Mitsubishi Fuso Canter FE534 FE639 FE649 FE659 FG649 FP-R FS FV FE 4D3 4M4 4M5 6M7 Hybrid Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Mitsubishi Fuso Model: Canter Chassis Codes: FE534, FE639, FE649, FE659, FG649, FP-R, FS, FV Engine Codes: 4D3 Series, 4M4 Series, 4M5 Series, 6M7 Series, Hybrid Powertrain 👋 Introduction Market Position Vehicle Segment: Light-duty commercial vehicle, often used for delivery, utility, and specialized applications. Competitive Analysis Competitors: Similar vehicles include Isuzu NPR, Hino 155, and Ford F-Series chassis cab (in certain configurations). Key Features Durability: Known for robust construction and reliability in commercial use. Versatility: Available in various wheelbase lengths and cab configurations, making it adaptable to a wide range of body styles. Compact Design: Relatively compact dimensions for its class, allowing for maneuverability in urban environments. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: PDF Download Manual Focus: Service, Repair, and Troubleshooting. Page Count Page Count: Hundreds (Exact count not specified, but described as very detailed) Additional Features Lifetime Usage: Licensed for unlimited, lifelong use on multiple devices. Compatibility: Compatible with all Windows and Mac operating systems. Updates: No expiry dates or renewal fees. Format Device Compatibility: Instant download and use on computers, tablets, and smartphones. 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage for 4D3, 4M4, 4M5, 6M7 diesel and hybrid powertrains, including component identification, diagnosis, disassembly, assembly, and repair procedures. Transmission: Service and repair of manual and automatic transmissions, including clutch systems, transfer cases (for 4WD variants), and drive shafts. Drivetrain: Covers front and rear axles, differentials, hub assemblies, and axle shafts for both 2WD and 4WD configurations. Suspension: Detailed procedures for inspecting, diagnosing, and repairing front and rear suspension components, including leaf springs, shock absorbers, and stabilizers. Steering: Includes service and repair of the steering gear, steering column, linkage, and power steering system. Brakes: Comprehensive coverage of hydraulic brake systems, including master cylinder, brake boosters, calipers, brake pads, rotors, and parking brake mechanisms. Also covers ABS system components and diagnostics. Electrical System: Extensive coverage of starting and charging systems, lighting, wipers, horns, instrumentation, and body electrical components. Includes wiring diagrams and component locations. Fuel System: Service and repair of diesel fuel injection systems, including pumps, injectors, fuel filters, and associated sensors. Also covers the hybrid system's fuel management. Cooling System: Covers radiator, fan, thermostat, water pump, coolant hoses, and heater core service. Exhaust System: Service and replacement of exhaust manifolds, pipes, mufflers, and catalytic converters. HVAC: Covers air conditioning system components, refrigerant handling, blower motor, and controls. Body And Chassis: Includes procedures for body panel repair, door mechanisms, seat adjustments, and chassis frame inspections. Hybrid System: Specific procedures and diagnostics for the hybrid powertrain, including battery management, electric motor, and hybrid control unit. Emissions Control: Covers components related to emissions control systems, such as EGR valves and catalytic converters, and their service. Chassis Lubrication: Lubrication points and schedules for chassis components. Lighting System: Headlights, taillights, turn signals, and interior lighting service. Body Panels: Removal and installation of body panels, doors, hoods, and bumpers. Interior Trim: Removal and installation of interior trim panels, dashboard components, and seats. Procedures Included Scheduled Maintenance: Detailed maintenance schedules with recommended service intervals for oil changes, filter replacements, fluid checks, and component inspections. Troubleshooting: Extensive troubleshooting guides with symptom-based diagnostic trees, fault code explanations, and step-by-step diagnostic procedures. Disassembly And Assembly: Step-by-step instructions for the removal, disassembly, inspection, repair, and reassembly of all major vehicle components and systems. Torque Specifications: Precise torque values for all critical fasteners, ensuring correct assembly and preventing damage. Diagnostic Trouble Codes: Listing and explanation of OBD-II (or equivalent) diagnostic trouble codes (DTCs) and guidance on their diagnosis and clearing. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems, including component tracing and connector pinouts. Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures. Rebuilds: Complete instructions for engine, transmission, and differential rebuilds. Alignment: Wheel alignment specifications and procedures. Tire Pressure: Recommended tire pressures for various load conditions. Technical Depth Depth: Comprehensive professional-level coverage, suitable for factory-trained technicians and experienced DIY mechanics. Includes detailed diagnostics, component-level repair, and system overhauls. Diagnostic Tools Required: May require common hand tools, diagnostic scanners, multimeter, and specialized Fuso-specific tools as outlined in the manual. Diagrams Illustrations: Hundreds of detailed photos and diagrams, including exploded views for precise component identification and assembly. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (implied by professional digital format) Print Quality Printable: Yes, single pages or entire manual Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Family Examples: 4D3 Series (e.g., 4D34), 4M4 Series (e.g., 4M40), 4M5 Series (e.g., 4M51), 6M7 Series (e.g., 6M70) Diesel Engine Displacement: Varies by specific engine code, typically ranging from 3.9L to 7.5L (e.g., 4D34: 3.9L, 4M51: 4.9L, 6M70: 7.5L). Hybrid Powertrain Description: Integrates a diesel engine with an...
