...

Page 122: ...11 1 Coolant 11 2 Engine oil 11 2 Fuels 11 2 Other recommendations for cold weather operation 11 3 Installing tire chains 11 4 11 In cold weather ...

Page 123: ... or anti corro sion additives since these can detract from its performance If a different coolant additive has been used and the FUSO DIESEL LONGLIFE COOLANT is to be used be sure to thoroughly flush the cooling system The viscosity of the engine oil increases in cold temperatures sometimes making it hard to start the engine especially early in the morning Therefore use an engine oil of a viscosit...

Page 124: ... attention to vehicles behind as well as in front and checking normal function of the brakes from time to time by slightly depressing the brake pedal If the brakes are sluggish depress the brake pedal repeatedly while driving at a low speed until normal braking returns When parking your vehicle select a site not directly exposed to wind or snow and face it away from the wind Do not apply the parki...

Page 125: ...er than 30 km h 19 mph when chains are installed on wheels Driving on a dry road with chains installed may damage the chains as well as the road surface Avoid doing so as far as possible Make sure that the chains and their spring bands are not excessively worn or otherwise damaged If you hear an abnormal noise while driving stop the vehicle in the nearest safe place and check the tire chains 1 Pla...

Page 126: ... flat on the tire sidewalls Also make sure that the chains are not twisted 7 Fasten 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 facing outward 9 After driving the vehicle for 5 to 10 minutes check the chains for looseness or disconnected hooks Z11190...

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Page 128: ...acement 12 39 V belts check and adjustment 12 46 Range selector lever check 12 47 Steering wheel check 12 48 Service brakes check 12 49 Parking brake check and adjustment 12 51 Clutch check 12 51 Tires check 12 52 Tire replacement 12 55 Wheel nuts check and retightening 12 61 Tire rotation 12 62 Wiper blade replacement 12 63 Windshield washer fluid level check and refilling 12 64 Battery check 12 ...

Page 129: ...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 it slowly to release the inter nal pressure before removing it com pletely Never crawl under the vehicle when it is supported only by a hydraulic jack since the jack could slip out of position and cause the vehicle to crush you The battery cables a...

Page 130: ...ervicing electrical equipment disconnect the negative 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 for replacements Also oils and greases should be those recommended in this manual Use of non genuine parts or oil and grease not recommended may lea...

Page 131: ...he 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 supporting the seat cushion to prevent it from dropping 2 Attach the retaining hook to the S spring on the bottom of the seat cushion to hold the hook in place 3 Gently lower the seatback and seat cushion then fas...

Page 132: ...reak 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 tilting or lowering the cab make sure that the area around the cab is clear of people and obstructions Never tilt the cab when the vehicle is on any kind of slope The cab will move too quickly under ...

Page 133: ...age the cab tilt mecha nism 1 Pull lever A With lever A still pulled pull up lever B 2 Grasp tilt grip and pull lever C The cab will rise slightly 3 Use the tilt grip to raise the cab After confirming that the lock lever is hooked onto the cab stay and the stay is secured fit the stopper into the notch in the lock lever Clearance in front 1 m or more 3 3 ft or more Clearance above 1 m or more 3 3 ...

Page 134: ...eft rags tools etc in the engine compartment Flammable objects left inside the engine compartment can cause fires The cab could come down too quickly if there are heavy objects inside or on the roof deck Always lower the cab slowly while supporting it Hold the cab tilt grip when lowering the cab Holding the lever B or any other part when lowering the cab could result in damage When you have unlock...

Page 135: ...ab lower it and lock it again Be sure to perform the pre operational checks for the items listed 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 authorized dealer before operating the vehicle 1 Before starting the engine WARNING If the lever B cannot...

Page 136: ...ervoir tank P 12 41 V belt tension and damage Check the belt for proper deflection when a force of 98 N 22 lbs 10 kgf is applied to the point midway between the pulleys Check also that the belt is not nicked or other wise damaged P 12 46 Engine oil level Check that there is sufficient engine oil using the oil level gauge or oil level check button P 12 19 Leakage of coolant fuel and oil Check the u...

Page 137: ...removed from the key cylinder P 12 47 Engine conditions Check the engine for smooth starting and quiet running Parking brake lever stroke Check that the parking brake lever stroke is 7 to 9 notches P 12 51 Service brake pedal Make sure that the brake pedal has 0 1 to 3 mm 0 0039 to 0 12 in free play when pressed by finger Check also that when the brake pedal is fully depressed there is a gap of 20...

Page 138: ... of the inspection window P 12 64 Steering wheel free play Gently turning the steering wheel check that its play is more than 5 mm 0 2 in and less than 50 mm 1 97 in P 12 48 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 and the wipers for normal action P 5 21 Z10682 Z11946 Z11...

Page 139: ...rt and dam age P 5 18 Gauge warning indicator lamp operation Check that gauges warning lamps and indica tors 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 mirrors are clean Door locks Push the lock knob and verify that the door does not open even when the inner handle is operated Z11696 Z12505 Z11949 Z1...

Page 140: ...eat belt buckles function cor rectly when fastening and unfastening Wheels and tires Check the disc wheels for cracks and other damage Check the tires for inflation pressure tread groove depth foreign objects in grooves cracks and uneven wear P 12 52 Z11943 Z11952 Z10752 ...

Page 141: ...nd reflector condition Check the license plate and reflectors for loose installation damage and dirt Steering wheel operation Check that the steering wheel does not vibrate or pull to one side and that it is not unduely heavy Also make sure that the steering wheel returns to its neutral position smoothly P 12 49 Brake performance Depress the brake pedal and check that the brakes work effectively a...

