Professional Documents
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be741
be741
Pre-Delivery and
Periodic Inspection Manual
(EURO VI)
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 Mitsubishi Fuso ROSA series bus.
PERIODIC INSPECTION
For more detailed information about standard val- 2
SCHEDULE
ues, tightening torques etc., please refer to related
shop manuals.
MAR. 2022
PERIODIC INSPECTION
3
Applicable models PROCEDURE
BE
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.
Inspections with
measurement
Cleaning
Lubricating
Replacement
GROUP-0
GENERAL
• PRECAUTIONS BEFORE SERVICE. . . . . . . . . . . . . . . . . . . 0-2
303093
0-2
PRECAUTIONS BEFORE SERVICE
0-3
TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS
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}
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}
0-4
TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS
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}
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}
0-5
TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS
Tightening torque for flare nut for general purpose (Unit: N·m {kgf·m})
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 +6 +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 {5.50 }
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 {6.50 }
0-6
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
the vehicle. Use only lubricants and hydraulic fluids that conform to the standards and grades of our recommenda-
tion as shown below.
* Use oil conforming to GL-5, SAE140 if the vehicle 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.
Note:
Special lubricants/fluids must be used in cold regions where the ambient temperature could drop below -25°C.
0-7
GROUP-1
PRE-DELIVERY
INSPECTION
• NOTES CONCERNING ENTRIES. . . . . . . . . . . . . . . . . . . . . 1-2
1. The column for model, chassis number, engine number, aggregate travelled distance (in kilometers), 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.
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.
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
Model Good
1. Exterior 20. Operation of accelerator linkage 37. Suspension spring pins, spring
2. Operation of lamps and switches 21. Exhaust gas condition and noise shakles and U-bolt nuts tightnees
3. Vehicle attitude (inclination) 22. Brake pedal play and clearance 38. Propeller shaft flange yoke bolts
4. Interior 23. Clutch pedal play tightness
5. Reflection of mirrors 24. Steering wheel play 39. Differential carrier attaching bolts
and nuts tightness
6. Operation of windshield wiper and 25. Engine stopping performance
washer 40. Body mounting bolts and nuts
26. Electrical wiring connection and
tightness
7. Operation of other electrical routing
equipments (horn, heater, etc.) 41. Front and rear wheel nuts tight-
27. Brake reservoir tank fluid level
ness
8. Operation of door, lock and win- 28. Fuel leaks from fuel tank
dows 42. Tire pressures (including spare
29. AdBlue® leaks from urea lines tire)
9. Operation of lid <vehicles with a BlueTec® system>
43. Transmission operation
10. Washer tank fluid level 30. Fluid leaks from shock absorber
44. Steering operation
11. Radiator coolant level 31. Engine oil leaks from oil pan and
45. Clutch operation
12. Radiator hoses and clamps oil cooler
46. Service brake operation
13. Engine oil level 32. Transmission operation (except
DUONIC) 47. Exhaust brake operation
14. Power steering fluid level
33. Fluid leaks from transmission 48. Parking brake operation
15. Fuel leaks from fuel system
cooling lines (DUONIC) 49. Noise
16. Installed condition of electrical
equipments 34. Fluid leaks from clutch and/or 50. Gauges function
17. Exhaust manifold tightness brake fluid lines 51. Jack and tool set
18. Coolant, gas and oil leaks from 35. Installed condition of exhaust 52. Installation of license plates
cylinder head and over head pipes and mufflers 53. Diagnosis codes
19. Engine starting performance 36. Oil level in, transmission and axle 54. Vehicle washing
housing
Remarks
AdBlue®: Registered trademark of the Verband der Automobilindustrie e.V. (VDA)
BlueTec®: A brand of Daimler AG
1-3
PRE-DELIVERY INSPECTION PROCEDURE
㻟㻜㻟㻜㻥㻡
3. VEHICLE ATTITUDE (INCLINATION)
1-4
PRE-DELIVERY INSPECTION PROCEDURE
4. INTERIOR
㻴㼑㼍㼐㻌㼘㼕㼚㼕㼚㼓
(1) Check that seats and head lining are installed
properly.
(2) Check that seats and head lining are not dam-
aged and dirty.
(3) Check painting, rusting and flaws.
(4) Check for drip and seepage of adhesive.
㻿㼑㼍㼠
㻟㻜㻟㻜㻥㻣
5. REFLECTION OF MIRRORS
U03219
/2 0(
2))
+,
303099
1-5
PRE-DELIVERY INSPECTION PROCEDURE
Grip
Door open/close
switch
Door open/close
switch
㻾㼑㼍㼞㻌㼐㼛㼛㼞
㻟㻜㻟㻝㻜㻜
1-6
PRE-DELIVERY INSPECTION PROCEDURE
9. OPERATION OF LID
Coolant lid
Fuel lid
㻟㻜㻟㻝㻜㻝
Washer tank
㻟㻜㻟㻝㻜㻞
1-7
PRE-DELIVERY INSPECTION PROCEDURE
1-8
PRE-DELIVERY INSPECTION PROCEDURE
㻼㼞㼑㼟㼟㼡㼞㼑㻌㼞㼑㼓㼡㼘㼍㼠㼛㼞㻌㼢㼍㼘㼢㼑 㻯㼛㼙㼙㼛㼚㻌㼞㼍㼕㼘
㻼㼞㼑㼟㼟㼡㼞㼑㻌㼟㼑㼚㼟㼛㼞
㻸㼛㼣㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌㼒㼡㼑㼘㻌㼞㼑㼠㼡㼞㼚㻌㼜㼕㼜㼑
㻵㼚㼖㼑㼏㼠㼛㼞
㻯㼔㼑㼏㼗㻌㼢㼍㼘㼢㼑㼟
㻲㼡㼑㼘㻌㼞㼑㼠㼡㼞㼚㻌㼜㼕㼜㼑
㻴㼕㼓㼔㻌㼜㼞㼑㼟㼟㼡㼞㼑
㼒㼡㼑㼘㻌㼜㼕㼜㼑 㻴㼕㼓㼔㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌㼒㼡㼑㼘㻌㼜㼡㼙㼜 㻲㼡㼑㼘㻌㼒㼕㼘㼠㼑㼞
㼀
㻻㼢㼑㼞㻌㼜㼞㼑㼟㼟㼡㼞㼑
㻲㼡㼑㼘㻌㼑㼘㼑㼏㼠㼞㼕㼏㻌㼜㼡㼙㼜 㼢㼍㼘㼢㼑
㼚㼛㼚㻙㼞㼑㼠㼡㼞㼚㻌㼢㼍㼘㼢㼑
㻲㼡㼑㼘㻌㼑㼘㼑㼏㼠㼞㼕㼏
㼜㼡㼙㼜
㻲㼡㼑㼘㻌㼠㼍㼚㼗
㻲㻹㼁㻌
㻔㼒㼡㼑㼘㻌㼙㼑㼠㼑㼞㼕㼚㼓㻌㼡㼚㼕㼠㻕
㻸㼑㼢㼑㼘㻌㼟㼑㼚㼟㼛㼞 㻶㼑㼠㻌㼜㼡㼙㼜
㻲㼡㼑㼘㻌㼑㼘㼑㼏㼠㼞㼕㼏㻌㼜㼡㼙㼜
㼕㼚㼠㼍㼗㼑㻌㼒㼕㼘㼠㼑㼞
㻟㻜㻟㻝㻞㻜
1-9
PRE-DELIVERY INSPECTION PROCEDURE
P118941E
(1) Check for coolant and gas leaks from the cylin-
der head.
(2) Check for oil leaks from the over head.
P118546E
303104
303105
1-10
PRE-DELIVERY INSPECTION PROCEDURE
303106
Height
06540E
1-11
PRE-DELIVERY INSPECTION PROCEDURE
Z21168
U03208
U03858
(1) Check for fuel leaks from the drain plug of the
fuel tank, the pipe connections and the seam.
1-12
PRE-DELIVERY INSPECTION PROCEDURE
WARNING
• If AdBlue® splashes into your eyes, wash it
away immediately with plenty of water and
seek medical attention as soon as possi-
ble.
• The AdBlue® is not harmful to the skin.
However, if it makes contact with your skin,
wash it off with water immediately. If the
skin swells or irritates, seek medical atten-
tion.
• Direct contact with white crystals can
cause the skin to inflame. In such a case,
wash the affected part thoroughly with
plenty of water without delay.
