(EURO VI)

Pub.No.11ELB0005, MAR. 2022

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

© 2022 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
• PRECAUTIONS BEFORE SERVICE. . . . . . . . . . . . . . . . . . . 0-2

• TIGHTENING TORQUES FOR GENERAL USE BOLTS

AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

• TABLE OF RECOMMENDED GRADE OF LUBRICANT . . . . 0-7

 PRECAUTIONS BEFORE SERVICE

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 Jack-up point

rack for the sake of safety.

303093

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.

0-2
 PRECAUTIONS BEFORE SERVICE

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 genuine parts

as replacements both to ensure safety and to obtain
maximum performance from your vehicle.
MITSUBISHI FUSO genuine parts are identical to
the parts used during the production of your vehi-
cle. All parts undergo the most stringent quality con- Y03339
trol and their quality is guaranteed by MITSUBISHI
FUSO TRUCK & BUS CORPORATION.

11. When servicing the electrical system, disconnect the

cable from the negative terminal of the battery.

0-3
 TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS

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}

0-4
 TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS

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}

0-5
 TIGHTENING TORQUES FOR GENERAL USE BOLTS AND NUTS

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 +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.

TABLE OF RECOMMENDED GRADE OF LUBRICANT

Viscosity
Parts Category Classification Atmospheric SAE viscosity Remarks
temperature number
ACEA C2 – 0W-30, –
5W-30
Below 0°C 10W-30
JASO DH-2 –
Above -15°C 15W-40

Engine (Oil) Engine oil Below 0°C 10W-30

MIL-L-2104C
API CJ-4 Above -15°C 15W-40
Above 30°C 40
ACEA E6 – 5W-30 –
ACEA E9 – 10W-40 –
FUSO DIESEL
LONGLIFE Mixture of soft water
Engine (Coolant) COOLANT – – – and the long life cool-
(green) ant.
(SAE J814-C)
General 80
API GL-3 –
Transmission (including Warm region 90
Gear oil
DUONIC system) General 80
API GL-4 –
Warm region 90
Clutch
<Vehicles with DUONIC Automatic transmis- FUSO ATF SPIII – – –
sion fluid
system>
Below 40°C 90
Differential gear * Gear oil API GL-5 –
Above 40°C 140

Power steering Automatic transmis- DEXRON II or – – –

sion fluid DEXRON III type
SAE J1703,
FMVSS
Brake Brake fluid No. 116 – – –
(Type DOT3)
Wheel bearing Consistency 265 to 295
Wheel hub bearing
Propeller shaft grease NLGI No. 2 – – (at 25°C)
(Multipurpose type (Li soap) Dropping point 185°C or
(universal joint, slip joint) grease) higher

* 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

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

• PRE-DELIVERY INSPECTION PROCEDURE . . . . . . . . . . . 1-4

 NOTES CONCERNING ENTRIES

NOTES CONCERNING ENTRIES

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.

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

Model Good

Chassis number A Requires adjustment

C Requires cleaning
Engine number
T Requires retightening
Distance travelled km
L Requires replenishment of lubricant, water, etc.
Owner
X Requires replacement
Date of inspection Requires repair
Place of inspection Servicing completed
Inspector

Engine key number

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

PRE-DELIVERY INSPECTION PROCEDURE

1. EXTERIOR

(1) Check distortion and damage of body panels.

(2) Check painting, rusting and flaws of body pan-
els.
(3) Check all door and other parts for proper spac-
ing at top and bottom, front and rear, in and out. 303094
(4) Check that all windows and mirrors are
installed properly.

2. OPERATION OF LAMPS AND SWITCHES

(1) Check operation of all lamps and switches.

Headlamps, clearance lamps
Front turn signal lamps
Front fog lamps
Front side turn signal lamps
Step lamp
Side marker lamps
Rear turn signal lamps
Stop and tail lamps
Backup lamp, rear fog lamp
License plate lamps
Destination indicator lamp

㻟㻜㻟㻜㻥㻡
3. VEHICLE ATTITUDE (INCLINATION)

(1) At the vehicle, check for rightward and leftward

inclination.