Page 142: ...ails 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 to seize up and cause an accident Any checking application or replacement of lubricants should be carried out with the vehicle parked on level ground Wipe all lubricant inspection windows and filling ports carefully to prev...

Page 143: ...12 16 Simple inspection and service Z12034 FE Z12506 FG ...

Page 144: ...n both sides King pin bearing 4 points in total on both sides Recommended lubricant Wheel bearing grease NLGI No 2 Li soap Propeller shaft universal joint Propeller shaft slip joint Propeller shaft double cardan joint FG NOTE The number of greasing points on the propeller shaft differs from model to model Z09225 Z09227 Z09392 Z09226 Z09228 Z09498 ...

Page 145: ...pheric temperature ranges are shown in the diagram The first engine oil replacement during the run in period should be performed at the first 4 000 km 2 500 miles CAUTION Replace the engine oil earlier if the engine is fre quently used at high speeds or under high load ing Recommended lubricant Engine oil API classification CD CD SF CE CE SF CF 4 or JASO classification DH 1 SAE40 30 20W 20 10W 30 ...

Page 146: ...nd at least 30 minutes after stopping it before checking the oil level 1 1 Checking by use of oil level check button simplified method 1 Press the button before starting the engine Esti mate the oil level from the color of the lamp that comes on Green Oil level is correct Amber Oil level is too low 2 If the amber lamp comes on replenish with the recommended engine oil NOTE Provided the engine is n...

Page 147: ...printed on the caution plate CAUTION INSPECT CAREFULLY AS THIS COVER AND INSIDE MAY BE EXTREMELY HOT 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 should be between the upper and lower notches If necessary replenish with the recommended engine oil If the engine...

Page 148: ...t to add more than the specified quantity of oil The engine can be severely damaged if the correct engine oil level is not maintained 1 4 Replacement 1 Clean the surfaces around the oil filler cap and remove the oil filler cap 2 Remove drain plug from the oil pan to remove the oil Replace the oil filter at the same time P 12 32 NOTE Oil removal is quicker if performed not so long after the vehicle...

Page 149: ...e engine can be severely damaged if the correct engine oil level is not maintained If the engine is frequently run at high speeds or under heavy loads the engine oil will deteriorate quickly and must be replaced sooner than specified 2 Manual transmission gear oil The first transmission gear oil replacement during the run in period should be performed at the initial 4 000 km 2 500 miles point Reco...

Page 150: ... magnet Wipe off any metal particles sticking to the magnet and install the drain plug 3 Add oil through the inspection plug hole until it reaches the bottom of the hole Model Quantity 5 speed transmission Approx 3 6 liters 3 8 qts 6 speed transmission Approx 4 4 liters 4 6 qts WARNING Do not check or replace the gear oil immedi ately after operating the vehicle since the engine transmission exhau...

Page 151: ...rence purposes when the oil temperature is low and accurate measurement will not be possible if the fluid temperature is low 1 Park the vehicle on level ground Prevent the vehicle from moving by pulling the parking brake lever and blocking the wheels with chocks 2 Start the engine With the engine idling and brake pedal depressed select each gear range in turn then put the range selector lever in t...

Page 152: ...engine oil level gauge are close to each other Be careful not to confuse them 4 Wipe the level gauge clean reinsert it then slowly remove it again Check the level of fluid on the level gauge 5 The fluid level should be in the HOT range 6 If the fluid level is too low add fluid via the level gauge guide NOTE Always carry out fluid level checks with the engine idling The fluid level rises as the flu...

Page 153: ... the same grade and viscosity as the oil originally placed in the trans fer 3 Install the inspection plug 4 2 Replacement 1 Remove inspection plug and drain plug to let the oil flow out NOTE Oil removal is quicker if performed soon after the vehicle has been stopped and while the oil is still hot 2 The drain plug is fitted with a magnet Wipe off any metal particles sticking to the magnet and insta...

Page 154: ... when the temperature is higher than 10 C 50 F 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 check the correct oil level by removing the inspection plug as indicated below Tightening torque 68 6 14 7 N m 51 11 ft lbs 7 0 1 5 kgf m Tightening torque ...

Page 155: ...gnet Wipe off any metal particles sticking to the magnet and install the drain plug 3 Add oil through the inspection plug hole until it reaches the bottom of the hole 4 Install the inspection plug 6 Brake fluid Have the brake fluid replacement performed by an authorized dealer Tightening torque 98 to 115 N m 72 to 87 ft lbs 10 to 12 kgf m WARNING The gear oil is extremely hot immediately after the...

Page 156: ...ause brake fluid is highly hygroscopic it should be kept in a dry place both during refilling and storage If brake fluid absorbs moisture the boiling point is lowered a condition which could result in vapor lock This is very dangerous Do not open the reservoir tank cap when checking the brake fluid Brake fluid dissolves paint If you spill the fluid wipe it clean or flush it off with water If not c...

Page 157: ... the cap firmly 7 Power steering fluid Have an authorized dealer replace the fluid Recommended fluid Automatic transmission fluid DEXRON DEXRON II or DEXRON III type WARNING The container used for adding brake fluid should be a clean one free of moisture mineral oil and dust Be extremely careful not to let dust and other foreign matter enter the reservoir tank as foreign matter in the tank could c...

Page 158: ...ilt the cab P 12 5 6 Observe the power steering fluid level in the res ervoir tank 7 If the fluid level is between the MAX and MIN lines it is acceptable 8 If the fluid level is below the MIN line clean the reservoir tank s cap and the surrounding area then open the cap and add power steering fluid until it reaches the MAX line 9 Securely fit the cap Crew cab model 1 Make sure the parking brake is...

