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Mitsubishi 2010 Fuso FE Owner's Manual

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Owner's Manual
2010 Model
Pub. No. MH996028

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Summary of Contents for Mitsubishi 2010 Fuso FE

  • Page 1 Owner’s Manual 2010 Model Pub. No. MH996028...
  • 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): SELLING DEALER IMPRINT HERE...
  • Page 4 Please keep this manual in the vehicle so it is always available for reference. If you sell the vehicle, make sure the next owner receives this manual and is aware of its contents. © 2009 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan...
  • Page 5 Reading the handbook The information in this manual is accurate as of the time of printing. Because of differ- ences in specifications and improvements that may be added after preparation of this manual, some of the explanations and illustrations in this handbook may not apply to your vehicle.

  • Page 6: Table Of Contents

    CONTENTS 1. Recommendation to drivers ......... . . 1-1 2.
  • Page 8 1. Recommendation to drivers Chassis and engine numbers .................... 1-2 Powerline label ........................1-2 Vehicle identification number (VIN) ..................1-3 Maintenance ........................1-4 Fuels ..........................1-5 Handling of the new vehicle ....................1-8 Reporting safety defects ....................1-9 Obtaining service ......................1-10...

  • Page 9: Recommendation To Drivers

    Recommendation to drivers Chassis and engine numbers 1 Chassis number The chassis number is indicated on the left frame, near the left front wheel. Example: FE84DD - Chassis number Vehicle model 2 Engine number The engine number is indicated on the left side of the crankcase.

  • Page 10: Vehicle Identification Number (Vin)

    4.1 to 4.39 m (13.45 to 14.40 ft.) 4.4 to 4.69 m (14.43 to 15.38 ft.) 4.7 to 4.99 m (15.41 to 16.37 ft.) Cab chassis type Chassis cab for Mitsubishi Fuso and make Engine 4.899 L Diesel turbo charged and charge air cooled...

  • Page 11: Maintenance

    Recommendation to drivers Maintenance Checking your vehicle at regular intervals is very important for maximizing performance and extend- ing service life. It is recommended that you make a habit of performing the following inspections. This manual describes simple maintenance checks and procedures that can be carried out by the owner.

  • Page 12: Fuels

    Mitsubishi Fuso trucks. 1 Diesel-fuel properties The following recommendations concerning diesel fuel used with Mitsubishi Fuso diesel engines are given for optimum fuel economy and performance. Use condition Recommendation Normal operation at...
  • Page 13 Recommendation to drivers 3 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. DANGER NEVER MIX DIESEL FUEL WITH GASOLINE, GASOHOL OR ALCOHOL.
  • Page 14 5 Refueling WARNING • Stop the engine before fueling. • Never smoke when fueling since diesel fuel could ignite or explode. Never operate lighters or other items that emit sparks. • If you inadvertently put gasoline in the fuel tank, pump it all out. Running the engine with gasoline in the tank could cause a fire or explosion endangering your or other people’s lives.

  • Page 15: Handling Of The New Vehicle

    Recommendation to drivers WARNING • When filling the fuel tank using a gun-type fuel pump, do not continue pumping after the pump automatically stops. (The tank is full at this point.) When filling the fuel tank using any other method, stop as soon as the surface of the fuel becomes visible through the opening of the fuel filler.

  • Page 16: Reporting Safety Defects

    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.

  • Page 17: Obtaining Service

    1-10 Recommendation to drivers Obtaining service At Mitsubishi Fuso Truck of America, Inc. (MFTA), we are proud of the quality and workmanship that is built into every MFTA Truck. We are equally proud of our corporate commitment to promote the highest possible degree of customer satisfaction with our products and services.
  • Page 18 1-11 You also may correspond with the Customer Ser- vice Representative in writing, addressed to: MITSUBISHI FUSO TRUCK OF AMERICA, INC. CUSTOMER SERVICE REPRESENTATIVE 2015 CENTER SQUARE RD. LOGAN TOWNSHIP, NJ 08085...

  • Page 20: Warning Labels

    2. Warning labels Locations in cab ......................... 2-3 Locations outside cab ......................2-6...
  • Page 21 Warning labels • The caution and warning labels show important information. Be sure to read them before using the vehicle. • If any label has peeled so it is difficult to read, is scratched or otherwise damaged, or has peeled off completely, please inform an authorized dealer.

  • Page 22: Locations In Cab

    Locations in cab High exhaust system Towing <Automatic Hydraulic brake booster temperature transmission vehicles> <FE85> Hydraulic brake booster <FE85> Transfer lever <FG> 113-liter fuel tank <FE: other than Crew-cab models> Limited slip differential Voltage Z18526...
  • Page 23 Warning labels DPF system DPF indicator lamp Fuse Parking Fuel <Automatic transmission vehicles> Z19698...
  • Page 24 Engine inspection hatch <Crew-cab models> Z17778...

  • Page 25: Locations Outside Cab

    Warning labels Locations outside cab Pressure cap Engine oil Automatic transmission fluid 113-liter fuel tank <FE: other than High-current fuse Crew-cab models> Oil cooler <Automatic transmission vehicles> <The oil cooler of Crew-cab model is installed in the other side> 113-liter fuel tank Oil cooler <FE: other than <Automatic...
  • Page 26 Cab tilt function Cab tilt function <Vehicles other than Crew-cab models> <Vehicles other than Crew-cab models> 125-liter fuel tank 125-liter fuel tank Limited slip differential Z17822...
  • Page 28 3. Opening and closing Starter key .......................... 3-2 Doors ..........................3-2 Central door locks ......................3-4 Keyless entry system ......................3-5 Entering and leaving the vehicle ..................3-10 Door window glass ......................3-12...

  • Page 29: Opening And Closing

    Opening and closing Starter key • There are two starter keys: a main key and a sub key You can use either of these starter keys for lock- ing/unlocking the doors and starting/stopping the engine. • Please make a note of the starter key number .
  • Page 30 1 From the outside • To open, pull the outer handle toward you. • Use the starter key to lock or unlock the door. • It is possible to lock each door without using the starter key. With the driver’s door or assistant driver’s door, push the lock knob toward the front of the vehicle then pull the outer handle...

  • Page 31: Central Door Locks

    Opening and closing 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, push the lock knob toward the front of the vehicle. To lock a rear door, push the lock knob down.

  • Page 32: Keyless Entry System

    Keyless entry system <Vehicles other than Crew-cab models> 1 The Grant of Equipment Authorization certificate for wireless transmitter (remote control switch) RKE Transmitter MDL E11TG 1. FCC ID: MOZE11TG 2. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: •...
  • Page 33 Opening and closing 2 The Grant of Equipment Authorization certificate for wireless receiver Tuner MDL E11UG 1. FCC ID: MOZE11TG 2. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: • This device may not cause harmful interference.
  • Page 34 3 Keyless entry system The keyless entry system allows you to lock/unlock the doors of the driver’s seat and assistant driver’s seat by operating the remote-control switch WARNING If you carry the keyless entry remote control switch with you when traveling on an air- plane, avoid pressing any button on the Z13209 switch.
  • Page 35 Opening and closing • When you press the buttons, be sure to press them for at least one second. If a button does not work after one press, press the button again after one or two seconds. • After locking the doors with the remote control switch, always check that the doors are locked by lifting the outside handle of a door.
  • Page 36 CAUTION • Use the designated standard type of battery. If the battery is replaced with an incorrect type, the battery could explode. • Attach the battery with the “+” mark facing upward. • Do not use a metal tool such as tweezers to replace the battery.

  • Page 37: Entering And Leaving The Vehicle

    3-10 Opening and closing Entering and leaving the vehicle WARNING • Always use the step to climb into or down from the vehicle. Never put your foot on the wheel or tire since it could easily slip off. • The step can become slippery in rain or snow.
  • Page 38 3-11 <FE> <FG> <Rear doors: Crew-cab models> Z17779 CAUTION • Climb into and out of the cab by holding only the grip. For FG models, do not climb into and out of the cab by holding HIGH-LOW selector lever . If you hold onto any other parts of the vehicle, they could break or fail.

  • Page 39: Door Window Glass

    3-12 Opening and closing 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.

  • Page 40: Power Window Lock Switch

    3-13 2 Power window lock switch <Vehicles other than Crew-cab models> WARNING When a child is in the cab, be sure to press the power window lock switch to prevent the child from opening and closing the assistant driver’s window. Otherwise, the child may accidentally operate the power window switch and get its hands or head trapped.
  • Page 41 3-14 Opening and closing 3 Window regulator handle <Front doors> <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.

  • Page 42: Seat And Steering Wheel Adjustments

    4. Seat and steering wheel adjustments Seats ..........................4-2 Seat belts ........................... 4-5 Steering wheel ........................4-8...
  • Page 43 Seat and steering wheel adjustments 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.
  • Page 44 Making adjustments • Slide seat forward or backward while holding slide adjustment lever raised. After making the adjustment, release the lever and move the seat back and forth slightly to lock it in position. • To adjust the angle of the seatback , raise reclining lever •...
  • Page 45 Seat and steering wheel adjustments 3 Rear seat – Crew-cab models Storage compartments are located under the rear seat. The rear seat can be folded up for access to them. When you wish to stow or remove something from these compartments, release the hooks the base of the seat and raise the seat cushion To retain the seat cushion, use the retaining bands that are attached to the seatback.

  • Page 46: Seat Belts

    Seat belts • To help prevent injury in the event of a sudden stop or accident, the driver and all passengers must wear their seat belts correctly. • When wearing your seat belt, sit back in your seat with your back straight. If a seat belt is used incorrectly, its effectiveness is greatly dimin- ished and it could aggravate injuries in the event Z11862...
  • Page 47 Seat and steering wheel adjustments 1 Lap and shoulder belts with ELR NOTE: It is not necessary to adjust the length of these seat belts. An ELR seat belt extends and retracts automatically as its wearer moves but locks automatically for pro- tection in the event of a sudden stop or shock.
  • Page 48 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.

