Rosa 2014

For Chile
Pub.No.11ELB0003, JANUARY 2014
Pre-Delivery and
Periodic inspection Manual
FUSO ASCENT-ALEJANDRO CANTO

For Chile
Pre-Delivery and
Periodic Inspection Manual
0 GENERAL
FOREWORD PRE-DELIVERY
1
INSPECTION
This manual gives you information about the key
points of Pre-Delivery Inspection and Periodic
Inspection for ROSA New Model.
For more detailed information about stan- PERIODIC INSPECTION

2
dard values, tightening torques etc, please SCHEDULE
refer to related shop manuals.
JANUARY 2014
PERIODIC INSPECTION
Applicable models 3
PROCEDURE
BE
© 2014 Mitsubishi FUSO Truck & Bus Corporation

MANUAL DESCRIPTION
With regards to each item subject in maintenance operation, the symbol marks given in the following table show-
ing operating condition and form of inspection respectively.
Symbol operating condition Symbol of inspection
Inspections in the vehicle Visual inspections
Inspections with the vehicle Inspections by the auditory

lifted up or inside a pit sense
Inspections with feeling or by

Inspections on the ground
test operations
Inspections with driving the Inspections with using a tool

vehicle or tightening
Inspections with
measurement
Cleaning
Lubricating
Replacement

GROUP-0
GENERAL
• INSPECTION AND MAINTENANCE
RECOMMENDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
• PRECAUTIONS BEFORE SERVICE. . . . . . . . . . . . . . . . . . . 0-4
• TIGHTENING TORQUES FOR GENERAL USE BOLTS

AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
• TABLE OF RECOMMENDED GRADE OF LUBRICANT . . . . 0-9

INSPECTION AND MAINTENANCE RECOMMENDATION
INSPECTION AND MAINTENANCE RECOM-

MENDATION
The inspection and maintenance schedule you need to

follow for ensuring lasting safety and satisfaction with
your vehicle includes the following inspections and
maintenance.
1. Pre-operational checks
This is an inspection which should be performed by
drivers.
These pre-operational checks must be performed
everytime before operating your vehicle for the day.
This simple daily inspection will often prove to be
effective in preventing trouble.
Make it a habit to perform these pre-operational
checks as a part of your vehicle operation routine.
These pre-operational checks are detailed in the
“Simple inspection and service” section in the
Owner’s Handbook.
2. New vehicle inspections

During the “run-in” period when various parts are
subject to initial settlement, the vehicle requires spe-
cial inspections which are important for extending
your vehicle’s life. On the two occasions when the
odometer reading has reached 5,000 km (3,000
miles), respectively, see your nearest authorized
MITSUBISHI FUSO distributor or dealer for the new
vehicle inspections.
Z10665
CAUTION
Do not operate your new vehicle beyond the
above distances without having it inspected.
3. Periodic inspection
This periodic inspection is performed on your own
initiative at intervals predetermined by distance trav-
eled (5,000 km / 3,000 miles) or period of use
(months) to ensure driving safety.
Inspections should be performed more frequently if
the vehicle is operated in severe conditions.
Over time, vehicle’s components wear down and

performance deteriorates as the vehicle is oper- Z01367
ated. To maintain a vehicle’s maximum performance
and ensure long term safety, therefore, you must
compensate for wear and reduced performance by
performing inspections and having servicing carried
out at regular intervals even after the lapse of the
“new vehicle inspection” period.
The periodic inspection intervals and items are indi-
cated in the “Periodic inspection schedule” section of
this manual.
0-2
INSPECTION AND MAINTENANCE RECOMMENDATION
4. Parts requiring regular replacement

Of various parts constituting the vehicle, those made
of rubber or similar material are liable to deteriorate
over time, but it is difficult to visually detect their
deterioration through ordinary periodic inspections.
Mitsubishi gives a list of important parts which they
recommend to be replaced at regular intervals for
safety. For the replacement intervals of these parts,
refer to the “Periodic inspection schedule” section of
this manual.
Always have these designated parts replaced as a
safe measure by your nearest authorized MITSUBI-
SHI FUSO distributor or dealer.
0-3
PRECAUTIONS BEFORE SERVICE

1. If there is a likelihood of damaging or smearing
painted parts or interior parts during service opera-
tion, it is necessary to protect them with suitable cov-
ers (such as seat covers, etc.).
2. Service operations should be performed on a level

ground whenever possible and make sure that the
wheels are blocked.
3. When the vehicles is raised on a jack, use a rigid

rack for the sake of safety.
4. Use special tools for disassembly and reassembly

operations.
5. Bolts and nuts should be tightened to specified

torques.
6. When no standard torque is specified, bolts and nuts

should be tightened in accordance with the TIGHT-
ENING TORQUES FOR GENERAL USE BOLTS
AND NUTS.
7. When disassembling an assembly comprising many

parts, similar parts, or those parts which are identical
for the right and left sides, place them separately so
that they will not become mixed with other parts at
the time of reassembly.
8. Before cleaning parts to be removed or disassem-

bled, carefully check the parts for oil leakage, etc.
0-4
9. If oil seals, gaskets, packings, O-rings, split pins, etc.

are disassembled, they should be replaced at the
time of reassembly.
10.Always use only MITSUBISHI FUSO/MITSUBISHI

MOTORS genuine parts as replacements both to
ensure safety and to obtain maximum performance
from your vehicle.
MITSUBISHI genuine parts are identical to the parts
used during the production of your vehicle. All parts Z10153
undergo the most stringent quality control and their
quality is guaranteed by Mitsubishi.
All MITSUBISHI FUSO/MITSUBISHI MOTORS
genuine parts are identified by the mark shown.
They are available from your nearest authorized
MITSUBISHI FUSO distributor or dealer.
11. When servicing the electrical system, disconnect the

cable from the negative terminal of the battery.
0-5
TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS

1. Use specified bolts and nuts and tighten them with applicable torques according to the following table, unless
otherwise specified.
2. Threads and contact seats shall be dry.
3. Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified
for the bolt shall apply.
Hex-head Bolts and Stud Bolt (Unit: N·m {kgf·m})
Strength 4T 7T 8T
Identification
symbol
Nominal
diameter (Stud) (Stud) (Stud) 02154
2 to 3 4 to 6 5 to 7
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
{0.5 to 0.7}
–
4 to 6 7 to 10 8 to 12
M6 {0.4 to 0.6}
–
{0.7 to 1.0}
–
{0.8 to 1.2}
–
9 to 13 16 to 24 19 to 28
M8 {0.9 to 1.3}
–
{1.7 to 2.5}
–
{2.0 to 2.9}
–
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10 {1.8 to 2.7} {1.8 to 2.6} {3.5 to 5.1} {3.3 to 4.9} {4.5 to 6.0} {3.8 to 5.7}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12 {3.4 to 5.1} {3.1 to 4.6} {7.0 to 9.5} {6.5 to 8.5} {8.5 to 11} {7.5 to 10}
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
M14 {6.0 to 8.0} {5.5 to 7.5} {11 to 15} {11 to 14} {13 to 17} {12 to 16}
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16 {9 to 12} {9 to 11} {17 to 23} {16 to 21} {20 to 27} {19 to 25}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18 {14 to 18} {12 to 16} {25 to 33} {23 to 30} {30 to 39} {26 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20 {19 to 25} {17 to 22} {35 to 47} {32 to 42} {41 to 55} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22 {25 to 33} {23 to 30} {47 to 63} {43 to 57} {55 to 73} {50 to 67}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24 {33 to 44} {29 to 39} {62 to 83} {55 to 73} {72 to 96} {63 to 85}
Hex-head Flange Bolt (Unit: N·m {kgf·m})
Strength 4T 7T 8T
Identification
symbol
Nominal
diameter 02154
4 to 6 8 to 12 10 to 14
M6 {0.4 to 0.6}
–
{0.8 to 1.2}
–
{1.0 to 1.4}
–
10 to 15 19 to 28 22 to 33
M8 {1.0 to 1.5}
–
{2.0 to 2.9}
–
{2.3 to 3.3}
–
21 to 31 20 to 29 45 to 55 37 to 54 50 to 65 50 to 60
M10 {2.1 to 3.1} {2.0 to 3.0} {4.5 to 5.5} {3.8 to 5.6} {5.0 to 6.5} {5.0 to 6.5}
38 to 56 35 to 51 80 to 105 70 to 95 90 to 120 85 to 110
M12 {3.8 to 5.5} {3.5 to 5.2} {8.0 to 10.5} {7.5 to 9.5} {9 to 12} {8.5 to 11}
0-6
Hex-head Nut (Unit: N·m {kgf·m})
Strength 4T 6T
Identification
symbol
02155
Nominal Standard screw Coarse screw
Standard screw thread Coarse screw thread
diameter thread thread
2 to 3 4 to 6
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
4 to 6 7 to 10
M6 {0.4 to 0.6}
–
{0.7 to 1.0}
–
9 to 13 16 to 24
M8 {0.9 to 1.3}
–
{1.7 to 2.5}
–
18 to 27 17 to 25 34 to 50 32 to 48
M10 {1.8 to 2.7} {1.8 to 2.6} {3.5 to 5.1} {3.3 to 4.9}
34 to 50 31 to 45 70 to 90 65 to 85
M12 {3.4 to 5.1} {3.1 to 4.6} {7.0 to 9.5} {6.5 to 8.5}
60 to 80 55 to 75 110 to 150 100 to 140
M14 {6.0 to 8.0} {5.5 to 7.5} {11 to 15} {11 to 14}
90 to 120 90 to 110 170 to 220 160 to 210
M16 {9 to 12} {9 to 11} {17 to 23} {16 to 21}
130 to 170 120 to 150 250 to 330 220 to 290
M18 {14 to 18} {12 to 16} {25 to 33} {23 to 30}
180 to 240 170 to 220 340 to 460 310 to 410
M20 {19 to 25} {17 to 22} {35 to 47} {32 to 42}
250 to 330 230 to 300 460 to 620 420 to 560
M22 {25 to 33} {23 to 30} {47 to 63} {43 to 57}
320 to 430 290 to 380 600 to 810 540 to 720
M24 {33 to 44} {29 to 39} {62 to 83} {55 to 73}
Hex-head Flange Nut (Unit: N·m {kgf·m})
Strength 4T
Identification
symbol
02155
Nominal Standard screw Coarse screw
diameter thread thread
4 to 6
M6 {0.4 to 0.6}
–
10 to 15
M8 {1.0 to 1.5}
–
21 to 31 20 to 29
M10 {2.1 to 3.1} {2.0 to 3.0}
38 to 56 35 to 51
M12 {3.8 to 5.6} {3.5 to 5.2}
0-7
Tightening torque for flare nut for general purpose (Unit: N·m {kgf·m})
Pipe diameter φ4.76 mm φ6.35mm φ8 mm φ10 mm φ12 mm φ15 mm

Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10.0}
Tightening torque for air piping nylon tube for general purpose (DIN Type) (Unit: N·m {kgf·m})
Standard diameter 6 × 1 mm 10 × 1.25 mm 12 × 1.5 mm 15 × 1.5 mm
Tightening torque +5.9 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
20 0 {2.0 0 } 34 0 {3.5 0 } 49 0 {5.0 0 } 54 0 {5.5 0 }
Tightening torque for air piping nylon tube for general purpose (SAE Type) (Unit: N·m {kgf·m})
Standard diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.
Tightening torque +4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
13 0 {1.3 0 } 29 0 {3.0 0 } 49 0 {5.0 0 } 64 0 {6.5 0 }
0-8
TABLE OF RECOMMENDED GRADE OF LUBRICANT
The use of proper oil, grease and hydraulic fluid is imperative to obtain the maximum performance that was built into
your vehicle. Use only lubricants and hydraulic fluids that conform to the standards and grades of our recommenda-
tion as shown below.
TABLE OF RECOMMENDED GRADE OF LUBRICANT
Viscosity
Parts Category Classification
Atmospheric SAE viscosity
Engine Engine oil API CD, CD/SF, CE, Below 0°C 10W-30
CE/SF, CF-4 or JASO
DH-1 –15 to 15°C 20W-20
–5 to 40°C 30
Above 30°C 40
Automatic transmission Automatic DEXRON III type – –
transmission fluid
Transmission, Gear oil API GL-3 General 80
Steering gear box*1 Warm region 90
API GL-4 General 80
– 90
Engine oil API CC Long period of high-speed 30 or 40
driving
Differential gear*2 Gear oil API GL-5 Below 40°C 90
Above 40°C 140
Power steering Automatic DEXRON, DEXRON II – –
transmission fluid or DEXRON III type
Brake, clutch Brake fluid SAE J1703F, – –
FMVSS No.116
(Grade DOT 3)
Drag link, Chassis grease NLGI No.1 – –
kingpin bearing, tie rod, (Li soap)
door hinge
Wheel hub bearing, Wheel bearing grease NLGI No.2 (Li soap) – –
propeller shaft (multipurpose type
(universal joint slip grease)
joint), Steering shaft
Propeller shaft center Bearing grease NLGI No.3 (Li soap) – –
bearing
*1: Use GL-3 or GL-4 SAE90.

