Mitsubishi Fuso 2002-2004 Service Repair Manual Wiring diagrams

Regular price: $133.00
Sale price: $133.00
Regular price
Unit price: per

🏷️ Basic Information Identification Make: Mitsubishi Fuso Model: FE, FG, FH, FK, FM Series Year: 2002-2004 👋 Introduction Market Position Segment: Light to medium-duty commercial trucks, popular for urban delivery, vocational applications, and small fleet operations. Competitive Analysis Competitors: Competes with Isuzu NPR/NRR, Hino 155/195, Ford F-Series (F-450/F-550 chassis cab variants), and other similar class commercial vehicles. Key Features Durability: Mitsubishi Fuso trucks are known for their robust construction and reliable powertrains, designed for demanding commercial use. Versatility: Available in various GVWRs and wheelbase configurations, allowing for diverse body upfits (box trucks, flatbeds, dump trucks, etc.). Manual Value: Provides essential, detailed information for maintaining and repairing a critical business asset, reducing downtime and operational costs. 📋 Manual Details Coverage Areas Primary Coverage: Maintenance, Repair, Electrical Wiring Diagrams Series Covered: FE, FG, FH, FK, FM Page Count Total Pages: 4655 Manual Type Type: Service Repair Manual with Wiring Diagrams Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul procedures for various Mitsubishi Fuso diesel engines common to these chassis, including but not limited to 4M4, 4D3, 4D3x, 6D1x, 6D1x, 6M6, and 6M6x series. Covers fuel system (injection pumps, injectors, common rail systems), lubrication, cooling, intake and exhaust systems, and engine management. Transmission: Covers manual and automatic transmission systems. Includes removal, installation, disassembly, assembly, inspection, and repair of gears, clutches, bearings, seals, and hydraulic or electronic control systems. Specifics on gear shifting mechanisms and transfer cases for 4WD models (FG series) included. Drivetrain: Includes drive axles, differentials, propeller shafts, universal joints, and wheel hubs. Covers troubleshooting, bearing replacement, seal replacement, and lubrication specifications. Brakes: Comprehensive coverage of hydraulic and air brake systems (depending on model variant). Includes component testing, caliper/wheel cylinder repair, brake pad/shoe replacement, rotor/drum inspection, parking brake systems, and ABS system diagnostics and repair (if equipped). Suspension: Covers front and rear suspension components, including leaf springs, shock absorbers, control arms, ball joints, tie rod ends, and bushings. Includes procedures for alignment, component replacement, and troubleshooting suspension noise and wear. Steering: Details on power steering systems, including hydraulic pump, steering gear/rack, steering linkage, and steering column. Includes leak diagnosis, fluid specifications, and component replacement procedures. Electrical System: Extensive coverage of the vehicle's electrical system, including battery, charging system (alternator, starter), lighting (headlights, taillights, interior), ignition system, instrumentation, sensors, actuators, and body control modules. Includes wiring diagrams for all major circuits. Climate Control: Covers HVAC (Heating, Ventilation, and Air Conditioning) systems, including refrigerant types, compressor operation, condenser, evaporator, blower motor, and control panel diagnostics. Includes troubleshooting leaks and performance issues. Body And Chassis: Includes procedures for body panel removal and installation, door mechanisms, window regulators, locks, mirrors, bumpers, and frame inspection and repair. Covers cab tilting mechanisms (where applicable). Wiring Diagrams: Dedicated section with detailed electrical schematics for engine control, chassis electronics, lighting, instrumentation, HVAC, power windows, door locks, and auxiliary circuits. Organized by system and component for easy troubleshooting. Procedures Included Scheduled Maintenance: Detailed service intervals for oil changes, filter replacements (oil, fuel, air, cabin), coolant flushes, brake inspections, suspension checks, and driveline lubrication, often specified by mileage or time. Troubleshooting: Step-by-step diagnostic guides for common and uncommon problems across all vehicle systems. Includes symptom-based troubleshooting and fault code interpretation (if applicable). Repair And Overhaul: Instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for major mechanical and electrical parts. Replacement: Guides for replacing specific parts such as spark plugs, belts, hoses, gaskets, seals, filters, bulbs, and fluid reservoirs. Adjustment And Calibration: Procedures for adjusting brakes, clutch, headlights, and performing wheel alignments. Calibration procedures for electronic systems may be included. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, advanced electrical diagnostics using wiring diagrams, and chassis component overhauls. Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text within the PDF for quick information retrieval, common in professionally scanned manuals. Print Quality Quality: Variable, but typically professional scans render diagrams and text clearly. Assumed to be good enough for printing. Binding Type Type: N/A (Digital PDF format) Paper Type Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Family Examples: 4M4 Series (e.g., 4M40, 4M41), 4D3 Series (e.g., 4D33, 4D34), 6D1 Series (e.g., 6D16), 6M6 Series (e.g., 6M60). Specific engines vary by model (FE, FG, FH, FK, FM) and GVWR. Displacement Examples Typical Displacements: Common displacements range from approximately 3.9L (4-cylinder) to 7.5L (6-cylinder), depending on the specific engine series and model. Fuel System Type: Typically diesel. Depending on the specific engine and year, can include indirect injection (IDI), direct injection (DI), or common rail direct injection (CRDI). Turbocharging and intercooling are common features for improved performance and efficiency. Performance Figures Horsepower Torque: Horsepower typically ranges from 100 HP...