Standard value (with a driver in the cab)

Rightward inclination measured at
20 mm or less
the vehicle front outside 303096
Leftward inclination measured at
15 mm or less
the vehicle front outside

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

(1) Check the mirrors for reflection and stain.

U03219

6. OPERATION OF WINDSHIELD WIPER AND

WASHER

(1) Check operation of the wiper in all ranges [Int,

Low, High].
(2) Check the wiper blade-stop position.
(3) Check the washer for operation and the nozzle
for clogging.
303098

7. OPERATION OF OTHER ELECTRICAL

EQUIPMENTS (HORN, HEATER, ETC.)

(1) Check operation of the horn, heater, defroster,

air conditioner and other electrical equipments.
SOURCE EMRG
2))

/2 0(
2))
+,

&22/ REAR HEATER

FAN THERMO

303099

1-5
 PRE-DELIVERY INSPECTION PROCEDURE

8. OPERATION OF DOOR, LOCK AND WIN-

DOWS

(1) Check that the doors can be easily opened and

closed securely.
(2) Check operation of the door lock from both
inside and outside the vehicle.
(3) Check the windows for smooth operation and
tight fit against weatherstrip.

Grip
Door open/close
switch

Lock lever handle

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

(1) Check that the lids can be easily opened and

closed securely.

Coolant lid
Fuel lid

<Trunk room lid>

Handle

㻟㻜㻟㻝㻜㻝

10. WASHER TANK FLUID LEVEL

<Front>
Washer tank
(1) 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
Tank cap
mixture of windshield washer fluid and tap
water until the level nears the top of the tank. Cover

<Rear (Vehicles with rear

wiper and washer)>
Tank cap

Washer tank

㻟㻜㻟㻝㻜㻞

11. RADIATOR COOLANT LEVEL

(1) 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.
(2) Check to see if FUSO DIESEL LONG LIFE
COOLANT has been added to the coolant.
303103

1-7
 PRE-DELIVERY INSPECTION PROCEDURE

12. RADIATOR HOSES AND CLAMPS

(1) Check the connecting conditions of the radiator

hoses and retighten the hose clamps.

13. ENGINE OIL LEVEL

(1) 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.

14. POWER STEERING FLUID LEVEL

(1) Check the fluid level on the level gauge, if the

fluid level is within the level gauge in the illus-
tration, it is normal.

Note: When the check is made, the front wheels

should be placed in straight ahead posi-
tion and do not twist the filler cap.

1-8
 PRE-DELIVERY INSPECTION PROCEDURE

15. FUEL LEAKS FROM FUEL SYSTEM

(1) Check the fuel system for leakage.

Fuel pump, Fuel filter, High pressure fuel pump,
Common rail, Injector, Piping, Tube, Hose, Fuel
tank.

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

16. INSTALLED CONDITION OF ELECTRICAL

EQUIPMENTS

(1) Check if the starter and alternator are properly

installed.
(2) Check the wiring connections for tightness.
If the wiring harness interferes with other parts,
correct it.
P118540

17. EXHAUST MANIFOLD TIGHTNESS

(1) Check if the exhaust manifold is correctly tight-

ened.
If the mounting nuts are loose, tighten them at
specified torque.

P118941E

18. COOLANT, GAS AND OIL LEAKS FROM

CYLINDER HEAD AND OVER HEAD

(1) Check for coolant and gas leaks from the cylin-
der head.
(2) Check for oil leaks from the over head.

P118546E

19. ENGINE STARTING PERFORMANCE

(1) Check to see if the engine starts smoothly.

(2) Check operation of the key switch and starter.
(3) Check the glowing condition of the preheat indi-
cator ( ).

303104

20. OPERATION OF ACCELERATOR LINKAGE

(1) Check the accelerator pedal for sticking, bind-

ing and full return.