  • Page 49: Steering Wheel

    Seat and steering wheel adjustments 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 seat belts from functioning properly.
  • Page 50 • Pull the lock lever then adjust the steering wheel to the height and angle that are most comfortable for you. • Push the lock lever back in to securely retain the steering wheel. Adjust Retain Z14892...
  • Page 52 5. Switches and controls Arrangement of switches and controls ................5-2 Starter switch ........................5-3 Starting the engine ......................5-5 Warming up the engine ...................... 5-9 Stopping the engine ......................5-11 Pedals ..........................5-12 Gearshift lever ........................5-13 Range selector lever ......................5-14 Overdrive switch ......................

  • Page 53: Switches And Controls

    Switches and controls Arrangement of switches and <Manual transmission vehicles> controls Starter switch Accelerator pedal Brake pedal Clutch pedal <manual transmission vehicles> Gearshift lever <manual transmission vehicles> Parking brake lever Hazard warning lamp switch Combination switch (wiper and washer switch, exhaust brake switch) Combination switch (lighting switch, passing/dimmer switch, turn sig- nal switch)

  • Page 54: Starter Switch

    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: •...
  • Page 55 Switches and controls • LOCK The starter key can be inserted and removed in this position only. To place the key in the “LOCK” position, turn it to the “ACC” position then press it in. Keep it pressed in while turning it to the “LOCK”...

  • Page 56: Starting The Engine

    Starting the engine WARNING • Do not start or 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 necessary as the accumulation of exhaust gas in closed areas is very dangerous.
  • Page 57 Switches and controls NOTE: • When the engine has started, allow it to warm up until the needle in the coolant temperature gauge starts to move. • Do not continue operating the starter for more than 15 seconds as this could damage it or dis- charge the battery.
  • Page 58 2. Check whether the indicator lamp illumi- nates or not. Z08914 • When the indicator lamp does not illumi- nate Automatic transmission vehicles: While holding down the brake pedal, turn the starter switch to the “START” position to start the engine. Manual transmission vehicles: While holding down the clutch pedal , turn the starter switch...
  • Page 59 Switches and controls 3. After the engine has started, let it warm up until the water temperature gauge needle begins to move. P. 5-9 Z08917 Engine idling speed 625 to 675 rpm 3 Starting the engine when vehicle has been parked over an extended period When the vehicle is not used for a week or more or the engine oil and oil filter are replaced, the engine becomes starved of oil.

  • Page 60: Warming Up The Engine

    4 Starting the engine with the cab tilted When you need to start the engine with the cab tilted for inspection or servicing purposes, be sure to observe the following safety precautions: • Set the parking brake firmly and chock the wheels.
  • Page 61 5-10 Switches and controls CAUTION Racing the engine immediately after it has started causes excessive wear of cylinders and pistons, leading to engine malfunction. Be sure to warm up the engine to operating temperature before full load operation according to the pro- cedures described here.

  • Page 62: Stopping The Engine

    5-11 Stopping the engine WARNING • Never allow the vehicle to coast with the engine stopped as braking may be danger- ously sluggish and extremely difficult steering may result. This may also cause trouble in the fuel injection system. • engine exhaust pipe...

  • Page 63: Pedals

    5-12 Switches and controls 3. Allow the engine to idle for more than 3 minutes More than before stopping it. 3 minutes 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.

  • Page 64: Gearshift Lever

    5-13 Brake pedal WARNING Allowing empty beverage cans or other objects to get under the brake pedal is extremely dangerous as they will interfere with brake pedal movement. Keep the floor free of any objects obstructive to operation of the pedal. •...

  • Page 65: Range Selector Lever

    5-14 Switches and controls CAUTION • Shifting from a forward gear to 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. •...
  • Page 66 5-15 NOTE: • Never push the button for the range selector lever movements indicated by the black arrows ) in the illustration. With the button pressed, the lever could unexpectedly slip into the “P”, “R”, “3” or “2” position. • For safety, the range selector lever cannot be moved out of the “P”...
  • Page 67 5-16 Switches and controls CAUTION When driving downhill with the range selector lever in the “3” or “2” position, use the service brakes as necessary to prevent the acceptable engine revolutions being exceeded and the tachometer needle entering the red zone. For extra convenience, a shift indicator in the meter cluster shows the position of the range selector lever.

  • Page 68: Overdrive Switch

    5-17 Overdrive switch <Automatic transmission vehicle> Overdrive can be switched on and off with the switch located on the range selector lever. When the switch is in the “OFF” position, an indicator lamp illuminates. • Overdrive ON Z11854 Overdrive should be switched on as desired for nor- mal driving and always for high-speed driving.

  • Page 69: Combination Switch

    5-18 Switches and controls Parking The parking brake is activated when the parking brake lever is fully pulled out. The warning lamp lights up simultaneously. Releasing Raise the lever slightly, press the end button , and lower the lever with the button still pressed. Make sure that the warning lamp goes out.

  • Page 70: Turn Signal Lamp Switch

    5-19 Identification, clearance and side marker, Headlamps parking, tail, license, and meter illumination lamps position position position *: Illuminated by daytime running light system NOTE: Even when the vehicle is operated with the lighting switch in the “OFF” or position, the daytime running light system causes the low-beam head- lamps to be lit.

  • Page 71: Exhaust Brake

    5-20 Switches and controls Lane changer Lightly pushing the lever forward or backward causes the corresponding turn signal lamp to flash while the lever is held in this position. 5 Exhaust brake WARNING 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...
  • Page 72 5-21 • The temperature of the transmission fluid is high. • The vehicle speed has dropped to 10 km/h (6 mph) or lower. • Gear shifting is being carried out. • The ABS is operating. NOTE: Do not place the range selector lever in the “P” posi- tion or “N”...

  • Page 73: Cruise Control

    5-22 Switches and controls • 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. Wipers operate at a slow speed. Wipers operate at a rapid speed.
  • Page 74 5-23 • On icy, snow-covered, or otherwise slippery roads • Steep downhill road The vehicle speed may become higher than the set speed on a steep downhill road. Stop using the cruise control if this occurs. Main switch This switch is used to activate and deactivate the cruise control function.
  • Page 75 5-24 Switches and controls 2. Depress the accelerator pedal until the desired speed is reached. Z11829 3. When the desired speed is reached, press the SET side of the SET/RESUME switch. The indicator lamp will illuminate indicating that the cruise control is activated. Now the desired speed is memorized, so release the accelerator pedal.
  • Page 76 5-25 • By using both accelerator pedal and SET/ RESUME switch 1. Use the accelerator pedal to reach the desired speed. Z11829 2. When the desired speed is reached, press the “SET” side of the SET/RESUME switch. The vehicle will cruise at the new, higher speed. Z16861 3 To decrease the set speed in cruise con- trol mode...
  • Page 77 5-26 Switches and controls 5 Automatic deactivation of the cruise control The cruise control is deactivated automatically and indicator lamp also goes out in the following conditions: • When the brake pedal is depressed • When the exhaust brake is activated •...

  • Page 78: Hazard Warning Lamp Switch

    5-27 7 To deactivate the cruise control Press the OFF side of the main switch. CAUTION • Consult an authorized dealer if you wish to install a radio transmitter/receiver equip- ment. Proper operation of the cruise control cannot be ensured if this equipment is installed in an inappropriate location or is Z16863 incorrectly adjusted.

  • Page 79: Rheostat Control Switch

    5-28 Switches and controls Rheostat control switch Bright Use the rheostat control switch to adjust the bright- ness of the meter cluster illumination lamps. With 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.

  • Page 80: Mirror Heater Switch

    5-29 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 81: Dpf Cleaning Switch

    5-30 Switches and controls DPF cleaning switch DPF is short for “diesel particulate filter”. The DPF system is essentially formed of a ceramic filter and an oxidation catalyst. The ceramic filter collects small particles (particulate matter or PM) contained in diesel engine exhaust, while the catalyst works to Muffler containing front oxidation continuously regenerate the ceramic filter (or catalyst and ceramic filter (with...

  • Page 82: Automatic Dpf Regeneration

    5-31 1 Automatic DPF regeneration The system actively removes PM by oxidation to prevent an overfilled DPF under automatic control. The operating sound and idling speed of the engine will change but you can drive the vehicle in its nor- mal manner.
  • Page 83 5-32 Switches and controls 3 How to perform the parked DPF regener- ation The parked DPF regeneration steps you should fol- low upon flashing of the indicator lamp are indi- cated below. You may perform the parked DPF regeneration only when the indicator lamp flashes.
  • Page 84 5-33 1. Park the vehicle in a safe place and warm up the engine. 2. Firmly set the parking brake and place the gear- shift lever in the neutral position if your vehicle is equipped with a manual transmission, or place the selector lever in the “P”...

  • Page 85: Warning Lamp Is Illuminated

    5-34 Switches and controls 4 If the warning lamp is illuminated warning lamp will be illuminated if you con- tinue to drive with the indicator lamp quickly flashing. A warning lamp that remains illumi- nated while driving probably indicates a blocked DPF and/or failure of the system.
  • Page 86 6. Instruments and warning lamps Arrangement of instruments and warning lamps ............... 6-2 Speedometer ........................6-2 Tachometer ........................6-3 Water temperature gauge ....................6-3 Fuel gauge ......................... 6-4 Warning/indicator lamps ....................6-5...

  • Page 87: Instruments And Warning Lamps

    Instruments and warning lamps Arrangement of instruments and warning lamps Speedometer Tachometer Water temperature gauge Fuel gauge Warning/indicator lamps Z11892 Speedometer 1 Speedometer The speedometer indicates vehicle speed in miles or kilometers per hour. Odometer/Tripmeter Z11893 2 Odometer/tripmeter With the starter switch in the “ON” position, either “ODO”...

  • Page 88: Tachometer

    Tachometer • The tachometer indicates engine speed in revo- lutions per minute. • If the needle enters the red zone , the engine is overrevved. Reduce the vehicle speed suffi- ciently during downhill driving or downshifting to keep the needle from entering this zone. P.

  • Page 89: Fuel Gauge

    Instruments and warning lamps <Manual transmission vehicles> Fuel gauge The fuel gauge indicates the amount of fuel still 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.