Urea line
Urea tank
Exhaust gas
㻼㻝㻝㻤㻜㻤㻤㻱
1-13
PRE-DELIVERY INSPECTION PROCEDURE
㻿㼔㼛㼏㼗㻌㼍㼎㼟㼛㼞㼎㼑㼞
㻌䠘㻾㼑㼍㼞䠚
㻟㻜㻟㻝㻜㻣
(1) Check for oil leaks from the engine oil pan and
oil filter support area.
㻳㼑㼍㼞㼟㼔㼕㼒㼠㻌㼘㼑㼢㼑㼞
㻿㼑㼘㼑㼏㼠㻌㼏㼍㼎㼘㼑
㻿㼔㼕㼒㼠㻌㼏㼍㼎㼘㼑
㻟㻜㻟㻝㻜㻤
1-14
PRE-DELIVERY INSPECTION PROCEDURE
P115859
㻮㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌㼠㼍㼚㼗
㻯㼘㼡㼠㼏㼔㻌㼎㼛㼛㼟㼠㼑㼞
㻯㼘㼡㼠㼏㼔㻌㼙㼍㼟㼠㼑㼞㻌㼏㼥㼘㼕㼚㼐㼑㼞
㻲㼞㼛㼚㼠㻌㼣㼔㼑㼑㼘 㻾㼑㼍㼞㻌㼣㼔㼑㼑㼘
㼎㼞㼍㼗㼑 㼎㼞㼍㼗㼑
㼂㼍㼏㼡㼡㼙 㻮㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌㼠㼍㼚㼗
㼎㼛㼛㼟㼠㼑㼞
㻮㼞㼍㼗㼑㻌㼙㼍㼟㼠㼑㼞
㼏㼥㼘㼕㼚㼐㼑㼞
㻮㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐 㻮㼞㼍㼗㼑㻌㼏㼛㼚㼠㼞㼛㼘
㼜㼞㼑㼟㼟㼡㼞㼑㻌㼟㼑㼚㼟㼛㼞 㻮㼞㼍㼗㼑㻌㼏㼛㼚㼠㼞㼛㼘 㼢㼍㼘㼢㼑㻌㻔㼞㼑㼍㼞㻕
㻰㼕㼞㼑㼏㼠㻌㼜㼛㼣㼑㼞㻌㼏㼥㼘㼕㼚㼐㼑㼞
㻨㻰㼁㻻㻺㻵㻯㻪 㼢㼍㼘㼢㼑㻌㻨㻰㼁㻻㻺㻵㻯㻪
㻯㼛㼚㼚㼑㼏㼠㼛㼞
㻴㼥㼐㼞㼍㼡㼘㼕㼏㻌㼡㼚㼕㼠
㻮㼞㼍㼗㼑㻌㼔㼛㼟㼑
㻮㼞㼍㼗㼑㻌㼔㼛㼟㼑
䠖㻌㻴㼛㼟㼑
䠖㻌㻲㼘㼡㼕㼐㻌㼘㼕㼚㼑
㻟㻜㻟㻝㻜㻥
1-15
PRE-DELIVERY INSPECTION PROCEDURE
Exhaust pipe
Tail pipe
㻟㻜㻟㻝㻝㻜
1-16
PRE-DELIVERY INSPECTION PROCEDURE
㻟㻜㻟㻝㻝㻝
1-17
PRE-DELIVERY INSPECTION PROCEDURE
1-18
PRE-DELIVERY INSPECTION PROCEDURE
P118462
1-19
PRE-DELIVERY INSPECTION PROCEDURE
<DUONIC>
(1) Allow the vehicle to creep forward and reverse
and start the vehicle in forward and reverse to
check for any faults in each operation.
(2) Check for smooth gearshift while driving.
303112
Note: If any faults are found, perform the Initial-
ization of DUONIC System as described
in Group 22ED of the Shop Manual.
<Except DUONIC>
(1) Check the operation of transmission and gean-
hift lever in all ranges.
604760
1-20
PRE-DELIVERY INSPECTION PROCEDURE
303113
303133
How to check
(1) Run the vehicle and turn on the exhaust
brake switch.
(2) Release your foot from the accelerator pedal.
(3) The indicator lamp lights and the exhaust
brake comes into operation.
1-21
PRE-DELIVERY INSPECTION PROCEDURE
㻟㻜㻟㻝㻝㻠
49. NOISE
303115
1-22
PRE-DELIVERY INSPECTION PROCEDURE
(1) Verify that the jack and tool sets are in 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
Z22616
1-23
PRE-DELIVERY INSPECTION PROCEDURE
Connector Connector
Personal computer
FUSO connect Connector
Tester Harness
1-24
GROUP-2
PERIODIC
INSPECTION
SCHEDULE
• PERIODIC INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . 2-2
PERIODIC INSPECTION SCHEDULE
CAUTION
• 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.
• 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.
2-2
PERIODIC INSPECTION SCHEDULE
Interval *1
Maintenance item x1,000 km Ref. Page
Months
40 80 120
Engine
Normal use • R: 20 R: 12
ACEA C2
Severe use*2 • R: 10 •
Engine oil 3-4
API CJ-4, JASO DH-2, Normal use • R: 13.5 R: 12
ACEA E6, ACEA E9 Severe use*2 • R: 10 •
Oil filter element • R R R R: 12 3-8
Fuel filter element • R R R R: 12 3-11
Air cleaner element • R R R R: 12 3-15
PCV filter • R R R • 3-19
Cooling system • I I I I: 12 3-20
Coolant • • • • R: 24 3-20
Belts (inspect) • I I I I: 12 3-25
Belts (replace) • • • R R: 48 3-30
Exhaust system • I I I I: 12 3-31
Urea line leakage & damage • I I I I: 12 3-32
DPF • I I I I: 12 3-33
DPF pressure hose • I I I I: 24 3-33
Alternator tensioner • R: 240 R: 60 3-33
Alternator • • • • I: 12 3-33
Normal use • • • • I: 24
Fuel line leakage & damage 3-34
Severe use*3 • • • • I: 12
Glow plug • R: 240 R: 60 3-35
Drive line
Clutch control fluid • • R • R: 24 3-38
Transmission gear oil • • R • R: 24 3-40
Propeller shaft bearing kit • R: 200 R: 120 3-41
Propeller shaft center bearing
• • I • I: 24 3-42
<Except double antivibration type>
Propeller shaft center bearing • • L • L: 24 3-43
Propeller shaft center bearing
I I: 50 •
<Double antivibration type>
3-44
Propeller shaft center bearing
• R: 150 •
<Double antivibration type>
Propeller shaft flange yoke bolts I I I I I: 12 3-45
Propeller shaft (universal joint/slip joint) L L L L L: 12 3-46
Front and rear wheel bearing grease • R: 60 R: 12 3-46
Rear axle differential gear oil • • R • R: 24 3-47
Tie rod ball joint dust boots • I I I I: 12 3-48
Tie rod ends • L L L L: 12 3-48
Wheel nut • I I I I: 12 3-49
Disc wheel • I I I I: 12 3-50
Tires • I I I I: 12 3-51
Tire rotation • I I I I: 12 3-53
*1 Maintain depending on either the odometer reading or operating period (months), whichever occurs first.
*2 If you drive your vehicle under any of the following conditions (severe conditions).
• Operating in slow vehicle speed (lower than 20 km/h in average and more than 30% of total operation) or operations
involving frequent starts and stops.
• Operations involving frequent engine starts and stops condition in 10 minutes and in 10 km distance.
• Operating on long distance (10,000 km/month or more).
• Operating on frequent mountainous roads (more than 30% in total operation).
• Operating on frequent uphill roads trip (more than 30% in total operation).
• Operating an engine with idling speed in a long time (When the rate of idling speed time per a day is 50% or more).
• Operating in a long time (500 hours/month or more).
*3 Perform vehicle inspection at this interval if you drive your vehicle under any of the following conditions (severe conditions).
• Operating on over loading condition (more than 30% in total operation).
• Operating on rough roads (more than 30% in total operation).
• Operating in tropical region (above 46°C).