303105

1-10
 PRE-DELIVERY INSPECTION PROCEDURE

21. EXHAUST GAS CONDITION AND NOISE

(1) After the engine has warmed up, check that

black smoke is not emitted at idling, medium
and high speeds.
(2) Check for abnormal engine noise.

303106

22. BRAKE PEDAL PLAY AND CLEARANCE

(1) With the engine stationary, ensure that the

pedal play conforms to the standard value.

Brake pedal play

0.1 to 1.7 mm
(at center of pedal pad)
Pedal play
06539E

(2) 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 floor
and brake pedal (when
40 mm or more
depressed with a force of
490 N {50 kgf})

Height
06540E

23. CLUTCH PEDAL PLAY

(1) Check clutch pedal play.

(2) Check clutch pedal engagement and disen-
gagement level. Pedal
play
Clutch pedal play
1 to 7 mm
(at center of pedal pad)
Clutch pedal 03480E

24. STEERING WHEEL PLAY

(1) Place the steering wheel in straight ahead posi-

tion and check for the play.
When
20 mm or
engine is
Steering wheel play less
turned off
(on the periphery of
steering wheel) When 604760
engine is 5 to 50 mm
idling

1-11
 PRE-DELIVERY INSPECTION PROCEDURE

25. ENGINE STOPPING PERFORMANCE

(1) Turn the starter switch to “ACC” to see if the

engine stops at once.

Z21168

(2) Flick the emergency engine stop switch to the

“ON” position to see if the engine stops at once.
Emergency engine
stop switch

U03208

26. ELECTRICAL WIRING CONNECTIONS AND

ROUTING

(1) Check the battery cable and other electrical

wiring connections for tightness.
(2) Visually check the electrical harness routings.
Correct on necessity.
Y03321

27. BRAKE RESERVOIR TANK FLUID LEVEL

(1) Check the fluid level in the reservoir tank. The

fluid level should be between the level lines
“MAX” and “MIN”. If the level is too low, check
for fluid leaks.

U03858

28. FUEL LEAKS FROM FUEL TANK

(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

29. AdBlue® LEAKS FROM UREA LINES

<VEHICLES WITH A BlueTec® SYSTEM>

(1) Check to confirm that there are not found any

white crystals or traces of AdBlue® leakage at
the connections of the urea lines to the urea
tank, urea dosing module, urea unit and urea
dosing nozzle.
(2) If any trace of AdBlue® leakage is found, wipe
the white crystals off with a cloth moistened
with AdBlue® and then check each connection
for tightening condition. Retighten any loose
connections.

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 supply module

Urea line
Urea tank

Urea dosing module (injection valve) Selective catalytic reduction muffler

Diesel particulate filter muffler

Exhaust gas

㻼㻝㻝㻤㻜㻤㻤㻱

1-13
 PRE-DELIVERY INSPECTION PROCEDURE

30. FLUID LEAKS FROM SHOCK ABSORBER

䠘㻲㼞㼛㼚㼠䠚

(1) Check the shock absorbers for fluid leaks.

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

31. ENGINE OIL LEAKS FROM OIL PAN AND

OIL COOLER

(1) Check for oil leaks from the engine oil pan and
oil filter support area.

32. TRANSMISSION OPERATION

(EXCEPT DUONIC)

(1) Check the control linkage for looseness.

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

33. FLUID LEAKS FROM TRANSMISSION

COOLING LINES (DUONIC)

(1) Check the fluid leakage in transmission cooling

system.

P115859

34. FLUID LEAKS FROM CLUTCH AND/OR

BRAKE FLUID LINES

(1) Check the clutch fluid line for leaks.

(2) Check the brake fluid line for leaks.
(3) Check that the pipes and hoses do not interfere
with other parts.