  • Page 90: Warning/Indicator Lamps

    Warning/indicator lamps <Automatic transmission shift indicator> Z18591 The illustration shows the standard arrangement of the warning and indicator lamps. Some lamps shown here, however, may not be installed on your vehicle. Illumination of certain warning lamps is accompa- nied by sounding of a buzzer. If the parking brake is applied, the buzzer will stop.
  • Page 91 Instruments and warning lamps Lamp Ref. Warning/indicator lamp If illuminates or flashes symbol page Turn signal or hazard warning lamps Turn signal indicator lamp 5-19 flashing Headlamp high beam indicator Headlamp high beams illuminated 5-19 lamp Exhaust brake indicator lamp Exhaust brake activated 5-20 Engine preheat indicator lamp...
  • Page 92 Lamp Ref. Warning/indicator lamp If illuminates or flashes symbol page (Red) Engine control warning Abnormality in engine control system lamp or DPF system 6-12 (Amber) Engine control warning Abnormality in exhaust gas control lamp system Four-wheel drive (4WD) mode 4WD indicator lamp <FG> selected Fault in antilock braking system ABS warning lamp...
  • Page 93 Instruments and warning lamps Lamp Warning lamp Operation symbol Charge warning lamp Goes off when engine 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 Goes off when engine is started.
  • Page 94 tion, depress the brake pedal with full force to slow down the vehicle, then pull off the road as soon as it is safe to do so, and perform the following checks: 1. Let the engine run at intermediate RPM until the warning lamp goes out.
  • Page 95 6-10 Instruments and warning lamps 3 Charge warning lamp The charge warning lamp lights up when the starter switch is turned to the “ON” position and goes out as soon as the alternator starts charging the battery after the engine has turned over. The lamp also lights up if a problem occurs in the battery charging system while the engine is running.
  • Page 96 6-11 5 Automatic transmission fluid tempera- ture warning lamp <Automatic transmission vehicles> This lamp comes on when the starter key is turned to “ON”. It should go out in a few seconds. • This lamp illuminates if the automatic transmis- sion fluid becomes excessively hot.
  • Page 97 6-12 Instruments and warning lamps 8 Engine control warning lamp This lamp comes on when the starter key is turned to “ON”. It should go out when the engine starts. Illumination of warning lamp (red) The red lamp illuminates when an abnormality is detected in the engine control system or DPF sys- tem.

  • Page 98: Abs Warning Lamp

    6-13 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 99 6-14 Instruments and warning lamps Range Limp-in mode selector Normal gearshift gearshift position Park Park Reverse Reverse Neutral Neutral ↔ ↔ Fixed to a ↔ ↔ certain gear ↔ (depending on the nature of ↔ 3rd only the fault) ↔ 2nd only 11 Engine overheating warning lamp This lamp illuminates and a buzzer sounds if the...
  • Page 100 6-15 12 Vehicle control warning lamp This lamp comes on when the starter key is turned to “ON”. It should go out in a few seconds. The vehicle control warning lamp lights up when problems occur in the vehicle’s electrical control system.
  • Page 102 7. Starting and driving Precautions when setting thevehicle in motion ..............7-2 Precautions for driving ....................... 7-3 Tips for improving fuel economy ..................7-7 Braking ..........................7-8 Antilock braking system (ABS) ................... 7-9 On uphill and downhill roads .................... 7-11 On rough roads and in bad weather ................

  • Page 103: Starting And Driving

    Starting and driving Precautions when setting the vehicle in motion • Do not carry containers of fuel or spray cans in the cabin. WARNING Carrying fuel in the cabin is extremely dan- gerous because an increase in the cabin tem- perature could cause fuel vapor to catch fire or cause the container to rupture.

  • Page 104: Precautions For Driving

    Precautions for driving Observe the following precautions while driving. Should you notice anything unusual about the vehi- cle, immediately stop the vehicle and inspect the relevant sections to find the cause of the trouble. If you are unable to identify the cause of the trouble or unable to do the repairs yourself, call your nearest authorized dealer.
  • Page 105 Starting and driving • 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.
  • Page 106 • 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”. If this should happen, you will lose control of both steering and braking.
  • Page 107 Starting and driving CAUTION “Overrev” refers to an operating state of the engine in which it rotates at an RPM higher than the recommended maximum RPM. Overrevving the engine could lead to an engine failure. 2 When driving an automatic transmis- sion vehicle •...

  • Page 108: Tips For Improving Fuel Economy

    Tips for improving fuel economy Observe the following precautions to achieve maxi- mum fuel economy and to extend tire life. • Continue warming up the engine only to the point at which the water temperature gauge needle begins to move. •...

  • Page 109: Braking

    Starting and driving Braking When driving downhill, use engine braking as well as exhaust braking in combination with the foot brake. P. 7-11 WARNING • When warning lamps and/or light up, immediately stop the vehicle and perform necessary checks. P. 6-6 •...

  • Page 110: Antilock Braking System (Abs)

    Antilock braking system (ABS) The ABS operates automatically without need for any manual control. However, you are requested to read the following instructions and precautions to ensure safe driving with your ABS-equipped vehi- cle. WARNING Even the ABS cannot remove limitations on the vehicle’s running and braking perfor- mance.
  • Page 111 7-10 Starting and driving • 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 between the right and left wheels (on a road covered by ice on one side and not on the other side, for example), you may need to correct...

  • Page 112: On Uphill And Downhill Roads

    7-11 On uphill and downhill roads 1 Uphill roads • Downshift early when the speed begins to drop to minimize the load on the engine. • With an automatic transmission vehicle, down- shifting can be performed either with the range selector lever or by depressing the accelerator pedal hard.
  • Page 113 7-12 Starting and driving WARNING • Never coast downhill with the gearshift lever in neutral (manual transmission vehi- cles) or the range selector lever in the “N” position (automatic transmission vehi- cles). Doing so makes both engine braking and exhaust brake inoperative, which in turn excessively burdens the service brakes.

  • Page 114: On Rough Roads And In Bad Weather

    7-13 NOTE: “Overrev” refers to an operating state of the engine in which it rotates at an RPM higher than the recom- mended maximum RPM. Overrevving the engine could lead to an engine failure. On rough roads and in bad weather •...

  • Page 115: Parking

    7-14 Starting and driving • Avoid driving when the road is covered with much water because of torrential rain or other causes. Should your vehicle be soaked by water, have it inspected by an authorized dealer as soon as possible. •...
  • Page 116 7-15 WARNING • On an automatic transmission vehicle, never park the vehicle without applying the parking brake. Do not rely only on set- ting the range selector lever in the “P” position. If you cannot avoid parking on a slope, be sure to apply the parking brake securely and apply chocks to the wheels.

  • Page 117: Vehicles With Limited Slip Differential

    7-16 Starting and driving 1. In a manual transmission vehicle, put the gear- shift lever in the neutral position when the vehi- cle is stationary. In an automatic transmission vehicle, pull the parking brake lever while keeping the brake pedal depressed, and then place the range selector lever in the “P”...
  • Page 118 7-17 WARNING When you raise the vehicle on one side for replacing a tire or any other purpose, never rotate the raised wheel. Doing so is danger- ous as power is transmitted to the wheel which is on the ground and the vehicle could move.

  • Page 119: Loading Cargo

    7-18 Starting and driving ones are inflated to the same pressure and not different in outside diameter. • Distribute the load weight evenly. If the load is heavier at the rear, the vehicle’s tendency to move in a straight line will slightly increase. Loading cargo 1 Do not overloading the vehicle.
  • Page 120 7-19 2 How to load cargo Improperly loaded cargo not only is unstable but also may result in uneven weight distribution which could damage the cargo deck and frame. 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...

  • Page 122: 8. 4Wd Operation

    8. 4WD operation <FG models> Control and indicator lamps for 4WD operation ..............8-2 Advice on use of the 4WD mode ..................8-8 Precautions to be taken when selecting the 4WD mode ..........8-10...
  • Page 123 4WD operation <FG models> Control and indicator lamps for 4WD operation Select the 2WD (rear-wheel-drive) mode or 4WD (all-wheel-drive) mode as necessary for the condi- tion of the road surface. The 4WD mode can be used for extra traction on rough road surfaces and on snow-covered road surfaces (in mountainous regions, for example).
  • Page 124 1 Location of control and indicator lamps HIGH-LOW selector lever Front drive switch 4WD indicator lamp LOW range indicator lamp Z14905 Front drive switch • The front drive switch is used to select either the two-wheel drive (2WD) mode that uses only the two rear wheels as driving wheels or the four- wheel drive (4WD) mode in which the engine power is transmitted to all four wheels.
  • Page 125 4WD operation <FG models> HIGH-LOW selector lever • When the 4WD mode is selected, this lever allows the driver to select 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 move the lever to the high-speed range position to select the high-speed range or to the low-...
  • Page 126 2 Selecting drive mode-transfer gear range combinations You can select any desired drive mode and transfer gear range combination from among those shown in the following table. Select the most suitable com- bination according to the driving conditions. Illumi- Mode-range nated Driving conditions combination...
  • Page 127 4WD operation <FG models> NOTE: • You do not need to depress the clutch pedal when switching from the 2WD-HIGH setting to the 4WD-HIGH setting or vice versa. • The mode-range setting cannot be switched from 4WD-LOW to 2WD-HIGH. The 4WD-HIGH setting must be selected before such switching can take place.
  • Page 128 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.

  • Page 129: Advice On Use Of The 4Wd Mode

    4WD operation <FG models> WARNING • Never drive with one free-wheeling hub in the “FREE” position and the other in the “LOCK” position. Doing so is very danger- ous. • The free-wheeling hub may be extremely hot after driving. Do not touch it. Advice on use of the 4WD mode When you select the 4WD mode to drive on off-road terrain (sandy or muddy ground) or snow-laden or...
  • Page 130 3 Climbing steep hills Select the “4WD-LOW” setting to make full use of engine torque. Choose the path that has the least stones, sand and bumps. At both the start and end of a climb, moderate slopes are preferable. 4 Descending steep hills •...