2-3
PERIODIC INSPECTION SCHEDULE
Interval *1
Maintenance item x1,000 km Ref. Page
Months
40 80 120
Steering
Power steering fluid • R: 50 R: 12 3-56
Steering system • I I I I: 12 3-57
Steering shaft • • • • L: 3 3-59
Brakes
Disc and Pad
• I I I I: 12 3-62
<Vehicles with disc brakes>
Brake fluid • • • • R: 24 3-62
Parking brake • I I I I: 12 3-68
Service brake system • I I I I: 12 3-69
Suspension
Suspension system I I I I I: 12 3-72
IFS system I I I I I: 12 3-72
Stabilizer rod ball joint dust boots
• I I I I: 12 3-73
<Vehicles with stabilizer>
Electrical
Battery • I I I I: 12 3-76
Air conditioner
Air compressor oil leak • • • • I: 12 3-82
Air compressor magnet clutch bearing • • • • I: 12 3-82
Air compressor magnet clutch gap adjustment • • • • I: 12 3-82
Air compressor magnet clutch operation • • • • I: 12 3-83
Air compressor magnet clutch center bolt • • • • I: 12 3-83
Others
Chassis frame damage and looseness • • I • I: 24 3-86
Chassis parts
(accelerator link shaft, accelerator pedal, transmission control
• • L • L: 24 3-86
linkage, gearshift select lever pin, parking brake lever, brake pedal
link, wheel brake parts, door lock, door inside and outside handles)
*1 Maintain depending on either the odometer reading or operating period (months), whichever occurs first.
2-4
GROUP-3
PERIODIC
INSPECTION
PROCEDURE
• ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
• STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
• BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
• SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
• ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
• AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
• OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
ENGINE
1. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
7. COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
8. BELTS-INSPECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
9. BELTS-REPLACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-3
ENGINE
1. ENGINE OIL
Every
Normal 20,000 km or
use every
ACEA-C2 12 months*1
Severe Every
Replacement use*2 10,000 km
intervals Every
API CJ-4, Normal 13,500 km or
JASO DH-2, use every 12
ACEA E6, months*1
ACEA E9 Severe Every
use*2 10,000 km
CAUTION
• If the warning and (amber) warning are
displayed alternately, the oil quality has
decreased. Replace the engine oil immedi-
ately. If the oil which quality has decreased is
used even after the warning, the engine may
suffer various problems, including uncon-
trolled revving of the engine in an extreme
case.
• Use only the specified engine oil. Any other
oils may contain substances that cause the
ceramic filter inside the DPF to be loaded with
particulate matter (PM) prematurely to the
capacity and thus shorten the effectively
functioning period of the DPF.
3-4
ENGINE
Recommended lubricant:
Engine oil
Viscosity
Classification Atmospheric SAE viscosity
temperature number
0W–30,
ACEA C2 –
5W–30
Below 0°C 10W–30
JASO DH-2
Above –15°C 15W–40
Below 0°C 10W–30
API CJ-4 Above –15°C 15W–40
Above 30°C 40
ACEA E6 – 5W–30
ACEA E9 – 10W–40
3-5
ENGINE
U04797
(3) Remove drain plug from the oil pan to remove the
oil.
Front of
vehicle
㼆㻞㻞㻢㻟㻠
WARNING
The engine 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.
(4) After oil has been drained out, clean the area
around the drain plug hole.
(5) Replace the O-ring with a new one and tighten
the drain plug.
30±10 N·m
Tightening torque
(3.0±1.0 kgf·m)
3-6
ENGINE
(7) Close the oil filler cap, wait for more than 5 min-
utes and check the oil level. If the oil is not
within the replenishing level range indicated in
the figure, add or remove oil to adjust the level.
(8) Crank the engine in accordance with the
engine starting procedure shown on the
Owner’s Handbook.
(9) Start the engine and warm it up until the water
temperature gauge moves to the center.
(10) Stop the engine and wait for more than 15 min- Z25880
utes before checking the oil level again. If the
(above notch): HIGH (for refilling)
oil is not within the replenishing level range (below notch): LOW
indicated in the figure, add or remove oil to
adjust the level, and return to step 9 to inspect
the oil level again.
(11) Check that there are no oil leaks from the drain
plug.
(12) Reset the engine control unit. See next
“RESETTING THE ENGINE CONTROL UNIT”
for the method.
CAUTION
• Do not add oil so that it exceeds HIGH (above
notch) on the oil level gauge. Doing so will
cause wasteful oil consumption, and cause
the oil level gauge to exceed FULL (for
inspection) ( symbol) quicker than usual.
• If the engine is frequently run at high speeds
or under heavy loads, the engine oil will dete-
riorate quickly and must be replaced sooner
than specified.
• When adding engine oil, take care not to spill
it. If oil is spilled on a belt, the belt will slip on
pulleys.
WARNING
Take care not to spill engine oil as engine oil
on the exhaust manifold, the starter or other
hot sections of engine could catch fire. Wipe
clean spilt oil.
3-7
ENGINE
CAUTION
After replacing the engine oil, reset the engine
control unit. The engine control unit calculates
the engine oil replacement time. The steps
above are necessary in order to reset the data
used for determining the engine oil replacement
time.
Every 40,000 km or
Replacement intervals
every 12 months*1
CAUTION
• Oil filter element must not be cleaned and
reused. Always replace the filter element with
a new one.
• When installing filter cases and air-releasing
plugs, be careful not to let the O-ring twist
and be damaged.
WARNING
• Spilt engine oil should be wiped off clean.
Oil remaining on the exhaust manifold, the
starter or other hot sections of engine sur-
face could catch fire.
• Do not replace the oil filter immediately
after operating the vehicle since the
engine, transmission, exhaust pipe, engine
oil, and other items will be extremely hot. 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.
3-8
ENGINE
Z21175
CAUTION
Use a 4 mm or 5/32 inch Allen wrench. Using a Z22308
larger Allen wrench may damage the air drain
plug O-ring seal surface, while using a smaller
one may pierce the element.
3-9
ENGINE
CAUTION
Use only the O-ring supplied with a new replace-
ment filter element.
(12) Install the new filter element with its holed end Z21178
facing down. Be sure to use a MITSUBISHI
FUSO genuine filter element.
(13) Install a new air-releasing plug to the oil filter
case.
Use a new air-releasing plug provided with a
new element.
1.5 ± 0.6 N·m
Tightening torque
(0.15 to 0.06 kgf·m)
25 to 30 N·m
Tightening torque
(2.5 to 3.0 kgf·m)
CAUTION
Do not tighten the air-releasing plug and filter
case beyond the specified torque. The air-
releasing plug and filter case could be broken if
over-tightened.
3-10
ENGINE
Every 40,000 km or
Replacement intervals
every 12 months*1
WARNING
• Fuel is highly flammable and should be
kept away from hot objects and open
flames owing to the risk of fire or explo-
sion. Wipe up any spilt fuel.
• Do not replace the fuel filter element imme-
diately after the vehicle has been driven as
the filter will be hot and could burn you.
Wait until the filter cools down.
• After installing the fuel filter, confirm that
no fuel is leaking out. Leaking fuel could
cause a fire or explosion.
• Use only the fuel filter specified for your
vehicle. Use of other filters could cause
fuel to leak and cause a fire or explosion.
• When replacing the fuel filter element, be
sure to use the special tool to remove and
reinstall the fuel filter case. If the fuel filter
case is inappropriately reinstalled, fuel
could leak and the filter itself could
become damaged, possibly resulting in a
fire and/or explosion.
• Be careful not to damage the filter case, as
this could cause fuel leakage.
• Keep cigarettes and other sources of heat
away from the vehicle while replacing the
fuel filter. They are dangerous because
they could set fire to the fuel.
• When replacing the fuel filter, you will be
working in a tight space. Be careful not to
injure yourself on the edges of nearby
components.
3-11
ENGINE
CAUTION
• Fuel filter element must not be cleaned and
reused.
• Always replace with a new, genuine fuel filter
element. Do not use the filter element beyond
the recommended replacement intervals. Fail-
ure to observe these may damage the fuel
injection system.
• Be careful not to allow foreign matter to get
into the fuel system when replacing the fuel
filter element. Foreign matter in the fuel sys-
tem could make the fuel injection system mal-
function.
• Do not kick or strike the fuel filter because it
could damage the internal sensor.
Z22618
㼆㻞㻟㻠㻤㻝
3-12
ENGINE
Z21455
Z21456
CAUTION
• Be sure to insert the special tool horizontally
from the opposite direction of the drain plug.
If the special tool is not inserted from the
opposite direction of the drain plug, the spe- Z25099
cial tool will be inserted only partially, and a
filter case might be damaged.
• When inserting the special tool, be careful not
to catch sensor harness .
Z25100
3-13
ENGINE
CAUTION
• Remove and install the filter element in par- Z21459
allel with the axis of the filter case. Otherwise,
the sensor inside the case could become
damaged.