Page 159: ... insert the level gauge and secure it in position CAUTION Use a clean container when adding the power steering fluid Never use a container that has held any other types of oil or fluid Foreign matter in the fluid could result in a failure Avoid adding more fluid than specified Insufficient oil can make the steering heavy or noisy and can damage power steering components 1 Oil filter replacement Th...

Page 160: ...Install the filter element assembly using this pro cedure Apply a thin coat 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 this point additionally tighten the filter ele ment assembly by three fourths of a turn The element assembly has four equally sp...

Page 161: ...fuel is leaking 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 filter element be sure to use the special tool to remove and reinstall the fuel filter If the fuel filter is tightened to an inappropriate torque when reinstalled fuel could leak and ...

Page 162: ...element and the sensor from the filter case 9 Replace the O ring and O ring with new ones Apply a thin coat of engine oil to each of the new O rings and install the O ring on the filter case and the O ring on the sensor 10 Clean the surfaces of the filter head and fil ter case that will come in contact with the O ring The O ring groove on the filter case should also be cleaned 11 Install the eleme...

Page 163: ...nt allowing dust and other foreign matter to be drawn into the engine NOTE Even if the cleaning interval has not elapsed clean or replace the element if clogging of the element causes a decrease in engine output The air cleaner is located in the illustrated position Sensor tightening torque 5 1 N m 3 7 0 7 ft lbs 0 5 0 1 kgf m Cleaning intervals Every 5 000 km 3 000 miles Replacement intervals Eve...

Page 164: ... Place a light in the element and check the filter paper for damage or places where it has worn thin Also check the packing for damage 5 Clean the inside of case and cover with a clean cloth 6 Replace the element with a new one if the check reveals a defective filter element or when the recommended replacement interval expires Use a genuine filter element for replacement 7 Install the element by r...

Page 165: ...hat fuel does not leak Draining water from fuel filter WARNING Fuel is highly flammable and should be kept away from hot objects and open flames owing to the risk of fire or explo sion Wipe up any spilt fuel Keep cigarettes and other sources of heat away from the vehicle while draining water from the fuel filter They are dangerous because they could set fire to the fuel Be careful not to injure yo...

Page 166: ...es 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 freezing up and mini mize corrosion use FUSO DIESEL LONGLIFE COOLANT or an equivalent FUSO DIESEL LONGLIFE COOLANT is an ethylene glycol based antifreeze SAE J814 C with both anti freeze and anti corrosion properties ...

Page 167: ...AN WATER AND SOAP IF YOU FEEL UNWELL OR PAIN ON YOUR SKIN IMMEDIATELY SEEK MEDICAL ATTENTION IN THE EVENT OF CONTACT WITH YOUR CLOTHES 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 LONGLIFE COOLANT MOVE TO A PLACE WITH FRESH AIR AND KEEP YOURSELF WARM ...

Page 168: ...ure is low When the coolant gets hot it expands making the level look higher than it actually is Deposition may occur in the reserve tank but this will not cause any problem The coolant level is sufficient if it is between the FULL and LOW marks on the coolant reser voir tank If the coolant level is below the LOW line make sure coolant is not leaking from the cool ing system then add coolant until...

Page 169: ...erheats the amount of coolant may be insufficient not only in the reservoir tank but also in the main body of the radiator 1 Allow the engine to cool down by keeping it run ning at a speed slightly higher than the specified idling speed P 5 5 2 When the needle in the coolant temperature gauge has come down to approximately the center of the scale stop the engine and perform the following checks an...

Page 170: ...erating the vehicle since the engine radiator coolant and other items will be extremely hot If you try to drain the coolant immediately after driving the vehi cle you may be scalded Give the coolant time to cool before starting the job Before removing the pressure cap on the engine grip it in a cloth and loosen it slowly to release the pressure Do not remove the pressure cap on the engine when the...

Page 171: ... pressure cap opening Refit the pressure cap tightly by turning it clockwise Lower the cab Start the engine then run the engine at a medium range RPM until the water temperature gauge needle points the center of the scale and continue running the engine for about 10 min utes more from that point Stop the engine and discharge the water Remember that the water is very hot Repeat the above procedure ...

Page 172: ...ep it running at a speed slightly higher than the specified idling speed to expel air from the cooling system When the needle in the coolant temperature gauge reaches approximately the center of the scale allow the engine to idle for 10 more minutes then stop it 15 When the engine has cooled open the pressure cap and if the coolant level is too low add cool ant until it reaches the top of the pres...

Page 173: ...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 V belts check and adjustment V belt inspection intervals At the time of pre operational check and every 10 000 km 6 000 miles or every 12 months WARNING Always stop the engine before inspecting or adjusting belts Ensur...

Page 174: ...in proper belt ten sion Turning the bolt clockwise increases the tension 4 After adjustment firmly tighten the tensioner pulley mounting nuts Automatic transmission vehicle If any abnormality is found in the following checks do not drive the vehicle Contact to an authorized dealer NOTE Be sure to check with the engine stationary 1 Confirm that the parking brake is fully applied 2 Set the starter s...

Page 175: ...ng check the steering wheel play as follows From its straight ahead neutral position turn the steering wheel clockwise and counterclock wise to the point where a resistance is first felt for each direction and measure the amount of the steering wheel movement between these points steering wheel play If the steering wheel play is out of specification contact an authorized dealer NOTE The above chec...

Page 176: ...e parking brake is securely applied 3 If your vehicle is equipped with a manual trans mission make sure that the gearshift lever is in the neutral position If your vehicle is an auto matic transmission vehicle make sure that the range selector lever is in the P position 4 Pump the brake pedal several times to release all the vacuum from the brake system zero vac uum 5 Measure the distance over whi...