Light-duty commercial vehicle, often used for delivery, utility, and specialized applications.
Competitive Analysis
Competitors:
Similar vehicles include Isuzu NPR, Hino 155, and Ford F-Series chassis cab (in certain configurations).
Key Features
Durability:
Known for robust construction and reliability in commercial use.
Versatility:
Available in various wheelbase lengths and cab configurations, making it adaptable to a wide range of body styles.
Compact Design:
Relatively compact dimensions for its class, allowing for maneuverability in urban environments.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
PDF Download
Manual Focus:
Service, Repair, and Troubleshooting.
Page Count
Page Count:
Hundreds (Exact count not specified, but described as very detailed)
Additional Features
Lifetime Usage:
Licensed for unlimited, lifelong use on multiple devices.
Compatibility:
Compatible with all Windows and Mac operating systems.
Updates:
No expiry dates or renewal fees.
Format
Device Compatibility:
Instant download and use on computers, tablets, and smartphones.
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage for 4D3, 4M4, 4M5, 6M7 diesel and hybrid powertrains, including component identification, diagnosis, disassembly, assembly, and repair procedures.
Transmission:
Service and repair of manual and automatic transmissions, including clutch systems, transfer cases (for 4WD variants), and drive shafts.
Drivetrain:
Covers front and rear axles, differentials, hub assemblies, and axle shafts for both 2WD and 4WD configurations.
Suspension:
Detailed procedures for inspecting, diagnosing, and repairing front and rear suspension components, including leaf springs, shock absorbers, and stabilizers.
Steering:
Includes service and repair of the steering gear, steering column, linkage, and power steering system.
Brakes:
Comprehensive coverage of hydraulic brake systems, including master cylinder, brake boosters, calipers, brake pads, rotors, and parking brake mechanisms. Also covers ABS system components and diagnostics.
Electrical System:
Extensive coverage of starting and charging systems, lighting, wipers, horns, instrumentation, and body electrical components. Includes wiring diagrams and component locations.
Fuel System:
Service and repair of diesel fuel injection systems, including pumps, injectors, fuel filters, and associated sensors. Also covers the hybrid system's fuel management.
Cooling System:
Covers radiator, fan, thermostat, water pump, coolant hoses, and heater core service.
Exhaust System:
Service and replacement of exhaust manifolds, pipes, mufflers, and catalytic converters.
HVAC:
Covers air conditioning system components, refrigerant handling, blower motor, and controls.
Body And Chassis:
Includes procedures for body panel repair, door mechanisms, seat adjustments, and chassis frame inspections.
Hybrid System:
Specific procedures and diagnostics for the hybrid powertrain, including battery management, electric motor, and hybrid control unit.
Emissions Control:
Covers components related to emissions control systems, such as EGR valves and catalytic converters, and their service.
Chassis Lubrication:
Lubrication points and schedules for chassis components.
Lighting System:
Headlights, taillights, turn signals, and interior lighting service.
Body Panels:
Removal and installation of body panels, doors, hoods, and bumpers.
Interior Trim:
Removal and installation of interior trim panels, dashboard components, and seats.
Procedures Included
Scheduled Maintenance:
Detailed maintenance schedules with recommended service intervals for oil changes, filter replacements, fluid checks, and component inspections.
Troubleshooting:
Extensive troubleshooting guides with symptom-based diagnostic trees, fault code explanations, and step-by-step diagnostic procedures.
Disassembly And Assembly:
Step-by-step instructions for the removal, disassembly, inspection, repair, and reassembly of all major vehicle components and systems.
Torque Specifications:
Precise torque values for all critical fasteners, ensuring correct assembly and preventing damage.
Diagnostic Trouble Codes:
Listing and explanation of OBD-II (or equivalent) diagnostic trouble codes (DTCs) and guidance on their diagnosis and clearing.
Wiring Diagrams:
Detailed electrical wiring diagrams for all vehicle systems, including component tracing and connector pinouts.
Special Tools:
Identification and usage instructions for any specialized tools required for specific repair procedures.
Rebuilds:
Complete instructions for engine, transmission, and differential rebuilds.
Alignment:
Wheel alignment specifications and procedures.
Tire Pressure:
Recommended tire pressures for various load conditions.