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

35. INSTALLED CONDITION OF EXHAUST

PIPES AND MUFFLERS

(1) Check the exhaust related pipes, DPF muffler,

exhaust muffler and SCR muffler installation
and connection for looseness.

Exhaust pipe

Tail pipe

Intermediate pipe Selective catalytic reduction muffler

Front pipe
Diesel particulate filter muffler

㻟㻜㻟㻝㻝㻜

1-16
 PRE-DELIVERY INSPECTION PROCEDURE

36. OIL LEVEL IN, TRANSMISSION AND AXLE

HOUSING

(1) Remove the inspection plug and check the oil

level.
1) Transmission
2) Axle housing

Note: The oil for clutch housing of the transmis-

sion should be checked as indicated in
the paragraph 18. CLUTCH CONTROL
FLUID of Chapter 3 PERIODIC INSPEC-
TION PROCEDURE (see page 3-38).

㻟㻜㻟㻝㻝㻝

37. SUSPENSION SPRING PINS, SPRING

SHACKELS AND U-BOLT NUTS TIGHT-
NESS

(1) Check that the spring pins, spring shackles and

U-bolt nuts are correctly tightened (knock them
to check). If they are loosed, tighten them to
specification.

1-17
 PRE-DELIVERY INSPECTION PROCEDURE

38. PROPELLER SHAFT FLANGE YOKE BOLTS

TIGHTNESS

(1) Check the flange yoke bolts for tightness

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

39. DIFFERENTIAL CARRIER ATTACHING

BOLTS AND NUTS TIGHTNESS

(1) Check the bolts and nuts attaching differential

carrier to axle housing for tightness (knock to
check). If they are loosed, tighten them to spec-
ification.

1-18
 PRE-DELIVERY INSPECTION PROCEDURE

40. BODY MOUNTING BOLTS AND NUTS

TIGHTNESS

(1) Check the body mounting bolts and nuts for

tightness (knock them to check).
If they are loosed, tighten them.

41. FRONT AND REAR WHEEL NUTS TIGHT-

NESS

(1) Check front and rear wheel nuts for tightness

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

P118462

42. TIRE PRESSURES

(INCLUDING SPARE TIRE)

(1) Check the tire pressures while the tires are

cold.
(2) If there are metal pieces, stones and other for-
eign objects caught in the tread grooves,
remove them.
Z21588
(3) Check that the spare tire is installed properly.

1-19
 PRE-DELIVERY INSPECTION PROCEDURE

43. TRANSMISSION OPERATION

<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.

44. STEERING OPERATION

(1) Check the steering wheel for smooth operation,

stability and returnability.

604760

45. CLUTCH OPERATION

(1) Check the operation of clutch in all driving

ranges.

46. SERVICE BRAKE OPERATION

(1) Check that brake operation is smooth and posi-

tive.

1-20
 PRE-DELIVERY INSPECTION PROCEDURE

(2) Check the ASR/ESP® cutoff switch and multiin-

formation display. ESP® OFF ESP® indicator Warning and indicator display
indicator lamp and warning lamp
: Vehicles with ESP® system. on the multiinformation display

Note: Operation of the ESP® system, see ASR/ESP® cutoff

“ESP® system” in chapter 5 of the switch
Owner’s Handbook.

303113

(3) Check the AEBS cutoff switch and multiinfor-

mation display. : Vehicles with AEBS. Multi-information
display indicator
Note: Operation of the AEBS, see “AEBS” in Indicator lamp
chapter 5 of the Owner’s Handbook.

AEBS cutoff switch

303133

47. EXHAUST BRAKE OPERATION

(1) 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.
(3) The indicator lamp lights and the exhaust
brake comes into operation.

Note:The exhaust brake temporarily deacti-

vates if
• The accelerator pedal or clutch pedal
<manual transmission vehicles> is
depressed.
㼆㻞㻞㻠㻢㻠
• The gearshift lever is in the neutral
position <Manual transmission vehi-
cles>, or the gearshift lever is in the
“N” position <Vehicles with a
DUONIC system>.
• The ABS is operated.