*2: At ambient temperatures higher than 10°C, use an oil conforming to SAE140 if the vehicle is used under such a
heavy load conditions as continuous upgrade climbing.
0-9
GROUP-1
PRE-DELIVERY
INSPECTION
• NOTES CONCERNING ENTRIES. . . . . . . . . . . . . . . . . . . . . 1-2
• PRE-DELIVERY INSPECTION SHEET
• PRE-DELIVERY INSPECTION PROCEDURE . . . . . . . . . . . 1-3

NOTES CONCERING ENTRIES
NOTES CONCERNING ENTRIES
1. The column for model, chassis number, engine number, aggregate travelled distance (in kilometers or miles),
inspection date and the inspector’s name must be filled.
2. The column for place of inspection, name of owner, and key number should be filled upon necessity.
3. Symbols for entries:

. . . . . . . . . . . . . . . . . . . . . . . Good
A ..................... Requires adjustment
C ..................... Requires cleaning
T ..................... Requires retightening
L ..................... Requires replenishment of lubricant, water, etc.
X ..................... Requires replacement
..................... Requires repair
. . . . . . . . . . . . . . . . . . . . . Servicing completed
If any malfunction or other problem is detected during the inspection, it must be indicated by entering the appro-
priate symbol (shown above) in the column Remedy of the problem is to be indicated by circling that symbol.
(Example)
Coolant level found too low
Radiator coolant level inspection . . . . . . . . . . . . . . . . . . .
↓
Put symbol “L”
↓
After adding coolant, circle symbol “L” like L .
4. In the space “Remarks”, enter the kind of servicing (such as repairs and adjustments) required as a result of
inspections, name of part replaced and other special matters.
1-2
PRE-DELIVERY INSPECTION SHEET
Good
Model
A Requires adjustment
C Requires cleaning
Chassis number
T Requires retightening
L Requires replenishment of lubricant, water, etc
Engine number
X Requires replacement
Requires repair
Distance travelled km
Servicing completed
miles
If any malfunction or other problem is detected during the

Owner
inspection, it must be indicated by entering the appropri-
ate symbol (shown above) in the column Remedy of the
Date of inspection problem is to be indicated by circling that symbol.
(Example)
Place of inspection Radiator coolant
level inspection . . . . . . Coolant level found too low
Inspector ↓
Put symbol “L”
Engine key number ↓
After adding coolant,
circle symbol “L” like L .
1. Exterior 19. Engine starting performance 36. Propeller shaft flange yoke bolts
2. Operation of lamps and switches 20. Operation of accelerator linkage tightness
3. Vehicle attitude (inclination) 21. Exhaust gas condition and noise 37. Differential carrier attaching bolts
4. Interior 22. Brake pedal play and clearance tightness
5. Reflection of mirrors 23. Clutch pedal play 38. Body mounting bolts and nuts
tightness
6. Operation of windshield wiper and 24. Steering wheel play
washer 39. Front and rear wheel nuts tight-
25. Engine stopping performance
ness
7. Operation of other electrical 26. Electrical wiring connection and
equipment (horn, heater, etc.) 40. Tire pressures (including spare
routing
tire)
8. Operation of door, lock and win- 27. Brake reservoir tank fluid level
dow 41. Transmission operation
28. Fuel leaks from fuel tank
9. Operation of lid 42. Steering operation
29. Fluid leaks from shock absorber
10. Washer tank fluid level 43. Clutch operation
30. Engine oil leaks from oil pan and
11. Radiator coolant level 44. Service brake operation
oil cooler
12. Radiator hoses and clamps 45. Exhaust brake operation
31. Transmission operation
13. Engine oil level 46. Parking brake operation
32. Fluid leaks from clutch and brake
14. Power steering fluid level fluid line 47. Noise
15. Fuel leaks from fuel system 33. Installed condition of exhaust pipe 48. Gauge function
16. Installed condition of electrical and muffler 49. Jack and tool set
equipments 34. Oil level in steering gear box, 50. Installation of license plates
17. Exhaust manifold tightness transmission and axle housing 51. Diagnosis codes
18. Coolant, gas and oil leaks from 35. Suspension shackle pin lock bolts 52. Vehicle washing
cylinder head and rocker case and U-bolt nuts tightnees

PRE-DELIVERY INSPECTION PROCEDURE

1. EXTERIOR
Check distortion and damage of body panels.

Check painting, rusting and flaws of body pan-
els.
Check all door and other parts for proper spac-
ing at top and bottom, front and rear, in and out.
Check that all windows and mirrors are installed
properly.
Check for secureness of the cab mounting.
2. OPERATION OF LAMPS AND SWITCHES
Check operation of all lamp and switches.

Head lamp
Front combination lamp
Fog lamp
Front side turn lamp
Stop/tail lamp
Rear turn signal lamp
Backup lamp
License plate lamp
Step lamp
Room lamp (incandescent)
3. VEHICLE ATTITUDE (INCLINATION)
At the front and rear of vehicle, check for right-

ward and leftward inclination.
Rightward inclination
measured at the vehicle 20 mm or less
front outside
Leftward inclination
measured at the vehicle 15 mm or less
front outside
1-3
4. INTERIOR
Check that seats, interior trims and head lining

are installed properly.
Check that seats, interior trims and head lining
are not damaged and dirty.
Check painting, rusting and flaws.
Check for drip and seepage of adhesive.
5. REFLECTION OF MIRRORS
Check the mirrors for reflection and stain.
6. OPERATION OF WINDSHIELD WIPER AND

WASHER
Check operation of the wiper in all ranges [High,

Low, Int].
Check the wiper blade-stop position.
Check the washer for operation and the nozzle
for clogging
7. OPERATION OF OTHER ELECTRICAL

EQUIPMENTS (HORN, HEATER, ETC.)
Check operation of the horn, heater, defroster,

air conditioner and other electrical equipments.
1-4
8. OPERATION OF DOOR, LOCK AND WIN-

DOWS
Check that the doors can be easily opened and

closed securely.
Check operation of the door lock from both
inside and outside the vehicle.
Check the windows for smooth operation and
tight fit against weatherstrip.
Switch lever
1-5
9. OPERATION OF LID
Check that the lids can be easily opened and

closed securely.
10. WASHER TANK FLUID LEVEL
Check the washer fluid level.

If the fluid level has dropped to the bottom of the
washer tank, add washer fluid.
Open windshield washer tank cap and pour in a
mixture of windshield washer fluid and tap water
until the level nears the top of the tank.
11. RADIATOR COOLANT LEVEL
Check the coolant level in the reservoir tank.

The coolant level should be between the level
lines “FULL” and “LOW”.
If the level is too low, check for coolant leaks.
Check to see if FUSO DIESEL LONG LIFE
COOLANT, FUSO antifreeze or antirust has
been added to the coolant.
12. RADIATOR HOSES AND CLAMPS
Check the connecting conditions of the radiator

hoses and retighten the hose clamps.
13. ENGINE OIL LEVEL
Check that there is sufficient engine oil using the

oil level gauge.
Note: At this time, the vehicle should be located

on level ground in straight ahead position.
1-6
14. POWER STEERING FLUID LEVEL
Check the fluid level on the level gauge. If the

fluid level is within the level gauge in the illustra-
tion, it is normal.
Note: When the check is made, the front wheels

should be placed in straight ahead posi-
tion.
1-7
15. FUEL LEAKS FROM FUEL SYSTEM
Check the fuel system for leakage.

Fuel feed pump*, Fuel filter, Injection pump, Injection nozzle, Piping, Hose, Water separator*, Fuel tank.
* Applicable to vehicles with 4D3-series engines
<4M40>
<4D3>
1-8
Check the fuel system for leakage.

Fuel filter, Supply pump, Common rail, Injector, Piping, Hose, Fuel tank.
<4M42, 4M50> Common rail

Supply pump
Fuel tank
: Supply fuel
Injector : Leak-off fuel
Fuel filter
P100396E
16. INSTALLED CONDITION OF ELECTRICAL

EQUIPMENTS
Check if the starter and alternator are properly

installed.
Check the wiring connections for tightness.
If the wiring harness interferes with other parts,
correct it.
17. EXHAUST MANIFOLD TIGHTNESS
Check if the exhaust manifold is correctly tight-

ened.
If the mounting nuts are loose, tighten them at
specified torque.
1-9
18. COOLANT, GAS AND OIL LEAKS FROM

CYLINDER HEAD AND ROCKER CASE
Check for coolant and gas leaks from the cylin-

der head.
Check for oil leaks from the rocker case.
19. ENGINE STARTING PERFORMANCE
Check to see if the engine starts smoothly.

Check operation of the key switch and starter.
Check the glowing condition of the preheat indi-
cator ( ) vehicle with engine preheat system.
20. OPERATION OF ACCELERATOR LINKAGE
Check the accelerator pedal for sticking, binding

and full return.
21. EXHAUST GAS CONDITION AND NOISE
After the engine has warmed up, check that

black smoke is not emitted at idling, medium and
high speeds.
Check for abnormal engine noise.
1-10
22. BRAKE PEDAL PLAY AND CLEARANCE
With the engine stationary, ensure that the pedal

play conforms to the standard value.
Brake pedal play

10 to 15 mm
(at center of pedal pad)
With the engine idling, depress the brake pedal

with a force of 490 N {50 kgf} and measure the
clearance between the brake pedal and floor.
With anti-lock 40 mm
Clearance between floor brake system or more
and brake pedal (when
depressed with a force of Without
45 mm
490 N {50 kgf}) anti-lock
or more
brake system
Height
06540E
23. CLUTCH PEDAL PLAY
Check clutch pedal play.

Check clutch pedal engagement and disengage-
ment level.
Clutch pedal play
0.1 to 7 mm
24. STEERING WHEEL PLAY
Place the steering wheel in straight ahead posi-

tion and check for the play.
Steering wheel play When
(on the periphery of engine is 0 to 25 mm
steering wheel) turned off
1-11
25. ENGINE STOPPING PERFORMANCE
Turn the starter switch to “ACC” to see if the

engine stops at once.
Flick the emergency engine stop switch to the

“ON” position to see if the engine stops at once.
26. ELECTRICAL WIRING CONNECTIONS AND

ROUTING
Check the battery cable and other electrical wir-

ing connections for tightness.
Visually check the electrical harness routings.
Correct on necessity.
Z22627
27. BRAKE RESERVOIR TANK FLUID LEVEL
Check the fluid level in the reservoir tank. The

fluid level should be between the level lines
“MAX” or “H” and “MIN” or “L”. If the level is too
low, check for fluid leaks.
28. FUEL LEAKS FROM FUEL TANK
Check for fuel leaks from the drain plug of the

fuel tank, the pipe connections and the seam.
1-12
29. FLUID LEAKS FROM SHOCK ABSORBER
Check the shock absorbers for fluid leaks.
30. ENGINE OIL LEAKS FROM OIL PAN AND

OIL COOLER
Check for oil leaks from the engine oil pan, oil
cooler and oil filter mounting area.
31. TRANSMISSION OPERATION
Check the control linkage for looseness.
1-13
32. FLUID LEAKS FROM CLUTCH AND BRAKE

FLUID LINES
Check the clutch fluid line for leaks.

Check the brake fluid line for leaks and check
the wheel cylinder union bolts for tightness.
Check that the pipes and hoses do not interfere
with other parts.
33. INSTALLED CONDITION OF EXHAUST PIPE

AND MUFFLER
Check the exhaust pipe and muffler installation

and connection for looseness.
1-14
34. OIL LEVEL IN TRANSMISSION AND AXLE

HOUSING
Remove the inspection plug (or filler plug in the

case of steerig gear box) and check the oil level.
(1) Transmission
(2) Axle housing
35. SUSPENSION SHACKLE PIN LOCK BOLTS

AND U-BOLT NUTS TIGHTNESS
Check that the shackle pin lock bolts and U-bolt

nuts are correctly tightened (knock them to
check). If they are loosed, tighten them to speci-
fication.
36. PROPELLER SHAFT FLANGE YOKE BOLTS

TIGHTNESS
Check the flange yoke bolts for tightness (knock

them to check). If they are loosed, tighten them
to specification.
1-15
37. DIFFERENTIAL CARRIER ATTACHING

BOLTS TIGHTNESS
Check the bolts attaching differential carrier to

axle housing for tightness (knock to check). If
they are loosed, tighten them to specification.
38. BODY MOUNTING BOLTS AND NUTS

TIGHTNESS
Check the body mounting bolts and nuts for

tightness (knock them to check).
If they are loosed, tighten them.
39. FRONT AND REAR WHEEL NUTS TIGHT-

NESS
Check front and rear wheel nuts for tightness

(knock them to check).
If they are loosed, tighten them to specification.
40. TIRE PRESSURES

(INCLUDING SPARE TIRE)
Check the tire pressures while the tires are cold.

If there are metal pieces, stones and other for-
eign objects caught in the tread grooves, remove
them.
Check that the spare tire is installed properly.
41. TRANSMISSION OPERATION
Check the operation of transmission and gear-

shift lever in all ranges.
1-16
42. STEERING OPERATION
Check the steering wheel for smooth operation,

stability and returnability.
43. CLUTCH OPERATION
Check the operation of clutch in all driving

ranges.
44. SERVICE BRAKE OPERATION
Check that brake operation is smooth and posi-

tive.
45. EXHAUST BRAKE OPERATION
Check operation of exhaust brake by operating

the exhaust brake switch.
How to check
(1) Run the vehicle and turn on the exhaust
brake switch.
(2) Release your foot from the accelerator pedal.
(Do not depress the clutch pedal.)
(3) The indicator lamp lights and the exhaust
brake comes into operation.
Note:If the gear shift lever is placed at neutral

position, the exhaust brake will not
operate.
46. PARKING BRAKE OPERATION
Check parking brake ratchet bar stroke and

braking effect, returning condition and
warning lamp condition.
Parking brake ratchet bar

80 to 120 mm
stroke
1-17
47. NOISE
Check for noise in each of the brakes, clutch,

engine, transmission, steering system, propeller
shaft, differential and others.
48. GAUGES FUNCTION
Inspect that all gauges are functioning properly.
Speedometer, Tachometer, Fuel gauge, Water

temperature gauge, etc.
Tachometer
Warning lamp, indicator lamp
Water temperature gauge
Fuel gauge
Trip knob
Speedometer
49. JACK AND TOOL SET
Verify that the jack and tool sets are on the vehi-
cle.
Tool bag
Spanner (10 × 12)
Spanner (14 × 17)
Screw driver
Socket wrench (for wheel nuts)
Pliers
Wrench handle (for socket wrench, oil jack)
Oil jack
Wheel chocks (a set)
Crank handle
1-18
50. INSTALLATION OF LICENSE PLATES
Install the license plates.
51. DIAGNOSIS CODES
Use the FUSO Diagnostics or MUT to check

whether a diagnosis code was issued for the rel-
evant system.
If there are any problems, erase the code by
doing an inspection and any necessary repairs.
52. VEHICLE WASHING
Clean the vehicle exterior and interior.
1-19
GROUP-2
PERIODIC
INSPECTION
SCHEDULE

PERIODIC INSPECTION SCHEDULE
In the periodic inspection schedule table that follows, the intervals at which inspection and servicing should be per-
formed are specified in both the distance traveled (odometer reading) and period of use (months). The table also
indicates the parts requiring regular replacement and their replacement periodicity.
Perform periodic inspections according to the tabled schedule.
CAUTION
• Determine the inspection period according to the distance traveled (odometer reading) or period of use
(months), whichever occurs first.
• If the vehicle is operated frequently under strenuous conditions (unpaved roads, coastal areas, deserts,
hilly or mountainous areas, cold areas, etc.), the intervals between inspections should be shortened
accordingly. Items for which shorter inspection and replacement intervals are particularly necessary are
shown in the periodic inspection schedule table.
• The parts replacement intervals have been established on the assumption that the vehicle is driven over a
distance of approximately 5,000 km (3,000 miles) every month. If your vehicle is driven over a monthly
average distance significantly greater than the above distance, shorten the parts replacement intervals
accordingly.
• Periodic inspection of rubber hoses (for brake system, fuel system, etc.) is quite important.
Because they decay, swell, chafe, and crack over time, it is necessary that they be inspected by techni-
cians regularly according to the periodic inspection schedule table and be replaced at regular intervals.
Hoses which are broken or have deteriorated must be replaced.
1. Periodic inspection schedule table

The items that have parenthesized numbers are explained with respect to inspection methods under NOTE at
the end of the table by the descriptions designated by the same numbers.
Symbols used
5: At the first 5,000 km (3,000 miles)
I: Inspect, and correct orreplace as necessary.
C: Clean.
R: Replace or change.
T: Tighten.
L: Lubricate.
•: No inspection is necessary.
When either 100,000 km (60,000 miles) or 20 months is reached, repeat the same inspection cycle beginning
with 5,000 km (3,000 miles) or one month.
x 1,000 km 5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ref.