Page 177: ...en depressed brake fluid leakage or presence of air in the brake hydraulic system may be a cause Have the brake system inspected by an autho rized dealer if the above conditions 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 sufficient and even If b...

Page 178: ...ake can hold the vehicle If an appropriate downgrade is not available drive the vehicle at a low speed and acti vate the parking brake to make sure that it exhibits satisfactory braking action If parking brake performance is in any way abnor mal vehicle operation could be dangerous Contact an authorized dealer Manual transmission vehicles Check the clutch for condition If anything abnormal is foun...

Page 179: ...gearshift lever easily to the various gear posi tions and that the clutch engages smoothly without slipping when the clutch pedal is released slowly 1 Inflation pressure check Tire pressure should be checked and adjusted before driving when the tires are still cool Make sure that the tire air valve caps are securely fit ted You can roughly judge the air pressure from the form of the tire tread but...

Page 180: ...ssure Unless the valve caps are replaced foreign matter may interfere with the valves and cause air to leak out Model Tire size Inflation pressure kPa psi kgf cm2 FE84 LT215 85R16 10PR Load Range E 550 80 5 5 FE85 215 75R17 5 124 123L Load Range F 690 100 7 0 FG LT235 85R16 10PR Load Range E 550 80 5 5 WARNING Excessively low or high tire pressures not only give a poor ride but also could cause ca...

Page 181: ... across the tire at the locations corresponding to the marks Replace the tire as soon as the slip signs show up as continued use is dangerous P 12 55 NOTE Hydroplaning can occur when driving on a wet roads at high speeds When a vehicle hydroplanes tires 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 object...

Page 182: ... 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 Block the tire diagonally opposite to the tire to be replaced with a chock Example Block the left front tire if the right rear tire is to be replaced Prepare a replacement tire NOTE Your vehicle is not provided with a replacement tire as standard equipm...

Page 183: ...the onboard tools WARNING After raising the vehicle slightly confirm that the jack is securely in position If the jack slipped out of position with the vehicle fully raised the vehicle could fall and cause a serious injury Apply the jack only to designated jacking points Applying the jack elsewhere could damage the vehicle and cause the jack to slip out of position Never rock or climb below the ve...

Page 184: ...t loosen the outer wheel nuts and remove outer tire then lower the jack loosen inner wheel nuts and jack up the vehicle again to remove inner tire 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 loosen the wheel nuts too much or you could damage the threads WARNING Do not rotate the jacked up wheel if the v...

Page 185: ...d nuts have stamped marks for easy identification an R mark for right hand wheels and an L mark for left hand 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 times Finally tighten the nuts to the specified torque WARNING If the above items are dirty the nuts will bec...

Page 186: ...f dual wheels is replaced retighten the inner wheel nuts to the specified torque before mounting the outer wheel 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 the nut by using your own weight Doing so can overtighten the nut Overtightening the nuts could o...

Page 187: ...omewhat 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 Thereafter retighten the nuts at regular intervals Do not paint disc wheel mounting surfaces dual wheel mating surfaces wheel nut seating surfaces and wheel hub mounting surfaces as resulting thicker paint film could cau...

Page 188: ...very 10 000 km 6 000 miles WARNING After changing a tire the wheel nuts will loosen somewhat during the initial stages of driving due to wear in Therefore retighten the wheel nuts to specification after you have driven 50 to 100 km 30 to 60 miles Wheel nut tightening torque 440 to 540 N m 325 to 398 ft lbs 45 to 55 kgf m WARNING A loose wheel nut could cause broken wheel bolts or a cracked disc wh...

Page 189: ... a ribbed tread for the front wheels and tires with a traction type tread for the rear wheels Tire rotation Tire rotation intervals Every 10 000 km 6 000 miles Model Tire size FE84 LT215 85R16 10PR Load Range E FE85 215 75R17 5 124 123L Load Range F FG LT235 85R16 10PR Load Range E WARNING Be sure to use the specified type of tires Mixing bias and radial tires results in poor steering and should b...

Page 190: ...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 arrows of blade rubber with your fingers and then pull the blade rubber so that claws are unhooked from grooves in the blade rubber 2 Slide out the blade rubber 3 Replace the old blade rubber with a new genu ine wiper b...

Page 191: ... washer nozzles or spots on painted surfaces NOTE When it is very cold the ratio of windshield washer fluid to water should be increased in order to pre vent the mixture from freezing up Windshield washer fluid level check and refilling Windshield washer fluid quantity Approx 3 liters 3 2 qts Battery check WARNING The battery generates flammable hydro gen gas and should be kept away from open flam...

Page 192: ...he LOWER LEVEL line remove the 6 vent plugs and add distilled water via the vent plug holes until the battery fluid level is between the UPPER LEVEL and LOWER LEVEL lines Replace the vent plugs and then change the battery 2 If the battery fluid level is correct or between the UPPER LEVEL and LOWER LEVEL lines simply recharge the battery Replace the battery if the indicator does not turn blue after...

Page 193: ...leaning apply a thin coat of grease to the ter minals CAUTION If the battery needs to be charged remove it from the vehicle and remove the vent plugs where possible before starting the procedure If it is charged in the vehicle due to unavoidable circumstances be sure to disconnect the nega tive battery cable NOTE Follow the correct procedure when jump starting a vehicle with a dead battery by conn...

Page 194: ...ing or air conditioning 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 before the outside air fil ter can be cleaned Have an authorized dealer do the job WARNING Be sure to observe the following instructions when storing a battery Select a storage place where...