ESP®: Registered trademark of Daimler AG

1-21
 PRE-DELIVERY INSPECTION PROCEDURE

48. PARKING BRAKE OPERATION

㻾㼑㼘㼑㼍㼟㼕㼚㼓
㻼㼞㼑㼟㼟㻌㼎㼡㼠㼠㼛㼚

(1) Check parking brake lever stroke and braking

effect, returning condition and warning
lamp condition.

Parking brake lever stroke 7 to 9 notches 㻼㼍㼞㼗㼕㼚㼓

㻟㻜㻟㻝㻝㻠

49. NOISE

(1) Check for noise in each of the brakes, engine,

transmission, steering system, propeller shaft,
differential and others.

303115

50. GAUGES FUNCTION

(1) Inspect that all gauges are functioning properly.

Tachometer, Fuel gauge, Speedometer, etc.

Speedometer
Tachometer
Fuel gauge Z20959
Warning/Indicator lamps
Urea level indicator
Multi-information display

1-22
 PRE-DELIVERY INSPECTION PROCEDURE

51. JACK AND TOOL SET

(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

52. INSTALLATION OF LICENSE PLATES

(1) Install the license plates.

1-23
 PRE-DELIVERY INSPECTION PROCEDURE

53. DIAGNOSIS CODES

(1) Use the FUSO Diagnostics or MUT to check

whether a diagnosis code was issued for the
relevant system.
(2) If there are any problems, erase the code by
doing an inspection and any necessary repairs.

Connector Connector

OBD cable OBD cable

XD-VCI XD-VCI

Personal computer Personal computer

Wi-Fi adapter USB cable

Personal computer
FUSO connect Connector

Tester Harness

LAN cable (cross)

303116

54. VEHICLE WASHING

(1) Clean the vehicle exterior and interior.

1-24
 GROUP-2

PERIODIC
INSPECTION
SCHEDULE
• PERIODIC INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . 2-2
 PERIODIC INSPECTION SCHEDULE

PERIODIC INSPECTION SCHEDULE

• In the periodic inspection schedule table that follows, the intervals at which inspection and servicing should be
performed at specified 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.

• Perform each item of inspection or replacement depending on either the odometer reading or operating period
(months), whichever occurs first.
• When 120,000 km are reached, repeat the same inspection cycle.

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.

: 1st maintenance at 2,000 km.

I: Inspect, and correct or replace as necessary.
R: Replace or change.
L: Lubricate.
•: No inspection is necessary.

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

• DRIVE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

• 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

2. OIL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3. FUEL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4. AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

5. PCV FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

6. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

7. COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

8. BELTS-INSPECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

9. BELTS-REPLACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

10. EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

11. UREA LINE LEAKAGE & DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

12. DPF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

13. DPF PRESSURE HOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

14. ALTERNATOR TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

15. ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

16. FUEL LINE LEAKAGE & DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

17. GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-3
 ENGINE

1. ENGINE OIL

Always use prescribed engine oil of proper viscosity

since engine oil has such a large impact on engine
performance, service life and start-up.

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

*1: The engine oil must be replaced depending on

either the odometer reading or operating period
(months), whichever occurs first.
*2: If you drive your vehicle under any of the fol-
lowing 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 fre-
quent 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).

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

• Change the engine oil at the specified inter-

vals. During the regeneration process of the
DPF, part of the fuel may mix into the engine
oil while the PM is being removed by burning.
If the engine oil is not changed at the speci-
fied intervals, it may excessively deteriorate
due to mixing of fuel and could cause engine
failure. In the worst case, the engine could
spontaneously run at an abnormally high
speed.

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

Engine oil quantity:

Replacing oil Approx. 5.5 liters

Oil quantity Replace the oil

and the filter at Approx. 6.0 liters
the same time

3-5
 ENGINE

Note: You must reset the engine control unit every

time after replacing the engine oil. See next
“RESETTING THE ENGINE CONTROL
UNIT” for details of the method.