Intervals: x 1,000 miles 3 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 Remarks
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 page
months
Engine
Engine oil R • R • R • R • R • R • R • R • R • R • R 3-3
Air cleaner element C C C C C C C C R C C C C C C C R C C C C 3-8
Oil filter element R • R • R • R • R • R • R • R • R • R • R 3-10
4M5 engine • • • • R • • • R • • • R • • • R • • • R
Fuel filter vehicles
3-12
element 4D3 engine
• • • • • R • • • • R • • • • R • • • • R
vehicles
Fuel feed pump gauze
filter <4D3 engine vehi- C • • • • C • • • • C • • • • C • • • • C 3-16
cles>
Engine condition I I I I I I I I I I I I I I I I I I I I I 3-16
Manifold bolts, nuts and • • • • • • • • • • T • • • • • • • • • T 3-17
engine support bolts
Valve clearance • • • • • • • • • • A • • • • • • • • • A 3-18
Engine compression
• • • • • • • • • • I • • • • • • • • • I 3-21
pressure
Injection nozzles • • • I • • I • • I • • I • • I • • I • • 3-21
2-2
x 1,000 km 5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ref.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 page
months
Injection timing • • • I • • I • • I • • I • • I • • I • • 3-21
Glow plug <vehicles
with engine preheating • • • • • I • • • • I • • • • I • • • • I 3-23
system>
Turbocharger <vehicles
• • • • • • • • • • I • • • • • • • • • I 3-23
with turbocharger>
4M5 engine
I I I I I I I I I I I I I I I I I I I I I 3-24
vehicles
FAN belt
4D3 engine
vehicles
Coolant I R: Every 50,000 km (30,000 miles) or every 24 months 3-27
Inside
engine com- • R: Every 24 months
Fuel partment
3-32
hose Outside
engine com- • R: Every 48 months
partment
Drive line
Transmission gear oil • • • I • • R • • I • • R • • I • • R • • 3-34
Automatic transmission
R I: Every 10,000 km R: Every 40,000 km 3-35
fliud
Propeller shaft
(universal joint, slip L L L L L L L L L L L L L L L L L L L L L 3-37
joint)
Propeller shaft center
• • • • • • • • • • L • • • • • • • • • L 3-38
bearing
Kingpin bearing L L L L L L L L L L L L L L L L L L L L L 3-38
Rear axle
I • • I • • R • • I • • R • • I • • R • • 3-38
differential gear oil
Front and rear wheel
• • • • • • R • • • • • R • • • • • R • • 3-40
hub bearing grease
Clutch system I I I I I I I I I I I I I I I I I I I I I 3-40
Front wheel bearing • • • I • • I • • I • • I • • I • • I • • 3-41
Rear wheel bearing • • • I • • I • • I • • I • • I • • I • • 3-42
Wheel nuts T T T T T T T T T T T T T T T T T T T T T 3-42
Propeller shaft flange
• • • T • • T • • T • • T • • T • • T • • 3-43
yoke bolts
Propeller shaft center
• • • T • • T • • T • • T • • T • • T • • 3-44
bearing bolts
Propeller shaft center R: Every
bearing <double I • • • • • • • • • I • • • • • • • • • I 150,000 km 3-44
activation type – option> (90,000 miles)
Propeller shaft dynamic R: Every

I • • • • • • • • • I • • • • • • • • • I 150,000 km 3-45
damper <option> (90,000 miles)
Disc wheel • I I I I I I I I I I I I I I I I I I I I 3-45
Tires • I I I I I I I I I I I I I I I I I I I I 3-45
Tire inflation pressure • A A A A A A A A A A A A A A A A A A A A 3-46
Tire rotation • • R • R • R • R • R • R • R • R • R • R 3-47
2-3
x 1,000 km 5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ref.

months 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 page
Steering
R: Every
50,000 km
Power steering fluid • I I I I I I I I I R I I I I I I I I I R (30,000 miles) 3-50
or every
12 months
Steering shaft L L L L L L L L L L L L L L L L L L L L L 3-51
Steering drag link • L L L L L L L L L L L L L L L L L L L L 3-51
Steering wheel • I I I I I I I I I I I I I I I I I I I I 3-52
Steering system I I I I I I I I I I I I I I I I I I I I I 3-53
Front wheel alignment • • • I • • I • • I • • I • • I • • I • • 3-53
Power steering hose • R: Every 24 months 3-54
Brakes
R: Every
25,000 km
Brake fluid I I I I I R I I I I R I I I I R I I I I R (15,000 miles) 3-56
or every
12 months
Service brake system I I I I I I I I I I I I I I I I I I I I I 3-62
Service brake shoe
clearance <except
vehicles with disc
• • • A • • A • • A • • A • • A • • A • • 3-63
brakes or automatic
shoe clearance
adjusters>
Brake drum and lining • • • I • • I • • I • • I • • I • • I • • 3-64
Parking brake I I I I I I I I I I I I I I I I I I I I I 3-65
Vacuum check valve • • • I • • I • • I • • I • • I • • I • • 3-66
Brake hose • R: Every 24 months 3-66
Rubber parts and
• R: Every 12 months 3-66
packing of brake system
Exhaust brake vacuum
chamber
Vacuum hose • R: Every 24 months 3-67
Brake fluid reservoir
tank tube
Suspension
Leaf spring U-bolts • T T T T T T T T T T T T T T T T T T T T 3-70
Leaf springs • I I I I I I I I I I I I I I I I I I I I 3-70
Electric system
Battery I I I I I I I I I I I I I I I I I I I I I 3-72
Lighting system I I I I I I I I I I I I I I I I I I I I I 3-74
Instrument panel I I I I I I I I I I I I I I I I I I I I I 3-75
2-4
x 1,000 km 5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ref.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 page
months
Other chassis parts
Chassis parts
(accelerator link shaft,
accelerator pedal,
transmission control
linkage, gearshift select
• • • • • L • • • • L • • • • L • • • • L 3-77
lever pin, parking brake
ratchet bar, brake pedal
link, wheel brake parts,
door lock, door inside
and outside handles)
Leaks – fuel, oil and
coolant
Bolts securing body and
• • T • T • T • T • T • T • T • T • T • T 3-77
chassis parts
2-5
GROUP-3
PERIODIC
INSPECTION
PROCEDURE
• ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
• DRIVE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
• STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
• BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
• SUSPENSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
• ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

• OTHER CHASSIS PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

ENGINE
1. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
2. AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3. OIL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
4. FUEL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
5. FUEL FEED PUMP GAUZE FILTER <4D3 ENGINE VEHICLES> . . . . . . . . . . . 3-16
6. ENGINE CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
7. MANIFOLD BOLTS, NUTS AND ENGINE SUPPORT BOLTS. . . . . . . . . . . . . . 3-17
8. VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
9. ENGINE COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
10. INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
11. INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
12. GLOW PLUG <VEHICLES WITH ENGINE PREHEATING SYSTEM> . . . . . . . 3-23
13. TURBOCHARGER <VEHICLES WITH TURBOCHARGER>. . . . . . . . . . . . . . . 3-23
14. FAN-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
15. COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
16. FUEL HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-2
ENGINE
1. ENGINE OIL
Inspection At the time of pre-operational

intervals check
Replacement
Every 10,000 km (6,000 miles)
intervals
The first engine oil replacement during the run-in

period should be performed at the first 5,000 km
(3,000 miles).
CAUTION
Replace the engine oil earlier if the engine is fre-
quently used at high speeds or under high load-
ing.
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
diagram.
Recommended lubricant:
Engine oil
Viscosity 00733
Classification Atmospheric SAE viscosity
temperature number
Below 0°C 10W–30
API CD, CD/SF, CE, –15 – 15°C 20W–20
CE/SF, CF-4 or JASO
classification DH-1 –5 – 40°C 30
Above 30°C 40
CAUTION
Engine oil with an API classification of CC can-
not be used. Be sure to use engine oil with a
classification of CD or higher.
Quantity required:
Oil pan Oil filter

Approx. 8 Approx. 1 liter
3-3
ENGINE
CAUTION
• Conduct inspections on level surfaces with
the engine stopped. Engine oil level cannot
be measured accurately if the vehicle is tilted,
or if the engine is running or has just been
turned off. Wait at least 30 minutes after stop-
ping the engine to inspect.
• On a 4M5 engine vehicle, be sure to do the
following before inspecting the engine oil
level: Warm up the engine until the needle of
the water temperature gauge moves up and
then wait for at least 30 minutes. Failure to do
this will lead you into determining an oil level
lower than the true level.
Note: If you check engine oil level immediately after

the engine has been stopped, all the oil that
has traveled to each engine part still has not
dropped into the oil pan, and the oil quantity
will appear to be less than it actually is.
CHECKING BY USE OF OIL LEVEL GAUGE
<4D3 engine vehicles>

1. Pull out the oil level gauge and wipe oil from it.
2. Insert oil level gauge again, then slowly pull it
out.
3. If the oil on the gauge is in the range illustrated,
the oil level is adequate.
If inadequate, replenish with prescribed oil.
Also, if the engine oil is dirty, replace it.
4. After inspection, insert the oil level gauge all the
way in to return it. 75651
76514
3-4
ENGINE
<4M5 engine vehicles>

1. Pull out the oil level gauge and wipe oil from it.
2. Insert oil level gauge again, then slowly pull it
out.
3. If the oil on the gauge is in the range illustrated,
the oil level is adequate.
If inadequate, replenish with prescribed oil.
Also, if the engine oil is dirty, replace it.
4. After inspection, insert the oil level gauge all the
way in to return it. T76568
76514
Adding oil
1. Clean the area around oil filler cap to prevent
dust and dirt from entering the engine.
2. Remove the oil filler cap and add oil as neces-
sary.
3. Make sure that the oil level is correct. If the oil
level is checked immediately after adding, the
reading may be lower than the actual level
because all added oil may have not yet reached
the oil pan. Wait for at least 5 minutes after add-
ing oil.
4. Install the oil filler cap.
CAUTION
The added oil should be of the same grade and
viscosity as the oil originally placed in the
engine.
WARNING
Take care not to spill engine oil as engine oil
on the exhaust manifold or other hot sections
of engine could catch fire. Wipe clean the oil
if spilt.
3-5
ENGINE
ENGINE OIL REPLACEMENT
WARNING
• Oil can be very hot after the engine has
been run. When draining oil, be careful to
avoid getting burnt.
• Be careful not to spill engine oil when
replenishing it. If oil gets on the exhaust
manifold or other components, the heat
could cause a fire. If you should spill oil,
wipe it off thoroughly.
<4D3 engine vehicles>

1. Before supplying oil, clean around the oil filler
cap so that dirt will not get inside, then remove
the cap.
2. Remove the oil pan drain plug and replace the
oil filter. Then drain the oil.
76842
Note: If the oil is replaced while it is still slightly

warm after the engine has been stopped, it
will drain out quickly. Be careful to avoid
burns.
3. Install the drain plug with a new gasket . The

side indicated on the figure of the gasket must
be faced toward the oil pan .
Drain plug tightening 34 to 39 Nm

01205
torque (3.5 to 4.0 kgfm)
4. Carefully pour fresh engine oil through the oil

filler.
5. Wait at least 5 minutes, then check with the oil
level gauge.
6. Let the engine idle until oil can seep throughout,
then stop the engine, wait for at least 30 minutes
and check the oil level again. Also, inspect to
see if there is any oil leakage.
7. Confirm that the drain plug, oil filler cap and oil Z10402
level gauge have all been properly reinstalled
after oil replacement.
CAUTION
Be careful not to put in too much engine oil.
3-6
ENGINE

1. Before supplying oil, clean around the oil filler
cap so that dirt will not get inside, then remove
the cap.
T76569
2. Remove the oil pan drain plug and replace the

oil filter. Then drain the oil.
Note: If the oil is replaced while it is still slightly

warm after the engine has been stopped, it
will drain out quickly. Be careful to avoid
burns.
T76647
3. Install the drain plug with a new gasket . The

side indicated on the figure of the gasket must
be faced toward the oil pan .
Tightening torque 39 Nm (4.0 kgfm)
4. Carefully pour fresh engine oil through the oil

filler.
5. Wait at least 10 minutes, then check with the oil
level gauge. Z10402
6. Let the engine idle until oil can seep throughout,

then stop the engine, wait for at least 30 minutes
and check the oil level again. Also, inspect to
see if there is any oil leakage.
7. Confirm that the drain plug, oil filler cap and oil
level gauge have all been properly reinstalled
after oil replacement.
CAUTION
• Be careful not to put in too much engine oil.
• 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.
3-7
ENGINE
2. AIR CLEANER ELEMENT
Every 5,000 km (3,000 miles),

Cleaning intervals
NVI: 5,000 km (3,000 miles)
Replacement
intervals
WARNING
When cleaning air cleaner element, wear gog-
gles and a mask to protect your eyes and res-
piratory organs from dust.
And, use a dust collector to prevent dust from
dispersing into the surroundings.
CAUTION
Clean the air filter at the specified cleaning
intervals. Unnecessary frequent cleaning can
damage the element, allowing dust and other
foreign matter to be drawn into the engine.
Note: Even if the cleaning interval has not elapsed,

clean or replace the element if clogging of the
element causes a drop in engine output.
The air cleaner is located in the illustrated position.
For vehicle without turbo-charged engine <LHD>
For vehicle with turbo-charged engine
Forward
75886
<RHD>
Forward
76104
3-8
ENGINE
1. Undo the three clamps and remove the cover

.
2. Pull element straight down to remove.
Z10772
3. From the inside of the element, blow com-

pressed air evenly up and down along the pleats
of the filter paper.
CAUTION
• Keep the air pressure under 700 kPa
(7 kg/cm2).
• Do not strike the element or hit it against
another object. Z10773
• If the element is contaminated with oily soot
or dust, replace it regardless of the scheduled
replacement time.
4. Place a light in the element and check the filter

paper for damage or places where it has worn
thin. Also check the packing for damage.
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 MITSUBISHI genuine filter element for
replacement. Z10774
7. Install the element by reversing the order of
removal. Be sure to align match marks on the
case and cover.
CAUTION
Install the element correctly.
If the packing is broken or the clamp is loose,
the engine will suck in dust and premature pis-
ton and cylinder liner wear could result.
3-9
ENGINE
3. OIL FILTER ELEMENT
Replacement intervals
NVI: 5,000 km (3,000 miles)
CAUTION
• Oil filter element must not be cleaned and
reused. Always replace the filter element with
a new one.
• Replace the oil filter element simultaneously
with engine oil change.
WARNING
• Spilt engine oil should be wiped off clean.
Oil remaining on the engine surface could
catch fire.
• The engine is extremely hot immediately
after the vehicle has been driven. If you try
to replace the oil filter immediately after
driving the vehicle, you may be scalded.
Give the engine time to cool before starting
the job.
• When replacing the element, you will be
working in a tight space. Be careful not to
injure yourself on the edges of nearby
components.
Replacement (spin on type)
WARNING
Be careful not to spill engine oil when replen-
ishing it. If oil gets on the exhaust manifold or
other components, the heat could cause a
fire. If you should spill oil, wipe it off thor-
oughly.
76366
1. Place an oil pan under the oil filter.
In case of vehicle with the drain plug, remove the
drain plug from the bottom of the oil filter, and
allow the oil in the filter to drain out.
2. Rotate the element assembly and remove it. If
it is tight, use a filter wrench (sold separately) to
easily remove it.
3. Replace element assembly with a new product.
Use MITSUBISHI genuine parts for replace-
ments.
3-10
ENGINE
4. Attach element assembly.

