Mitsubishi Fuso CANTER FE85DE6SLGP Install guide

TOYO CF10163BLACK
Pub.No.00ELT0087, MARCH 2015
Shop ManualShop Manual
Pub.No.00ELT0085 MARCH 2015
4M5 diesel engine4M5 diesel engine ForFor ColombiaColombia
(EURO 4)
Shop ManualShop Manual
4M5 diesel engine4M5 diesel engine
Pub.No.00ELT0085, MARCH 2015
For ColombiaFor Colombia
(EURO 4)

13
12
00
11
GROUP INDEX
14
17
15
13E
15E
17E
GENERAL ........................................
ENGINE ............................................
LUBRICATION .................................
FUEL AND ENGINE CONTROL ......
ENGINE CONTROL SYSTEM .........
COOLING .........................................
INTAKE AND EXHAUST..................
TURBOCHARGER CONTROL
SYSTEM ...........................................
EMISSION CONTROL .....................
EXHAUST GAS RECIRCULATION SYSTEM
AND DIESEL PARTICULATE FILTER ........
FOREWORD
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of
Mitsubishi Fuso CANTER series truck, and includes pro-
cedures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with
no wastage.
For more details, please consult your nearest authorized
Mitsubishi Fuso dealer or distributors.
Kindly note that the specifications and maintenance ser-
vice figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.
MARCH 2015
Applicable models (engine)
4M50T5
Shop Manual
4M5 diesel engine
For Colombia
(EURO 4)
©2015 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

This Shop Manual contains the information classified into the following groups.
If any system or equipment has two or more variations with significantly different construction, the variations are
handled as different groups. These groups are identified by different alphabets preceded by the same number.
1. ENGINE volume (Pub.No. 00ELT0085)
2. CHASSIS volume (Pub.No. 00ELT0086)
3. ELECTRICAL volume (Pub.No. 00ELT0087)
Group No. Group subject
00 GENERAL
11 ENGINE
12 LUBRICATION
13 FUEL AND ENGINE CONTROL
13E ENGINE CONTROL SYSTEM
14 COOLING
15 INTAKE AND EXHAUST
15E TURBOCHARGER CONTROL SYSTEM
17 EMISSION CONTROL
17E EXHAUST GAS RECIRCULATION SYSTEM AND DIESEL PARTICULATE FILTER
Group No. Group subject
00 GENERAL
21 CLUTCH
22 MANUAL TRANSMISSION
25 PROPELLER SHAFT
26 FRONT AXLE
27 REAR AXLE
31 WHEEL, TIRE
33 FRONT SUSPENSION
34 REAR SUSPENSION
35 BRAKE
36 PARKING BRAKE
37 STEERING
41 BUMPER AND FRAME
42 CAB MOUNTING, TILT
43 DOOR
51 EXTERIOR
52 INTERIOR
55 HEATER, VENTILATION
Group No. Group subject
54 ELECTRICAL

00-1
13E
13A
GROUP 00 GENERAL
VEHICLE MODEL CODING SYSTEM ................................................ 00-2
EQUIPMENT TYPE CODES LIST ...................................................... 00-3
POWER TRAIN TABLE ...................................................................... 00-4
HOW TO READ THIS MANUAL ......................................................... 00-6
CHASSIS NUMBER, ENGINE NUMBER AND
VEHICLE IDENTIFICATION NUMBER............................................. 00-14
PRECAUTIONS FOR MAINTENANCE OPERATION
1. General Precautions ................................................................... 00-16
2. Handling of Battery..................................................................... 00-19
3. Handling of Sensors, Relays and Electronic Control Units ......... 00-19
4. Handling Precautions for Electric Circuits .................................. 00-20
5. Service Precautions for Alternators............................................ 00-23
6. Intermittent Faults ...................................................................... 00-24
7. Precautions for Arc Welding....................................................... 00-25
8. Precautions When Repainting .................................................... 00-25
JACKING UP THE VEHICLE............................................................ 00-26
DIAGNOSIS CODES
1. Diagnosis Codes ........................................................................ 00-28
2. Access and Clearing of Stored Diagnosis Code.......................... 00-28
TABLE OF STANDARD TIGHTENING TORQUES
1. Tightening Torques..................................................................... 00-32
2. Table of Standard Tightening Torque .......................................... 00-32

00-2
1 Basic vehicle type F Cab-over engine truck
2 Load capacity, drive system E 2 ton class and over, 4 ×2
3 Cab type 8 Wide cab
4 Vehicle variations, Suspension 5 Rigid axle
Light duty vehicle (G.V.M. 7000 kg or more)
5 Engine D 4M50T
6 Wheelbase
E 3350 mm
G 3850 mm
H 4710 mm
7
Chassis arrangement for use None Standard use
Z Wide frame
Rear tire arrangement, Payload 6 Rear double
Payload 3000 kg to 4000 kg
8 Vehicle specification S With turbocharger
9 Steering position L Left-hand drive vehicle
1 7
4
3 52 9 86
FE85DE
10 11
VEHICLE MODEL CODING SYSTEM