23 people are viewing this right now

Type: Truck

Vendor:

Sku: 206409

Collections: ALL Trucks

Availability: In stock

Tags: 2002 2003 2004 Canter Models Mitsubishi Mitsubishi Fuso Truck Trucks

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi Fuso

Model:

FE, FG, FH, FK, FM Series

Year:

2002-2004

👋 Introduction

Market Position

Segment:

Light to medium-duty commercial trucks, popular for urban delivery, vocational applications, and small fleet operations.

Competitive Analysis

Competitors:

Competes with Isuzu NPR/NRR, Hino 155/195, Ford F-Series (F-450/F-550 chassis cab variants), and other similar class commercial vehicles.

Key Features

Durability:

Mitsubishi Fuso trucks are known for their robust construction and reliable powertrains, designed for demanding commercial use.

Versatility:

Available in various GVWRs and wheelbase configurations, allowing for diverse body upfits (box trucks, flatbeds, dump trucks, etc.).

Manual Value:

Provides essential, detailed information for maintaining and repairing a critical business asset, reducing downtime and operational costs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Maintenance, Repair, Electrical Wiring Diagrams

Series Covered:

FE, FG, FH, FK, FM

Page Count

Total Pages:

Manual Type

Type:

Service Repair Manual with Wiring Diagrams

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, and overhaul procedures for various Mitsubishi Fuso diesel engines common to these chassis, including but not limited to 4M4, 4D3, 4D3x, 6D1x, 6D1x, 6M6, and 6M6x series. Covers fuel system (injection pumps, injectors, common rail systems), lubrication, cooling, intake and exhaust systems, and engine management.

Transmission:

Covers manual and automatic transmission systems. Includes removal, installation, disassembly, assembly, inspection, and repair of gears, clutches, bearings, seals, and hydraulic or electronic control systems. Specifics on gear shifting mechanisms and transfer cases for 4WD models (FG series) included.

Drivetrain:

Includes drive axles, differentials, propeller shafts, universal joints, and wheel hubs. Covers troubleshooting, bearing replacement, seal replacement, and lubrication specifications.

Brakes:

Comprehensive coverage of hydraulic and air brake systems (depending on model variant). Includes component testing, caliper/wheel cylinder repair, brake pad/shoe replacement, rotor/drum inspection, parking brake systems, and ABS system diagnostics and repair (if equipped).

Suspension:

Covers front and rear suspension components, including leaf springs, shock absorbers, control arms, ball joints, tie rod ends, and bushings. Includes procedures for alignment, component replacement, and troubleshooting suspension noise and wear.

Steering:

Details on power steering systems, including hydraulic pump, steering gear/rack, steering linkage, and steering column. Includes leak diagnosis, fluid specifications, and component replacement procedures.