Lightly coat engine oil over the gasket on the
element assembly surface, then gently twist in
reverse direction by hand until the gasket con-
tacts the seal surface of the filter head .
There are four marks equally spaced on the
periphery of element assembly. Twist the ele-
ment as follows with these marks as reference.
Number of turns after seal surface is contacted

3/4 turn
5. Replenish engine oil from the oil filler.

After replacing the element assembly alone with-
out replacing the engine oil, replenish engine oil
from the oil filler as indicated in the table below.
Engine oil replenish quantity

Approx. 1 liter
6. Start the engine and check to be sure there are

no oil leaks.
7. Stop the engine and wait for at least 30 minutes,
then inspect oil level.
CAUTION
Be careful not to tighten the element assembly
too much. If overtightened, the element might
become damaged.
Replacement (element replacement type)

1. Place an oil receiving pan under the drain plug
of the oil filter, remove the drain plug and drain
out engine oil. After oil draining is completed,
attach and tighten the drain plug.
2. Loosen the center bolt and remove filter case
or element , etc.
3. Replace element, gasket , O-ring and wash-
ers with new products.
Use the element kit of MITSUBISHI genuine
parts for replacements.
4. Clean all other components not replaced.
5. Assemble each component to its original posi-
tion.
When attaching gasket and O-ring, lightly coat
them with engine oil so they will not twist.
CAUTION
If you twist and attach components, they might
be damaged. 75420
3-11
ENGINE
6. Attach and tighten center bolt.
39 to 49 Nm
Tightening torque
(4.0 to 5.0 kgfm)
7. Replenish engine oil.

After replacing the element alone without replac-
ing engine oil, replenish about 1 liter of engine oil
from the oil filler.
8. Start engine and inspect for oil leaks.
9. Stop engine and wait for at least 30 minutes,
then inspect oil volume.
4. FUEL FILTER ELEMENT
Replacement interval
Every 25,000 km
4D3 engine vehicles (15,000 miles)
Every 20,000 km
4M5 engine vehicles (12,000 miles)
CAUTION
Fuel filter element must not be cleaned and
reused.
WARNING
Wipe away spilled light oil thoroughly. Also,
always check for fuel leakage since it can
cause fires.
4.1 4D32, 4D33, 4D34T2 and 4D34T4 engine

vehicles
When replacing the fuel filter, open it through the
inspection port at the rear of the engine.
75660
3-12
ENGINE
<Replacement (element replace type)>

1. Place a receptacle beneath the vinyl pipe from
drain cock .
2. Loosen air plug , loosen drain cock and
drain the fuel in the fuel filter; then tighten the air
plug and drain cock.
3. Loosen center bolt , remove filter case and
element .
4. Clean all parts except the element and reassem-
ble.
• Replace O-ring and gasket with new
ones. Make sure that the O-ring is not twisted
when installing.
• Insert center bolt into the filter case
beforehand; then place spring , washer
and the element on the center bolt.
• Insert O-ring in the filter case and tighten
the center bolt in filter head .
Tightening torque: 20 to 29 Nm (2 to 3 kgfm)
5. Operate the fuel pump to feed some fuel. Refer
to page 11-48 for the method for bleeding air
from the fuel system. 75453
6. Wipe off any fuel spilled on the engine.
7. Start the engine and inspect for oil leaks.
CAUTION
If you twist and attach components, they might
be damaged.
<Replacement (spin on type)>

1. Remove the element assembly by turning it
counterclockwise.
2. Replace element assembly with a new product.
Use MITSUBISHI genuine parts for replace-
ments.
3. Lightly coat engine oil over the gasket on the
element assembly, then gently twist the element
clockwise by hand until the gasket contacts the
seal surface on the filter head . Twist further 76028
3/4 to 1 turn from this condition. There are four
marks equally spaced on the periphery of ele-
ment assembly. Twist the element with these
marks as reference.
4. After tightening, bleed out the air.
5. Inspect for fuel leaks.
3-13
ENGINE
CAUTION
Wipe off any spilled light fuel since it can cause
a fire.
4.2 4D34T6 engine vehicles

inspection port .
1. Clean the filter and the surrounding area to pre-

vent dirt from entering the new element.
2. Place a can under the fuel filter to catch fuel.
3. Undo the connector then remove the sensor
from the element assembly .
4. Turn the element assembly in the direction of the
arrow to remove it. If it is hard to turn, use a fil- T76084
ter wrench (available from your nearest MIT-
SUBISHI FUSO distributor or dealer).
5. Check the surface of the filter head that will
make contact with the new element for dirt and
contamination. If necessary, clean it.
6. Replace the element assembly and O-ring
with new ones.
Use the parts included in the MITSUBISHI genu-
ine element kit for replacement.
7. Install the element assembly as follows:
Apply a thin coat of engine oil to the gasket on
the assembly's mounting end. Turn the assem- T76088
bly in the direction of the arrow until the gasket
touches the sealing surface of the filter head.
From this point, tighten the element assembly by
another 3/4 of a turn.
There are four evenly spaced marks around
the periphery of the element assembly. Use
these marks as a guide when tightening the ele-
ment assembly.
8. Install the warning lamp switch on the element
assembly.
2.5 ± 0.5 Nm
Tightening torque
(0.25 ± 0.05 kgfm)
9. Reconnect the connector.

10.Bleed the fuel system.
11. Start the engine to test for fuel leakage.
3-14
ENGINE
4.3 4M5 engine vehicles

inspection port .
1. Clean the filter and the surrounding area to pre-

vent dirt from entering the new element.
2. Place a can under the fuel filter to catch fuel.
3. Disconnect the connector on the sensor .
4. Turn the sensor counterclockwise to loosen it,
and then extract all of the fuel from the filter case
. After the fuel has been extracted, tighten the T76084
sensor by turning it clockwise.
5. Place the sensor and its harness inside the spe-
cial tool (available from an authorized dealer).
6. Remove the filter case using the special tool
(available from an authorized dealer), by turning
it in the direction of the arrow . Drain the fuel
from the filter case.
7. Remove the element and the sensor from the
filter case.
8. Replace the O-ring and O-ring with new
ones. Apply a thin coat of engine oil to each of
the new O-rings and install the O-ring on the
filter case and the O-ring on the sensor. T77148
9. Clean the surfaces of the filter head and fil-

ter case that will come in contact with the O-ring
. The O-ring groove on the filter case should
also be cleaned.
10.Install the element with the hole of its end facing
upward. Be sure to use a genuine replacement
element.
CAUTION
• Use the O-rings that are supplied with the
new replacement element.
• When installing the filter case, be careful not
to let the O-ring twist and be damaged.
• Do not reuse the element.
Z11924
3-15
ENGINE
11. 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.
Tightening torque 30 ± 2 Nm (3 ± 0.2 kgfm)
Z12054
CAUTION
Do not tighten the filter case too strongly. Over-
tightening could damage the filter case.
12.Install the sensor to the filter case and connect

the connector.
Sensor tightening
5 ± 1 Nm (0.5 ± 0.1 kgfm)
torque
13.Bleed the fuel system.

14.Start the engine to test for fuel leakage.
5. FUEL FEED PUMP GAUZE FILTER

<4D3 ENGINE VEHICLES>
Cleaning intervals
NVI: 5,000 km (3,000 miles)
WARNING
Wipe off any spilled fuel. Also be sure to
check for fuel leaks which could cause a fire.
1. Disconnect connector from the suction port of

the fuel feed pump.
2. Remove gauze filter from inside the connec-
tor.
3. Wash the gauze filter in diesel fuel.
4. Install the gauze filter and connect the connector
by reversing the order of removal.
5. Bleed the fuel system.
6. Start the engine and check for fuel leaks.
Connector tightening 25 to 29 Nm Z11294
torque (2.5 to 3 kgfm)
6. ENGINE CONDITION
Inspection intervals
NVI: 5,000 km (3,000 miles)
3-16
ENGINE
ENGINE STARTING PERFORMANCE AND

ABNORMAL NOISE
Check the engine starting performance and

abnormal noise.
Z09197
ENGINE SPEED
After the engine has warmed up, check the

engine idling speed.
Engine idling speed 650 rpm
EXHAUST CONDITION
After the engine has warmed up, verify that

black smoking and any other abnormal exhaust
are not emitted during idling and acceleration.
7. MANIFOLD BOLTS, NUTS AND ENGINE

SUPPORT BOLTS
Tightening intervals
Check that the inlet and exhaust manifold bolts,

nuts and engine support bolts are tightened to
specifications. If not, tighten them to specifica-
tions.
3-17
ENGINE
8. VALVE CLEARANCE
Adjusting intervals
Valve clearances should be checked and adjusted
as follows while the engine is still cold.
<4M50>
[Inspection]
Remove the rocker cover. "I, IV"
Bring the No. 1 or No. 4 cylinder piston to the top Pointer
dead center (TDC) on the compression stroke by
the following procedure:
This will place either the No. 1 or No. 4 cylin-
I IV
der piston at TDC on the compression stroke.
The cylinder in which the rocker arms for
both the intake and exhaust valves can be
pushed down by hand by the valve clearance P69238E
amounts has its piston at TDC. Rotate the
engine by one full turn to switch the TDCs of
the No. 1 and No. 4 cylinder pistons.
With the No. 1 or No. 4 cylinder piston at TDC,

Valve clearance
measure the clearance of the valves marked Thickness
with a circle in the table below. gauge
Cylinder No. 1 2 3 4
Valve IN EX IN EX IN EX IN EX
No. 1 cylinder
piston at TDC on
O O O – – O – –
compression
stroke
P48701E
No. 4 cylinder
piston at TDC on
– – – O O – O O
compression
stroke
The thickness gauge cannot be inserted under

the adjusting screw pad without carrying out the
above step, as the pad will block the thickness
gauge as shown in the illustration.
Thickness
Pad gauge
P30149E
3-18
ENGINE
To insert the thickness gauge under the adjust-

ing screw pad, push the pad at the bottom on Adjusting
one side with a flat-blade screwdriver or a similar screw
tool. Insert the thickness gauge into the small
Pad
space created under the other side of the pad,
as shown in the illustration.
The thickness gauge must have a slight drag
when taking measurements.
If the thickness gauge can be moved without any
resistance, the measurement will be incorrect. Flat-blade screwdriver Thickness gauge
If the measurements are not within the standard P30148E
value range, adjust the value clearance by the
following procedures.
[Adjustment]
Adjust the valve clearance by loosening the lock
nut and rotating the adjusting screw so that the Thickness gauge
thickness gauge can only be moved with a slight Valve clearance
drag. Adjusting
After the adjustment, fold the adjusting screw in screw
place with a screwdriver and tighten the lock nut Lock nut
to the specified torque.
Recheck the valve clearance with the thickness
gauge, and readjust if the measurements are not
within the specified value range.
P48702E
<4D34>
[Inspection]
Remove the rocker cover.
Bring the No. 1 or No. 4 cylinder piston to the top
dead center (TDC) on the compression stroke
according to the following procedure:
Rotate the crankshaft pulley in the illustrated
direction so that the pointer is aligned with
the “0” mark next to the “1 - 4” mark on the
inscribed scale on the crankshaft pulley.
Either one of the two pointers can be used for
this purpose. 49928E
This will place either the No. 1 or No. 4 cylin-
der piston at TDC on the compression stroke.
The cylinder in which the rocker arms for
both the intake and exhaust valves can be
pushed down by hand by the valve clearance
amounts has its piston at TDC. Rotate the
engine by one full turn to switch the TDCs of
the No. 1 and No. 4 cylinder pistons.
3-19
ENGINE
With the No. 1 or No. 4 cylinder piston at TDC,

measure the clearance of the valves marked
with a circle in the table below.
The feeler gauge must have a slight drag when
taking measurements. If the feeler gauge can be
moved without any resistance, the measurement
will be incorrect.
Cylinder No. 1 2 3 4
Valve IN EX IN EX IN EX IN EX
48362E
No. 1 cylinder
piston at TDC
O O O – – O – –
on compres-
sion stroke
No. 4 cylinder
piston at TDC
– – – O O – O O
on compres-
sion stroke
If the measurements are not within the standard

value range, adjust the value clearance via the
following procedures.
[Adjustment]
Adjust the valve clearance by loosening the lock
nut and rotating the adjusting screw so that the
feeler gauge can only be moved with a slight
drag.
After the adjustment, hold the adjusting screw in
position with a screwdriver and tighten the lock
nut to the specified torque.
Recheck the valve clearance with the feeler
gauge, and readjust if the measurements are not
within the specified value range.
48363E
When carrying out valve clearance adjustment

with the engine still mounted on the vehicle, use
to facilitate rotation of the adjusting screw.
06207E
3-20
ENGINE
9. ENGINE COMPRESSION PRESSURE
Check the engine compression pressure using a

compression gauge.
Engine compression pressure
Cracking
Engine Standard
speed Limit
value
2.55 MPa 1.96 MPa
4D3 200 rpm
(26 kgf/cm2) (20 kgf/cm2)
2.55 MPa 1.96 MPa
4M5 200 rpm
(26 kgf/cm2) (20 kgf/cm2)
10. INJECTION NOZZLE
Measure the fuel injection pressure with a nozzle

tester to check for conformance with the stan-
dard value.
Check for proper spray condition, clogged injec-
tion orifices and fuel leakage from the injection
orifices.
11. INJECTION TIMING
<4D3>
[Inspection]
Remove union nut of the injection pipe, lock
plate, delivery valve holder, stopper, delivery
valve spring and delivery valve from the injection
pump of No.1 cylinder.
After removing these parts, install delivery valve
holder.
CAUTION
Be sure to keep all the removed parts in gas oil
to keep them free from dirt.
3-21
ENGINE
Mount an extra injection pipe on No.1 cylinder.