  • Page 131: Precautions To Be Taken When Selecting The 4Wd Mode

    8-10 4WD operation <FG models> Precautions to be taken when selecting the 4WD mode • In the 4WD mode, you may feel the steering wheel move differently from the way it does in the 2WD mode. Operate the steering wheel carefully until you get the complete feel of 4WD operation.
  • Page 132 9. Heating and air conditioning Front air outlets ........................9-2 Air conditioner ........................9-3 Heater ..........................9-8 Outside air inlets ......................9-12...

  • Page 133: Heating And Air Conditioning

    Heating and air conditioning Front air outlets Z14908 1 Adjusting the airflow 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.

  • Page 134: Air Conditioner

    Air conditioner WARNING Never leave children alone in the cab espe- cially when the air-conditioning is on. They will suffer from dangerously high interior temperatures should the air conditioning accidentally stop. NOTE: • The heater uses heat produced by the engine coolant.
  • Page 135 Heating and air conditioning Fan speed dial Fan speed dial allows you to select 4 fan speeds. Select the desired speed. 0: Turned off 1: Breeze 2: Weak 3: Medium 4: Strong Z05610 Temperature adjustment dial Turn the dial in the direction of arrow to increase the air temperature and in the direction of arrow to reduce it.
  • Page 136 Air conditioner switch Pressing the air conditioner switch activates the air conditioner, which has cooling and dehumidifying functions. The indicator lamp in the switch comes on at this time. Pressing the air conditioner switch once more stops the air conditioner. Z05613 Mode selector dial Use the mode selector dial to select outlets as...
  • Page 137 Heating and air conditioning • For airflow toward the feet and toward the windshield 1. With the dial in the position , most air is directed toward the feet and the rest of the air is directed toward the windshield. Z14913 2.
  • Page 138 For cool airflow toward the head and warm airflow toward the feet Place the mode selector dial in the position or in the position. Z08870 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 select the maximum temperature.

  • Page 139: Heater

    Heating and air conditioning 3 When the performance of the air condi- tioner is poor If there is insufficient refrigerant gas, the perfor- mance of the air conditioner will be poor. Check the amount of refrigerant gas in the air condi- tioner.
  • Page 140 Temperature adjustment dial Turn the dial in the direction of arrow to increase the air temperature and in the direction of arrow to reduce it. Z05611 Air selector switch Pressing the air selector switch allows you to toggle the setting between recirculation of inside air and introduction of outside air.
  • Page 141 9-10 Heating and air conditioning • For airflow toward the upper body and toward the feet Place the mode selector dial in the position. Z14911 • For airflow toward the feet Place the mode selector dial in the position. Z14912 •...
  • Page 142 9-11 • For airflow toward the windshield Place the mode selector dial in the position. Z14915 2 Using the controls To heat the cab Place the mode selector dial in the position or in the position. Z11307 For cool airflow toward the head and warm airflow toward the feet Place the mode selector dial in the position or...

  • Page 143: Outside Air Inlets

    9-12 Heating and air conditioning To ventilate the cab Press the air selector switch to select outside air, and place the mode selector dial in the position. Z11312 3 Cleaning the air filter Clean the air filter every 6 months. A dust-loaded filter may cause malfunction of the blower motor.
  • Page 144 10-1 10. Interior equipment and accessories Cigarette lighter ........................ 10-2 Ashtrays ........................... 10-3 Coat hooks ........................10-4 Sun visors ........................10-4 Interior lamp ........................10-4 Small article compartments ....................10-5 Using the radio ......................... 10-8 Accessories ........................10-8...

  • Page 145: Interior Equipment And Accessories

    10-2 Interior equipment and accessories Cigarette lighter The cigarette lighter can be used when the starter switch is in the “ON” or “ACC” position. Push the cigarette lighter all the way in. It will soon pop back to the original position with its core red hot.

  • Page 146: Ashtrays

    10-3 Ashtrays Remove and empty the ashtrays when they become full. 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.

  • Page 147: Coat Hooks

    10-4 Interior equipment and accessories Coat hooks <Vehicles other than Crew-cab models> Use the coat hooks if you wish to hang up clothing or similar items. CAUTION Z08840 Do not pull the coat hooks with excessive force or hang heavy items on them. They could break. Sun visors The sun visor screens your eyes from sunlight.

  • Page 148: Small Article Compartments

    10-5 Crew-cab models (front and rear seats) • “ON” position The lamp is illuminated regardless of the door positions. • “•” position The lamp comes on when a door is opened and goes off when the door is closed. • “OFF”...
  • Page 149 10-6 Interior equipment and accessories CAUTION • Fuses, relays, and other electrical items are located below the glove compartment 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.
  • Page 150 10-7 Cup holder Pull out the cup holders to use them. Keep them pushed in when they are not being used. WARNING • The contents in a cup or can held in the cup holder may spill during movement of the vehicle.

  • Page 151: Using The Radio

    10-8 Interior equipment and accessories Using the radio 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. •...

  • Page 152: 11. In Cold Weather

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

  • Page 153: Coolant

    11-2 In cold weather Coolant • When vehicles are shipped from the factory, genuine FUSO DIESEL LONGLIFE COOLANT is added to the coolant in their cooling systems. This additive combines both antifreeze and anti- rust capabilities to sufficiently protect the cooling system from freezing up.

  • Page 154: Fuels

    11-3 Fuels Ordinary diesel fuel gels in freezing temperatures, making it impossible to start the engine. If you are bound for a cold area, it is recommended that you fuel your vehicle so that it burns more than half the fuel by the time you reach your destination. This allows you to refuel with a grade of diesel fuel appropriate to the colder weather conditions.

  • Page 155: Installing Tire Chains

    11-4 In cold weather • 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 parking brake in extremely cold conditions that could cause it to freeze up and become impossible to release.
  • Page 156 11-5 1. Place the chains over the tires with the hook ends of cross chains facing outward. Z09325 2. Connect the hook of inside chain , leaving no excess links. Then, take up the slack in the inside chain by pulling cross chains for the inside tire outward.
  • Page 157 11-6 In cold weather 6. Ensure that hooks are 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.

  • Page 158: 12. Simple Inspection And Service

    12-1 12. Simple inspection and service General precautions for servicing the vehicle ..............12-2 To reach the engine access opening ................12-4 Tilting the cab ........................12-5 Pre-operational checks ....................12-10 Lubrication ........................12-19 Greasing ........................12-19 Oils and fluids ........................ 12-23 Filter elements .......................

  • Page 159: General Precautions For Servicing The Vehicle

    12-2 Simple inspection and service General precautions for servicing the vehicle WARNING • Never run the engine in a poorly ventilated area. Exhaust emissions contain carbon monoxide, which can cause unconscious- ness or death if breathed. • Never smoke when servicing your vehicle since its fuel and the gases given off by its battery are highly flammable.
  • Page 160 12-3 WARNING • Put away all tools and rags after use. Items left in the engine bay could get hot and catch fire. Please take the following precautions when servic- ing your vehicle: • Make sure the vehicle is on safe, level ground. •...

  • Page 161: To Reach The Engine Access Opening

    12-4 Simple inspection and service To reach the engine access opening <Crew-cab models> There is an opening under the assistant driver’s seat which provides access to the engine for inspection and servicing. Uncover and cover the opening as follows: • To uncover the opening 1.

  • Page 162: Tilting The Cab

    12-5 Tilting the cab <Vehicles other than Crew-cab models> NOTE: A Crew-cab cannot be tilted. 1 Preparation 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.
  • Page 163 12-6 Simple inspection and service • Before tilting the cab, make sure there is ade- quate clearance in front of the cab and above it. Clearance in front 1 m or more (3.3 ft. or more) Clearance above 1 m or more (3.3 ft. or more) If there are any obstructions within the clear- ance areas shown above, remove them.

  • Page 164: Lowering The Cab

    12-7 3. Hold the tilt grip and raise the cab until the end of cab stay engages with the notch of the lock lever . The cab is secured when they are engaged. Z18601 4. Still holding the tilt grip, insert the stopper into the notch of the lock lever.
  • Page 165 12-8 Simple inspection and service 2. Hold the tilt grip to support the cab. Lift the lock lever and fold the cab stay WARNING • When you have unlocked the cab stay, immediately move your hands away from the lock lever. The cab stay will tip toward the rear of the vehicle, so your hands could otherwise get trapped.
  • Page 166 12-9 4 Checking locking of the cab When the cab is lowered down, the state of locking should be checked as follows. If incomplete locking is identified, repeat the cab tilting procedure and lower once again. If incomplete locking still exists, never drive the vehicle and contact your authorized dealer.

  • Page 167: Pre-Operational Checks

    12-10 Simple inspection and service Pre-operational checks 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.
  • Page 168 12-11 Coolant level Check that the coolant level is between the “FULL” and “LOW” marks on the reservoir tank. P. 12-52 Z11188 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.
  • Page 169 12-12 Simple inspection and service 2 In the driver’s seat First, check the range selector lever with the engine stationary. Then, start the engine and per- form the following checks and after while allowing the engine to warm up. Z12716 Range selector lever <Automatic transmission vehicle>...
  • Page 170 12-13 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 mm (0.79 in.) or more between the pedal and the floor.
  • Page 171 12-14 Simple inspection and service Steering wheel free play Gently turning the steering wheel, check that its play is more than 10 mm (0.39 in.) and less than 20 mm (0.79 in.). P. 12-60 Z11947 Horn operation Press the horn button to check that the horn is working properly.
  • Page 172 12-15 Lighting system Make sure that each lamp lights up or flashes properly. Check lamp lenses for dirt and dam- age. P. 5-18 Z12505 Gauge, warning/indicator lamp operation Check that gauges, warning lamps and indi- cators are working properly. P. 6-2 Z11949 Rearview mirrors Seated in the driver’s seat, adjust the angles...
  • Page 173 12-16 Simple inspection and service Seat belts Confirm that the seat belt buckles function correctly when fastening and unfastening. Z11943 3 While walking around the vehicle Z17516...
  • Page 174 12-17 Wheels and tires Check the disc wheels for cracks and other damage. Check the tires for inflation pres- sure, tread groove depth, foreign objects in grooves, cracks, and uneven wear. P. 12-66 Z18454 Suspension springs Check for broken springs and tilt of vehicle body toward either side.
  • Page 175 12-18 Simple inspection and service Battery fluid level Check that the battery fluid level is between the “UPPER” and “LOWER” level lines marked on the sides of the battery case. P. 12-82 Z17518 4 While driving at slow speeds Perform the following checks while driving in a safe place at speeds lower than 20 km/h (12 mph).