Page 195: ...el 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 compartment then remove the two screws 5 Remove the three sets of plugs and screws then remove the tray 6 Withdraw the air filter Z11171 Z11620 ...

Page 196: ...surfaces Wash not only the surfaces around the cab but also the wheel housings and the underside of the chassis Especially after you have driven in a coastal area or on salted road in the winter your vehicle should be given a thorough washing Also try to wax the body surfaces once a month Cleaning your vehicle WARNING Some cleaning fluids are poisonous or flammable Carefully follow the safety pre ...

Page 197: ...pressure water Do not use concentrated soap or synthetic detergents Rinse the detergent off with water Take care that none remains on the paintwork since it could discolor the paint Cleaning plastic parts with thinner or gaso line could result in cracking or discoloration In cold weather the key holes and rubber parts of the door sometimes freeze making it hard to open the door After washing remov...

Page 198: ...eaner into the outside air inlets Water would get into the cab and the wiper motor could malfunction When the vehicle is washed braking perfor mance can be reduced by water entering the brake drums or splashed over the brake discs In this event drive slowly with light pressure on the brake pedal to dry out the brakes Pay attention to nearby vehicles while doing so There are ABS electric wiring loc...

Page 199: ...erior of the vehicle with a sponge or soft cloth Remove stubborn dirt with a soft brush Use the appropriate cleaning technique for each interior item to avoid discoloration and stains Do not water wash the floor with the floor mat left in place as this could cause the floor to rust and could also damage the relays and other electrical components If water collects in the cab either remove the drain...

Page 200: ...8 5 fl oz of luke warm water and use the solution to clean the affected area 4 If necessary lightly wipe the area with a fabric cleaning solvent 2 5 Other contaminants Use this method to remove contamination by candy ice cream mayonnaise and chili sauce 1 Carefully clean off the contamination then wash the area with water and dry it 2 If any spot remains clean with a fabric cleaning solvent 2 6 Cl...

Page 201: ...he end from the pedal 2 To return the pedal to the original state fit accel erator arm inside the stopper and force the hooked end of the stopper in the hole of the pedal 3 Check to ensure that the stopper does not dis engage CAUTION Do not use force to disengage the stopper from the pedal Always pull it while twisting After cleaning the floor mat dry the felt backing before putting the mat back o...

Page 202: ...mp has burn out 13 14 When braking is sluggish 13 21 If the engine stalls while the vehicle is in motion 13 21 If a tire goes flat while the vehicle is in motion 13 21 When the battery has run down 13 22 When the fuel has run out Bleeding the fuel system 13 23 Towing 13 24 When the vehicle becomes stuck in soft ground 13 26 13 Useful advice for emergencies ...

Page 203: ...harge or replace the battery 13 22 Battery cable is disconnected loose or cor roded Remove corrosion and connect the cable correctly 12 66 Connection to ground terminal is open Connect securely Engine oil viscosity is too high Replace the oil with an oil of proper viscosity 12 18 Possible cause Remedy Ref page Fuel has run out Refuel and bleed the system 13 23 Air is present in the fuel system Ble...

Page 204: ...ly Install the cap firmly The fan belt is loose Adjust the belt tension 12 46 The coolant is contaminated Flush the cooling system and replace the coolant 12 39 Possible cause Remedy Ref page Insufficient quantity of engine oil Add engine oil 12 18 Engine oil viscosity is not adequate Replace the engine oil with one of a proper viscosity 12 18 Possible cause Remedy Ref page There is a fuel leak Ch...

Page 205: ...fluid 12 28 Clutch pedal play is excessive Adjust 12 51 Possible cause Remedy Ref page Vacuum is insufficient Increase the engine speed to boost vacuum Brake fluid is insufficient Add brake fluid 12 28 There is vacuum leak Check the vacuum circuit and retighten con nections as necessary The disc brake pads or drum brake linings are worn Have an authorized dealer perform neces sary inspection There...

Page 206: ...venly Replace tires 12 55 Tires are damaged Replace tires 12 55 Unbalance is in tires or brakes Have an authorized dealer perform neces sary inspection Possible cause Remedy Ref page Parts are insufficiently greased Grease parts 12 15 Possible cause Remedy Ref page The bulb is out Replace the bulb 13 14 The fuse is blown Replace the fuse with one of the correct amperage 13 8 There is an open circu...

Page 207: ...r vehicle carries reflective triangles erect them by the side of the road behind the vehicle 2 Repair Check the mechanical failure and if you judge it readily repairable fix it while paying attention to the traffic If you are unable to repair it call an autho rized dealer for help Stopping your vehicle in an emergency WARNING Stopping your vehicle in a tunnel could be dangerous Wherever possible d...

Page 208: ...imately the middle of the scale stop the engine and perform the following inspections and corrective steps 1 Check that coolant is not leaking from the radia tor hoses or from other parts 2 Check that the fan belt is not broken and that its tension is normal P 12 46 3 Check the coolant level If the level is too low add coolant Remove the pressure cap then add coolant until it reaches the top of th...

Page 209: ...ove the cover 2 To install the cover align and insert the tabs at the top then press the bottom of the cover into place 2 Removal and installation of high current fuse box cover 1 Pull down the clamps then lift the cover straight upward to remove it 2 To install 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 c...

Page 210: ...select a spare fuse of the specified amperage for replacement CAUTION If the cause of a blown fuse cannot be deter mined or the same fuse blows frequently have an authorized 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 WARNING Be sure to use fuses of the ...