Direct the free end of the pipe downwards so
that fuel discharge can be clearly observed.
Turn the crankshaft more than 180° in the for-
ward running direction and bring No.1 cylinder to
approximately 30° before top dead center in the
compression cycle.
Turn the engine in the forward running direction

slowly while discharging fuel from injection pipe,
deliver fuel using priming pump.
Note: Engine stop lever located on top of the

governor should be at engine start-up
position.
When the discharge of fuel from injection pipe

becomes intermittent, turn the crankshaft slower,
stop turning the crankshaft when the discharge
stops completely.
Make sure that indent on the crankshaft pulley

and pointer on the timing gear case show the
standard fuel injection timing.
49928E
3-22
ENGINE
12. GLOW PLUG <VEHICLES WITH ENGINE

PREHEATING SYSTEM>
If the vehicle has a preheating system, measure
the time required for the engine preheat indicator
lamp to go out to judge if the glow plugs are
functioning properly. If not, remove the glow plug
and clean off the carbon or other deposits.
Coolant temperature Preheat indicator lamp ON time
60°C and higher OFF
17°C Approx. 1.5 sec
–15°C and lower Approx. 4 sec
13. TURBOCHARGER <VEHICLES WITH TUR-

BOCHARGER> Turbocharger
Remove the hose of compressor wheel side and
check the play of the rotor shaft and the rotating
condition of the turbine wheel.
Compresser wheel P100329E
3-23
ENGINE
14. FAN-BELT
Fan-belt inspection intervals

At the time of pre-operational check and every 5,000 km
(3,000 miles)
NVI: 5,000 km (3,000 miles)
An excessively slack or tight belt could cause an

improperly charged battery, malfunction of the alter-
nator or water pump. Always keep belts adjusted to
the proper tension.
WARNING
Be sure to stop the engine before inspecting
the fan belt. If the engine was running and
your hands, clothes, or other items touched
or came into close proximity to the engine’s
rotating parts, they could be dragged into the
mechanism, resulting in injuries.
If you must unavoidably perform an inspec-
tion with the engine running, do not on any
account touch the fan or any other rotating
part.
CAUTION
Prevent the belt from any contact with oil or
grease during check and adjustment.
CHECK
1. Open engine inspection ports (at engine and at

pressure cap).
2. Open the belt inspection panel on the passenger
side (of a left hand drive vehicle) , or driver
side (of a right hand drive vehicle) . Roll back
the carpet flap, loosen the screw on the
inspection lid and remove the inspection lid.
3. Press the belt center with your finger [at a force
of about 98 N (10 kgf)] and inspect the amount
of deflection.
4. Press the belt at the center with your finger. If
the deflection is within the range given in the fol-
lowing table, the belt is at proper tension.
T77128
3-24
ENGINE
Tension per single belt <4D3 engine vehicles>

[Deflection when belt center is pressed at a force of
about 98 N (10 kgf)]
Fan belt 12 to 16 mm
4D3 engine
vehicles Cooler compres- 8 to 11 mm
sor belt
4M5 engine
vehicles Fan belt 10 to 12 mm
<Without
cooler> T77149
9.5 to 11.5
4M5 engine Fan belt mm
vehicles
<With cooler> Cooler compres- 6 to 8 mm
sor belt
5. Inspect the belt for damages.

T76997
3-25
ENGINE
6. Checking Fan-belt condition

If a belt is cracked otherwise damaged, have it replaced it as soon as possible. Belt replacement requires
component disassembly.
Belt condition
Remaining service life (reference)
All except 4M5 engine vehicles 4M50 engine vehicles
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 since
Wrinkled the vehicle was new or since the belt was
No abnormality; replaced (whichever is more recent).
or tiny cracks in tips of ribs
Z14645 Z14706

which the belt can still be used is about half of
that over which the belt has been used since the
Cracked vehicle was new or since the belt was replaced
Cracks extending to (whichever is more recent).
base of ribs
Z14646 Z14707

which the belt can still be used is about a
quarter of that over which the belt has been
Cracks extending to Cracks extending to used since the vehicle was new or since the belt
base rubber base of ribs was replaced (whichever is more recent).
Z14647 Z14708
Cracks extending to cords
Z14648
The belt has reached the end of its service life
and must be replaced.
Piece(s) missing from rib(s)
Z14709
Piece(s) missing from belt
Z14649
3-26
ENGINE
15. COOLANT
At the time of pre-operational

check
Every 50,000 km (30,000
Replacement Intervals
miles) or every 24 months
CAUTION
• Continuing to use the coolant after the speci-
fied replacement period could damage the
engine and cooling system components due
to rusting and other problems. Replace the
coolant at the specified replacement period
intervals.
• When replacing or adding coolant, be sure to
use FUSO DIESEL LONGLIFE COOLANT or
an equivalent. Using any coolant other than
FUSO DIESEL LONGLIFE COOLANT or an
equivalent could cause corrosion and dam-
age to the radiator.
(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-freez-
ing properties, the additive protects the cooling
system all year around.
Replace and top off the coolant only with water
containing FUSO DIESEL LONGLIFE COOL-
ANT or an equivalent.
(2) Water used with coolant

Use soft water with the properties shown in the
following table. Do no use hard water from wells
and rivers as it is liable to form scales and cause
corrosion.
Total hardness 300 ppm or less
Sulfate SO4– 100 ppm or less
Chloride CI– 100 ppm or less

Total dissolved solids 500 ppm or less
pH 6 to 8
3-27
ENGINE
(3) Using FUSO DIESEL LONGLIFE COOLANT

The FUSO DIESEL LONGLIFE COOLANT is an
ethylene glycol base antifreeze (SAE J814-C)
with both antifreeze and anticorrosive properties.
The FUSO DIESEL LONGLIFE COOLANT is
used as a coolant additive by mixing it with soft
water at the specified concentration.
Z09270
DANGER
• FUSO DIESEL LONGLIFE COOLANT IS
TOXIC. IF A PERSON HAS ACCIDENTALLY
SWALLOWED IT, FORCE HIM/HER TO
VOMIT AND CONSULT A DOCTOR IMMEDI-
ATELY. IF IT SPLASHES IN THE EYES,
IMMEDIATELY FLUSH THE EYES WITH
WATER FOR MORE THAN 15 MINUTES,
AND SEEK MEDICAL ATTENTION.
• SHOULD FUSO DIESEL LONGLIFE COOL-
ANT COME IN CONTACT WITH YOUR SKIN,
IMMEDIATELY WIPE IT OFF, AND THEN
THOROUGHLY WASH YOUR SKIN WITH
LOTS OF CLEAN WATER AND SOAP. IF
YOU FEEL UNWELL OR PAIN ON YOUR
SKIN, IMMEDIATELY SEEK MEDICAL
ATTENTION.
IN THE EVENT OF CONTACT WITH YOUR
CLOTHES, IMMEDIATELY FLUSH FUSO
LONGLIFE COOLANT WITH WATER AND
SOAP.
• DO NOT USE FUSO DIESEL LONGLIFE
COOLANT IN A CLOSED OR POORLY VEN-
TILATED SPACE. SHOULD YOU INHALE A
LARGE AMOUNT OF GAS OF FUSO DIE-
SEL LONGLIFE COOLANT, MOVE TO A
PLACE WITH FRESH AIR AND KEEP
YOURSELF WARM AND AT REST. IF YOU
FEEL NAUSEOUS OR OTHERWISE
ABNORMAL, IMMEDIATELY SEEK MEDI-
CAL ATTENTION.
• CLOSE THE CAP OF THE FUSO DIESEL
LONGLIFE COOLANT CONTAINER IMME-
DIATELY AFTER USING THE PRODUCT.
• DO NOT STORE FUSU DIESEL LONGLIFE
COOLANT WHERE CHILDREN COULD
REACH AND ACCIDENTALLY DRINK IT.
• FUSO DIESEL LONGLIFE COOLANT IS
FLAMMABLE; AVOID EXPOSING IT TO
OPEN FLAME.
• WHEN HANDLING FUSO DIESEL
LONGLIFE COOLANT, WEAR AN ORGANIC
GAS MASK, PROTECTION GOGGLES, OIL-
RESISTANT GLOVES, AND/OR PROTEC-
TIVE APRON AS NECESSARY.
3-28
ENGINE
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. If a different long-life coolant has been
used and the FUSO DIESEL LONGLIFE COOL-
ANT is to be used, be sure to thoroughly flush
the cooling system.
Use the following table to determine the correct

concentration of FUSO DIESEL LONGLIFE COOL-
ANT according to the lowest temperature at which
your vehicle is to be operated.
FUSO DIESEL LONGLIFE COOLANT concentra-

tion (in volume percentage)
-10 °C
Lowest -15 -20 -25 -30 -35 -40
or
temperature °C °C °C °C °C °C
higher
35 40 45 50 55 60
Concentration 30%
% % % % % %
Coolant With rear heater Approx. 22 liters

quantity Without rear heater Approx. 18 liters
CAUTION
Use FUSO DIESEL LONGLIFE COOLANT at a
concentration of between 30% and 60%. The
proper concentration under normal tempera-
tures is 30%. At a concentration below 30%, this
additive performs poorly as an anticorrosive,
while at a concentration exceeding 60%, it per-
forms poorly as an antifreeze.
(4) Check
Inspection intervals Pre-operational check
1. Open the front door and inspect through the

inspection window at the step.
2. If the coolant level in the reservoir tank lies
between “FULL” and “LOW”, the coolant volume
is adequate. Inspect before starting the engine
when the water temperature is low. 75889
3. Inspect for leaks from radiator and radiator hose.
If water remains on a surface where the vehicle
was parked, there may be water leakage.
If there is water leakage, consult your nearest
authorized MITSUBISHI FUSO distributor or
dealer.
3-29
ENGINE
CAUTION
Conduct inspection when the water temperature
is low, prior to starting the engine.
Note: Deposition may occur in the reserve tank but

this will not cause any problem.
(5) Adding coolant
1. Remove screw and step plate , then replen-

ish.
2. If the volume is lower than “LOW”, remove the
reservoir tank cap and replenish a mixture of
longlife coolant and soft water until the level
reaches “FULL”.
3. After replenishing, attach the cap securely,
and confirm that the hose attached to cap
has been inserted all the way to the tank bottom
then attach the step plate. 76583
WARNING
• Replenish coolant at the reservoir tank. Do
not open the pressure cap on the engine
side.
• Open the pressure cap only after the water
temperature drops. If the cap is opened
while the water is hot, the water could
spurt out and cause burns.
75973
CAUTION
When using longlife coolant, rust inhibitor or
antifreeze in coolant, if you replenish water
alone, these additives will drop in concentra-
tion, causing antifreeze and rust inhibiting
actions to weaken.
Be sure to prepare a coolant mixture with addi-
tives in the same percentages as previously and
replenish this mixture only.
3-30
ENGINE
(6) Replacement
WARNING
• In replacing coolant, there are times when
the coolant may be very hot. Be careful to
avoid burns.
• Close the pressure cap before running the
engine.
If the pressure cap is left open, when
engine rpm increases, the rise in water
temperature will cause the coolant to
expand and spill out of the pressure cap.
1. If the vehicle has a water cock attached, turn the

cock all the way to counterclockwise to fully
open it.
2. Unlock the pressure cap by raising the fas-
tener .
3. Remove pressure cap and reservoir tank cap .
4. Open the engine drain plug and the radiator
drain cock , and drain out coolant. Also drain
coolant inside the reservoir tank.
5. After draining is completed, close the drain plug 76244
and the drain cock.
Tightening torque
24 Nm
Engine drain plug
4D3 engine (2.5 kgfm)
vehicles Radiator drain 2.5 ± 0.5 Nm
cock (0.25 ± 0.05 kgfm)
24.5 ± 4.9 Nm
Engine drain plug
4M5 engine (2.5 ± 0.5 kgfm)
vehicles Radiator drain 2.5 ± 0.5 Nm
cock (0.25 ± 0.05 kgfm)
6. Wash the cooling system.

Pour tap water (preferably warm water) into the
pressure cap port and start the engine. Increase
engine rpm until the water temperature reaches
90°C or above, operate the engine for about 10
minutes; then drain out coolant. The coolant
becomes very hot, so please be careful. Repeat
the above procedure until the water drained out
becomes clear.
T77121
CAUTION
If the coolant is extremely dirty, have it
inspected at your nearest authorized MITSUB-
ISHI FUSO distributor or dealer.
7. Pour coolant (longlife coolant + soft water)

through the pressure cap port until it reaches the
brim.
8. Run the engine a while with the pressure cap left
open and bleed air from the cooling system.
3-31
ENGINE
9. Stop engine. If the coolant volume is inadequate,

replenish until it reaches the brim.
10.Close the pressure cap securely.
Lock the pressure cap by pressing down the fas-
tener.
11. Replenish coolant (longlife coolant + soft water)
until it reaches the “FULL” line in the reservoir
tank, then attach the cap.
12.Run the engine and inspect for water leakage.
Clean the radiator core.

If the radiator front gets clogged with soil or dust,
cooling performance will drop or rusting might
occur, so clean the radiator periodically.
CAUTION
If the tank cap is not closed securely, high-tem-
perature coolant may burst out when over-
heated.
16. FUEL HOSE
Inside engine compartment Every 24 months
Outside engine compartment Every 48 months
FUEL HOSE REPLACEMENT
Replace the fuel hoses in the engine compart-

ment.
Replace the fuel hoses outside the engine com-
partment.
FUEL HOSE DAMAGE
Check if there is any deterioration, swelling,

scratch or crack.
3-32
DRIVE LINE
17. TRANSMISSION GEAR OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
18. AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
19. PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
20. PROPELLER SHAFT CENTER BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
21. KING PIN BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
22. REAR AXLE DIFFERENTIAL GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
23. FRONT AND REAR WHEEL HUB BEARING GREASE . . . . . . . . . . . . . . . . . . 3-40
24. CLUTCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
25. FRONT WHEEL HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
26. REAR WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
27. WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
28. PROPELLER SHAFT FLANGE YOKE BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
29. PROPELLER SHAFT CENTER BEARING BOLTS . . . . . . . . . . . . . . . . . . . . . . 3-44
30. PROPELLER SHAFT CENTER BEARING <DOUBLE ANTIVIBRATION

TYPE – OPTION>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
31. PROPELLER SHAFT DYNAMIC DAMPER<OPTION> . . . . . . . . . . . . . . . . . . . 3-45
32. DISC WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
33. TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
34. TIRE INFLATION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
35. TIRE ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
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17. TRANSMISSION GEAR OIL
Inspection intervals Every 15,000 km (9,000 miles)

Replacement intervals Every 30,000 km (18,000 miles)
Gear oil
API classification GL-3,
SAE 80 (general) or 90 (warm region)
API classification GL-4, SAE 80 (general)
SAE 90 (tropical region)
Engine oil
API classification CC,
SAE 30 or SAE 40
(long period of high-speed driving)
Quantity required:
Model Quantity
BE635 2.7 liters
M035S5 transmission 3.1 liters
BE637, 647 M035S6, M036S6 4.4 liters
transmission
BE639 3.1 liters
CHECK
1. Inspection
1. Remove the inspection plug from the plug port

and check if the oil is up to the brim or not.
2. If not, add oil until it does.
07358
CAUTION
Replenish with oil of the same grade and vis-
cosity as the oil currently in use.
3. Attach inspection plug.