Electrical System:

Extensive coverage of the vehicle's electrical system, including battery, charging system (alternator, starter), lighting (headlights, taillights, interior), ignition system, instrumentation, sensors, actuators, and body control modules. Includes wiring diagrams for all major circuits.

Climate Control:

Covers HVAC (Heating, Ventilation, and Air Conditioning) systems, including refrigerant types, compressor operation, condenser, evaporator, blower motor, and control panel diagnostics. Includes troubleshooting leaks and performance issues.

Body And Chassis:

Includes procedures for body panel removal and installation, door mechanisms, window regulators, locks, mirrors, bumpers, and frame inspection and repair. Covers cab tilting mechanisms (where applicable).

Wiring Diagrams:

Dedicated section with detailed electrical schematics for engine control, chassis electronics, lighting, instrumentation, HVAC, power windows, door locks, and auxiliary circuits. Organized by system and component for easy troubleshooting.

Procedures Included

Scheduled Maintenance:

Detailed service intervals for oil changes, filter replacements (oil, fuel, air, cabin), coolant flushes, brake inspections, suspension checks, and driveline lubrication, often specified by mileage or time.

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon problems across all vehicle systems. Includes symptom-based troubleshooting and fault code interpretation (if applicable).

Repair And Overhaul:

Instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for major mechanical and electrical parts.

Replacement:

Guides for replacing specific parts such as spark plugs, belts, hoses, gaskets, seals, filters, bulbs, and fluid reservoirs.

Adjustment And Calibration:

Procedures for adjusting brakes, clutch, headlights, and performing wheel alignments. Calibration procedures for electronic systems may be included.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, advanced electrical diagnostics using wiring diagrams, and chassis component overhauls. Suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text within the PDF for quick information retrieval, common in professionally scanned manuals.

Print Quality

Quality:

Variable, but typically professional scans render diagrams and text clearly. Assumed to be good enough for printing.

Binding Type

Type:

N/A (Digital PDF format)

Paper Type

Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Family Examples:

4M4 Series (e.g., 4M40, 4M41), 4D3 Series (e.g., 4D33, 4D34), 6D1 Series (e.g., 6D16), 6M6 Series (e.g., 6M60). Specific engines vary by model (FE, FG, FH, FK, FM) and GVWR.

Displacement Examples

Typical Displacements:

Common displacements range from approximately 3.9L (4-cylinder) to 7.5L (6-cylinder), depending on the specific engine series and model.

Fuel System

Type:

Typically diesel. Depending on the specific engine and year, can include indirect injection (IDI), direct injection (DI), or common rail direct injection (CRDI). Turbocharging and intercooling are common features for improved performance and efficiency.

Performance Figures

Horsepower Torque:

Horsepower typically ranges from 100 HP to over 200 HP, with torque figures from 250 lb-ft to over 500 lb-ft, depending on engine size and tuning. Specific values require consulting the relevant engine section within the manual.

🔧 Transmission

Standard Transmission

Type Examples:

Manual transmissions are common, often 5-speed or 6-speed. Automatic transmissions were also available on certain models or as an option.

Optional Transmission

Type Examples:

Allison automatic transmissions were frequently offered as an option, particularly on heavier duty variants or for specific vocational uses.

Features

4Wd Transfer Case:

FG series models often feature 4WD with a selectable transfer case, requiring specific maintenance and operational knowledge.

📐 Dimensions

Exterior

Configurations:

Highly varied due to custom body builds. Standard cab dimensions, chassis length, width, and height depend on the specific chassis model (FE, FG, FH, FK, FM) and wheelbase chosen by the original upfitter.

Weights

Gvwr:

Gross Vehicle Weight Rating (GVWR) varies significantly, from around 14,000 lbs for lighter FE models to over 30,000 lbs for heavier FM models, dictating legal road use and payload capacity.

🛡️ Safety Features

Ratings

Crash Test:

Commercial trucks of this era typically have different safety testing standards than passenger vehicles. Focus is on structural integrity for payload and operator protection. Specific ratings may not be directly comparable to consumer vehicle crash tests.