  • Page 176: Lubrication

    12-19 Lubrication Application and replacement of lubricants at the specified intervals is vital to the vehicle’s perfor- mance, longevity, and safety. Following the mainte- nance schedule will give optimum results. P. 15-1 • If the vehicle is often used in demanding condi- tions, for example, on unpaved roads, near the coast, or in cold regions, lubricants should be applied and replaced more quickly than speci-...
  • Page 177 12-20 Simple inspection and service Every 10,000 km Greasing intervals (6,000 miles) <FE> Z12034 <FG> Z12506...
  • Page 178 12-21 Z09225 Z09226 Grease nipple Dust cover Z09227 Z09228 Grease nipple Dust plug hole Z16543 Z09498 Recommended lubricant: Chassis grease NLGI No. 1 (Li soap) Rear spring pin, front (2 points each on both sides) Rear spring pin, rear (4 points each on both sides) King pin bearing (4 points in total on both sides)
  • Page 179 12-22 Simple inspection and service Recommended lubricant: Wheel bearing grease NLGI No. 2 (Li soap) Propeller shaft universal joint Pump in grease until it comes out of the dust covers (at 4 places) of the universal joint. Propeller shaft slip joint Pump in grease until it comes out of the dust plug hole of the slip joint.

  • Page 180: Oils And Fluids

    12-23 Atmospheric temperatures when engine is started. Oils and fluids 1 Engine oil Performance, life, and startability of the engine depend to a large degree on the engine oil. Always use oil of the specified grade and viscosity. The proper engine oil viscosity numbers for various atmospheric temperature ranges are shown in the Z17775 diagram.
  • Page 181 12-24 Simple inspection and service Quantity required: Approx. 7 liters (7.4 qts) Oil pan Approx. 8 liters (8.5 qts) Oil filter Approx. 1 liter (1.1 qts) The engine oil level can be checked by using either the oil level gauge or the oil level check button on the instrument panel.
  • Page 182 12-25 Checking by use of oil level gauge • Preparation <Crew-cab models> <Vehicles other than Crew-cab models> 1. Tilt the cab. <Crew-cab models> 1. Open the inspection cover in the rear floor mat. 2. Release the lock , then open the hatch 3.
  • Page 183 12-26 Simple inspection and service CAUTION If the oil level is above the round hole on the oil level gauge, change the engine oil immediately. Because this is a sign of deteriorated engine oil performance, continued use of the same oil will cause engine failure and could even cause uncontrolled revving of the engine.
  • Page 184 12-27 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. 12-41 WARNING The engine oil is extremely hot immediately Z16869 after the vehicle has been operated.

  • Page 185: Manual Transmission Gear Oil

    12-28 Simple inspection and service CAUTION • Take care not to add more than the specified quantity of oil. The 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.
  • Page 186 12-29 Check WARNING Do not check the oil level immediately after driving, as you could be scalded by extremely hot oil. Give the oil time to cool before performing the inspection. *: 6-speed transmission Z17519 1. Remove inspection plug 2. Check that the oil surface reaches the open- ing of the inspection plug hole by putting your...

  • Page 187: Automatic Transmission Fluid

    12-30 Simple inspection and service 68.6 ± 14.7 N·m (51 ± 11 Tightening torque ft.lbs., 7.0 ± 1.5 kgf·m) 4. Add oil through the inspection plug hole until it reaches the bottom of the hole. Put your finger straightly into the inspection plug hole after one minute has passed, and check that the oil is filled up to the opening of the hole.
  • Page 188 12-31 Checking NOTE: Inspection of the fluid level should be carried out when the fluid is at a high temperature after driving and with the level gauge indicating “HOT”. The “COLD” level is for reference purposes when the oil temperature is low, and accurate measurement will not be possible if the fluid temperature is low.
  • Page 189 12-32 Simple inspection and service can be severely damaged if the correct fluid level is not maintained. • To prevent foreign matters entering and damaging the automatic transmission, add fluid from a clean container. 4 Transfer gear oil <FG> Every 10,000 km Inspection intervals (6,000 miles) Every 30,000 km...

  • Page 190: Axle Housing Gear Oil

    12-33 3. Install the inspection plug. 68.6 ± 14.7 N·m (51 ± 11 Tightening torque ft.lbs., 7.0 ± 1.5 kgf·m) Replacement 1. Remove inspection plug and drain plug let the oil flow out. WARNING Do not replace the oil immediately after driv- ing, as you could be scalded by extremely hot oil.
  • Page 191 12-34 Simple inspection and service Recommended oil: Gear oil API classification GL-5 Below 40°C (104°F) SAE90 40°C (104°F) or higher SAE140 or 85W-140 CAUTION • Use oil conforming to GL-5, SAE140 or SAE85W-140 if the vehicle is to be driven under heavy load conditions as for example driving up long uphill grades.
  • Page 192 12-35 2. Check that the oil surface reaches the open- ing of the inspection plug hole by putting your finger straightly into it. If insufficient, add the oil from the inspection plug hole up to the opening. CAUTION The added oil should be of the same grade and viscosity as the oil originally placed in the dif- ferential gears.

  • Page 193: Brake Fluid

    12-36 Simple inspection and service 6 Brake fluid Inspection At the time of pre-operational intervals check Replacement Every 50,000 km (30,000 miles) intervals or every 24 month Have the brake fluid replacement performed by an authorized dealer. Recommended fluid: Brake fluid SAE J1703 FMVSS No.
  • Page 194 12-37 WARNING • Be sure to use the recommended brake fluid. • Use only one brand of recommended brake fluid. Mixing of different brands or types of fluid will change the properties of the fluid possibly resulting in a lower fluid boiling point and damaged brake compo- nents.
  • Page 195 12-38 Simple inspection and service Check The fluid level should be between the “MAX” and “MIN” lines on reservoir tank . Check whether the reservoir tank contains foreign matter. If you see foreign matter in the reservoir tank, have the reser- voir tank inspected and cleaned by an authorized dealer.

  • Page 196: Power Steering Fluid

    12-39 7 Power steering fluid Every 10,000 km Inspection intervals (6,000 miles) Every 50,000 km Replacement intervals (30,000 miles) or every 12 months Have an authorized dealer replace the fluid. Recommended fluid: Automatic transmission fluid DEXRON, DEXRON II or DEXRON III type CAUTION When adding power steering fluid, be sure to use fluid of the same brand as the existing fluid.
  • Page 197 12-40 Simple inspection and service 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. •...

  • Page 198: Filter Elements

    12-41 7. If the fluid level on the level gauge is not between the notches, add fluid through the guide pipe. Add a little fluid at a time, checking the new level with the level gauge each time. 8. When the fluid level is acceptable, insert the level gauge and secure it in position.
  • Page 199 12-42 Simple inspection and service WARNING • Spilt engine oil should be wiped off clean. Oil remaining on the engine surface could catch fire. • Do not replace the oil filter immediately after operating the vehicle since the engine, transmission, exhaust pipe, engine oil, and other items will be...
  • Page 200 12-43 9. Start the engine and check for oil leakage. 10. Stop the engine and, after letting it stand for more than 30 minutes, check the oil level. 2 Fuel filter replacement Replacement Every 20,000 km (12,000 miles) intervals or every 12 months WARNING •...
  • Page 201 12-44 Simple inspection and service 1. Confirm that the parking brake lever is pulled. Prevent the vehicle from moving by blocking the wheels with chocks. 2. Clean the filter and the surrounding area to pre- vent dirt from entering the new element. 3.
  • Page 202 12-45 12. Install the filter case by turning it in the direction of the arrow . Tighten the filter case using the special tool (available from an authorized dealer) and a torque wrench to within the fol- lowing torque range. 30 ±...
  • Page 203 12-46 Simple inspection and service The air cleaner is located in the illustrated position. Z12059 1. Undo the three clamps and remove the cover 2. Pull element straight down to remove. Z12060 3. From the inside of the element, blow com- pressed air evenly up and down along the pleats of the filter paper.

  • Page 204: Draining Water From Fuel Filter

    12-47 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.

  • Page 205: Engine Coolant - Check And Replacement

    12-48 Simple inspection and service 5 ± 1 N·m (3.7 ± 0.7 ft.lbs., Tightening torque 0.5 ± 0.1 kgf·m) 4. Bleed the fuel system. P. 13-28 5. Start the engine and check that fuel does not leak. WARNING • The drain contains not only water but also fuel.
  • Page 206 12-49 1 Recommended coolant Use a coolant containing the FUSO DIESEL LONGLIFE COOLANT additive and soft water in the specified proportions. Having both corrosion preventive and anti-freezing properties, the additive protects the cooling system all year around. Replace and top off the coolant only with water con- taining FUSO DIESEL LONGLIFE COOLANT or an equivalent.
  • Page 207 12-50 Simple inspection and service DANGER • FUSO DIESEL LONGLIFE COOLANT IS TOXIC. IF A PERSON HAS ACCIDEN- TALLY SWALLOWED IT, FORCE HIM/HER TO VOMIT AND CONSULT A DOCTOR IMMEDIATELY. IF IT SPLASHES IN THE EYES, IMMEDIATELY FLUSH THE EYES WITH WATER FOR MORE THAN 15 MIN- UTES, AND SEEK MEDICAL ATTENTION.
  • Page 208 12-51 CAUTION Do not use methanol-based or methoxypro- panol-based antifreeze products. They can severely damage the engine. Never mix FUSO DIESEL LONGLIFE COOLANT with other brands of long-life coolant or any antifreeze or corrosion-preventive additives. Doing so would reduce the performance of the coolant.
  • Page 209 12-52 Simple inspection and service 4 Check NOTE: • Always check the coolant level before starting the engine when the coolant temperature is low. When the coolant gets hot, it expands, making the level look higher than it actually is. •...
  • Page 210 12-53 Adding coolant following an engine over- heat If the engine overheats, the amount of coolant may be insufficient not only in the reservoir tank but also in the main body of the radiator. Refer to “If the engine overheats” with regard to the filling of coolant in situations where the engine has overheated.
  • Page 211 12-54 Simple inspection and service 1. Place a can under the engine drain plug a can under the radiator drain cock to receive the coolant. Z19695 2. Remove the cap from the reservoir tank 3. Tilt the cab. P. 12-5 If the vehicle is a Crew-cab model vehicle, uncover the engine inspection opening.
  • Page 212 12-55 7. Flush the cooling system. Pour soft water (preferably after heating moder- ately) through the 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-...