• Use only the O-ring supplied with a new
replacement filter element.
CAUTION
• Install the fuel filter case carefully so as not to
twist or damage the O-ring.
• Do not reuse the filter element. Z21460
CAUTION
• Be sure to insert the special tool horizontally
from the opposite direction of the drain plug.
If the special tool is not inserted from the
opposite direction of the drain plug, the spe-
cial tool will be inserted only partially, and a
filter case might be damaged.
• When inserting the special tool, be careful not
to catch sensor harness .
CAUTION Z25177
3-14
ENGINE
Every 40,000 km or
Replacement intervals
every 12 months*1
*1: The air cleaner element must be replaced
depending on either the odometer reading or
operating period (months), whichever occurs
first.
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 cleaner element at the specified
interval. Failure to follow this instruction will
result in premature accumulation of PM in the
DPF and eventually cause the systems to mal-
function. On the contrary, unnecessarily fre-
quent cleaning can damage the air cleaner
element, allowing dust and other foreign matter
to be drawn into the engine.
3-15
ENGINE
Z22820
Z22620
REMOVAL
(1) Undo the two clamps and then pull the cover
toward the clamps to remove it.
Z22621
3-16
ENGINE
Z21180
Z21181
INSTALLATION
(1) Insert the air cleaner element into the air
cleaner element case in a straight line.
(2) Move the lock lever in the air cleaner element
case to the “LOCK” position.
Z21182
CAUTION
Install the air cleaner element in the case and
close the case completely. A broken packing or
loose fastening of the clamps will cause dust or
other foreign material to be sucked in by the Z21183
engine, causing the pistons and cylinder liners
to become worn prematurely.
3-17
ENGINE
CAUTION
• Dust can damage your health. Wear a dust
mask to avoid inhaling dust while cleaning
the air cleaner element. Also, wear thick
gloves while removing and installing the
cover.
• Keep the air pressure under 685 kPa (7 kgf/
cm2) to prevent the element from being dam-
aged.
• Do not strike the element or hit it against
another object.
• If the element is contaminated with oily soot
or dust, replace it regardless of the scheduled
replacement time.
Z21184
Z21185
Z21186
3-18
ENGINE
REPLACEMENT
(1) Use a genuine cleaner element for replace-
ment.
Remove the air cleaner element from the case
and replace it with a new one.
Z21187
5. PCV FILTER
Removal
(1) Remove the nut, then remove the PCV cover.
㻼㻯㼂㻌㼏㼑㼚㼠㼑㼞㻌㼟㼔㼍㼒㼠
(2) Remove the PCV snap ring. (Rotate the ring 㻼㻯㼂㻌㼒㼕㼘㼠㼑㼞
opening to a position where it can be easily 㻼㻯㼂㻌㻿㼚㼍㼜
㼞㼕㼚㼓
operated with a tool and then remove it)
(3) Remove PCV filter. (Pinch and extract the two
rib panel diagonally positioned in the surface
with a needle nose plier)
㻺㼡㼠
CAUTION 㻼㻯㼂㻌㼏㼛㼢㼑㼞
600804
• Since the PCV center shaft becomes the slid-
ing surface of the shaft seal on the PCV cover
side, it will not be damaged when removing
the PCV snap ring.
• PCV center shaft internal bolt must not
loosen as engine timing changes as it loos-
ens temporarily.
CAUTION 㻼㻯㼂㻌
Carefully direct the bar during insertion so as 㼟㼔㼍㼒㼠㻌㼟㼑㼍㼘
not to injure the diaphragm thin film at the back 㻮㼍㼞
side of the PCV cover.
㻼㻯㼂㻌㼏㼛㼢㼑㼞
㻔㻮㼍㼏㼗㻕 600805
Installation
(1) Check the installation direction of PCV shaft PCV (Front)
shaft seal ring
seal ring. (Half arc part)
Diaphragm
Metal surface
(2) Press the PCV shaft seal ring at the step of the thin film
PCV cover till it comes to bottom. (Back)
(3) Apply white Industrial petroleum Jelly at PCV Rubber surface
O-ring of PCV cover. PCV
O-ring
(4) Install PCV O-ring on PCV cover.
(Level difference)
PCV cover
301207
3-19
ENGINE
6. COOLING SYSTEM
㻼㼞㼑㼟㼟㼡㼞㼑㻌㼏㼍㼜
Every 40,000 km or
Inspection intervals
every 12 months*1
㻾㼍㼐㼕㼍㼠㼛㼞㻌㼔㼛㼟㼑
*1: The cooling system must be inspected depend-
ing on either the odometer reading or operating
period (months), whichever occurs first. 㼃㼍㼠㼑㼞㻌㼔㼛㼟㼑
㻾㼍㼐㼕㼍㼠㼛㼞㻌㼔㼛㼟㼑
㻟㻜㻟㻝㻝㻣
7. COOLANT
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.
• Use the specified long life coolant. Using any
coolant other than the specified long life cool-
ant could cause corrosion and damage to the
cooling systems.
• When replacing or adding coolant, use the
same brand of long life coolant as that
already in the system. Never mix a different
coolant of antifreeze or anti-corrosion addi-
tives since these can detract from its perfor-
mance. If you use other brands or types
coolant, be sure to thoroughly flush the cool-
ing system.
• Do not use methanol-based or methoxypro-
panol- based antifreeze products. They can
severely damage the engine.
• Adding only soft water reduces the concen-
tration of the coolant already in the system,
resulting in less protection against freezing
and corrosion. Additional coolant should
always contain the correct proportions of the
additive and soft water.
3-20
ENGINE
COOLANT
To prevent the cooling system freezing up and to
minimize corrosion, use the specified long life cool-
ant. Dilute it with soft water to the specified concen-
tration.
3-21
ENGINE
DANGER
• LONGLIFE COOLANT IS TOXIC. IF A PER-
SON HAS ACCIDENTALLY SWALLOWED
IT, FORCE HIM/HER TO VOMIT AND CON-
SULT A DOCTOR IMMEDIATELY. IF IT
SPLASHES IN THE EYES, IMMEDIATELY
FLUSH THE EYES WITH WATER FOR
MORE THAN 15 MINUTES, AND SEEK
MEDICAL ATTENTION.
• SHOULD LONGLIFE COOLANT COME IN
CONTACT WITH YOUR SKIN, IMMEDI-
ATELY WIPE IT OFF, AND THEN THOR-
OUGHLY WASH YOUR SKIN WITH LOTS
OF CLEAN WATER AND SOAP. IF YOU
FEEL UNWELL OR PAIN ON YOUR SKIN,
IMMEDIATELY SEEK MEDICAL ATTEN-
TION.
IN THE EVENT OF CONTACT WITH YOUR
CLOTHES, IMMEDIATELY FLUSH
LONGLIFE COOLANT WITH WATER AND
SOAP.
• DO NOT USE LONGLIFE COOLANT IN A
CLOSED OR POORLY VENTILATED
SPACE. SHOULD YOU INHALE A LARGE
AMOUNT OF GAS OF LONGLIFE COOL-
ANT, MOVE TO A PLACE WITH FRESH AIR
AND KEEP YOURSELF WARM AND AT
REST. IF YOU FEEL NAUSEOUS OR OTH-
ERWISE ABNORMAL, IMMEDIATELY SEEK
MEDICAL ATTENTION.
• CLOSE THE CAP OF THE LONGLIFE
COOLANT CONTAINER IMMEDIATELY
AFTER USING THE PRODUCT.
• ALWAYS STORE COOLANT AT A LOCA-
TION OUT OF THE REACH OF CHILDREN.
• THE LONGLIFE COOLANT IS INFLAMMA-
BLE. BE CAREFUL TO NEVER EXPOSE IT
TO FIRE.
• WHEN HANDLING LONGLIFE COOLANT,
WEAR AN ORGANIC GAS MASK, PROTEC-
TION GOGGLES, OIL-RESISTANT GLOVES,
AND/OR PROTECTIVE APRON AS NECES-
SARY.
-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%
% % % % % %
3-22
ENGINE
CAUTION
Longlife coolant is used in the range of 30% to
60%. At normal temperature, the rate is about
30%. At lower than 30% the coolant’s rust inhibi-
tion effect diminishes and at more than 60%, its
antifreeze action drops.
REPLACEMENT
Be sure to flush the cooling system when replacing
the coolant.
WARNING
• Do not replace the coolant immediately
after operating the vehicle since the
engine, radiator, coolant, and other items
will be extremely hot. If you try to drain the
coolant immediately after driving the vehi-
cle, you may be scalded. Give the coolant
time to cool before starting the job.