Inspection plug 54 to 84 Nm
tightening torque (55 to 8.5 kgfm)
3-34
DRIVE LINE
2. Replacement
1. Remove the inspection plug and drain plug

and drain the oil.
WARNING
Since the oil reaches very high temperature
after operation of the vehicle, exercise
extreme care when draining the oil.
Note: If you replace oil shortly after the engine has

been stopped, while the oil is still slightly
warm, it will drain out faster.
2. The drain plug is fitted with a magnet. Wipe off

any metal particles sticking to the magnet.
3. When all of the transmission gear oil has drained
out, install the drain plug.
Drain plug 54 to 84 Nm
tightening torque (55 to 8.5 kgfm)
4. Add oil though the inspection plug port until it

reaches to the brim.
5. Attach inspection plug.
18. AUTOMATIC TRANSMISSION FLUID
Fluid quantity Approx. 4.5 litres

Inspection time Every 10,000 km (6,000 miles)
Replacement time Every 40,000 km (24,000 miles)
The replacement time for new vehicle is after the

first 5,000 km (3,000 miles).
Recommended transmission fluid:

Automatic transmission fluid DEXRON III type.
18.1 Inspection
To check the oil level, check the “HOT” side of the

oil level gauge .
1. Park the vehicle on level ground, firmly apply the
parking brake, and apply chocks to the tires.
2. With the engine idling, step on the brake pedal
and shift the range selection lever in order
T76342
through all the ranges and then place the lever in
neutral . Open the transmission inspection
door.
3. With the engine running, pull out level gauge
and wipe it clean. Carefully reinsert and remove
the level gauge and then read the fluid level from
the gauge by noting how far up the gauge is
coated with fluid.
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DRIVE LINE
4. The level is satisfactory if the fluid position is

within the “HOT” level range.
5. When the fluid level is low, add more transmis-
sion fluid through the fluid level gauge port.
6. Make a final check of the fluid level when the
fluid is hot after the vehicle has been driven.
CAUTION
• As the temperature of the fluid increases, so
does the fluid level, so do not add transmis-
sion fluid above the specified level gauge
range.
• When checking the fluid level, first remove
the debris and muck from around the level
gauge.
• Use a clean funnel, etc., when adding more
transmission fluid. Do not use a funnel, etc.,
that has been used for another type of oil,
such as gear oil. If foreign matter gets into the
transmission fluid it could cause problems.
Note:
• The automatic transmission oil cannot checked if
it is not at a high temperature. Be sure to drive
the vehicle before performing this check.
• Conduct the fluid level inspection while the
engine is idling. The fluid level cannot be cor-
rectly read if the engine is stopped or if the
engine speed is increased.
REPLACEMENT
1. Place a container under the transmission oil pan.

Remove the drain plug near the front of the oil
pan and allow the automatic transmission fluid to
drain out. It is not possible to drain out the auto-
matic transmission fluid that is in the hydraulic
circuit, torque converter, and oil cooler. At the
same time, check whether the drained automatic
transmission fluid is dirty and whether it contains
metallic particles.
Note that the automatic transmission fluid will
drain out more quickly if you warm it by allowing
the engine to warm up.
CAUTION
The automatic transmission fluid is extremely
hot immediately after driving. To avoid the risk
of being scalded, wait for the automatic trans-
mission fluid to cool to a safe temperature
before starting work.
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2. Fit the oil pan drain plug and gasket in their orig-
inal conditions.
3. Supply new automatic transmission fluid through
the filler tube in a quantity equivalent to that of
the drained automatic transmission fluid. Be
careful not to allow dirt and other foreign matter
to enter.
4. Place the range selector lever in the P position.
Start the engine and allow it to idle for at least 2
minutes.
5. Place the range selector lever in every position
then return it to the P position.
CAUTION
Keep the engine idling. Do not rev the engine.
6. Check the automatic transmission fluid level.

7. Immediately after filling the automatic transmis-
sion fluid, it still remaining over the inner wall of
the filler tube. This may make it difficult to check
the automatic transmission fluid level. Wait a
while before checking the fluid level.
8. The automatic transmission fluid level should be
within the range indicated on the level gauge.
Add the automatic transmission fluid if it is lower
than the minimum level.
9. When adding the automatic transmission fluid,
run the engine at idle and slowly fill the auto-
matic transmission fluid while paying much
attention to its level.
10.As the automatic transmission fluid temperature
increases, the automatic transmission fluid level
rises. Therefore, do not fill the fluid exceeding
the COLD range on the level gauge when the
fluid is cold.
19. PROPELLER SHAFT
Greasing intervals
NVI: 5,000 km (3,000 miles)
Z09228
Greasing
After removing dust and dirt from the grease nip-
ple of the propeller shaft universal joint , slip
joint .
Z09392
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DRIVE LINE
20. PROPELLER SHAFT CENTER BEARING
Move the vicinities of center bearing manually to

check for looseness of the bearing.
21. KING PIN BEARING

<4 points in total on both sides>
Lubricating intervals
NVI: 5,000 km (3,000 miles)
Recommended lubricant: Z09227

Chassis grease
NLGI No.1 (Li soap)
22. REAR AXLE DIFFERENTIAL GEAR OIL

Recommended oil:
Gear oil
API classification GL-5
SAE90 (Below 40°C) or 140 (Above 40°C)
SAE140 (countries in vicinity of Andes
mountains)
CAUTION
Use oil conforming to GL-5, SAE140 if the vehi-
cle is to be driven under heavy load conditions
as for example driving up long uphill grades.
Remember, however, that this oil is to be used
only when the temperature is higher than 10°C.
Quantity required:
Model Quantity
BE635 2.7 liters
BE637 D2H, D3H differential 2.7 liters
BE639
BE647 D033H differential 4.5 liters
These oil quantities are given only as guidelines. Be

sure to check the correct oil level by removing the
inspection plug as indicated below.
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DRIVE LINE
CHECK
1. Remove inspection plug and make sure that

the oil is topped off.
2. If insufficient, add oil through the inspection plug
hole until it is full to the brim.
CAUTION 75655
The added oil should be of the same grade and

viscosity as the oil originally placed in the dif-
ferential gears.
3. Install the inspection plug.

Tightening torque 98 to 115 Nm (10 to 12 kgfm)
REPLACEMENT
1. Remove inspection plug and drain plug to

let the oil flow out.
WARNING
The gear oil is extremely hot immediately
after the vehicle has been operated. Take care
to avoid being scalded when draining hot oil.
Give the oil time to cool before draining it.
Note: Oil removal is quicker if performed soon after

the vehicle has been stopped and while the
oil is still hot.
2. The drain plug is fitted with a magnet. Wipe off

any metal particles sticking to the magnet and
install the drain plug.
3. Add oil through the inspection plug hole until it

reaches the bottom of the hole.
4. Install the inspection plug.
3-39
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23. FRONT AND REAR WHEEL HUB BEARING

GREASE <Rear>
After disassembly, replace the oil seals and

apply hub grease to the lips.
After the bearing and wheel hub have been

cleaned and dried, apply hub grease generously <Front>
to the bearing inner race, and apply specified
quantity of hub grease in the wheel hub.
In case of the front wheel hub, apply hub grease
to the wheel cap inside.
24. CLUTCH SYSTEM
NVI: 5,000 km (3,000 miles)
CLUTCH PEDAL PLAY
Clutch pedal play

0.1 to 7 mm
1. Make sure the engine is not running.

2. Make sure the parking brake is securely applied.
3. Make sure the gearshift lever is in the neutral
position.
4. To check clutch pedal play, use your finger to
press the clutch pedal to the point where resis-
tance is felt and measure the distance over
which the pedal has moved (play) . If the
degree of play is not as specified above, adjust-
ment is necessary.
01233
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DRIVE LINE
Gap to floor board when clutch is released.

Inspect the pedal with the clutch engaged.
1. Let the engine idle and engage the parking
brake.
2. Step down on the clutch pedal and shift the gear
lever to the highest gear in forward.
3. Release the clutch pedal slowly and measure
the gap between the pedal and the floor board
just before the clutch engages.
Gap to floor board 17 mm or more
CAUTION
Be careful not to set the vehicle in motion sud-
denly. Also watch out for surrounding condi-
tions.
Note: The clutch is self-adjusting. The clutch

engagement position cannot be adjusted.
CLUTCH OPERATION
Check if there is abnormal sound when the clutch

pedal is stepped on, then check if the pedal is
abnormally heavy. Next, step on the pedal and see
if the gear level can be shifted easily. Slowly release
the pedal and check for sliding and for smooth
clutch engagement.
Note: The clutch is self-adjusting. If the clutch disc

is worn beyond the prescribed limit; the
clutch pedal will be heavy when you first step
on it, then return to original heaviness if then
you step down on the pedal to a certain
degree. This lets you know it is time to
replace the clutch.
At such times, have the vehicle inspected.
25. FRONT WHEEL HUB BEARING

With the front axle jacked up, move the tire hold-
ing its top and bottom to check for bearing loose-
ness.
Replace wheel hub bearing hub seals.
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26. REAR WHEEL BEARING
Disassemble the rear wheel and check for wear

and damage of the hub bearing.
27. WHEEL NUTS
Tightening intervals
Normal Every 5,000 km (3,000 miles)
NVI 5,000 km (3,000 miles)
Using a torque wrench, check for loose wheel

nuts and tighten as necessary.
Tighten the wheel nuts to the specified torque.
WARNING
After changing a tire, the wheel nuts will
loosen somewhat during the initial stages of
driving due to “wear-in.” Therefore, retighten
the wheel nuts to specification after vehicle
have driven 50 to 100 km.
Using a torque wrench, check for loose wheel

nuts and tighten as necessary.
CAUTION
Be sure to use a torque wrench to tighten the
wheel nuts.
Wheel nut tightening 450 to 550 N·m
torque (45 to 55 kgf·m)
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.
• Fit the socket wrench securely on the
wheel nut. If fitted improperly, the wrench
will slip off the nut, and could cause injury.
<Single nut type>

Tighten the wheel nuts to the specified torque. Fol-
low the diagonal tightening sequence indicated in
the figure.
3-42
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<Double nut type>

Retighten the wheel nuts using the following 2-pro-
cess procedure.
1st process
1. Loosen the outer wheel nuts as follows:
Loosen the nuts numbered 1 – 2 – 3 or 4 – 5 in
the figure in this order.
2. Tighten the inner wheel nuts corresponding to
the loosened outer wheel nuts to the specified
torque. T77021
3. Tighten the loosened outer wheel nuts to the

specified torque.
2nd process
4. Perform the above steps through for the
remaining outer wheel nuts and inner wheel
nuts.
WARNING
In the case of dual wheels, one often retight-
Z09315
ens outer wheel nuts while forgetting to
retighten inner wheel nuts. Always follow the
above procedure to tighten all the nuts.
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” mark for left-hand wheels.
28. PROPELLER SHAFT FLANGE YOKE BOLTS
Check the flange yoke bolts and center bearing

attaching bolts (vehicles with center bearing) for
looseness.
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BOLTS
Check the propeller shaft center bearing

attaching bolts for looseness.
Center bearing attaching 47 to 65 N·m
bolt tightening torque (4.8 to 6.6 kgf·m)
Center bearing
P119662E

<DOUBLE ANTIVIBRATION TYPE –
OPTION>
NVI: 5,000 km (3,000 miles)
Check the center bearing for free play. Also,

check the center bearing for security and dam-
age.
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DRIVE LINE
31. PROPELLER SHAFT DYNAMIC

DAMPER<OPTION>
NVI: 5,000 km (3,000 miles)
Check the dynamic damper for looseness of

installation and damage.
32. DISC WHEEL

Side ring Disc Rim
wheel
Check the disc wheel, rim and side ring for cor-
rosion, deformation and cracks.
33. TIRES
CHECKING TREAD DEPTH
Make sure that the remaining tread depth is suffi-
cient.
Tread groove depth limit 1.6 mm
When the tread wears down, slip signs (inter-

rupted sections of the grooves) appear across the
tire at the locations corresponding to the marks.
Replace the tire as soon as the slip signs show up
as continued use is dangerous.
WARNING
If the remaining tread is too shallow, the tires
tend to skid and chances of “hydroplaning”
during high speed driving increase. Hydro- 75273
planing can occur when driving on a wet
roads at high speeds. When a vehicle hydro-
planes, tires ride up on and slide over a film
of water, causing the driver to lose control of
both steering and braking.
00315
3-45
DRIVE LINE
CHECKING FOR CRACKS, DAMAGE, AND

OBJECTS EMBEDDED IN TREAD
Check both the tread and the sides of each tire for
cracks, damage, and excessive or unusual wear.
Check also for metal pieces, nails, and stones that
might be embedded in the tread or caught between
the tires of dual wheels.
Z10805
34. TIRE INFLATION PRESSURE
(3,000 miles)
INFLATION PRESSURE CHECK
1. Use an air pressure gauge to check for proper

tire inflation pressure.
If the pressure is incorrect, adjust it to the indi-
cated standard pressure.
2. Tire pressure should be checked and adjusted
before driving when the tires are still cool.
Z21588
3. The air in the spare tire will gradually leak out by
itself. Once a year, use an air gauge to check
whether the spare tire’s inflation pressure is
slightly higher than the standard pressure. If you
use the spare tire, reduce the inflation pressure
to the standard level.
4. There is a label affixed to the driver’s door
indicating the standard inflation pressure. Keep
the tires inflated to the pressures shown on the
label.
WARNING
• Excessively low or high tire pressures not T75454
only give a poor ride but also could cause
cargo to be damaged. Moreover, if the pres-
sure is too low, tires could overheat and
burst.
• Both the inner and outer tires on dual
wheels should be inflated to the same pres-
sure.
• You need not increase tire pressure before
high-speed driving.
3-46
DRIVE LINE
CAUTION
These standard tire inflation pressures have
been established and are recommended by the
JATMA (Japan Automobile Tire Manufacturers
Association) and the ETRTO (The European Tire
and Rim Technical Organization). If the tires on
your vehicle were not made by one of the
JATMA and the ETRTO member companies, use
the inflation pressures recommended by your
tires’ manufacturer or adjust the pressures
according to your local standards.
Note: The tire inflation pressures will be higher just

after vehicle operation than before vehicle
operation. The increases in pressure are not
abnormal; they occur because the air in the
tires expands as the tires get hot while the
vehicle is moving. Do not release air from the
tires at this time. The pressures will return to
normal as the tires cool down.
5. Never fail to install tire valve caps after checking

or adjusting the air pressure.
35. TIRE ROTATION
Each tire wears differently depending on its loca-

tion. Rotate the tires so they will wear uniformly and
have longer service life.
Every 10,000 km
Tire rotation intervals (6,000 miles)
*1: The tire must be rotated depending on either

the odometer reading or operating period
(months), whichever occurs first.
Always use the same type of tire on the same

axle. If tires of different type are used on an
axle, the vehicle will go left or right upon brak-
ing and the steering wheel will turn by itself.
Front tires
Rear tires
Spare tire
Z76299
3-47
DRIVE LINE
WARNING
Be sure to use the specified type of tires and
disc wheels. Mixing bias and radial tires
results in poor steering and should be
avoided at all cost.
In addition, mixed use of different types of
tires can produce the following undesirable
effects:
• On vehicles with an ABS, the ABS system
cannot work as intended.
• The speedometer indicates a different
speed from the actual vehicle speed.
• On vehicles with a DUONIC system, the
DUONIC system (transmission) cannot
change gear at the optimum timing, so fuel
consumption becomes worse.
• The tires may touch the frame and steering
components.
• 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”. Therefore, it is neces-
sary to retighten the wheel nuts to the
specified torque after driving 50 to 100 km.
Thereafter, retighten the nuts at regular
intervals.
• If as a result of tire rotation, an additionally
painted face of the disk wheel mounting
face becomes the mounting face for the
mating part (wheel hub and disk wheel),
remove the paint from the mounting face of
the disk wheel and the seating face of
the wheel nut, clean these surfaces with a
wire brush or the like, and then install the
wheel.
If you use the wheel without removing the
Z09613
paint, the wheel nuts are likely to become
loose because the paint film is thick.
CAUTION
• Because of their propensity to generate heat,
new tires tend to wear quickly. Install two tires
as a set on the front of the vehicle where the
load is smaller. Break in new tires by driving
200 km or more at 60 km/h or less. After this
run-in period, check tire pressure.
• If there is a difference in diameter between
inner and outer tires of a rear dual wheel, the
difference should be within 6 mm and install
the smaller tire as the inner tire.
3-48
STEERING SYSTEM
36. POWER STEERING FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
37. STEERING SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
38. STEERING DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
39. STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
40. STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
41. FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
42. POWER STEERING HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-49
STEERING SYSTEM
36. POWER STEERING FLUID

Recommended fluid:
Automatic transmission fluid
DEXRON ll or DEXRON lII type
1. Jack up the front wheels.