  • Page 213: V-Belts - Check And Adjustment

    12-56 Simple inspection and service 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 pressure cap opening. 16. Screw the pressure cap down tightly by turning it clockwise.
  • Page 214 12-57 CAUTION Prevent the V-belt from any contact with oil or grease during check and adjustment. If soiled with oil or grease, the belts will slip and this will shorten their service life. 1 Check 1. Confirm that the parking brake lever is pulled. Prevent the vehicle from moving by blocking the wheels with chocks.
  • Page 215 12-58 Simple inspection and service If a belt is cracked or otherwise damaged, have it replaced it as soon as possible. Belt replacement requires component disassembly. Please contact a authorized dealer to have the work done. Belt condition Remaining service life (reference) The driving distance (or time period) over the which the belt can still be used is at least as long as that over which the belt has been used...

  • Page 216: Range Selector Lever - Check

    12-59 2 Adjustment WARNING Never perform belt tension adjustments when the engine is running. Vehicles with air conditioner 1. Tilt the cab. P. 12-5 If the vehicle is a Crew-cab model vehicle, uncover the engine inspection opening. P. 12-4 2. Slightly loosen the upper and lower alternator mounting bolts and nuts 3.

  • Page 217: Steering Wheel - Check

    12-60 Simple inspection and service 2. Set the starter switch in ON position. 3. While shifting the range selector lever to each position, check the following. • Check if the range selector lever operates smoothly and clicks at each range position (“P”...
  • Page 218 12-61 between the two points is the extent of steering wheel play. Check the steering wheel play both with the engine running and with the engine turned off. If it is out of specification either with the engine running or with the engine turned off, con-tact your nearest authorized dealer.

  • Page 219: Service Brakes - Check

    12-62 Simple inspection and service Service brakes – check The service brakes are safety-critical parts of the vehicle. If an inspection reveals any abnormality, contact an authorized dealer and have the abnor- mality rectified before you again drive the vehicle. Driving the vehicle with the abnormality unrectified could result in a serious accident.
  • Page 220 12-63 pressed with light finger force to the point where resistance is felt (brake pedal play). Check whether the distance is within specification. Brake pedal play 0.1 to 3 mm (at center of pedal pad) (0.0039 to 0.12 in.) 5. If the brake pedal play is not as specified, have the pedal inspected and ajusted by an autho- rized dealer.

  • Page 221: Parking Brake - Check And Adjustment

    12-64 Simple inspection and service Parking brake – check and adjustment Inspection At the time of pre-operational intervals check 1 Parking brake lever stroke check 1. Depress the brake pedal firmly so that the vehi- cle cannot move. 2. Starting with the parking brake lever in the fully released position, pull the parking brake lever with a force of 295 N (66 Ibs., 30 kgf) until it stops moving.

  • Page 222: Clutch - Check

    12-65 Clutch – check <Manual transmission vehicles> At the time of pre-operational Inspection check and every 10,000 km intervals (6,000 miles) Check the clutch for condition. If anything abnormal is found, see an authorized dealer. 1 Clutch pedal play Clutch pedal play 0.2 to 4 mm (at center of pedal pad) (0.0079 to 0.16 in.)

  • Page 223: Tires - Check

    12-66 Simple inspection and service Tires – check At the time of pre-operational Inspection check and every 10,000 km intervals (6,000 miles) 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.
  • Page 224 12-67 WARNING • Excessively low or high tire pressures not only give a poor ride but also could cause cargo to be damaged. Under-inflated or over-inflated tires are also very dangerous and can be easily damaged. Moreover, if the pressure is too low, tires could over- heat and burst.
  • Page 225 12-68 Simple inspection and service 2 Checking tread depth Check the entire circumference of each tire to make sure that the remaining depth of the tread pattern on the part that contacts the road surface is sufficient. Tread groove depth 1.6 mm (0.06 in.) limit When the tread wears down, slip signs...

  • Page 226: Tire Replacement

    12-69 Tire replacement 1 Preparation for tire replacement • Park the vehicle on a flat, hard surface. Pull the parking brake all the way on. If your vehicle has a manual transmission, place the gearshift lever in the neutral position. If your vehicle has an automatic transmission, place the range selec- tor lever in the “P”...
  • Page 227 12-70 Simple inspection and service 2 Removing the wheel Front axle jacking points • Bottom surface of the leaf spring at the rear of tie rod. Z12085 • Jack support under the front axle. Z12567 Rear axle jacking point • Bottom surface of the axle housing (beside leaf spring U-bolt mounting) Z12086...
  • Page 228 12-71 How to remove a wheel 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. •...
  • Page 229 12-72 Simple inspection and service 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.
  • Page 230 12-73 WARNING • If the above items are dirty, the nuts will become loose during vehicle operation. If wheel bolt or nut threads are damaged or the disc wheel is cracked or otherwise damaged, replace the wheel with a new genuine part.
  • Page 231 12-74 Simple inspection and service • On the 6-stud wheels, wheel nuts , outer wheel nuts and inner wheel nuts <6-stud front wheels> marked with “ST” or “S·A”. The “ST” mark indi- cates that these fasteners are for steel wheels Left wheel Right wheel and the “S·A”...
  • Page 232 12-75 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.

  • Page 233: Wheel Nuts - Check And Retightening

    12-76 Simple inspection and service 6. If only the outer wheel of dual wheels is replaced, retighten the inner wheel nuts to the specified torque before mounting the outer wheel. WARNING As the vehicle is driven after a wheel has been replaced, the wheel nuts loosen up somewhat during the early stages of driving due to “wear-in.”...
  • Page 234 12-77 WARNING • A loose wheel nut could cause parts dam- age, and result in a tire falling off. This could result in impossibility of driving, and damage of the vehicle and physical injury. Be sure to check the wheel nuts regularly. •...

  • Page 235: Tire Rotation

    12-78 Simple inspection and service NOTE: The wheel bolts and nuts on the right-hand wheels have right-hand threads, and those on the left-hand wheels have left-hand threads. The bolts and nuts have stamped marks for easy identification; an “R” mark for right-hand wheels and an “L”...
  • Page 236 12-79 WARNING • Be sure to use the specified type of tires. Mixing bias and radial tires results in poor steering and should be avoided at all cost. • As the vehicle is driven after a wheel has been replaced, the wheel nuts loosen up somewhat during the early stages of driv- ing due to “wear-in”.

  • Page 237: Wiper Blade - Replacement

    12-80 Simple inspection and service Wiper blade – replacement 1 Replacing wiper blade 1. Raise wiper arm , and then push clip spring in the direction of the arrow (see figure). Z05981 2. With the clip spring kept in the pushed position, press wiper toward the wiper arm.

  • Page 238: Windshield Washer - Fluid Level Check And Refilling

    12-81 Windshield washer – fluid level check and refilling 1 Fluid level check Check the washer fluid level through level check window When the level has dropped to the lower part of the window or is not visible at all, refill the tank with washer fluid.

  • Page 239: Battery - Check

    12-82 Simple inspection and service Battery – check Inspection At the time of pre-operational intervals check WARNING • The battery generates flammable hydro- gen gas and should be kept away from open flame and spark. • When removing the battery, always dis- connect the negative (–) terminal first and reconnect it last.
  • Page 240 12-83 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 charging. DANGER BATTERY FLUID IS DILUTE SULFURIC ACID HARM MOST THINGS...

  • Page 241: Battery Removal And Installation

    12-84 Simple inspection and service 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.

  • Page 242: Cleaning Dpf Of Ashes

    12-85 CAUTION Install the battery securely in position. If it is left loose, shocks and vibrations from road surface could damage the battery case and electrode plates, shortening battery life. Cleaning DPF of ashes Your vehicle is equipped with a diesel particulate fil- ter (DPF) system.

  • Page 243: Refrigerant - Check

    12-86 Simple inspection and service Refrigerant – check <Vehicles with air conditioner> If refrigerant is insufficient, the cooling efficiency will be diminished. Therefore, check the refrigerant level from time to time. Run the air conditioner so it gives maximum cooling performance (place the fan speed dial in the position and the temperature adjustment dial in the position...

  • Page 244: Air Filters - Cleaning

    12-87 Air filters – cleaning Remove and clean the air filters (heater or air condi- tioner filters) with water or compressed air to elimi- nate dust and dirt at regular intervals (6 months or so). Clogged filters may cause inefficient heating or air- conditioning, and even malfunction of the blower motor.
  • Page 245 12-88 Simple inspection and service 2 Dashboard air filter Z11171 • Removal 1. Remove the four screws that retain the bot- tom of the lower center panel and the bottom of the lower panel 2. Release the tabs on the lower panel and lower center panel, then remove the lower panel.