• Never remove the pressure cap while the
coolant is still hot. Carelessly removing it
is dangerous since boiling coolant and hot
steam will gush out and could scald you.
Only after the coolant has cooled down
sufficiently, remove the pressure cap by
gripping it in a folded piece of thick cloth
and opening it slowly.
• Tighten the pressure cap before operating
the engine. If the engine speed is increased
with the pressure cap left open, steam and
boiling coolant will overflow from the pres-
sure cap opening as its temperature rises.
U04800
U04801
3-23
ENGINE
Z22624
CAUTION
If the radiator tubing is clogged or coolant is
more contaminated than usual, have the vehicle
inspected.
U04802
(10) Check that the coolant level in the pressure cap
opening does not go down, then fit the pres-
sure cap (turn it clockwise until it is tight).
CAUTION
If air is not completely removed from the cool-
ing system, this may lead to reduced cooling
efficiency and engine parts failure. After replac-
ing the coolant, drive the vehicle and then check
the coolant level.
3-24
ENGINE
8. BELTS-INSPECT
Every 40,000 km or
Inspection intervals every 12 months*1
*1 The belts must be inspected depending on
either the odometer reading or operating period
(months), whichever occurs first.
WARNING
Always stop the engine before inspecting or
adjusting belts.
Ensure that the engine cannot be started
while you are performing checks or adjust-
ments.
3-25
ENGINE
CAUTION
• If the belt is found to be damaged, have it
replaced. The engine could fail if the belt
breaks.
• Prevent the belt from any contact with oil or
grease during inspection.
If soiled with oil or grease, the belts will slip
and this will shorten their service life.
LOOSENESS OF BELT
(1) Use a sonic belt tension gauge (special tool) to
check to see that the belt tension is within the
standard.
P1: Fan belt tension measuring point
P2: Second compressor belt tension measur-
ing point
(2) Direct the sensor microphone of sonic belt ten-
sion gauge (special tool) to the position shown
in the illustration and measure the belt tension.
For the operation of the sonic belt tension
gauge (special tool), see the instruction manual
of the tension gauge.
CAUTION
When checking or adjusting the belt tension,
measure the belt tension with the belt surface
temperature being similar to the room tempera-
ture. Higher temperature will increase the belt
tension, leading to incorrect tension measure-
ments.
Measuring point on
Unit mass of the belt
the belt
P1 0.016 kg/m
P2 0.016 kg/m
P102974E
3-26
ENGINE
(7) Select the type of the belt. (Select “3” for ribbed
belt.)
P106964E
Measuring point on
Number of ribs
the belt
P1 7
P2 7
95138E
Measuring point on
Length of span
the belt
P1 202 mm
P2 203 mm
P119350E
3-27
ENGINE
P113418E
(16) If the belt is not in correct alignment with ten-
sion pulley, check the auto tensioner or replace
the belt with a new one.
25 ± 3 N·m
Lock nut tightening torque
(2.5 ± 0.3 kgf·m)
CAUTION
Be sure to adjust the belt to proper tension.
Overstraining could damage the belt and rele-
vant component bearings.
3-28
ENGINE
Z14709
3-29
ENGINE
9. BELTS-REPLACE
Every 120,000 km
Replacement intervals
or every 48 months*1
*1: The belts must be replaced depending on
either the odometer reading or operating period
(months), whichever occurs first.
P125684E
㻮㼞㼍㼏㼗㼑㼠
㻮㼑㼘㼠
504538E
㻰㼞㼕㼢㼑㼞
P125684E
3-30
ENGINE
Every 40,000 km or
Inspection intervals
every 12 months*1
Exhaust pipe
Tail pipe
㻟㻜㻟㻝㻝㻤
3-31
ENGINE
Every 40,000 km or
Inspection intervals
every 24 months*1
WARNING
®
• If AdBlue splashes into your eyes, wash it
away immediately with plenty of water and
seek medical attention as soon as possible.
• The AdBlue® is not harmful to the skin. How-
ever, if it makes contact with your skin, wash
it off with water immediately. If the skin
swells or irritates, seek medical attention.
• Direct contact with white crystals can
cause the skin to inflame. In such a case,
wash the affected part thoroughly with
plenty of water without delay.
Urea line
Urea tank
Exhaust gas
㻼㻝㻝㻤㻜㻤㻤㻱
3-32
ENGINE
12. DPF
Every 40,000 km or
Inspection intervals
every 12 months*1
Every 40,000 km or
Inspection intervals
every 24 months*1
*1: The DPF pressure hose must be inspected
depending on either the odometer reading or
operating period (months), whichever occurs first. DPF muffler
303119
Every 240,000 km or
Replacement intervals 㻮㼛㼘㼠
every 60 months*1
㻭㼡㼠㼛㼙㼍㼠㼕㼏
*1: The alternator tensioner must be replaced 㼎㼑㼘㼠㻌㼠㼑㼚㼟㼕㼛㼚㼑㼞
depending on either the odometer reading or
operating period (months), whichever occurs first.
P125669E
15. ALTERNATOR
Alternator
pulley
3-33
ENGINE
(1) Check the fuel line for fuel leaks and damages.
(2) If there is any deterioration, swelling, scratch or
crack, replace it.
㻼㼞㼑㼟㼟㼡㼞㼑㻌㼞㼑㼓㼡㼘㼍㼠㼛㼞㻌㼢㼍㼘㼢㼑 㻯㼛㼙㼙㼛㼚㻌㼞㼍㼕㼘
㻼㼞㼑㼟㼟㼡㼞㼑㻌㼟㼑㼚㼟㼛㼞
㻸㼛㼣㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌㼒㼡㼑㼘㻌㼞㼑㼠㼡㼞㼚㻌㼜㼕㼜㼑
㻵㼚㼖㼑㼏㼠㼛㼞
㻯㼔㼑㼏㼗㻌㼢㼍㼘㼢㼑㼟
㻲㼡㼑㼘㻌㼞㼑㼠㼡㼞㼚㻌㼜㼕㼜㼑
㻴㼕㼓㼔㻌㼜㼞㼑㼟㼟㼡㼞㼑
㼒㼡㼑㼘㻌㼜㼕㼜㼑 㻴㼕㼓㼔㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌㼒㼡㼑㼘㻌㼜㼡㼙㼜 㻲㼡㼑㼘㻌㼒㼕㼘㼠㼑㼞
㼀
㻻㼢㼑㼞㻌㼜㼞㼑㼟㼟㼡㼞㼑
㻲㼡㼑㼘㻌㼑㼘㼑㼏㼠㼞㼕㼏㻌㼜㼡㼙㼜 㼢㼍㼘㼢㼑
㼚㼛㼚㻙㼞㼑㼠㼡㼞㼚㻌㼢㼍㼘㼢㼑
㻲㼡㼑㼘㻌㼑㼘㼑㼏㼠㼞㼕㼏
㼜㼡㼙㼜
㻲㼡㼑㼘㻌㼠㼍㼚㼗
㻲㻹㼁㻌
㻔㼒㼡㼑㼘㻌㼙㼑㼠㼑㼞㼕㼚㼓㻌㼡㼚㼕㼠㻕
㻸㼑㼢㼑㼘㻌㼟㼑㼚㼟㼛㼞 㻶㼑㼠㻌㼜㼡㼙㼜
㻲㼡㼑㼘㻌㼑㼘㼑㼏㼠㼞㼕㼏㻌㼜㼡㼙㼜
㼕㼚㼠㼍㼗㼑㻌㼒㼕㼘㼠㼑㼞
㻟㻜㻟㻝㻞㻜
3-34
ENGINE
Every 240,000 km or
Replacement intervals
every 60 months*1
*1: The glow plug must be replaced depending on
either the odometer reading or operating period
(months), whichever occurs first.
3-35
DRIVE LINE
18. CLUTCH CONTROL FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-37
DRIVE LINE
Every 80,000 km or
Replacement intervals
every 24 months*1
Recommended oil:
FUSO ATF SP III
WARNING
Automatic transmission fluid is hot immedi-
ately after driving. Perform work when the
fluid is cold.
P114893E
(2) After draining automatic transmission fluid,
tighten the drain plug.
9 to 13 N·m
Drain plug
Drain plug (0.9 to 1.3 kgf·m)
tightening torque 39 N·m
Drain plug
(4.0 kgf·m)
CAUTION
After draining automatic transmission fluid,
promptly install the inspection plug to prevent
dirt and dust from entering the clutch housing.