2. Clean the port areas of pipes to prevent entry of
dirt, dust, and other foreign material inside the
power steering booster.
3. Loosen pipes connected to the power steering
booster.
4. Repeatedly turn the steering wheel fully left and
right to drain the fluid from the power steering
booster.
5. After draining the fluid, tighten the pipes to spec-
ified torque.
Feed pipe tightening 29.4 to 39.2 Nm

torque (3 to 4 kgfm)
Return pipe tightening 39.2 to 49.0 Nm
torque (4 to 5 kgfm)
6. Pour fluid into the power steering oil tank up to

the bottom of the filler cap.
7. Repeatedly turn the steering wheel fully left and
right. When the fluid level has dropped, add suf-
ficient fluid to maintain the fluid level within the
specified range.
8. Start the engine to idle.
9. When the fluid level has dropped, stop the
engine and add sufficient fluid to maintain the
fluid level within the specified range.
10. Restart the engine. While checking for a drop in
fluid level, turn the steering wheel fully left and
right and add fluid as much as necessary.
Repeat this practice until the fluid level is stabi-
lized within the specified range.
11. Turn the steering wheel fully left and right
repeatedly.
CAUTION
• To avoid seizure of the power steering oil
pump, do not keep the steering wheel turned
fully to left or right for more than 10 seconds
when the engine is running.
• Do not rev the engine during air bleeding;
otherwise, the power steering pipe may to
break. Run the engine at idle.
3-50
STEERING SYSTEM
12. If there is any abnormal noise or a fluid level

fluctuation, there is likely still some air trapped in
the power steering system. Turn the steering
wheel several times to raise the fluid tempera-
ture to approximately 60 to 80°C.
13. Stop the engine and wait for approximately five
minutes.
14. Lower the front wheels and turn the steering
wheel several times. If there is no noise or fluid
level fluctuation, the bleeding of the power steer-
ing system is completed.
15. Repeat starting and stopping the engine several
times to remove small air bubbles left in the
power steering oil tank.
16. If air bubbles are not removed completely, drive
the vehicle for a while, then check for abnormal
noise and oil level fluctuation.
17. When bleeding is finished, check that fluid in the
power steering oil tank is within the specified
level range. Also check pipe and hose connec-
tions for fluid leaks.
37. STEERING SHAFT
Greasing intervals
NVI: 5,000 km (3,000 miles)
Recommended lubricant: 75656

Wheel bearing grease
NLGI No. 2 (Li soap)
1. Remove all dust and dirt from the grease fittings

before using it.
2. Apply grease to grease nipple.
38. STEERING DRAG LINK
Every 5,000 km
Greasing intervals
(3,000 miles)
Wheel bearing grease
NLGI No. 2 (Li soap)
1. Remove all dust and dirt from the grease fittings

before using it.
2. Apply grease to grease nipple.
3-51
STEERING SYSTEM
39. STEERING WHEEL
STEERING WHEEL PLAY
1. From its straight-ahead (neutral) position, turn

the steering wheel clockwise and counterclock-
wise to the point where a resistance is first felt
for each direction, and measure the amount of
the steering wheel movement between these
points (steering wheel play). 75897
Steering wheel 5 to 50 mm on the periphery of
play steering wheel
Note: On vehicles equipped with power steer-

ing, the above check must be performed
with the engine running.
2. Try moving steering wheel up and down and
also right and left to check for excessive loose-
ness.
STEERING WHEEL LOOSENESS
Grasp the steering wheel and move it up and

down, forward and backward, and to right and
left to check for looseness.
75898
STEERING WHEEL OPERATING CONDI-

TION
While driving slowly, make sure that the steering

wheel is free from shake and the vehicle does
not pull to one side. Also check for excessive
operating resistance and unsmooth return to the
neutral position.
WARNING
Perform the checks in a safe place that pro-
vides good visibility all around. During the
checks, be sufficiently attentive to surround-
ing traffic conditions.
3-52
STEERING SYSTEM
40. STEERING SYSTEM

Steering wheel
Every 5,000 km (3,000 miles) Steering column
NVI: 5,000 km (3,000 miles)
Power steering gear assembly
LOOSENESS AND PLAY OF STEERING

SYSTEM Pitman arm
Drag link Knuckle arm
Check the steering system for looseness and

play.
FLUID LEAKAGE FROM STEERING SYS-

TEM
Power steering oil tank

Check the steering gear case and power steer-
Power steering oil pump
ing system for fluid leakage.
Check the power steering hoses and pipes for

looseness.
Power steering gear
: Direction of oil flow
41. FRONT WHEEL ALIGNMENT
Measure the toe-in, camber, caster and king pin

inclination angle to check for conformance with
the standard values.
Note: The front suspension, steering system and
wheels should be serviced to normal con-
dition prior to measurement of wheel
alignment.
3-53
STEERING SYSTEM
42. POWER STEERING HOSE

POWER STEERING HOSE DAMAGE
Check the power steering hoses for deteriora-
tion, swelling, chafing, and cracks. Power steering oil tank
Check also for loose connections.
Power steering oil pump
POWER STEERING HOSE REPLACEMENT
Power steering gear
Every 24 months
Replace the hose in the power steering system.
: Direction of oil flow
3-54
BRAKE SYSTEM
43. BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
44. SERVICE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
45. SERVICE BRAKE SHOE CLEARANCE <EXCEPT VEHICLES WITH

DISCBRAKES OR AUTOMATIC SHOE CLEARANCE ADJUSTERS> . . . . . . . 3-63
46. BRAKE DRUM AND LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
47. PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
48. VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
49. BRAKE HOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
50. RUBBER PARTS AND PACKINGS OF BRAKE SYSTEM . . . . . . . . . . . . . . . . . 3-66
51. EXHAUST BRAKE VACUUM CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
52. VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
53. BRAKE FLUID RESERVOIR TANK TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3-55
BRAKE SYSTEM
43. BRAKE FLUID

Inspection At the time of pre-operational check
intervals and every 5,000 km (3,000 miles)
NVI: 5,000 km (3,000 miles)
Replacement Every 25,000 km (15,000 miles) or
intervals every 12 months
Recommended fluid:
Brake fluid SAE J1703, FMVSS No.116,
Type DOT3
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 components.
If you wish to change the brand of brake
fluid, replace all the existing fluid in the
brake system with the new brand fluid.
• Never allow engine oil, diesel fuel, gear oil,
automatic transmission fluid, or any other
mineral oil to mix with the brake fluid.
When mixed with the brake fluid even very
small in amounts, such oils will cause the
rubber parts of the brake system to swell,
and could cause brakes to become slug-
gish or to drag. Also, do not use containers
which have been used for mineral oil for
brake fluid.
• Because brake fluid is highly hygroscopic,
it should be kept in a dry place both during
refilling and storage. If brake fluid absorbs
moisture, the boiling point is lowered, a
condition which could result in vapor lock.
This is very dangerous.
• Brake fluid dissolves paint. If you spill the
fluid, wipe it clean or flush it off with water.
• If the brake fluid is used over long periods,
its boiling point drops significantly due to
the moisture it has absorbed, thereby
increasing the likelihood of dangerous
vapor lock. Therefore, be sure to change
brake fluid at least once every 12 months.
• When adding brake fluid, be careful not to
allow dirt and other foreign matter to enter
the reservoir tank. Any foreign matter
entering the reservoir tank could cause the
braking system to malfunction.
• If the brake fluid level drops abnormally,
brake fluid may be leaking from a pipe or
other component. Have the braking system
inspected by your nearest authorized
MITSUBISHI FUSO distributor or dealer.
3-56
BRAKE SYSTEM
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 for-
eign matter in the reservoir tank, have the reservoir
tank inspected and cleaned by a MITSUBISHI
FUSO distributor or dealer.
75874
Note: The warning lamp is illuminated when
the brake fluid level drops below the “MIN”
line.
CAUTION
Do not open cap of reservoir tank for inspec-
tion purposes.
Adding fluid
1. If the fluid level is lower than the “MIN” line,
remove cover , clean the surfaces around cap
of reservoir tank, open cap , and add the rec-
ommended brake fluid up to the “MAX” line.
75882
2. Close the cap firmly.
WARNING
• The container used for adding brake fluid
should be a clean one free of moisture,
mineral oil, and dust.
• Be extremely careful not to let dust and
other foreign matter enter the reservoir
tank, as foreign matter in the tank could
cause a failure of the brake system.
• Be careful not to exceed the “MAX” line
when adding brake fluid.
• If the fluid level is unusually low, there is a
fluid leak in the brake line. In this case,
have your vehicle inspected at your near-
est authorized MITSUBISHI FUSO distribu-
tor or dealer.
REPLACEMENT <VACUUM-SERVO
HYDRAULIC BRAKE VEHICLES>
Brake fluid is shared by the brake and clutch sys-

tems, and is divided in the brake fluid tank into the
two systems. This section describes the replace-
ment of the brake fluid for the brake system. In
order to completely replace the brake fluid, the
brake fluid in the clutch system should also be
replaced.
3-57
BRAKE SYSTEM
CAUTION
• Brake fluid is corrosive on paintwork. Be
careful not to spill it onto the paintwork. If
brake fluid is spilled onto the paintwork,
immediately wipe it off.
• During brake fluid replacement operation, a
change in color of the brake fluid being dis-
charged indicates that the old brake fluid in
the system has been replaced with new brake
fluid.
• During the replacement, be sure to keep the
brake fluid level at the “MAX” mark on the
tank.
1. Start the engine and let it idle until you complete

brake fluid replacement.
2. Attach vinyl pipes to air bleeders of the front
wheel cylinder and the rear wheel cylinder, and
put the free ends into vessels.
3. Loosen air bleeders and depress the brake

pedal several times to drain brake fluid com-
pletely.
4. Maintaining a supply of new brake fluid up to the
“MAX” level of the brake fluid tank, depress the
brake pedal repeatedly until the old brake fluid of
the brake system is replaced with new fluid, and
after you complete the work, tighten each air
bleeder at specified torque.
Tightening torque 6.9 to 8.8 N·m {0.7 to 0.9 kgf·m}
5. Bleed air from the brake system.
Note: As to the detailed procedure, please refer

to the related shop manuals.
3-58
BRAKE SYSTEM
AIR BLEEDING OF BRAKE SYSTEM

<WITHOUT ANTI-LOCK BRAKE SYSTEM>
1. Start the engine and let it idle until you have

completed the brake fluid replacement.
2. Attach vinyl pipes to air bleeders of the front
wheel cylinder front disc brake, rear wheel cylin-
der, and put one end of the pipes in container to
bleed air.
<Front brake system>

Right wheel cylinder or right disc brake
Left wheel cylinder or left disc brake
<Rear brake system>

Right wheel cylinder
Left wheel cylinder
3. Depress the brake pedal slowly several times,

and with the brake pedal depressed, loosen air
bleeder to discharge air together with the brake
fluid. After closing the air bleeder, release the
brake pedal.
CAUTION
Make sure you maintain the brake fluid at the
Air bleeder
“MAX” level of the brake fluid tank because the
brake fluid decreases during air bleeding.
4. Repeat the above operation until air bubbles are

no longer present in the brake fluid discharged
from air bleeder.
5. When the discharged fluid is free of air bubbles,
tighten air bleeder at the specified torque.
Air bleeder tightening 6.9 to 8.8 Nm

torque (0.7 to 0.9 kgfm)
6. Make sure that the brake fluid level is at the

“MAX” level of the brake fluid tank, and depress
the brake pedal several times to ensure that the
brake fluid does not leak from anywhere. Then
conduct a brake test.
3-59
BRAKE SYSTEM
<WITH ANTI-LOCK BRAKE SYSTEM>

1. At normal air bleeding or replacement of the
hydraulic unit, brake fluid is filled at the second-
ary side (operation circuit) of the hydraulic unit.
Air bleeding must be performed only at the pri-
mary side (normal circuit).
2. If the system is operated with inclusion of air at
the primary side, air may enter the secondary
side. Air bleeding at the secondary side must be
performed using the Multi-use tester II.
3. If the system is operated with inclusion of air at
the secondary side, air may enter the primary
side. Air bleeding at both the primary side and
the secondary side must be performed.
<Air bleeding at primary side>

Remove the power fuse of the hydraulic unit or CAUTION
remove the battery connection -
• When the battery connection – is
removed, do not connect the battery until
air bleeding at the primary side is com-
Open the brake bleeder. pleted. If the battery is connected, air
may be included at the secondary side
due to operation of the system. Air bleed-
Repeat depression and release of the brake
ing at the secondary side must also be
pedal slowly and run sufficient amount of the
brake fluid. performed.
• If it is necessary to connect the battery
before air bleeding, remove the power
Tighten the brake bleeder. fuse of the hydraulic test.
• If air bleeding is found at the primary side
due to elongated travel of the brake
After pumping the brake pedal a few times, pedal, air may be included at the second-
maintain the depression status. ary side. Air bleeding at the secondary
side must also be performed.
Open the brake bleeder. Complete the work in the thick line for each
wheel in the sequence below:
Discharge the brake fluid.
Front axle right wheel
Front axle left wheel

Air is included in the Air is not included in
brake fluid. the brake fluid.
Rear axle right wheel
Tighten the brake bleeder to the specified torque. Rear axle left wheel
Air bleeder tightening 6.9 to 8.8 N.m

torque (0.7 to 0.9 kgf.m)
Connect the power fuse of the hydraulic unit or

the battery.
Perform initial check of the system.