  • Page 246: Cleaning Your Vehicle

    12-89 • Installation 1. Return the air filter to its original position by inserting it with its front facing you. Press the air filter securely into the guides (one on each side at the top and two at the bottom). 2.
  • Page 247 12-90 Simple inspection and service • Been driven on roads where road chemicals have been applied • Become contaminated by coal tar, smoke, soot, powder dust, iron powder, lime powder, sap, bird droppings, etc. • Adhesion of dust and/or mud Using a hose, wash the mud and dirt off the body surfaces.
  • Page 248 12-91 • Thoroughly wash the vehicle, especially the wheelhouses and underside of the chassis after driving on coastal roads or roads where road chemicals have been applied. Thor- ough washing is also important if your vehi- cle is frequently used to transport marine products or lime because seawater will affect the vehicle and lime will severely dam- age the vehicle’s paintwork.
  • Page 249 12-92 Simple inspection and service • There are ABS electric wiring located behind the wheels. When removing snow or ice hav- <Front wheel> ing adhered to the wheel areas after driving on snow-covered roads, be careful not to damage the ABS components and wiring. Also, avoid exposing the ABS components and wiring to high-pressure water or cleaner steam as the system could be damaged and...
  • Page 250 12-93 2 Rust and corrosion • Rust and corrosion developing on the underside and/or undercarriage of the vehicle could cause an unexpected failure and even lead to an acci- dent. Check these areas occasionally (such as after washing) for rust/corrosion and resulting holes.
  • Page 251 12-94 Simple inspection and service 2. Dilute the cleaner in water to the specified con- centration. The best results can usually be obtained with a thinner solution. When soapsuds are used, apply them with a sponge or soft cloth. 3. Wipe up any remaining cleaner with a towel or other absorbent cloth.
  • Page 252 12-95 • Tar, asphalt, and shoe polish can leave stains if not cleaned off quickly. With a clean cloth impregnated with vinyl cleaner, wipe the area clean. Cleaning seat belts • Keep your vehicle’s seat belts clean and dry at all times.

  • Page 253: Intercooler - Cleaning

    12-96 Simple inspection and service Intercooler – cleaning If the front of the intercooler is heavily clogged with dust or mud, the engine performance may be affected. Clean it from time to time by using a soft brush or something also appropriate. Z16080 CAUTION The intercooler could be damaged if a bristle...
  • Page 254 13-1 13. Useful advice for emergencies Possible failures, causes and remedies ................13-2 Stopping your vehicle in an emergency ................13-7 If the engine overheats ....................13-8 When a fuse has blown ....................13-9 When a lamp has burned out ..................13-17 When braking is sluggish ....................

  • Page 255: Useful Advice For Emergencies

    13-2 Useful advice for emergencies Possible failures, causes and remedies Performing daily checks and good maintenance are keys to preventing mechanical failures and the resultant accidents. Be sure to check and service your vehicle regularly. Should your vehicle suffer a mechanical failure or malfunction, the measures needed to correct the problem can be found using the following chart.
  • Page 256 13-3 The engine starts but stalls immediately. Possible cause Remedy Ref. page Idling speed setting is too low. Have an authorized dealer perform – necessary inspection. The fuel filter is clogged. Replace the filter element. 12-43 The air cleaner is clogged. Clean or replace the filter element.
  • Page 257 13-4 Useful advice for emergencies Fuel consumption is excessive. Possible cause Remedy Ref. page There is a fuel leak. Check the fuel system and retighten – connections as necessary. The air cleaner is clogged. Clean or replace the air cleaner ele- 12-45 ment.
  • Page 258 13-5 The clutch disengages incompletely. <only manual transmission vehicles> Possible cause Remedy Ref. page Clutch fluid is insufficient. Add clutch fluid (brake fluid). 12-36 Clutch pedal play is excessive. Have an authorized dealer perform 12-65 necessary inspection. Braking is sluggish. <other than FE85> Possible cause Remedy Ref.
  • Page 259 13-6 Useful advice for emergencies Steering is difficult. Possible cause Remedy Ref. page Cargo is over-loaded on the front Load cargo evenly. 7-18 side. Power steering fluid is insufficient. Add power steering fluid. 12-38 Front tire pressure is insufficient. Inflate tires to recommended pres- 12-66 sures.

  • Page 260: Stopping Your Vehicle In An Emergency

    13-7 The battery frequently runs down. Possible cause Remedy Ref. page The battery terminals are loose or Scrape off corrosion and tighten down 12-83 corroded. terminals. The fan belt is loose. Adjust the belt tension. 12-56 The battery is short of electrolyte. Add battery electrolyte.

  • Page 261: If The Engine Overheats

    13-8 Useful advice for emergencies 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. WARNING Never attempt to perform repairs on an expressway or in a tunnel as doing so is very...

  • Page 262: When A Fuse Has Blown

    13-9 1. Tilt the cab. P. 12-5 If the vehicle is a Crew-cab model vehicle, uncover the engine inspection opening. P. 12-4 2. Check that coolant is not leaking from the radia- tor hoses or from other parts. 3. Check that the fan belt is not broken and that its tension is normal.
  • Page 263 13-10 Useful advice for emergencies 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.
  • Page 264 13-11 3. If a fuse is blown, be sure to select a spare fuse of the specified amperage for replacement. WARNING Be sure to use fuses of the specified amper- ages. A fire could result if a fuse of incorrect amperage is used.
  • Page 265 13-12 Useful advice for emergencies <Fuse box> Z16872 Fuse <High-current fuse box> Amperage Protected circuit Cigarette lighter Audio system Auxiliary power supply (starter switch ACC circuit) Stop lamps Meter cluster Turn signal lamps Auxiliary power supply (circuit directly connected to battery) Audio system Interior lamps Power window (driver’s)
  • Page 266 13-13 Fuse Amperage Protected circuit Automatic transmission Tester Headlamps (high beam) Left headlamp (low beam) Right headlamp (low beam) Tail lamps Horn Air conditioner Air conditioner condenser Air conditioner blower fan, heater blower fan Van body dome light Automatic transmission fluid cooler fan Engine drive unit Backup lamps...
  • Page 267 13-14 Useful advice for emergencies Fuse Amperage Protected circuit Spare fuse Automatic transmission troubleshooting (diagnosis) ABS troubleshooting (diagnosis) ABS troubleshooting (memory clear) MVCU troubleshooting (diagnosis) MVCU troubleshooting (memory clear) Engine ECU troubleshoot- ing (diagnosis)
  • Page 268 13-15 2 High-current fuse There are high-current fuses between the battery <Type 1> <Type 2> and fuse box, and between the battery and alterna- tor. These protect circuits in the same way that ordi- nary fuses do. If a high-current fuse is blown, most of the vehicle’s electrical circuits become inopera- tive.
  • Page 269 13-16 Useful advice for emergencies Amperage <Type 1> Protected circuit (casing color) Fuse box (S1, A1 – A5, 60A (yellow) M1 – M12) Fuse box 60A (yellow) (B1 – B12) Fuse box 40A (green) (B13 – B16) FH12 40A (green) ABS motor 40A (green) ABS valve...

  • Page 270: When A Lamp Has Burned Out

    13-17 If the engine is difficult to start after the indicator lamp has gone out in cold weather, check to see if the fuse of the preheating circuit has blown out. If the fuse is blown out, first disconnect the cable from the (–) terminal of the battery and then replace the fuse with a new 127A fuse.
  • Page 271 13-18 Useful advice for emergencies CAUTION • The turn signal lamps have plastic lenses. Do not clean these lenses with alcohol or thinner. Also, be careful not to splash brake fluid on them when adding it to the braking system. Contact with such a substance could discolor or crack the lenses.
  • Page 272 13-19 Z15042 Ref. No. Lamp Bulb wattage (bulb type) Q’ty Headlamp 12V-60/55W (HB2) Parking lamp 12V-5W (W5W) Front and side turn signal lamp 12V-21W (P21W) Stop/tail lamp (double filament) 12V-21/5W (P21/5W) Rear turn signal lamp 12V-21W (P21W) Backup lamp 12V-21W (P21W) License plate lamp 12V-7.5W (A12V7.5W) License plate lamp <Crew-cab or...
  • Page 273 13-20 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. Headlamp removal and installation •...
  • Page 274 13-21 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. •...
  • Page 275 13-22 Useful advice for emergencies 8. Raise the headlamp slightly to remove the tabs from the holes , then pull it out toward you. Z11271 • Headlamp installation 1. Insert the tabs on the headlamp into the holes , and fit the headlamp in place. Z11272 2.
  • Page 276 13-23 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. Z11274 8. Open the door, then tighten the screws behind the front and side turn signal lamp the screw behind the dummy lamp...
  • Page 277 13-24 Useful advice for emergencies • 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 278: When Braking Is Sluggish

    13-25 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.

  • Page 279: If The Engine Stalls While The Vehicle Is In Motion

    13-26 Useful advice for emergencies If the engine stalls while the vehicle is in motion The vehicle will be set into the following very dan- gerous condition. Pull the vehicle over when safe to do so and try to start the engine. •...

  • Page 280: When The Battery Has Run Down

    13-27 When the battery has run down Perform the following procedure to start your engine by connecting your battery to the well charged bat- tery of another vehicle with booster cables. WARNING • Check the battery’s fluid level before con- necting booster cables.

  • Page 281: When The Fuel Has Run Out (Bleeding The Fuel System)

    13-28 Useful advice for emergencies 1. Stop the engine of the vehicle giving the boost. 2. Remove the battery cover. P. 12-82 <Connection> 3. Connect one end of the red booster cable to the positive (+) terminal of the dead battery. Con- nect the other end of the red booster cable to the positive (+) terminal of the booster bat-...
  • Page 282 13-29 CAUTION The fuel injection system may fail if the engine stops due to lack of fuel. 1. Loosen air vent plug on the fuel filter by using a wrench. NOTE: Use whichever of the two air vent plugs is the most convenient;...

  • Page 283: Towing

    13-30 Useful advice for emergencies Towing 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.

  • Page 284: When The Vehicle Becomes Stuck In Soft Ground

    13-31 • Never use the tie-down hook(s) under the <FE> 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. <FG>...
  • Page 285 13-32 Useful advice for emergencies • Never use the tie-down hook(s) under the <FE> 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. <FG>...
  • Page 286 13-33 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 become slightly slack before stopping the towed vehicle.