Active Features

Anti-lock Braking System (ABS) was available or standard on many models, particularly those equipped with air brakes or for specific market regulations.

Passive Features

Seat Belts:

Standard 3-point seatbelts for driver and passenger.

Cab Structure:

Reinforced cab structure designed to withstand operational stresses and provide occupant protection.

💡 Technology Features

Infotainment

Features:

Basic infotainment systems were typical for this era, usually including an AM/FM radio, CD player, and possibly auxiliary inputs. Advanced navigation or touchscreens were uncommon in standard configurations.

Driver Assistance

Features:

Limited driver assistance technologies. Focus was on mechanical and electrical reliability. Features like cruise control were optional or standard on higher trims.

Connectivity

Features:

Basic connectivity through standard wiring harnesses for lights, signals, and diagnostics. OBD-II (or earlier J1939 for diesel) ports for fault code retrieval would be present.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 3,000-6,000 miles or 250-500 operating hours, depending on operating conditions (severe vs. normal duty). Specific intervals are detailed in the manual for each engine type.

Air Filter:

Check and replace as needed based on operating environment; typically every 15,000-30,000 miles or as indicated by filter restriction sensors/indicators.

Fuel Filter:

Replace every 15,000-30,000 miles or per manufacturer recommendation, critical for diesel engine longevity.

Fluid Specifications

Engine Oil:

Diesel engine oil, typically API CJ-4 or equivalent, with viscosity grades like 15W-40 or 10W-30 depending on ambient temperature. Capacity varies by engine size (e.g., 8-15 quarts).

Coolant:

Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Heavy-duty diesel specific coolant may be required. Capacity varies by engine and radiator size.

Transmission Fluid:

Manual transmissions usually require GL-4 or GL-5 gear oil. Automatic transmissions require specific ATF fluids (e.g., Dexron-III/VI or equivalent for older models, or specific Allison fluids).

Brake Fluid:

DOT 3 or DOT 4 heavy-duty brake fluid for hydraulic systems. Air brake systems use specific air brake fluid or compressor oil, as detailed in the manual.

Known Issues

Diesel Particulate Filter:

For later models or those with aftermarket DPFs, clogging can be an issue if regeneration cycles are incomplete or due to poor fuel quality. (Note: DPFs were less common on these specific early 2000s models but precursor technologies existed).

Egr System:

Exhaust Gas Recirculation (EGR) systems on diesel engines can accumulate carbon deposits, leading to reduced performance or fault codes. Cleaning or replacement of EGR components is a common repair.

Glow Plugs:

Diesel engine starting can be affected by failing glow plugs, especially in colder climates. Testing and replacement are routine maintenance items.

Turbocharger:

Wear and tear on turbochargers, including seal leaks or bearing failure, can occur with high mileage. Proper oil changes and allowing the turbo to spool down are important for longevity.

📚 Vehicle History

Brand Heritage

Origin:

Mitsubishi Fuso is a global brand with a long history in commercial vehicle manufacturing, originating from Japan. Part of Mitsubishi Motors Corporation and later DaimlerChrysler and now Mitsubishi Fuso Truck and Bus Corporation (under Daimler Truck AG).

Model Evolution

Legacy:

The FE, FG, FH, FK, and FM series represent a lineage of reliable and practical work trucks, with continuous evolution in engine technology, safety, and emissions compliance over decades.

Production

Manufacturing:

These models were produced in various global manufacturing facilities, including Japan and North America, to serve diverse market needs.

🏆 Awards & Recognition

Recognitions

Industry Accolades:

Mitsubishi Fuso trucks are generally recognized within the commercial vehicle industry for their reliability, durability, and operational efficiency, making them a common choice for businesses.

Ratings

Customer Satisfaction:

Customer satisfaction is typically high due to the workhorse nature of the vehicles, though specific satisfaction metrics are best found through industry fleet surveys rather than general consumer reviews.

Certifications

Emissions Compliance:

Vehicles from this period comply with the emissions standards in place for their respective model years and sales regions (e.g., EPA standards in the US, Euro III/IV in Europe).