Page 211: ... 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 Engine control unit B11 20A Heater mirror B12 10A Automatic transmission B13 15A Tester B14 20A Headlamps high beam B15 20A Left headlamp low beam B16 20A Right headlamp low beam B25 15A Tail lamps Z12081 B16 B8 B9 B11 B12 B7 B6 B5 B4 B3 B2 B1 M8 M5 M9 M4 M6 M11 M3 M2 M1...

Page 212: ...0A Automatic transmission fluid cooler fan B36 20A Engine drive unit M1 10A Backup lamps M2 10A Meter cluster M3 15A Wipers M4 10A Auxiliary power supply starter switch ON circuit M5 10A Relay control M6 10A Automatic transmission M8 10A Exhaust brake M9 5A Engine control unit M11 10A ABS S1 10A Starter 5A Spare fuse 10A 15A 20A 30A Fuse No Amperage Protected circuit ...

Page 213: ...ps then lift the cover straight upward to remove it To install the cover place it on the box and press it straight down ward Align the holes of the clips with the pro trusions While still pressing the cover downward retain it with the clamps The amperage and protected circuit of each high current fuse are shown on the inside of the high current fuse box cover 2 Check for a blown high current fuse ...

Page 214: ...No Amperage casing color Protected circuit FH1 60A yellow Fuse box S1 A1 A5 M1 M12 FH2 60A yellow Fuse box B1 B12 FH3 40A green Fuse box B13 B16 FH5 60A yellow Hydraulic brakes booster FH7 40A green ABS motor FH8 40A green ABS valve BATT1 120A white Alternator BATT2 120A white Alternator WARNING Replacement high current fuses should always be of the specified amperage Using a high current fuse of ...

Page 215: ...r crack the lenses 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 condensation can form on the inside surfaces of the headlamp lenses Just as the windows mist up in rainy weather the condensation forms owing to a temperature difference between the ...

Page 216: ...tail lamp double filament 12V 21 5W 2 Rear turn signal lamp 12V 21W 2 Backup lamp 12V 21W 2 License plate lamp 12V 7 5W 1 License plate lamp Crew cab or FG models 12V 8W 2 Clearance and side marker lamp 12V 7 5W 2 Identification lamp 12V 7 5W 3 Interior lamp 12V 10W 1 Interior lamp rear seats of Crew cab models 12V 10W 1 Z12087 ...

Page 217: ...en the door then loosen the screws behind the front and side turn signal lamp and the screw behind the dummy lamp until they spin freely NOTE The screws are designed not to come out 3 Pull out screw toward you CAUTION Unless the screw is pulled out the front and side turn signal lamp and dummy lamp will catch on it and you will not be able to remove them 4 Close the door 5 Remove the front and sid...

Page 218: ... adjusting screw would change the beam setting thus creating a nuisance for drivers of other vehicles If you accidentally turn the beam adjusting screw have an authorized dealer perform neces sary inspection When setting down the removed headlamp place it on a soft cloth to avoid scratching the lens 8 Raise the headlamp slightly to remove the tabs from the holes then pull it out toward you Z11268 ...

Page 219: ... vehicle 4 Insert the stud pin on the dummy lamp into the grommet hole fit the dummy lamp in place and tighten the bottom screw CAUTION Do not tighten the screw too tightly or the mounting could get damaged 5 Install the connector on the front and side turn signal lamp 6 Pull out screws 7 Align the tabs with the holes then press the lamp in toward the centerline of the vehicle Z11272 Z11625 Z11273...

Page 220: ...adlamp bulb replacement Removal 1 Remove the cover by pressing it and turning it in the direction of arrow 2 Pull the connector toward you to remove it 3 Remove the spring that retains the bulb 4 Remove the bulb Installation 1 Align the tabs on the bulb with the grooves fit the bulb in place and retain the bulb with the spring 2 If the packing is dirty clean it If the packing is twisted untwist it...

Page 221: ... tabs on the top of the lens and press the lens into place 3 2 Crew cab models front and rear seats 1 Insert a flat blade screwdriver between the lens and the interior lamp and use it to release the tabs on the bottom of the lens Remove the lens 2 Push the bulb retainer rightward and remove the bulb 3 To install the lens insert the tabs on the top of the lens and press the bottom of the lens into ...

Page 222: ...l to apply 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 wheel firmly and gradually slow down before pulling over at a safe place To replace the tire select a flat surface where your vehicle will not hinder traffic P 12 55 When braking is sluggis...

Page 223: ...tery has run down WARNING Check the battery s fluid level before con necting booster cables If the fluid is below the LOWER level line add battery fluid or distilled water If the battery was charged with an excessively 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 conn...

Page 224: ...gine has been refu eled after running dry In these cases bleed the fuel system by performing the following steps CAUTION The fuel injection system may fail if the engine stops due to lack of fuel 1 Connect a hose with an inside diameter of 8 mm 0 31 in to one of the air vent plugs of the fuel filter NOTE Use whichever of the two air vent plugs is the most convenient both plugs provide the same eff...

Page 225: ...After the fuel system has been completely bled wipe off spilt fuel and start the engine 7 Check that there is no fuel leakage If you are forced to tow the vehicle take the follow ing precautions Disconnect either the propeller shaft or the rear axle shaft whichever is easier If you disconnect the rear axle shaft cover the opening to prevent oil and grease from escap ing CAUTION Before towing an au...

Page 226: ...e If the chain looks likely to cause damage use a thicker L shaped protection plates to hold the chain further from the vehicle Tow the vehicle only with a specially designed towing truck If you disconnect the rear axle shaft to tow the vehicle the axle housing gear oil may be depleted Check the axle housing gear oil and add more if necessary P 12 28 Never use the tie down hook s under the frame f...