The hydraulic unit operates (for 3 seconds).
Air bleeding at the primary side is completed.
3-60
BRAKE SYSTEM
<Air bleeding at the secondary side>

Air bleeding at primary side (normal air bleeding) CAUTION
• Do not perform the actuator test (Anti-
lock brake system operation) with the
Depress the brake pedal. Multi-use tester II continuously. Abnor-
mal heating of Anti-lock brake system
motor valves may result in damage to the
hydraulic unit.
Perform the actuator test with the Multi-use tester II • Do not perform the actuator test with the
while the brake pedal is depressed.
Operate the solenoid valve. Multi-use tester II during air bleeding at
the primary side. Air at the primary side
may be moved to the secondary side.
• * Perform air bleeding of the axle
(another wheel) that completed the actu-
Release the brake pedal after operation of the
solenoid valve. ator test.
Perform the actuator test with the Multi-use

tester II and complete the work in the thick line
Perform air bleeding at the primary side (normal air
for each wheel in the sequence below.
bleeding).
(Air bleeding of the axle wheel that completed the Front axle right wheel [Display No.11 FR
actuator test)
ABS MV ON → Y]
Front axle left wheel [Display No.12 FL ABS

Air is included in the Air is not included in
MV ON → Y]
brake fluid. the brake fluid.
Rear axle right wheel [Display No.13 RR
ABS MV ON → Y]
Tighten the brake Tighten the brake
bleeder and release bleeder to the
the pedal. specified torque. Rear axle left wheel [Display No.14 RL ABS
MV ON → Y]
Air bleeder tightening 6.9 to 8.8 N.m

torque (0.7 to 0.9 kgf.m)
Completion air bleeding at the primary and the secondary sides
3-61
BRAKE SYSTEM
44. SERVICE BRAKE SYSTEM
(3,000 miles)
NVI: 5,000 km (3,000 miles)
BRAKE SYSTEM DAMAGE
Check the hoses and pipes for damage and

looseness.
Check the brake fluid leakage.
BRAKE PEDAL STROKE CHECK
With the engine idling, depress the brake pedal

with a force of 490 N {50 kgf} and measure the
clearance between the brake pedal and floor.
Clearance between With anti-lock
40 mm or more
floor and brake pedal brake system Height
(when depressed
with a force of 490 N Without anti-lock 06540E
45 mm or more
{50 kgf}) brake system
BRAKE PEDAL PLAY
1. Make sure the engine is not running.

2. Make sure the parking brake is securely applied.
3. Make sure the gearshift lever is in the neutral
position.
4. Pump the brake pedal several times to release Pedal play
all the vacuum from the brake system (zero vac-
uum). 06539E
5. Measure the distance over which the brake
pedal moves when the center of the pedal pad is
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

10 to 15 mm
6. If the brake pedal play is not as specified, have

the pedal inspected and adjusted.
3-62
BRAKE SYSTEM
BRAKING PERFORMANCE
Perform braking tests in a safe place. After

checking that warning lamp , , is not
illuminated, drive the vehicle at a low speed to
make sure that braking power is sufficient and
even. If braking seems in any way abnormal,
operating the vehicle could be dangerous.
WARNING
Perform brake tests in a safe place that
allows for good visibility all around. During
the tests, be attentive to surrounding traffic
conditions.
45. SERVICE BRAKE SHOE CLEARANCE

<EXCEPT VEHICLES WITH DISCBRAKES
OR AUTOMATIC SHOE CLEARANCE
ADJUSTERS>
Adjustment intervals Every 15,000 km (9,000 miles)
1. Jack up the vehicle to raise the wheel of which

the brake shoe clearance is to be adjusted. <Front wheel>
Chock the other wheels to prevent the vehicle
from moving.
2. Rock the raised wheel by hand to check for
excessive wheel bearing play.
3. Remove the dust cover from adjusting hole in
the backing plate.
4. Using a screwdriver through one of the adjusting
holes, turn adjuster in the direction of the
arrow marked on the backing plate until the
wheel slightly drags when rotated by hand. Do
the same through the other adjusting hole. <Rear wheel>
5. Then turn the adjuster in the direction opposite
to the arrow mark by the number of notches indi-
cated below.
Number of notches by Front wheels 4 to 5 notches
which the adjuster is to
be turned back Rear wheels 4 to 5 notches
CAUTION
(1) On any wheel, be sure to make adjustments
via both adjusting holes.
(2) If adjustments are performed for either a
right or left wheel, they should also be per-
formed for the other wheel, i.e. front right
and front left, rear right and rear left. Avoid
performing adjustments for only one wheel.
3-63
BRAKE SYSTEM
6. Rotate the wheel by hand to make sure that it

does not drag. If the wheel drags, repeat the
above adjustment procedure.
7. Depress the brake pedal to a position where the
brakes slightly drag. Rotate each wheel by hand
to make sure that the front wheels rotate with a
resistance slightly less than or equal to the resis-
tance experienced when the rear wheels are
rotated.
Also check that right and left wheels rotate with a
same resistance. This applies to both front and
rear axles.
8. Plug the adjusting holes with the dust covers,
and perform brake tests while driving slowly.
WARNING
Perform brake tests in a safe place that pro-
tests, be sufficiently attentive to surrounding
traffic conditions.
46. BRAKE DRUM AND LINING

Inspection hole
Brake lining
Cover
1. Remove the cover from the backing plate. Side
Through the inspection hole, check the thick- shoulder P100308E
ness of the brake lining.
4.0 (side shoulder means
Brake lining thickness
wear limit) mm
2. If any lining is worn down to the step on the side

face, replace all linings on that axle.
3. After the inspection, be sure to install the cover.
4. Check the brake drums for wear, cracks and
damage.
P118266
3-64
BRAKE SYSTEM
47. PARKING BRAKE
(3,000 miles)
NVI: 5,000 km (3,000 miles)
PARKING BRAKE RATCHET BAR STROKE

CHECK
1. Depress the brake pedal firmly so that the vehi-
cle cannot move.
2. Starting with the parking brake ratchet bar in the
fully released position, pull the parking brake
ratchet bar with a force of 294 N (30 kgf) until it
stops moving. Check whether the ratchet bar
stroke (the distance moved by the ratchet bar) is
within specification. If the stroke is out of specifi-
cation, have the vehicle inspected.
Parking brake ratchet bar
80 to 120 mm
stroke
3. Make sure the parking brake ratchet bar locks

securely in the pulled position.
BRAKING PERFORMANCE
1. Stop the vehicle on a dry downgrade, set the
parking brake and check to see if the parking
brake can hold the vehicle. If an appropriate
downgrade is not available, drive the vehicle at a
low speed and activate the parking brake to
make sure that it exhibits satisfactory braking
action.
2. If parking brake performance is in any way
abnormal, vehicle operation could be danger-
ous.
WARNING
Perform brake tests in safe place that pro-
tests, be sufficiently attentive to surrounding
traffic conditions.
3-65
BRAKE SYSTEM
48. VACUUM CHECK VALVE
CAUTION
• Be careful not to allow moisture into the
check valve.
• During the inspection, ensure that the check
valve opens as well as closes correctly.
• Do not attempt to remove the check valve
from the vacuum hose.
Perform the following inspections. If the check

valve does not pass both inspections, replace
the check valve complete with the vacuum hose.
Blow into the hose. The check valve should
close, preventing the breath from passing it.
Suck on the hose. The check valve should
open, allowing air to pass.
49. BRAKE HOSE

BRAKE HOSE REPLACEMENT
Replacement intervals Every 24 months
Replace the hose in brake system.
50. RUBBER PARTS AND PACKINGS OF

BRAKE SYSTEM
Every 12 months
BRAKE MASTER CYLINDER
Replace brake master cylinder packing and rub-

ber parts.
3-66
BRAKE SYSTEM
WHEEL CYLINDER
Every 12 months
Replace wheel cylinder packing and rubber

parts.
51. EXHAUST BRAKE VACUUM CHAMBER
Power chamber
Every 12 months
Replace exhaust brake Power chamber. Butterfly valve
52. VACUUM HOSE

VACUUM HOSE REPLACEMENT
Vacuum
hose
Every 24 months
Replace the vacuum hose in brake system.
3-67
BRAKE SYSTEM
53. BRAKE FLUID RESERVOIR TANK TUBE
Every 48 months
Replace brake fluid packing and rubber parts.
Reservoir tank tube
Master cylinder
3-68
SUSPENSION SYSTEM
54. LEAF SPRING U-BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
55. LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-69
SUSPENSION SYSTEM
54. LEAF SPRING U-BOLTS
Check the U-bolts for looseness.
55. LEAF SPRINGS
Check the leaf springs for cracked, broken or

displaced leaves.
3-70
ELECTRIC SYSTEM
56. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
57. LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
58. INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3-71
ELECTRIC SYSTEM
56. BATTERY
NVI: 5,000 km (3,000 miles)
WARNING
(1) The battery generates flammable hydro-
gen gas and should be kept away from
open flame and spark.
(2) When removing the battery, always dis-
connect the negative (–) terminal first and
connect it last. A spark can occur if a tool
touches the positive (+) terminal and
frame with the negative (–) terminal con-
nected.
BATTERY FLUID LEVEL CHECK
1. The battery fluid level should be between the

UPPER and LOWER level lines marked on
the battery case. If the battery fluid level is low,
add electrolyte or distilled water to the UPPER
level line.
2. If your battery has no level line markers, the fluid
should be 10 to 15 mm above the tops of the
electrode plates.
DANGER
BATTERY FLUID IS DILUTE SULFURIC ACID
AND CAN HARM MOST THINGS IT TOUCHES,
INCLUDING HUMAN SKIN AND CLOTHING. IF
YOU GET IT ON YOUR SKIN OR CLOTHING,
FLUSH IT OFF WITH SOAP AND WATER.
CAUTION
Whenever fluid has been added, either charge
the battery or run the vehicle for a while. It is
especially important in cold weather as the bat-
tery can freeze up and be damaged.
3-72
ELECTRIC SYSTEM
CHECKING SPECIFIC GRAVITY OF BAT-

TERY FLUID
You can determine the battery’s state of charge by

checking the specific gravity of its fluid.
Use a hydrometer to measure the specific gravity of
the battery fluid. If the specific gravity is lower than
1.220 (battery fluid temperature at 20°C), the bat-
tery must be recharged.
If the battery fluid temperature is higher or lower
than 20°C, you may convert a specific gravity mea-
surement into its 20°C temperature equivalent by
using the following formula:
S20 = St + 0.0007 (t – 20)

S20: specific gravity at fluid temperature of 20°C
St: specific gravity measurement
t: battery fluid temperature
DANGER
BATTERY FLUID IS DILUTE SULFURIC ACID
AND CAN HARM MOST THINGS IT TOUCHES,
INCLUDING HUMAN SKIN AND CLOTHING. IF
YOU GET IT ON YOUR SKIN OR CLOTHING,
FLUSH IT OFF WITH SOAP AND WATER.
CONNECTED CONDITION OF TERMINALS
Make sure the battery cables are securely

attached to the battery terminals.
Z22627
CLEANING THE TERMINALS
Clean the battery terminals if they become dirty or

corroded.
Use warm water to remove any white powder
caused by corrosion.
If a terminal is seriously corroded, remove the bat-
tery cable and clean the terminal with a wire brush Z09334
or sandpaper.
After cleaning, apply a thin coat of grease to the ter-
minals.
3-73
ELECTRIC SYSTEM
CHARGING OR REPLACING BATTERY
CAUTION
(1) 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.
(2) If the battery needs to be charged, remove it
from the vehicle and remove the caps where
possible before starting the procedure. If it is
charged in the vehicle owing to unavoidable
circumstances, be sure to disconnect the
negative (–) battery cable.
Note: Follow the correct procedure when jump

starting a vehicle with a dead battery by con-
necting it to a live battery using a booster
cable.
57. LIGHTING SYSTEM
NVI: 5,000 km (3,000 miles)
Check operation, damage and installation of

each lighting equipment.
Head lamp
Front combination lamp
Fog lamp
Front side turn lamp
Stop/tail lamp
Rear turn signal lamp
Backup lamp
License plate lamp
Step lamp
Room lamp (incandescent)
3-74
ELECTRIC SYSTEM
58. INSTRUMENT PANEL
NVI: 5,000 km (3,000 miles)
Check if the gauges, warning lamps and indica-

76072
tor lamps function properly.
Tachometer
Warning lamp, indicator lamp
Water temperature gauge
Fuel gauge
Trip knob
Speedometer
3-75
OTHER CHASSIS PARTS
59. CHASSIS PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
60. LEAKS – FUEL, OIL AND COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
61. BOLT SECURING BODY AND CHASSIS PARTS . . . . . . . . . . . . . . . . . . . . . . 3-77
3-76
OTHER CHASSIS PARTS
59. CHASSIS PARTS
Lubrication intervals
60. LEAKS – FUEL, OIL AND COOLANT
NVI: 5,000 km (3,000 miles)
Check the leakage, fuel, oil, coolant.
61. BOLT SECURING BODY AND CHASSIS

PARTS
Check the bolts of the body and chassis compo-

nent for damage and looseness.
3-77
For Chile
Pre-Delivery and
Periodic Inspection Manual
JANUARY 2014
114 (H)

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For Chile

Pub.No.11ELB0003, JANUARY 2014

FUSO ASCENT-ALEJANDRO CANTO

For more detailed information about stan- PERIODIC INSPECTION

© 2014 Mitsubishi FUSO Truck & Bus Corporation

FUSO ASCENT-ALEJANDRO CANTO

Symbol operating condition Symbol of inspection

Inspections in the vehicle Visual inspections

Inspections with the vehicle Inspections by the auditory

Inspections with feeling or by

Inspections with driving the Inspections with using a tool

FUSO ASCENT-ALEJANDRO CANTO

• PRECAUTIONS BEFORE SERVICE. . . . . . . . . . . . . . . . . . . 0-4

• TIGHTENING TORQUES FOR GENERAL USE BOLTS

• TABLE OF RECOMMENDED GRADE OF LUBRICANT . . . . 0-9

FUSO ASCENT-ALEJANDRO CANTO

INSPECTION AND MAINTENANCE RECOM-

The inspection and maintenance schedule you need to

2. New vehicle inspections

Over time, vehicle’s components wear down and

4. Parts requiring regular replacement

PRECAUTIONS BEFORE SERVICE

2. Service operations should be performed on a level

3. When the vehicles is raised on a jack, use a rigid

4. Use special tools for disassembly and reassembly

5. Bolts and nuts should be tightened to specified

6. When no standard torque is specified, bolts and nuts

7. When disassembling an assembly comprising many

8. Before cleaning parts to be removed or disassem-

9. If oil seals, gaskets, packings, O-rings, split pins, etc.

10.Always use only MITSUBISHI FUSO/MITSUBISHI

11. When servicing the electrical system, disconnect the

TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS

Hex-head Bolts and Stud Bolt (Unit: N·m {kgf·m})

Hex-head Flange Bolt (Unit: N·m {kgf·m})

Hex-head Nut (Unit: N·m {kgf·m})

Hex-head Flange Nut (Unit: N·m {kgf·m})

Pipe diameter φ4.76 mm φ6.35mm φ8 mm φ10 mm φ12 mm φ15 mm

TABLE OF RECOMMENDED GRADE OF LUBRICANT

*1: Use GL-3 or GL-4 SAE90.

• PRE-DELIVERY INSPECTION SHEET

• PRE-DELIVERY INSPECTION PROCEDURE . . . . . . . . . . . 1-3

FUSO ASCENT-ALEJANDRO CANTO

NOTES CONCERNING ENTRIES

3. Symbols for entries:

If any malfunction or other problem is detected during the

FUSO ASCENT-ALEJANDRO CANTO

PRE-DELIVERY INSPECTION PROCEDURE

Check distortion and damage of body panels.

2. OPERATION OF LAMPS AND SWITCHES

Check operation of all lamp and switches.

3. VEHICLE ATTITUDE (INCLINATION)

At the front and rear of vehicle, check for right-

Check that seats, interior trims and head lining

Check the mirrors for reflection and stain.

6. OPERATION OF WINDSHIELD WIPER AND

Check operation of the wiper in all ranges [High,

7. OPERATION OF OTHER ELECTRICAL