(1) Open the engine inspection lid.

(2) Clean the surfaces around the oil filler cap
and remove the oil filler cap.

U04797

(3) Remove drain plug from the oil pan to remove the
oil.

Front of
vehicle

㼆㻞㻞㻢㻟㻠

Drain the oil until only droplets come out.

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.

Note: Oil removal is quicker if performed shortly Z25877

after the vehicle has been stopped and while
the oil is still warm.

(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)

(6) Carefully pour fresh engine oil through the oil

filler.

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

RESETTING THE ENGINE CONTROL UNIT

(1) Turn the starter switch to “ON”. Do not start the
engine.
(2) Depress the accelerator pedal to the floor and
keep it there for at least 20 seconds.
(3) While still keeping the accelerator pedal
depressed to the floor, pump the brake pedal at
least 6 times.
When the engine control unit is reset, the
(amber) warning lamp flashes for about 10 sec-
onds.
(4) Turn the starter switch to “LOCK”, and wait for
2 minutes.

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.

2. OIL FILTER ELEMENT

Every 40,000 km or
Replacement intervals
every 12 months*1

*1: The oil filter element must be replaced depend-

ing on either the odometer reading or operating
period (months), whichever occurs first.

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

(1) Make sure that the parking brake is firmly

applied.
(2) Chock the wheels.
(3) If the engine is cold, warm it up until the engine
oil temperature reaches approximately 40°C. (It
takes approximately 20 minutes of idling to
raise the engine oil temperature from 0°C to
40°C.)
After the oil has heated, stop the engine.
Note: Be sure to warm up the engine. Unless you
warm up the engine, engine oil may spill out
when you remove the oil filter case.

(4) Uncover the engine inspection opening.

(5) Clean the area surrounding the oil filter case to
prevent dirt from entering the new filter ele-
ment.
(6) Turn the oil filter case counterclockwise
(about two and a half turns) to loosen it.
(7) Remove the air-releasing plug of the oil filter
case by turning it counterclockwise. Replace
the removed air-releasing plug with a new plug.
Wait for at least 5 minutes after removing the
air-releasing plug to let oil inside the case drain
out completely.
When replacing engine oil, remove the oil filler
cap and then the drain plug. Z22617

(8) Remove the oil filter case by turning it counter-

clockwise. Use a rag to prevent oil from drip-
ping down.

Z21175

(9) Remove the filter element from the filter

case.
If the claw of the filter element is too firmly
engaged to remove the element, insert an Allen
wrench and tap it with a hammer to
remove the element.

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.

(10) Clean the O-ring contact surface of the oil filter

support and the O-ring groove of the oil filter
case.

3-9
 ENGINE

(11) Replace the O-ring of the oil filter case with a

new one. Apply a light coat of engine oil to the
new O-ring before installing it.

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)

(14) Tighten the oil filter case.

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.

If the engine oil is replaced, add the necessary

quantity of engine oil.

(15) Crank the engine in accordance with the

engine starting procedure shown on the
Owner’s Handbook.
(16) Start the engine and warm it up until the water
temperature gauge moves to around the 8th
segment on the scale (center of indicator).
(17) Stop the engine and wait for more than 15 min-
utes before checking the oil level. If the oil is
not within the replenishing level range indicated
in the figure, add or remove oil to adjust the Z25880
level, and return to step 16 to inspect the oil
Oil level gauge
level again. (above notch): HIGH (for refilling)
(18) Check that there are no oil leaks from the oil fil- (below notch): LOW
ter or drain plug.

3-10
 ENGINE

3. FUEL FILTER ELEMENT

Every 40,000 km or
Replacement intervals
every 12 months*1

*1: The fuel filter element must be replaced

depending on either the odometer reading or
operating period (months), whichever occurs
first.

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.

The fuel filter of your vehicle is installed at the left

side of the vehicle, behind the rear door.