Technical Depth
Depth:
Comprehensive professional-level coverage, suitable for factory-trained technicians and experienced DIY mechanics. Includes detailed diagnostics, component-level repair, and system overhauls.
Diagnostic Tools Required:
May require common hand tools, diagnostic scanners, multimeter, and specialized Fuso-specific tools as outlined in the manual.
Diagrams Illustrations:
Hundreds of detailed photos and diagrams, including exploded views for precise component identification and assembly.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (implied by professional digital format)
Print Quality
Printable:
Yes, single pages or entire manual
Binding Type
Binding:
Digital Download (No physical binding)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Family Examples:
4D3 Series (e.g., 4D34), 4M4 Series (e.g., 4M40), 4M5 Series (e.g., 4M51), 6M7 Series (e.g., 6M70)
Diesel Engine Displacement:
Varies by specific engine code, typically ranging from 3.9L to 7.5L (e.g., 4D34: 3.9L, 4M51: 4.9L, 6M70: 7.5L).
Hybrid Powertrain Description:
Integrates a diesel engine with an electric motor and battery pack for improved fuel efficiency and reduced emissions.
Performance
Horsepower Range:
Typically ranges from approximately 100 HP to over 200 HP, depending on the specific engine and model year.
Torque Range:
Ranges from approximately 200 lb-ft to over 450 lb-ft, providing ample power for hauling and towing.
Fuel System
Fuel Type:
Diesel, with hybrid variants also utilizing diesel.
Injection System:
Direct injection, often with electronically controlled unit pumps or common rail systems for later models.
Engine Layout
Configuration:
Inline 4-cylinder or Inline 6-cylinder diesel engines.
🔧 Transmission
Standard
Transmission Types:
Typically a 5-speed or 6-speed manual transmission. Automatic transmission options may be available on certain models/configurations.
Optional
Automatic Transmission:
Some models offered an automatic transmission, often a heavy-duty unit suitable for commercial use.
Features
4Wd Transfer Case:
Available on FG and similar 4WD models, with manual engagement procedures.
📐 Dimensions
Exterior
Wheelbase Options:
Multiple wheelbase options available, ranging from approximately 100 inches to over 170 inches, depending on chassis code and configuration.
Cab Types:
Standard Cab and Crew Cab configurations are common.
Weights
Gvwr Range:
Gross Vehicle Weight Rating (GVWR) can vary significantly, generally from 11,000 lbs to over 26,000 lbs, depending on the model variant (FE, FG, etc.).
🛡️ Safety Features
Active Features
ABS:
Anti-lock Braking System (ABS) is a common safety feature on many models.
Passive Features
Seat Belts:
Standard three-point seat belts for driver and passengers.
💡 Technology Features
Infotainment
Radio Options:
Basic AM/FM radio, CD players, and optional auxiliary inputs were common on earlier models. Later models may feature more integrated audio systems.
Driver Assistance
ABS:
As mentioned, ABS is a significant driver assistance feature.
Connectivity
Diagnostics Ports:
OBD-II port for engine diagnostics, and potentially proprietary diagnostic connectors for deeper system checks.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 to 10,000 miles or 6 months, but consult the specific manual for exact intervals based on operating conditions.
Fuel Filter Replacement:
Recommended at intervals such as 15,000 to 30,000 miles for diesel fuel filters.
Transmission Fluid Change:
Intervals vary for manual and automatic transmissions, often between 30,000 to 60,000 miles.
Fluid Specifications
Engine Oil Type:
API CJ-4 or CK-4 rated diesel engine oil, with specific viscosity grades (e.g., 15W-40, 10W-30) depending on ambient temperature. Refer to manual for precise specifications.
Coolant Type:
Ethylene glycol-based coolant (e.g., green or orange long-life type), typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
Gear oil, typically GL-4 or GL-5 rated, with specific viscosity (e.g., 75W-90, 80W-90).
Transmission Fluid Automatic:
Dexron-III or equivalent automatic transmission fluid (ATF), or a specialized commercial ATF.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Brake pads/rotors, clutch components (on manual transmissions), suspension bushings, and exhaust system components can be subject to wear due to commercial use.
Diesel Injection Maintenance:
Regular fuel filter replacement and maintenance of the injection pump are crucial for diesel engine longevity and performance.
Hybrid Battery Lifespan:
While not a common 'issue', hybrid battery health and lifespan should be considered for long-term maintenance, as detailed in the manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Fuso Truck and Bus Corporation, a subsidiary of Daimler Truck AG.
Model Evolution
Generation Overview:
The Canter is a long-standing model with numerous generations and updates over its production history, evolving with engine technology and safety features.
Powertrain Advancements:
Progression from mechanical fuel injection to electronic fuel injection, and the introduction of hybrid technology.
Production
Global Presence:
The Mitsubishi Fuso Canter is a globally recognized commercial vehicle, manufactured and sold in numerous markets worldwide.