00
00-3
Component Name plate marking Code description
Engine
4M50T5 4 M 5 0 T 5
Power version number
Turbocharged
Order of development within same series
Order of development among different series
Diesel engine
No. of cylinders (4)
Clutch
C5W33 C 5 W 33
Disc OD
Facing material (W: Woven)
Load capacity (in tonnes) of main model
Initial letter of the clutch
Transmission
M035S6 M 035 S 6
Forward speeds
Type of mesh (S: Synchromesh)
Load capacity (in tonnes) of main model
Initial letter of the transmission
Propeller shaft
P3 P 3
Load capacity (in tonnes) of main model
Initial letter of the propeller shaft
Front axle
F350T F 350 T
Vehicle type (T: Truck)
Load capacity of main model
Initial letter of the front axle
Rear axle
R035T R 03 5 T
Vehicle type (T: Truck)
Order of development within same series
Load capacity (in tonnes) of main model
Initial letter of the rear axle
Reduction and differential
D035H D 03 5 H
Tooth profile (H: Hypoid gear)
Order of development within same series
Load capacity (in tonnes) of main model
Initial letter of the reduction & differential
EQUIPMENT TYPE CODES LIST

00-4
Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Reduction &
Differential
FE85DE6SLGP 4M50T5 C5W33 M036S6 P3 R035T D035H
FE85DG6SLGP 4M50T5 C5W33 M036S6 P3 R035T D035H
FE85DHZSLGP 4M50T5 C5W33 M036S6 P3 R035T D035H
POWER TRAIN TABLE

M E M O
00-5
00

00-6
This manual consists of the following parts:
•Specifications
•Structure and Operation
•Troubleshooting
•Circuits
•Electrical Equipment Installation Positions
•Inspection of Electrical Equipment
•On-vehicle Inspection and Adjustment
•Service procedures
•Connector configuration chart
On-vehicle Inspection and Adjustment
•Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedures
•Procedures for servicing components and parts off the vehicle are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
•Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.
•Some routine visual checks and cleaning of some reused parts are not described but must always be included in
actual service work.
Caution
•This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:
Terms and Units
•Front and rear
The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred
to as the rear.
•Left and right
Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left
and right.
Standard value
•Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
•When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
DANGER
Precautions that should be taken in handling potentially dangerous substances
such as battery fluid and coolant additives.
WARNING
Precautionary instructions, which, if not observed, could result in serious injury or
death.
CAUTION
Precautionary instructions, which, if not observed, could result in damage to or de-
struction of equipment or parts.
NOTE Suggestions or supplementary information for more efficient use of equipment or
better understanding.
HOW TO READ THIS MANUAL

00
00-7
Tightening torque
•Values are directly specified for out-of-standard tightening torques for bolts and nuts.
•Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
(Values for standard tightening torques are based on thread size and material.)
•When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.
Units
•Tightening torques and other parameters are given in SI* units with metric units added in brackets { }.
*SI: Le Système International d’Unités
Unit SI unit {metric unit} Conversion factor
Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
Pressure
Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}
Vacuum pressure kPa {mmHg} 0.133322 kPa {1 mmHg}
Pa {mmH2O} 9.80665 Pa {1 mmH2O}
Volume dm3{L} 1 dm3{1 L}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Power kW {PS} 0.7355 kW {1 PS}
Example: 390 N·m {40 kgf·m}
Metric unit
SI unit

00-8
Illustrated Parts Breakdown and Service Procedures
Symbol Denotation Application Remarks
Tightening torque
Parts not tightened to standard torques
(standard torques specified where neces-
sary for servicing)
Specified values shown in table
See Table of Standard Tightening Torques for
parts for which no tightening torques are speci-
fied.
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or
sealant
Parts to be coated with lubricant or sealant
for assembly or installation
Necessary lubricant and/or sealant, quantity re-
quired, etc. are specified in table.
Special tool Parts for which special tools are required for
service operation
Tool name/shape and part number are shown in
table.
*a Associated part Parts associated with those removed/disas-
sembled for servicing
HOW TO READ THIS MANUAL

00
00-9

00-10
How to Read Circuits (Electrical)
HOW TO READ THIS MANUAL

00
00-11
1.1 Index number: to
•Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its
own index number.
1.2 Key number: A01 to Z99
•Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip-
ment can be easily found using its key number shown in a circuit diagram.
All of the electrical equipment installation locations are listed in Gr54-10.
1.3 Part name
1.4 Connector type (type indication)
•A list of the connectors used is included in Gr54-14.
1.5 Connector terminal number
1.6 Major harness division
• Major harness divisions are shown.
1.7 Wiring variations between different specifications
• Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown.
1.8 Circuit number, wire diameter, wire color
1.9 Code number: #001 to #999
•Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec-
tion procedure for an electrical equipment can be found using its code number shown in a circuit diagram.
1.10Grounding point: [1] to [99]
•Locations where wires are grounded to the vehicle. All of the grounding points are listed in .
1.11 Harness connection
•The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.
100
999
130

