Mitsubishi Fuso Truck FE FG FH FK FM 2008-2011 Service Repair Shop Manual
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🏷️ Basic Information Identification Make: Mitsubishi Fuso Model Line: Fuso FE, FG, FH, FK, FM Model Years Covered: 2008, 2009, 2010, 2011 Codes Chassis Codes Implied: FE, FG, FH, FK, FM Series 👋 Introduction Market Position Target Audience: Independent repair shops, fleet maintenance, owner-operators, DIY mechanics Competitive Analysis Value Proposition: Cost savings on repairs, increased vehicle uptime, comprehensive DIY support Key Features Ease Of Use: Step-by-step instructions, visual aids, organized layout Accessibility: Downloadable for PC, MAC, Tablets, Smartphones Instant Delivery: Instant download upon payment, no shipping costs 📋 Manual Details Coverage Areas General Repair Coverage: Comprehensive Maintenance Coverage: Routine and Scheduled Diagnostic Coverage: Extensive Troubleshooting Guides Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Service Repair Shop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain Systems: Engine (mechanical and electrical), Fuel System, Cooling System, Exhaust System, Ignition System, Emissions Control Drivetrain Systems: Transmission (manual/automatic), Clutch, Drive Axles, Differential, PTO (Power Take-Off) if applicable Chassis Systems: Suspension (front and rear), Steering System, Brakes (hydraulic, air, ABS), Wheels and Tires Electrical Systems: Battery, Charging System, Starting System, Lighting, Instrumentation, Body Electrical, HVAC Electrical Body And Frame: Body Panels, Doors, Windows, Interior Trim, Chassis Frame, Bumpers, Towing Attachments Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks, lubrication, filter replacements, brake adjustments Mechanical Repairs: Engine component overhaul, transmission rebuild, suspension repair, brake caliper replacement, steering box overhaul Electrical Diagnostics: Troubleshooting wiring harnesses, component testing, sensor diagnosis, ECU/ECM related issues Troubleshooting Guides: Step-by-step fault finding procedures with symptom-based diagnostics Wiring Diagrams: Detailed and specific wiring schematics for all vehicle systems Technical Depth Diagnostic Depth: Advanced diagnostics, including OBD-II (On-Board Diagnostics) information and interpretation Repair Depth: Complete rebuild procedures for major components and systems Specification Detail: Precise torque specifications, clearances, tolerances, and diagnostic parameters 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Image Resolution: High resolution for clear diagrams and images Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Families Expected: Likely includes various diesel engines such as 4M50, 4M51, 4D3x series, and potentially others depending on specific chassis codes (FE, FG, FH, FK, FM). Performance Horsepower Torque Range: Varies widely by engine and GVWR, but expect ranges from approximately 125 HP to over 230 HP and corresponding torque figures suitable for commercial duty. Fuel System Fuel Injection Type: Commonly electronically controlled direct injection (Common Rail Diesel Injection - CRDI) for this era. Emission Controls: Exhaust Gas Recirculation (EGR), Diesel Particulate Filter (DPF) may be present depending on configuration and market. Cooling System Cooling Type: Liquid-cooled, typically with a belt-driven fan and a robust radiator system. 🔧 Transmission Standard Transmission Types: Likely manual transmissions (e.g., 5-speed, 6-speed) as standard on many models. Automatic transmissions may be optional on some configurations. Optional Optional Transmission Types: Possible availability of Allison or Mitsubishi proprietary automatic transmissions. Features Transmission Fluid Type: Specific ATF (Automatic Transmission Fluid) or gear oil types will be detailed in the manual, dependent on transmission model. Clutch Type: Typically a single-plate, dry-type clutch for manual transmissions. 📐 Dimensions Exterior Gvwr Range: Varies significantly across FE, FG, FH, FK, FM series, ranging from light-duty (around 11,000 lbs GVWR for FE) to medium-duty (up to 33,000 lbs GVWR for some FM models). Wheelbase Options: Multiple wheelbase options available to suit various body configurations and applications. Weights Curb Weight: Varies by model configuration, chassis, and body type. Payload Capacity: Dependent on GVWR and curb weight, designed for commercial payloads. 🛡️ Safety Features Ratings Crash Test Ratings: Commercial vehicles of this era were often not subjected to the same consumer-focused crash testing as passenger cars. Focus is on structural integrity for payload and driver protection. Active Features Braking Systems: Hydraulic disc brakes (front), drum or disc brakes (rear), with available Anti-lock Braking System (ABS). Lighting: Halogen headlamps, turn signals, brake lights, side marker lights. Passive Features Restraint Systems: Seat belts (three-point for driver and passenger). Airbags were less common in this segment during these years but could be present on higher trims or specific models. 💡 Technology Features Infotainment Audio Systems: Basic AM/FM radio, CD player, or digital media receiver depending on trim level and options. Driver Assistance ABS: Anti-lock Braking System availability on some models. Traction Control: May be available on select configurations, particularly 4x4 FG models. Connectivity Auxiliary Inputs: Possible 12V power outlets, USB or AUX inputs depending on the factory stereo system. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000 to 10,000 miles or 6-12 months, depending on operating conditions and oil type. Specific recommendations will be in the manual. Transmission Service Interval: Variable, often 30,000 to 60,000 miles for fluid and filter changes, with...