㻵㼚㼟㼜㼑㼏㼠㼕㼛㼚㻌㼜㼘㼡㼓㻌㼔㼛㼘㼑
㻻㼕㼘㻌㼟㼡㼞㼒㼍㼏㼑
P121234E
3-38
DRIVE LINE
Operation finished.
3-39
DRIVE LINE
CAUTION
After filling automatic transmission fluid,
promptly install the inspection plug to prevent
dirt and dust from entering the clutch housing.
Every 80,000 km or
Replacement intervals
every 24 months*1
*1: The transmission gear oil must be replaced
depending on either the odometer reading or
operating period (months), whichever occurs
first.
Recommended oil:
Gear oil
Viscosity
Classification SAE viscosity
Condition
number
General 80
API GL-3
Warm region 90
General 80
API GL-4
Tropical region 90
Quantity required:
WARNING
Since the oil reaches very high temperature
after operation of the vehicle, exercise
extreme care when draining the oil. Give the
oil time to cool before draining it.
P117456E
Note: If you replace oil shortly after the engine has
been stopped, while the oil is still slightly
warm, it will drain out faster.
3-40
DRIVE LINE
600504
68.6 ± 14.7 N·m
Tightening torque
(7.0 ± 1.5 kgf·m)
Every 200,000 km or
Replace intervals
every 120 months*1
3-41
DRIVE LINE
Every 80,000 km or
Inspection intervals
every 24 months*1
3-42
DRIVE LINE
Every 80,000 km or
Greasing intervals
every 24 months*1
Recommended lubricant:
Heat-resisting grease
NLGI No. 3
3-43
DRIVE LINE
CAUTION
The propeller shaft center bearing shall be
checked for looseness before grease is packed.
The looseness could not be found if grease is
applied first.
3-44
DRIVE LINE
Every 40,000 km or
Inspection intervals every 12 months*1
3-45
DRIVE LINE
Every 40,000 km or
Greasing intervals
every 12 months*1
Recommended lubricant:
Wheel bearing grease 75649
NLGI No. 2 (Li soap)
(1) Remove all dust and dirt from the grease fit-
tings before using them.
(2) Apply grease to each grease nipples.
㻻㼕㼘㻌㼟㼑㼍㼘
㻴㼡㼎㻌㼏㼍㼜
Every 60,000 km or
Replacement intervals every 12 months*1
*1: The front and rear wheel bearing grease must 㻸㼛㼏㼗㻌㼚㼡㼠 㻵㼚㼚㼑㼞㻌㼎㼑㼍㼞㼕㼚㼓
be replaced depending on either the odometer 㻸㼛㼏㼗㻌㼣㼍㼟㼔㼑㼞 㻻㼡㼠㼑㼞㻌㼎㼑㼍㼞㼕㼚㼓
reading or operating period (months), which- <Rear>
ever occurs first. 㻭㼤㼘㼑㻌㼟㼔㼍㼒㼠
㻻㼡㼠㼑㼞㻌㼛㼕㼘㻌㼟㼑㼍㼘
Recommended lubricant:
Wheel bearing grease
NLGI No. 2 (Li soap)
㻸㼛㼏㼗㻌㼣㼍㼟㼔㼑㼞
(1) Replace the front and rear wheel bearing 㻸㼛㼏㼗㻌㼚㼡㼠
grease. 㻻㼡㼠㼑㼞㻌㼎㼑㼍㼞㼕㼚㼓
(2) Check the wheel bearings as well. 㻵㼚㼚㼑㼞㻌㼎㼑㼍㼞㼕㼚㼓 㻻㼕㼘㻌㼟㼑㼍㼘 㻟㻜㻟㻝㻞㻝
3-46
DRIVE LINE
Every 80,000 km or
Replacement intervals every 24 months*1
Recommended oil:
Gear oil
Viscosity
Classification Atmospheric SAE viscosity
temperature number
Below 40°C 90
API GL-5
Above 40°C 140
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.
WARNING
The oil is hot after the vehicle has been
driven. When draining the oil, be careful not
to get burnt. Give the oil time to cool before
draining it. 75655
3-47
DRIVE LINE
Z18456
Every 40,000 km or
Inspection intervals
every 12 months*1
(1) Check the ball joint dust boots for cracks and
wear.
Every 40,000 km or
Greasing intervals
every 12 months*1
Recommended lubricant:
Wheel bearing grease
NLGI No. 2 (Li soap)
(1) Remove all dust and dirt from the grease fit-
tings before using them.
3-48
DRIVE LINE
Every 40,000 km or
Inspection intervals
every 12 months*1
WARNING
When a tire has been replaced, tightening
force on the nuts will drop due to initial set-
ting. Tighten nuts initially after the vehicle
has been driven about 50 to 100 km.
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.
• Insert the wrench handle until it slightly
protrudes from the socket wrench. Insert
the socket wrench deep into the wheel nut.
If inserted only partially over the nut, the
wrench handle or socket wrench might slip
off when force is applied, resulting in
injury.
T77021
3-49
DRIVE LINE
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-
ens outer wheel nuts while forgetting to
retighten inner wheel nuts. Always follow the
above procedure to tighten all the nuts.
Every 40,000 km or
Inspection intervals every 12 months*1
3-50
DRIVE LINE
32. TIRES
Every 40,000 km or
Inspection intervals every 12 months*1
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.
3-51
DRIVE LINE
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
3-52
DRIVE LINE
Every 40,000 km or
Tire rotation intervals every 12 months*1
WARNING
• As the vehicle is driven after a wheel has Z76299
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.
3-53
STEERING
34. POWER STEERING FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-55
STEERING
Every 50,000 km or
Replacement intervals
every 12 months*1
Recommended fluid:
Automatic transmission fluid
DEXRON ll or DEXRON lII type
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.
3-56
STEERING
Every 40,000 km or
Inspection intervals
every 12 months*1
U01510
3-57
STEERING
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.
3-58
STEERING
Recommended lubricant:
Wheel bearing grease
NLGI No. 2 (Li soap)
75656
(1) Remove all dust and dirt from the grease fit-
tings before using it.
(2) Apply grease to grease nipple.
3-59
BRAKES
37. DISC AND PAD
<VEHICLES WITH DISC BRAKES>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-61
BRAKES
Every 40,000 km or
Inspection intervals
every 12 months*1
Torque member
*1: The disc and pad must be inspected depending
on either the odometer reading or operating
period (months), whichever occurs first. Caliper Disc rotor
<Rear>
Piston
Inner pad
Disc rotor
Torque member
Outer pad
Caliper 㻟㻜㻟㻝㻞㻠
Recommended fluid:
Brake fluid SAE J1703
FMVSS No.116, DOT3
3-62
BRAKES
REPLACEMENT
WARNING
• Be sure to use new brake fluid. Do not mix
it with brake fluid of different properties or
mineral oil (gas oil, engine oil, gear oil,
automatic transmission fluid, etc.). This
will alter the original properties of brake
fluid, causing the boiling point to drop as
well as the brake rubber parts to swell.
Faulty operation of the brake will result.
• Ensure that no foreign matter or water
enter into the brake fluid when refilling it,
as they will cause faulty brake operation.
• Use a mug exclusively kept for the speci-
fied brake fluid. This ensures that no brake
fluid of different properties or mineral oil
enter into the 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.
WARNING
Do not install the power fuse until after the
brake fluid replacement is completed. Other-
wise, the initial system check starts, possibly Spare Spare Spare Spare
F18
F01
F02
F03
F04
F05
F06
F07
F08
F09
F10
F11
F12
F13
F14
F15
F16
F17
F27
F28
F29
F30
F31
F32
F33
F34
3-63
BRAKES
WARNING
Do not install the power fuse until after the air
bleeding of the primary brake system (normal
circuit) is completed. Otherwise, the initial Spare Spare Spare Spare
F18
F01
F02
F03
F04
F05
F06
F07
F08
F09
F10
F11
F12
F13
F14
F15
F16
F17
system check starts, possibly causing air to
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
F33
F34
enter into the secondary system (anti-lock
brake system operating circuit). 608024
㻭㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞
㻭㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞 P58286E
CAUTION
• If air has entered into the secondary brake
system (anti-lock brake system operating cir-
cuit), bleed air from the secondary system
after completing the air bleeding of the pri-
mary system (normal circuit).