  • Page 288: 14. Service Data

    14-1 14. Service data Recommended lubricants/hydraulic fluids and quantities ..........14-2 Service data ........................14-4...
  • Page 289 14-2 Service data Recommended lubricants/hydraulic fluids and quantities 1 Quantities of lubricants/hydraulic fluids liters (qts) Item Quantity Approx. 7 (7.4) Oil pan Engine Approx. 8 (8.5) Oil filter Approx. 1 (1.1) 5-speed Approx. 3.6 (3.8) Manual transmission 6-speed Approx. 4.4 (4.6) Total quantity Approx.
  • Page 290 14-3 2 Recommended lubricants/hydraulic fluids Be sure to use the specified lubricants. Viscosity Parts Category Classification Atmospheric SAE viscosity temperature number Below 0°C (32°F) 10W–30 Engine Engine oil API CJ-4 Above –15°C (5°F) 15W–40 Above 30°C (86°F) General API GL-3 Gear oil Warm region Manual transmission...

  • Page 291: Service Data

    14-4 Service data Service data Description Standard value Engine idling speed 625 to 675 rpm New belt (when installed): 9 to 11 mm (0.35 to 0.43 in.) Vehicles without Used belt (when air conditioner inspected or reinstalled): 11 to 13 mm Belt tension [amount of deflection (0.43 to 0.51 in.) under a 98 N (22 lbs., 10 kgf) pres-...

  • Page 292: 15. Maintenance Schedule

    15-1 15. Maintenance schedule Maintenance schedule ........... 15-2 Lubrication schedule .
  • Page 293 15-2 Maintenance schedule Regular maintenance is vital to maximizing your vehicle’s performance, service life, and safety. Following the maintenance schedule will give optimum results. The preceding sections describe simple maintenance checks and procedures that can be carried out by the owner. If you have difficulty or your vehicle needs maintenance work that is not shown in this manual, please take the vehicle to an authorized dealer.
  • Page 294 15-3 Time of inspection and maintenance Inspection interval Ref. Item Working procedures page Inspect the fuel tank, cap Every 20,000 km/12,000 miles or Fuel line • • and lines for damage caus- – 12 months ing leakage. Belts ten- Every 10,000 km/6,000 miles or Inspect belts for crack, •...
  • Page 295 15-4 Maintenance schedule Time of inspection and maintenance Inspection interval Ref. Item Working procedures page Operation check of the Exhaust brake • • • • • • • • – exhaust brake POWER TRAIN Check the clutch pedal for Clutch pedal play •...
  • Page 296 15-5 Time of inspection and maintenance Inspection interval Ref. Item Working procedures page Check wheel nuts for looseness. Retightening • • • • • • • Check at the first 50 to 100 12-76 wheel nuts km/30 to 60 miles after changing a wheel.
  • Page 297 15-6 Maintenance schedule Time of inspection and maintenance Inspection interval Ref. Item Working procedures page STEERING SYSTEM Turn steering wheel right and left to measure play at Steering wheel • • • • • • • • steering wheel rim. Mea- 12-60 play sure while engine is run-...

  • Page 298: Lubrication Schedule

    15-7 Time of inspection and maintenance Inspection interval Ref. Item Working procedures page ELECTRICAL SYSTEM Press the horn button to Horn operation • • • • • • • • check that the horn is – working properly. Confirm that the windshield Windshield washer fluid level is above •...
  • Page 299 15-8 Maintenance schedule Time of inspection and maintenance Inspection interval Reference Item page Manual transmission oil level • • • • • • 12-28 Manual transmission oil replace- • • • • • ment Automatic transmission fluid level • • •...
  • Page 300 15-9 Time of inspection and maintenance Inspection interval Reference Item page Center bearing • • • • • • – Universal joint, Lubrication of • • • • • • 12-19 slip joint propeller shaft Double cardan • • • •...

  • Page 302: 16. Alphabetical Index

    16-1 16. Alphabetical index...

  • Page 303: Maintenance Record

    16-2 Alphabetical index 4WD operation ........8-1 Exhaust brake ........5-20 Accelerator pedal ........ 5-12 Free-wheeling hub ........ 8-7 Air cleaner ........12-45 Front air outlets ........9-2 Air conditioner ........9-3 Front drive switch ........8-3 Air filters ..........12-87 Fuel filter ...........
  • Page 304 16-3 Alphabetical index Parking brake lever ......5-17 Van body dome light switch ....5-28 Passing signal ........5-19 V-belts ..........12-56 Periodic inspection ........ 1-4 Vehicle identification number (VIN) ..1-3 Possible failures, causes and Warming up the engine ......5-9 remedies ..........

  • Page 306: 17. Maintenance Record

    17. MAINTENANCE RECORD NOTE: The symbols prefixed to some check items stand for Exhaust Emission Control item and Noise Control item respectively. 17-1...
  • Page 308 4,000 km / 2,500 miles 4,000 km / 2,500 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement Manual transmission oil replacement Transfer gear oil replacement <FG> Address: Rear axle housing gear oil replacement Front axle housing gear oil replacement <FG>...
  • Page 310 10,000 km / 6,000 miles 10,000 km / 6,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...

  • Page 311: Steering System

    Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 312 20,000 km / 12,000 miles 20,000 km / 12,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 313 Suspension system Spring U-bolt nuts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 314 30,000 km / 18,000 miles 30,000 km / 18,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 315 Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc...
  • Page 316 40,000 km / 24,000 miles 40,000 km / 24,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil level (Manual) Transfer gear oil level <FG> Address: Automatic transmission fluid replacement Rear axle housing gear oil level...
  • Page 317 Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 318 50,000 km / 30,000 miles 50,000 km / 30,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil replacement Front axle housing gear oil level <FG>...
  • Page 319 Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 320 60,000 km / 36,000 miles 60,000 km / 36,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 321 Check DPF for blocking (or 12 months) Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system...
  • Page 322 70,000 km / 42,000 miles 70,000 km / 42,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 323 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 324 80,000 km / 48,000 miles 80,000 km / 48,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil level (Manual) Automatic transmission fluid replacement Address: Transfer gear oil level <FG>...
  • Page 325 Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 326 90,000 km / 54,000 miles 90,000 km / 54,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 327 Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc...
  • Page 328 100,000 km / 60,000 miles 100,000 km / 60,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 329 EGR valve cleaning Operation check of exhaust brake Power train Clutch pedal and clutch disc wear Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts Braking system Disc brake pad and disc...
  • Page 330 110,000 km / 66,000 miles 110,000 km / 66,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 331 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 332 120,000 km / 72,000 miles 120,000 km / 72,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid replacement Transfer gear oil replacement <FG> Address: Rear axle housing gear oil replacement Front axle housing gear oil replacement...
  • Page 333 Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts...
  • Page 334 130,000 km / 78,000 miles 130,000 km / 78,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 335 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 336 140,000 km / 84,000 miles 140,000 km / 84,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 337 Suspension system Spring U-bolt nuts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 338 150,000 km / 90,000 miles 150,000 km / 90,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 339 Coolant replacement (24 months) Air cleaner element cleaning Check DPF for blocking (or 12 months) Intake throttle valve cleaning EGR valve cleaning Operation check of exhaust brake Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness...
  • Page 340 160,000 km / 96,000 miles 160,000 km / 96,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil level (Manual) Automatic transmission fluid replacement Address: Transfer gear oil level <FG>...
  • Page 341 Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 342 170,000 km / 102,000 miles 170,000 km / 102,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 343 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 344 180,000 km / 108,000 miles 180,000 km / 108,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 345 Check DPF for blocking (or 12 months) DPF Ash cleaning (185,000 km / 110,000 miles) Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement...
  • Page 346 190,000 km / 114,000 miles 190,000 km / 114,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 347 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 348 200,000 km / 120,000 miles 200,000 km / 120,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil level (Manual) Automatic transmission oil replacement Address: Transfer gear oil level <FG>...
  • Page 349 Intake throttle valve cleaning EGR valve cleaning Operation check of exhaust brake Power train Clutch pedal and clutch disc wear Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts Braking system...
  • Page 350 210,000 km / 126,000 miles 210,000 km / 126,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 351 Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc...
  • Page 352 220,000 km / 132,000 miles 220,000 km / 132,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 353 Suspension system Spring U-bolt nuts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 354 230,000 km / 138,000 miles 230,000 km / 138,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 355 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 356 240,000 km / 144,000 miles 240,000 km / 144,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid replacement Transfer gear oil replacement <FG> Address: Rear axle housing gear oil replacement Front axle housing gear oil replacement...
  • Page 357 Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts...
  • Page 358 250,000 km / 150,000 miles 250,000 km / 150,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 359 Propeller shaft flange torque and universal joint looseness Propeller shaft center bearing Front and rear axle Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 360 260,000 km / 156,000 miles 260,000 km / 156,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 361 Suspension system Spring U-bolt nuts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 362 270,000 km / 162,000 miles 270,000 km / 162,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 363 Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months) Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel hub bearing Wheel hub bearing hub seals replacement Wheel and tire Retightening wheel nuts Braking system Disc brake pad and disc...
  • Page 364 280,000 km / 168,000 miles 280,000 km / 168,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil level (Manual) Automatic transmission fluid replacement Address: Transfer gear oil level <FG>...
  • Page 365 Front and rear axle Wheel and tire Retightening wheel nuts Suspension system Retightening U-bolts Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 366 290,000 km / 174,000 miles 290,000 km / 174,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil or fluid level Transfer gear oil level <FG> Address: Rear axle housing gear oil level Front axle housing gear oil level <FG>...
  • Page 367 Braking system Disc brake pad and disc Brake lining Looseness, play and damage of brake sys- tem parts Steering system Steering system...
  • Page 368 300,000 km / 180,000 miles 300,000 km / 180,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission fluid level (Automatic) Manual transmission oil replacement Address: Transfer gear oil replacement <FG>...
  • Page 369 V-belts tension and damage (or 12 months) Cooling system Coolant replacement (24 months) Air cleaner element cleaning Exhaust system Check DPF for blocking (or 12 months) Intake throttle valve cleaning EGR valve cleaning Operation check of exhaust brake Power train Clutch pedal and clutch disc wear Operate performance of range selector lever (or 6 months)
  • Page 370 Pub. No. MH996028 JANUARY ’09 Printed in Japan...

This manual is also suitable for:

2010 fuso fg

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