Page 227: ...wn use the method described in the previous section The stranded vehicle must be unloaded com pletely Never use the tie down hook s under the frame for towing purpose The tie down hook is to secure the vehicle when transporting it If the hook is used for towing damage to the front bumper or frame may result 1 Tow the stranded vehicle using a vehicle whose gross weight is equal to that of the stran...

Page 228: ... hooks 4 Start each vehicle s engine and prepare to start driving 5 If the rope or wire rope is slack eliminate the slackness by moving the towing vehicle 6 Slowly drive both vehicles forward Do not race 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 be...

Page 229: ......

Page 230: ...14 1 Recommended lubricants hydraulic fluids and quantities 14 2 Service data 14 4 14 Service data ...

Page 231: ...ulic fluids and quantities Item Quantity Engine Oil pan FE Approx 9 9 5 FG Approx 10 11 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 Approx 12 9 14 Replacement quantity Approx 6 4 6 8 Transfer FG Approx 3 1 3 3 Axle housing FE Approx 4 5 4 8 FG Front axle Approx 3 0 3 2 Rear axle Approx 4 5 4 8 Power steering FE Mod...

Page 232: ... or equivalent Axle housing 1 Gear oil API GL 5 Below 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 90 Power steering Automatic transmis sion fluid DEXRON DEXRON II or DEXRON III type Brake Clutch Brake fluid SAE J1703 FMVSS No 116 Grade DOT3 Chassis...

Page 233: ...3 in Coolant quantity Approx 14 4 liters 15 2 qts Clutch pedal play at center of pedal pad 0 2 to 4 mm 0 0079 to 0 16 in Brake pedal play 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 stroke 7 to 9 notches Steering wheel play as measured on the periphery of steering wheel 5 to 50 mm 0 2 to 1 97 in Tire tread groove depth 1 6 ...

Page 234: ...15 1 Maintenance schedule 15 2 Lubrication schedule 15 7 15 Maintenance schedule ...

Page 235: ...50 000 km 30 000 miles Every 90 000 km 54 000 miles Every 250 000 km 150 000 miles ENGINE Leakage of coolant fuel and oil Check the underneath of the vehicle for any sign of leakage Engine conditions Check the engine for smooth starting and quiet running Manifold bolts and nuts torque Check inlet exhaust mani fold bolts and nuts for looseness Check and adjust valve clear ance Check valve clearance...

Page 236: ...8 000 miles or 6 months Check the operate perfor mance of range selector lever 12 47 Propeller shaft flange torque and universal joint looseness Check flange yoke bolts for looseness and universal joint for play Propeller shaft center bearing Check center bearing if trace of grease flowing out is evident Check center bearing for wear damage and play FRONT AND REAR AXLE Wheel hub bearing Check whee...

Page 237: ...1 000 km 600 miles after removing and retightening U bolt nuts BRAKING SYSTEM Service brake pedal Check brake pedal play and stroke 12 49 Brake performance Depress the brake pedal and check that the brakes work effectively and evenly on all wheels 12 50 Disc brake pad and disc Check disc brake pad and disc for damage and wear Brake lining Check lining for wear through inspection hole Brake drum Di...

Page 238: ... 12 48 CAB Defroster Make sure that warm air blows properly onto the windshield 9 3 9 7 Rearview mirrors 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 and reflector condition Check the license plate and reflectors for loose installa tion damage and dirt Door locks Push down the lock knob and verify that the door do...

Page 239: ...21 Lighting system Make sure that each lamp lights up or flashes properly Check lamp lenses for dirt and damage 5 18 Gauge warning indicator lamp operation Check that gauges warning lamps and indicators are working properly 6 2 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 mil...

Page 240: ...replacement Transfer gear oil level FG 12 26 Transfer gear oil replacement FG Rear axle housing gear oil level 12 27 Rear axle housing gear oil replacement Front axle housing gear oil level FG Front axle housing gear oil replacement FG Hub bearing grease replacement Front axle birfield joint grease replacement FG Front axle kingpin bearing grease replacement FG Front axle steering knuckle grease r...

Page 241: ...han Crew cab models 12 18 Item Time of inspection and maintenance Reference page Pre operational checks New vehicle at 4 000 km 2 500 miles Inspection interval Every 10 000 km 6 000 miles Every 20 000 km 12 000 miles Every 30 000 km 18 000 miles Every 40 000 km 24 000 miles Every 50 000 km 30 000 miles ...

Page 242: ...16 1 16 Alphabetical index ...

Page 243: ... Fuel has run out 13 23 Fuels 1 5 11 2 Fuse 13 8 Gearshift lever 5 14 Greasing 12 15 Handling of the new vehicle 1 7 Hazard warning lamp switch 5 22 Heater 9 3 HIGH LOW selector lever 8 3 Indicator lamps 6 5 Interior lamp 10 4 Jacking points 12 55 Lamp 13 14 Lane changer 5 19 Lighting switch 5 18 Limited slip differential 7 13 Loading cargo 7 15 Lubrication 12 15 Maintenance record 17 3 Maintenanc...

Page 244: ...proving fuel economy 7 6 Tire chains 11 4 Tire replacement 12 55 Tire rotation 12 62 Tires 12 52 To reach the engine access opening 12 4 Towing 13 24 Tripmeter 6 2 Turn signal lamp switch 5 19 Van body dome light switch 5 22 V belts 12 46 Vehicle identification number VIN 1 3 Warming up the engine 5 10 Warm up switch 5 4 Warning labels 2 1 Warning lamps 6 5 Washer switch 5 21 Water temperature gau...

Page 245: ......