• Normally, during air bleeding operation, air
cannot enter into the secondary system (anti-
lock brake system operating circuit) which is
filled with brake fluid and is closed off. There-
fore, only the primary system (anti-lock brake
system operating circuit) needs to be bled of
air.
3-64
BRAKES
With the brake pedal still depressed, allow the brake fluid
to drain.
3-65
BRAKES
CAUTION
• If the ABS system operates with insufficient
air bleeding on the primary side (normal cir-
cuit), air may enter the secondary side (ABS
operating circuit).
• If air enters the secondary side (ABS opera-
tion circuit), air flows to the primary side (nor-
mal circuit) when the ABS system is
operating, and the stroke of the brake pedal
may increase.
3-66
BRAKES
㻱㼘㼕㼙㼕㼚㼍㼠㼕㼚㼓㻌㼠㼔㼑㻌㼜㼞㼕㼙㼍㼞㼥㻌㼟㼕㼐㼑㻌㻔㼚㼛㼞㼙㼍㼘㻌㼟㼕㼐㼑㻕
䇾
䖪㼃㼕㼠㼔㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘㻌㼐㼑㼜㼞㼑㼟㼟㼑㼐㻘㻌㼠㼔㼑㻌㻲㼁㻿㻻㻌㻰㼕㼍㼓㼚㼛㼟㼠㼕㼏㼟㼍㼏㼠㼡㼍㼠㼛㼞㻌㼠㼑㼟㼠㻌㻌㻹㼍㼚㼡㼍㼘㻌㼎㼘㼑㼑㼐㼕㼚㼓䇿㻌㼣㼍㼟㻌㼜㼑㼞㼒㼛㼞㼙㼑㼐㻌㼛㼚㼏㼑㻚
㻯㼍㼡㼠㼕㼛㼚
䞉㻿㼕㼚㼏㼑㻌㼍㼕㼞㻌㼠㼔㼍㼠㻌㼔㼍㼟㻌㼒㼘㼛㼣㼑㼐㻌㼛㼡㼠㻌㼛㼒㻌㼠㼔㼑㻌㼟㼑㼏㼛㼚㼐㼍㼞㼥㻌㼟㼕㼐㼑㻌㻔㻭㻮㻿㻌㼛㼜㼑㼞㼍㼠㼕㼚㼓㻌㼏㼕㼞㼏㼡㼕㼠㻕㻌㼠㼛㻌㼠㼔㼑㻌㼜㼞㼕㼙㼍㼞㼥㻌㼟㼕㼐㼑㻌㻔㼚㼛㼞㼙㼍㼘㻌㼏㼕㼞㼏㼡㼕㼠㻕㻌
㼙㼍㼥㻌㼞㼑㼠㼡㼞㼚㻌㼠㼛㻌㼠㼔㼑㻌㼟㼑㼏㼛㼚㼐㼍㼞㼥㻌㼟㼕㼐㼑㻌㼍㼓㼍㼕㼚㻘㻌㻌㼏㼛㼚㼠㼕㼚㼡㼑㻌㼠㼔㼑㻌㼜㼞㼛㼏㼑㼟㼟㻌㼠㼣㼕㼏㼑㻌㼛㼞㻌㼙㼛㼞㼑㻚
㻷㼑㼑㼜㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘㻌㼐㼑㼜㼞㼑㼟㼟㼑㼐㻌㼑㼢㼑㼚㻌㼍㼒㼠㼑㼞㻌㼠㼔㼑㻌㼍㼏㼠㼡㼍㼠㼛㼞㻌㼠㼑㼟㼠㻚
䖩㻌㻭㼒㼠㼑㼞㻌㼞㼑㼜㼑㼍㼠㼑㼐㼘㼥㻌㼐㼑㼜㼞㼑㼟㼟㼕㼚㼓㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘㻌㼟㼑㼢㼑㼞㼍㼘㻌㼠㼕㼙㼑㼟㻘㻌㼙㼍㼕㼚㼠㼍㼕㼚㻌㼠㼔㼑㻌㼐㼑㼜㼞㼑㼟㼟㼑㼐㻌㼟㼠㼍㼠㼑㻚
㻸㼛㼛㼟㼑㼚㻌㼒㼞㼛㼚㼠㻌㼞㼕㼓㼔㼠㻌㻔㻲㻾㻕㻌㼍㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞
㻰㼞㼍㼕㼚㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌㼣㼔㼕㼘㼑㻌㼐㼑㼜㼞㼑㼟㼟㼕㼚㼓㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘
㻭㼕㼞㻌㼕㼟㻌㼙㼕㼤㼑㼐㻌㼣㼕㼠㼔㻌㼎㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌 㻭㼕㼞㻌㼕㼟㻌㼚㼛㼠㻌㼙㼕㼤㼑㼐㻌㼣㼕㼠㼔㻌㼎㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌
㼀㼕㼓㼔㼠㼑㼚㻌㼠㼔㼑㻌㼒㼞㼛㼚㼠㻌㼞㼕㼓㼔㼠㻌㻔㻲㻾㻕㻌㼣㼔㼑㼑㼘㻌㼍㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞
㼀㼕㼓㼔㼠㼑㼚㼕㼚㼓㻌㼠㼛㼞㼝㼡㼑 㻤㻚㻤㻌㼠㼛㻌㻝㻞㻚㻣㻺㻚㼙䡗㻜㻚㻥㻌㼠㼛㻌㻝㻚㻟㼗㼓㼒㻚㼙䡙
㻭㼒㼠㼑㼞㻌㼞㼑㼜㼑㼍㼠㼑㼐㼘㼥㻌㼐㼑㼜㼞㼑㼟㼟㼕㼚㼓㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘㻌㼟㼑㼢㼑㼞㼍㼘㻌㼠㼕㼙㼑㼟㻘㻌㼍㼚㼐㻌㼙㼍㼕㼚㼠㼍㼕㼚㻌㼠㼔㼑㻌㼐㼑㼜㼞㼑㼟㼟㼑㼐㻌㼟㼠㼍㼠㼑
㼀㼕㼓㼔㼠㼑㼚㻌㼒㼞㼛㼚㼠㻌㼘㼑㼒㼠㻌㻔㻲㻸㻕㻌㼍㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞
㻰㼞㼍㼕㼚㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌㼣㼔㼕㼘㼑㻌㼐㼑㼜㼞㼑㼟㼟㼕㼚㼓㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘
㻭㼕㼞㻌㼕㼟㻌㼙㼕㼤㼑㼐㻌㼣㼕㼠㼔㻌㼎㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌 㻭㼕㼞㻌㼕㼟㻌㼚㼛㼠㻌㼙㼕㼤㼑㼐㻌㼣㼕㼠㼔㻌㼎㼞㼍㼗㼑㻌㼒㼘㼡㼕㼐㻌
㼀㼕㼓㼔㼠㼑㼚㻌㼒㼞㼛㼚㼠㻌㼘㼑㼒㼠㻌㻔㻲㻸㻕㻌㼍㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞
㼀㼕㼓㼔㼠㼑㼚㼕㼚㼓㻌㼠㼛㼞㼝㼡㼑 㻤㻚㻤㻌㼠㼛㻌㻝㻞㻚㻣㻺㻚㼙䡗㻜㻚㻥㻌㼠㼛㻌㻝㻚㻟㼗㼓㼒㻚㼙䡙
㻼㼑㼞㼒㼛㼞㼙㻌㼠㼔㼑㻌㼒㼛㼘㼘㼛㼣㼕㼚㼓㻌㼣㼛㼞㼗㻌㼛㼚㻌㼠㼔㼑㻌㼞㼣㼍㼞㻌㼣㼔㼑㼑㼘㻌㼕㼟㻌㼣㼑㼘㼘㻚㻌㻾㼑㼍㼞㻌㼞㼕㼓㼔㼠㻌㻔㻾㻾㻕㻌㼣㼔㼑㼑㼘㻙㻪
㻼㼑㼞㼒㼛㼞㼙㻌㼕㼚㻌㼠㼔㼑㻌㼛㼞㼐㼑㼞㻌㼛㼒㻌㼠㼔㼑㻌㼞㼑㼍㼞㻌㼘㼑㼒㼠㻌㻔㻾㻸㻕㻌㼣㼔㼑㼑㼘
䖪㻼㼑㼞㼒㼛㼞㼙㻌㼠㼔㼑㻌㼒㼛㼘㼘㼛㼣㼕㼚㼓㻌㼛㼜㼑㼞㼍㼠㼕㼛㼚㼟㻌㼍㼎㼛㼡㼠㻌㼠㼔㼑㼞㼑㻌㼠㼕㼙㼑㼟㻌㻔㼡㼚㼠㼕㼘㻌㼥㼛㼡㻌㼒㼑㼑㼘㻌㼟㼠㼞㼛㼚㼓㻌㼗㼕㼏㼗㼎㼍㼏㼗㻌㼛㼚㻌㼠㼔㼑㻌㼎㼞㼍㼗㼑㻌㼜㼑㼐㼍㼘㻌㼣㼔㼑㼚
㻌㻌㻌㻌㼜㼑㼞㼒㼛㼞㼙㼕㼚㼓㻌㼠㼔㼑㻌㼍㼏㼠㼡㼍㼠㼛㼞㻌㼠㼑㼟㼠㻌䇾㻹㼍㼚㼡㼍㼘㻌㼎㼘㼑㼑㼐㼕㼚㼓䇿㻌㼎㼥㻌㻲㼁㻿㻻㻌㻰㼕㼍㼓㼚㼛㼟㼠㼕㼏㼟㻕㻚
㻿㼑㼏㼛㼚㼐㼍㼞㼥㻌㼟㼕㼐㼑㻌㻔㻭㻮㻿㻌㼛㼜㼑㼞㼍㼠㼕㼛㼚㻌㼏㼕㼞㼏㼡㼕㼠㻕㻌㼍㼕㼞㻌㼞㼑㼘㼑㼍㼟㼑㻌㼏㼛㼙㼜㼘㼑㼠㼑㼐
㻢㻜㻤㻜㻞㻡
3-67
BRAKES
Every 40,000 km or
Inspection intervals
every 12 months*1
U02637
(3) Make sure the parking brake lever 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-
vides good visibility all around. During the
tests, be sufficiently attentive to surrounding
traffic conditions.