Troubleshooting wiring harnesses, component testing, sensor diagnosis, ECU/ECM related issues
Troubleshooting Guides:
Step-by-step fault finding procedures with symptom-based diagnostics
Wiring Diagrams:
Detailed and specific wiring schematics for all vehicle systems
Technical Depth
Diagnostic Depth:
Advanced diagnostics, including OBD-II (On-Board Diagnostics) information and interpretation
Repair Depth:
Complete rebuild procedures for major components and systems
Specification Detail:
Precise torque specifications, clearances, tolerances, and diagnostic parameters
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High resolution for clear diagrams and images
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Families Expected:
Likely includes various diesel engines such as 4M50, 4M51, 4D3x series, and potentially others depending on specific chassis codes (FE, FG, FH, FK, FM).
Performance
Horsepower Torque Range:
Varies widely by engine and GVWR, but expect ranges from approximately 125 HP to over 230 HP and corresponding torque figures suitable for commercial duty.
Fuel System
Fuel Injection Type:
Commonly electronically controlled direct injection (Common Rail Diesel Injection - CRDI) for this era.
Emission Controls:
Exhaust Gas Recirculation (EGR), Diesel Particulate Filter (DPF) may be present depending on configuration and market.
Cooling System
Cooling Type:
Liquid-cooled, typically with a belt-driven fan and a robust radiator system.
🔧 Transmission
Standard
Transmission Types:
Likely manual transmissions (e.g., 5-speed, 6-speed) as standard on many models. Automatic transmissions may be optional on some configurations.
Optional
Optional Transmission Types:
Possible availability of Allison or Mitsubishi proprietary automatic transmissions.
Features
Transmission Fluid Type:
Specific ATF (Automatic Transmission Fluid) or gear oil types will be detailed in the manual, dependent on transmission model.
Clutch Type:
Typically a single-plate, dry-type clutch for manual transmissions.
📐 Dimensions
Exterior
Gvwr Range:
Varies significantly across FE, FG, FH, FK, FM series, ranging from light-duty (around 11,000 lbs GVWR for FE) to medium-duty (up to 33,000 lbs GVWR for some FM models).
Wheelbase Options:
Multiple wheelbase options available to suit various body configurations and applications.
Weights
Curb Weight:
Varies by model configuration, chassis, and body type.
Payload Capacity:
Dependent on GVWR and curb weight, designed for commercial payloads.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Commercial vehicles of this era were often not subjected to the same consumer-focused crash testing as passenger cars. Focus is on structural integrity for payload and driver protection.
Active Features
Braking Systems:
Hydraulic disc brakes (front), drum or disc brakes (rear), with available Anti-lock Braking System (ABS).
Lighting:
Halogen headlamps, turn signals, brake lights, side marker lights.
Passive Features
Restraint Systems:
Seat belts (three-point for driver and passenger). Airbags were less common in this segment during these years but could be present on higher trims or specific models.
💡 Technology Features
Infotainment
Audio Systems:
Basic AM/FM radio, CD player, or digital media receiver depending on trim level and options.
Driver Assistance
ABS:
Anti-lock Braking System availability on some models.
Traction Control:
May be available on select configurations, particularly 4x4 FG models.
Connectivity
Auxiliary Inputs:
Possible 12V power outlets, USB or AUX inputs depending on the factory stereo system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 to 10,000 miles or 6-12 months, depending on operating conditions and oil type. Specific recommendations will be in the manual.
Transmission Service Interval:
Variable, often 30,000 to 60,000 miles for fluid and filter changes, with specific intervals in the manual.
Brake Maintenance:
Inspection at regular intervals, pad/shoe replacement based on wear.
Fluid Specifications
Engine Oil Grade:
Likely API CJ-4 or newer for diesel engines, with specific viscosity grades like 15W-40 or 5W-40 depending on climate. Manual will specify.
Coolant Type:
Heavy-duty OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) coolant, typically red or orange, with a 50/50 mix with distilled water. Specific type will be in manual.
Brake Fluid Type:
DOT 3 or DOT 4 for hydraulic systems. Air brake systems will have different fluid requirements.
Known Issues
Common Wear Items:
Brake components, suspension bushings, clutch (if manual), glow plugs (diesel), EGR valve and DPF (if equipped) for emissions systems.
Electrical Gremlins:
Can occur with aging wiring harnesses and connectors, especially in commercial environments. Manual's wiring diagrams are crucial.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Fuso Truck and Bus Corporation, a subsidiary of Daimler Truck AG.
Model Evolution
Historical Context:
The Fuso FE, FG, FK, and FM series are established lines of light, medium, and heavy-duty commercial trucks known for their durability and reliability in various vocational applications.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with potential assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Mitsubishi Fuso trucks are generally recognized for their robustness and suitability for a wide range of commercial applications. Specific awards for these model years are not typically highlighted in general service manual descriptions.
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