Page 246: ...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 247: ...ribed by MFTA Owner s Name Address City State Zip Vehicle identification number Date NVI was Performed Mileage at time of NVI Dealer Code of Servicing Dealer Dealer Reference R O Dealer Claim No J L Dealer imprint Dealership Name and Address Dealer Representive Signature Date MFTA COPY New Vehicle 4 000 km 2 500 Miles FREE INSPECTION AND SERVICE CERTIFICATE NVI FE FG ...

Page 248: ...ibed by MFTA Owner s Name Address City State Zip Vehicle identification number Date NVI was Performed Mileage at time of NVI Dealer Code of Servicing Dealer Dealer Reference R O Dealer Claim No J L Dealer imprint Dealership Name and Address Dealer Representive Signature Date DEALER COPY New Vehicle 4 000 km 2 500 Miles FREE INSPECTION AND SERVICE CERTIFICATE NVI FE FG ...

Page 249: ...ip Name and Address Dealer Representive Signature Date OWNER COPY New Vehicle 4 000 km 2 500 Miles FREE INSPECTION AND SERVICE CERTIFICATE NVI NEW VEHICLE 4 000 km 2 500 miles SERVICE OPERATIONS Owner s name Date Address Vehicle identification number Lubrication Engine oil replacement Manual transmission oil replacement Transfer gear oil replacement FG Rear axle housing gear oil replacement Front ...

Page 250: ...ints 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 Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train Clutch pedal and clutch disc wear Prope...

Page 251: ......

Page 252: ...ication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element cleaning Exhaust system Power train Clutch ...

Page 253: ......

Page 254: ...teering knuckle grease replacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage o...

Page 255: ......

Page 256: ...dan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element replacement Exhaust system...

Page 257: ......

Page 258: ...tion 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 Vehicles other than Crew cab models Inspection and maintenance Engine Manifold bolts and nuts torque Check and adjust valve clearance Oil filter replacement or 12 months V belts tension and damage or 12 mon...

Page 259: ......

Page 260: ...Front axle steering knuckle grease replacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter repl...

Page 261: ...12 Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Brake drum Looseness play and damage of brake system parts Steering system Steering system ...

Page 262: ...id 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train Clu...

Page 263: ......

Page 264: ...rdan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element replacement Exhaust syste...

Page 265: ......

Page 266: ...ring knuckle grease replacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 1...

Page 267: ......

Page 268: ...ints 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 Vehicles other than Crew cab models Inspection and maintenance Engine Manifold bolts and nuts torque Check and adjust valve clearance Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 mon...

Page 269: ...20 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake system parts Steering system Steering system ...

Page 270: ...uid 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train Cl...

Page 271: ......

Page 272: ...placement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 ...

Page 273: ...24 Braking system Disc brake pad and disc Brake lining Brake drum Looseness play and damage of brake system parts Steering system Steering system ...

Page 274: ...id 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element replacement Power train ...

Page 275: ......

Page 276: ...ication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element replacement Exhaust system Power train Clut...

Page 277: ......

Page 278: ...se replacement FG Brake and clutch fluid replacement Power steering fluid replacement Lubrication of propeller shaft center bearing 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engi...

Page 279: ...30 Braking system Disc brake pad and disc Brake lining Brake drum Looseness play and damage of brake system parts Steering system Steering system ...

Page 280: ...ardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element replacement Exhaust syst...

Page 281: ......

Page 282: ...luid 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train C...

Page 283: ......

Page 284: ...Front axle steering knuckle grease replacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter repl...

Page 285: ...36 Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Brake drum Looseness play and damage of brake system parts Steering system Steering system ...

Page 286: ...luid 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train C...

Page 287: ......

Page 288: ...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 Vehicles other than Crew cab models Inspection and maintenance Engine Manifold bolts and nuts torque Check and adjust valve clearance Oil filter replacement or 12 months Fuel filter replacement or 12 month...

Page 289: ...40 Braking system Disc brake pad and disc Brake lining Looseness play and damage of brake system parts Steering system Steering system ...

Page 290: ...e steering knuckle grease replacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damag...

Page 291: ......

Page 292: ...ubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element cleaning Exhaust system Power train Clut...

Page 293: ......

Page 294: ...luid 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train C...

Page 295: ......

Page 296: ...eplacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12...

Page 297: ...48 Braking system Disc brake pad and disc Brake lining Brake drum Looseness play and damage of brake system parts Steering system Steering system ...

Page 298: ...nts 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 Vehicles other than Crew cab models Inspection and maintenance Engine Manifold bolts and nuts torque Check and adjust valve clearance Oil filter replacement or 12 months V belts tension and damage or 12 months Coolant replaceme...

Page 299: ......

Page 300: ...cation of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element cleaning Exhaust system Power train Clutch p...

Page 301: ......

Page 302: ...e steering knuckle grease replacement 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 door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damag...

Page 303: ......

Page 304: ...cardan joint FG Lubrication of rear suspension spring pin Lubrication of king pins Lubrication of door hinge Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months Fuel filter replacement or 12 months Fuel line or 12 months V belts tension and damage or 12 months Cooling system Air cleaner element replacement Exhaust sys...

Page 305: ......

Page 306: ...luid 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Oil filter replacement or 12 months V belts tension and damage or 12 months Air cleaner element cleaning Power train C...

Page 307: ......

Page 308: ... FG Brake and clutch fluid replacement Power steering fluid replacement Lubrication of propeller shaft center bearing 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 Lubrication of anchor hook Vehicles other than Crew cab models Inspection and maintenance Engine Manifold bo...

Page 309: ... bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retightening U bolts Braking system Disc brake pad and disc Brake lining Brake drum Looseness play and damage of brake system parts Steering system Steering system ...

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