3-68
BRAKES
Every 40,000 km or
Inspection intervals
every 12 months*1
3-69
BRAKES
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.
BRAKING PERFORMANCE
(1) Perform braking tests in a safe place. After
checking that warning lamp or 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.
3-70
SUSPENSION
41. SUSPENSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3-71
SUSPENSION
Every 40,000 km or
Inspection intervals
every 12 months*1
Every 40,000 km or
Inspection intervals
every 12 months*1
Recommended lubricant :
Wheel bearing grease
NLGI No.2 (Li soap)
3-72
SUSPENSION
Every 40,000 km or
Inspection intervals
every 12 months*1
*1: The stabilizer rod ball joint dust boots must be
inspected depending on either the odometer
reading or operating period (months), which-
ever occurs first.
㻿㼠㼍㼎㼕㼘㼕㼦㼑㼞
(1) Check the ball joint dust boots for cracks and 303128
wear
3-73
ELECTRICAL
44. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3-75
ELECTRICAL
44. BATTERY
Every 40,000 km or
Inspection intervals
every 12 months*1
WARNING
• Flammable hydrogen gas is produced in
the battery. Do not use flame near the bat-
tery or allow sparks to fly. Doing so is
extremely dangerous because the hydro-
gen gas could ignite and explode.
• Do not store used batteries where children
can reach them. Burns or blindness can
result from leaking fluid, etc.
• Always store used batteries with the termi-
nals facing upward. Leaving a battery on
its side can result in fluid leakage and fire.
WARNING
• When only the (–) terminal of the 12-volt
battery for engine is disconnected, there
may still be voltage at the (–) terminal of
the 24-volt battery for body. If a wrench or
other metallic object touches the (–) termi-
nal of the 24-volt battery and the frame in
this condition, a short circuit may occur.
• Store any used battery in a place where chil-
dren cannot touch it. Leaking fluid could
otherwise cause burns and blindness.
• Store any used battery with its terminals
uppermost. Placing a battery on its side
could cause fluid leakage and fire.
CAUTION
• The vehicle systems continue to operate for
about 2 minutes after the starter switch has been
put in the “LOCK” position. Wait for at least 2
minutes before disconnecting the battery.
• When removing or installing the battery, do
not disconnect the terminals of the battery
equalizer at the near side of the battery box.
If the terminals get disconnected.
3-76
ELECTRICAL
<Removal>
(1) Open the battery lid.
(2) Pull off the battery terminal cap and disconnect
the battery cables from the battery terminals
(marked with ) in the order shown in the
drawing.
• Disconnect the (–) terminal of the 12-volt
battery for engine .
• Disconnect the (–) terminal of the 24-volt
battery for body .
• Disconnect the (+) terminal of the 12-volt
battery for engine .
• Disconnect the (+) terminal of the 24-volt
battery for body .
CAUTION
Do not remove the connectors and cables
from the battery. Also, do not disconnect the ter-
minals of the battery equalizer at the near side
of the battery box. Y03317
Y03318
3-77
ELECTRICAL
<Installation>
Install the batteries by following the removal steps in
reverse. Both end of battery support
For the battery support , incline the J bolt and
insert it to slotted holes from outside of battery.
After that, tighten the battery support mounting nuts
securely.
19 to 24 N·m
Tightening torque
(1.9 to 2.4 kgf·m)
Y03319
CAUTION
Do not reuse the battery support mounting nuts.
After removing the nuts, replace it to new one to
prevent loosening.
CAUTION
• Incorrect wiring could result in a fire or an elec-
trical system failure.
• Properly install the battery terminal cap. Failure
to do so will cause a fire or electrical system fail-
ure.
• If the battery terminal cap is damaged, have the
battery terminal cap replaced immediately. Any
damage could cause a fire or electrical system
failure.
• In cold temperatures, the battery terminal cap
becomes easy to be damaged, so please be
careful about handling.
3-78
ELECTRICAL
DANGER U03112
WARNING
Do not use the battery with the fluid below the
“LOWER” level line. The battery would deteri-
orate rapidly, and it could overheat or
explode.
CAUTION
• After adding fluid, always recharge the bat-
tery or drive the vehicle. Otherwise the bat-
tery might freeze and be damaged, especially
in winter.
• Do not add so much fluid that the fluid in the
battery rises above the “UPPER” level line.
With the fluid above the “UPPER” level, fluid
could leak out and corrode the battery termi-
nals.
3-79
ELECTRICAL
Y03321
TERMINAL CLEANING
Clean the terminals whenever there is dirt or corro-
sion on them.
When there is white powder on terminals due to cor-
rosion, pour warm water on them and wipe them
clean. If the corrosion is conspicuous, remove bat-
tery cable and clean affected parts with wire brush
or sandpaper. After cleaning, apply a light coat of
grease over terminals.
76510
CAUTION
• Install the battery securely. If it is not installed
completely, the case or plate might be dam-
aged by vibration while the vehicle is running,
and battery service life would be shortened.
• To charge battery, remove the battery from
the vehicle whenever possible and remove
cap. If the battery must be charged while left
inside the vehicle, be sure to remove the neg-
ative terminal battery cable.
3-80
AIR CONDITIONER
45. AIR COMPRESSOR OIL LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3-81
AIR CONDITIONER
㻨㻮㻱㻣㻠㻝㻶㻾㻹㻿㻰㻱㻮㻪
㻟㻜㻟㻝㻞㻥
3-82
AIR CONDITIONER
CAUTION
Do not allow the lead wire connected to the pos- 㻟㻜㻟㻝㻟㻝
itive terminal of the battery to touch any other
component around the connector. Otherwise, a
short circuit will occur and the component may
fail.
3-83
OTHERS
50. CHASSIS FRAME DAMAGE AND LOOSENESS . . . . . . . . . . . . . . . . . . . . . . . 3-86
3-85
OTHERS
Every 80,000 km or
Inspection intervals
every 24 months*1
Every 80,000 km or
Greasing intervals
every 24 months*1
Recommended lubricant:
Transmission control linkage, gear shift
select lever pin:
Wheel bearing grease
NLGI No.2 (Li soap)
Accelerator link shaft, accelerator pedal,
parking brake lever, brake pedal link, door
lock, door inside and outside handles:
Chassis grease
NLGI No. 1 (Li soap)
(1) Remove all dust and dirt from the grease fit-
tings before.
(2) Apply grease to the following parts;
Accelerator link shaft, accelerator pedal, trans-
mission control linkage, gear shift select lever
pin, parking brake lever, brake pedal link, door
lock, door inside and outside handles.
3-86
(EURO VI)
Pre-Delivery
and Periodic
Inspection Manual
MAR. 2022
120 (H)
Pub.No.11ELB0005, MAR. 2022