🏷️ Basic Information Identification Make: Mitsubishi Fuso Model: Canter FE FG Series Model Years Covered: 2002, 2003, 2004 Codes Chassis Codes: FE639, FE649, FG639, FG640, FG649 Engine Codes: 4M5 Series, 4D3 Series 👋 Introduction Market Position Segment: Light-duty commercial truck Target User: Fleet owners, independent repair shops, owner-operators, DIY mechanics Competitive Analysis Competitors: Isuzu NPR, Hino 155, Ford F-Series Chassis Cab, Chevrolet Express Cutaway (depending on configuration) Key Features Vehicle Purpose: Versatile platform for various vocational applications (delivery, service, utility, etc.) Manual Value Proposition: Enables efficient repair, maintenance, and troubleshooting, reducing downtime and service costs. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital Download (PDF, ZIP, RAR, EXE) Page Count Page Count: 1559 📖 Manual Coverage Systems Covered Engine Mechanical: 4M5 Series Engine Mechanical, 4D3 Series Engine Mechanical Engine Management: 4M5 Engine Fuel & Engine Control, 4D3 Engine Fuel & Engine Control, 4M5 Electronically Controlled Fuel System, 4D3 Electronically Controlled Fuel System Cooling System: 4M5 Cooling System, 4D3 Cooling System Intake Exhaust: 4M5 Intake & Exhaust, 4D3 Intake & Exhaust Lubrication: 4M5 Lubrication, 4D3 Lubrication Drivetrain Clutch: Clutch System Drivetrain Transmission: Manual Transmission, Automatic Transmission Drivetrain Transfer Case: Transfer Case (if applicable to FG series) Drivetrain Axles: Front Axle, Rear Axle Suspension: Front Suspension, Rear Suspension Brakes: Brake System, Anti-Lock Brake System (ABS), Parking Brake Steering: Steering System Frame Chassis: Frame Construction Body Cabin: Cab Construction and Trim Electrical: Electrical System (Wiring Diagrams, Components) HVAC: Air Conditioning, Heater System Procedures Included Maintenance: Scheduled Maintenance, Fluid Level Checks, Filter Replacements Troubleshooting: Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting Repair Rebuild: Component Removal and Installation, Overhaul Procedures, Specific Component Rebuilding Diagnostics: Engine Diagnostics, Electrical System Diagnostics, ABS Diagnostics Technical Depth Depth: Comprehensive (covering basic maintenance to complete engine rebuilds and electrical system diagnosis) Illustrations: Clear, step-by-step illustrated instructions Precision: Factory level detail, suitable for professional technicians and DIY enthusiasts 📊 Manual Specifications File Format File Type: PDF (primarily), may be bundled as ZIP or RAR Compatibility: Compatible with Windows, Linux, Mac operating systems Accessibility: Requires PDF reader, unzipping software (WinZip/WinRAR) for compressed files Print Quality Printability: Printable on any computer and printer Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) File Size Estimated Size: Up to 4000 MB (variable depending on compression) ⚙️ Engine Specifications Primary Engine Engine Family 1: Mitsubishi 4M5 Series Engine Family 2: Mitsubishi 4D3 Series Performance Engine Type 1: Typically turbocharged, intercooled diesel (4M5 models) Engine Type 2: Typically naturally aspirated or turbocharged diesel (4D3 models) Fuel System Fuel Delivery 1: Direct Injection, Mechanical or Electronic Fuel Injection Fuel Delivery 2: Direct Injection, Mechanical Fuel Injection Technical Details Cylinder Configuration: Inline 4-Cylinder Displacement Range: Approximately 3.9L (4M5) to 4.7L (4D3) 🔧 Transmission Standard Transmission Options: Manual and Automatic transmissions available, depending on specific chassis variant and configuration. Optional Transmission Types: Examples include Mitsubishi's own manual gearboxes and potentially Aisin automatic transmissions. Features Overdrive: Likely equipped with overdrive gears for highway efficiency. 📐 Dimensions Exterior Cab Styles: Standard Cab, Crew Cab (availability may vary by chassis code and market). Weights Gvwr Range: Typical GVWRs range from 11,000 lbs to 14,050 lbs for FE and FG models, but specific configurations can vary. 🛡️ Safety Features Ratings Crash Testing: Commercial vehicles of this era were typically tested to different standards than passenger cars; specific NHTSA or IIHS ratings may not be directly comparable. Active Features Braking System: Hydraulic disc brakes front, drum brakes rear (typical configuration), ABS available. Passive Features Occupant Protection: Seat belts, reinforced cab structure. 💡 Technology Features Infotainment Features: Base level infotainment typically includes AM/FM radio, possibly CD player. Advanced features unlikely for this model year. Driver Assistance ABS: Anti-lock Braking System (ABS) was an available option, especially on heavier duty configurations. Connectivity Features: Minimal to no modern connectivity features (Bluetooth, USB, etc.) expected for this era. 🔧 Maintenance Service Intervals Oil Change: Typically 3,000-5,000 miles or 6 months, depending on operating conditions. Refer to manual for exact interval. Fuel Filter: Intervals vary; typically 15,000-30,000 miles. Consult manual. Air Filter: Inspect regularly, replace as needed or at recommended mileage intervals (e.g., 15,000-30,000 miles). Fluid Specifications Engine Oil: Diesel engine oil, likely API CI-4 or CH-4 specification, viscosity grade 15W-40 common. Manual will specify exact grade and API classification. Coolant: Ethylene glycol based coolant (long-life or conventional, depending on original fill). Manual will specify type and mixture ratio. Transmission Fluid Manual: Gear oil, likely GL-4 or GL-5 specification, viscosity grade 75W-90 or 80W-90. Manual is critical for specification. Transmission Fluid Automatic: Automatic Transmission Fluid (ATF) – specific type (e.g., DEXRON III or equivalent) is crucial. Manual is essential. Brake Fluid: DOT 3 or DOT 4 brake fluid. Manual will specify exact requirement. Known Issues Engine Wear: Common for older diesel engines to experience injector wear,...