00-12
Wire color
Wire color Base color + tracer
BBlack
BW Black/
white BY Black/ yellow BR Black/red BG Black/ green BL Black/ blue BO Black/ orange
BP Black/
pink BV Black/
violet B Br Black/
brown
Br Brown
BrW Brown/
white BrB Brown/ black BrY Brown/ yellow BrR Brown/ red BrG Brown/ green BrL Brown/ blue
BrGr Brown/
gray BrV Brown/ Violet
GGreen
GW Green/
white GR Green/
red GY Green/
yellow GB Green/
black GL Green/
blue GO Green/
orange
GGr Green/
gray GBr Green/ brown GV Green/ violet
Gr,
Gy Gray
GrL,
GyL
Gray/
blue
GrR,
GyR
Gray/
red
GrB,
GyB
Gray/
black
GrG,
GyG
Gray/
green
GrW,
GyW
Gray/
white GrY Gray/ yellow
GrG Gray/
green GrBr Gray/ brown
LBlue
LW Blue/
white LR Blue/red LY Blue/
yellow LB Blue/
black LO Blue/
orange LG Blue/
green
LGr Blue/gray LBr Blue/
brown
Lg Light
green LgR
Light
green/
red
LgY
Light
green/
yellow
LgB
Light
green/
black
LgW
Light
green/
white
O Orange OL Orange/
blue OB Orange/ black OG Orange/ green
PPinkPB
Pink/
black PG Pink/ green PL Pink/ blue PW Pink/ white PGr Pink/gray PV Pink/ violet
Pu Purple
RRed
RW Red/
white RB Red/
black RY Red/
yellow RG Red/
green RL Red/blue RO Red/
orange
RBr Red/
brown Rgr Red/ Gray
Sb Sky blue
V Violet VY Violet/yel-
low VW Violet/
white VR Violet/red VG Violet/
green VGr Violet/ gray VB Violet/ black
WWhite
WR White/
red WB White/
black WL White/
blue WG White/
green WO White/
orange WV White/
violet
WBr White/
brown WY White/ yellow
Y Yellow
YR Yell ow/
red YB Yellow/ black YG Yellow/ green YL Yellow/ blue YW Yellow/ white YO Yellow/ orange
YP Yell ow/
pink YV Yellow/
violet YGr Yellow/
gray YBr Yello w/
brown
HOW TO READ THIS MANUAL

M E M O
00-13
00

00-14
•Serial chassis and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every
vehicle and engine has its own number. These numbers are required for registration and related inspection of the
vehicle.
Chassis number
Engine number
•An engine name plate indicates the following item.
•Engine model
CHASSIS NUMBER, ENGINE NUMBER AND VIHICLE IDENTIFICATION NUMBER

00
00-15
Vehicle identification number (V.I.N.)
The nameplate shows the following.
Vehicle identification number (VIN)
Maximum permitted laden mass of the vehicle
Maximum permitted laden mass of the combination
Maximum permitted load mass for 1st axle
Maximum permitted load mass for 2nd axle
The meanings of VIN are listed below.
Example:
(1) Geographic area
J: Asia (Japan)
(2) Country
L: Japan
(3) Manufacture
C: Mitsubishi Fuso Truck & Bus
(4) GVW & Brake type
B: 3.5 t < GVW ≦12 t/Hydraulic
(5) Model
C: FE84P
D: FE85P
1: FE85D
(6) Series (wheel base)
E: 3.2 to 3.49 m
G:3.8 to 4.09 m
H: 4.1 to 4.39 m
(7) Cab type
6: Cab over
(8) Engine type
J: 3.907 L, Diesel
3: 4.899 L, Diesel
(9) Check digit
(10) Model year
F: 15M/Y
G: 16M/Y
•
•
(11) Plant
K: Kawasaki
(12) Plant Sequential Number
3
4
5
J CL F K
(1) (2) (3) (10)(11) (12)
BC E 6 J
(4) (5) (6) (7) (8) (9)

00-16
1. General Precautions
•Before performing service operations, inquire into the customer’s complaints and ascertain the condition by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.
•Check the location of the fault, and identify its cause. Based on
your findings, determine whether parts must be removed or dis-
assembled. Then, follow the service procedure given in this
manual.
•Perform service operations on a level surface. Before starting,
take the following preparatory steps:
•To prevent soiling and damage, place covers over the seats,
trim and floor in the cab and over the paintwork of the body.
•Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
•After manually tilting the cab, be sure to engage the stopper with
the lock lever to secure the cab stay in a rigid state.
•Take extreme care when removing/installing heavy items such
as engine, transmission and axle. When lifting heavy items using
a cable etc., observe the following precautions.
•Identify the weight of the item being lifted. Use the cable that
is strong enough to support the weight.
PRECAUTIONS FOR MAINTENANCE OPERATION

00
00-17
•If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item’s center of
gravity.
•Do not allow anyone to pass or stay under a lifted item which
may possibly fall.
•Never work in shoes that have oily soles.
When working with a partner or in a group, use pre-arranged sig-
nals and pay constant attention to safety. Be careful not to touch
switches and levers unintentionally.
•Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
•Prepare replacement parts ready for installation.