Z22618

(1) Make sure that the parking brake is firmly

applied.
(2) Chock the wheels.
(3) Clean the area around the filter to prevent dirt
from contaminating the new filter element when
it is installed later.
(4) Place a container under the fuel filter to collect
the fuel.
(5) Disconnect the two fuel tubes. To remove each
fuel tube, pull the connector while pressing
the lock button . Fuel will momentarily spurt
out when you undo the connector. Hold a rag
against the connector.

㼆㻞㻟㻠㻤㻝

3-12
 ENGINE

(6) Using pen or something, put match marks on

the filter case and drain plug .
(7) Loosen the drain plug by turning it in the
direction of the arrow indicated in the figure to
allow the fuel in the fuel filter to drain out. Use
pliers or a similar tool to loosen the plug.
(8) After the fuel has been discharged, turn the
drain plug clockwise until the match marks on
the drain plug and filter case are aligned with
each other. Z25178

Tightening torque 1.5 N·m (0.15 kgf·m)

(9) Disconnect the sensor connector . Do this

after pulling up the connector's lock knob
and then pulling out the top part of the con-
nector.

Z21455

(10) Disconnect the connector from the fuel filter

case . Do this by pulling the bottom part of
the connector toward you to release the lock
and then pulling the connector directly upward.

Z21456

(11) Insert the special tool (separately available)

horizontally from the opposite direction of the
drain plug .

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 .

(12) Remove the fuel filter case by turning it coun-

terclockwise. Let the fuel inside the case drain
out.

Z25100

3-13
 ENGINE

(13) Remove the filter element out of the case by

pulling it straight upward.
(14) Replace the O-ring of the fuel filter case
with a new one. After applying a light coat of
engine oil to the new O-ring, install it on the fuel
filter case.

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.

(15) Install a new, genuine filter element into the fil-

ter case as shown in the illustration, paying
attention to its direction.
Insert the filter element in a straight line.

CAUTION
• Install the fuel filter case carefully so as not to
twist or damage the O-ring.
• Do not reuse the filter element. Z21460

(16) Insert the special tool (separately available)

horizontally from the opposite direction of the
drain plug .

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 .

(17) Install the fuel filter case by turning it clockwise.

Make sure the projection on the case is in
the area indicated in the figure past the pro-
jection on the filter head.
When you are hard to confirm a projection, put
match marks on a filter head and the case as a
guide.

CAUTION Z25177

Always check that the projection on the fuel fil-

ter case is in the area indicated in the figure
past the projection on the filter head. If the fuel
filter case is turned insufficiently or excessively,
fuel will leak or the fuel filter case will be dam-
aged.

3-14
 ENGINE

(18) Install the sensor connector to the fuel filter

case and then connect the connector. Do this
by following the removal procedure in reverse.
(19) Connect the connector of the fuel tube to the
fuel filter. Insert the connector deep into the fuel
filter, and insert a little further after a click is
heard.
(20) After connecting, hold the connector and move
it slightly forward and backward to confirm that
the connector is locked securely.
(21) Bleed air from the fuel system as follows: Hold
the starter switch in the "ON" position for 30
seconds and then set it to the "ACC" position to
supply fuel to the fuel system.
(22) Start the engine and check that there is no fuel
leakage.
Note: Air enters the fuel system while replacing the
filter element and will prevent the engine from
starting. Before starting the engine after
replacing the filter element, bleed air from the
fuel system.

4. AIR CLEANER ELEMENT

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.

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.

3-15
 ENGINE

CHECKING THE AIR CLEANER ELEMENT

CONDITION WITH DUST INDICATOR
If the indicator’s window shows a red signal, the
air cleaner element is clogged. Clean the element
immediately.

Z22820

RESETTING THE DUST INDICATOR

After cleaning the air cleaner element, push the
reset button . The red signal will disappear from
the window of the dust indicator.

Z22620

REMOVAL
(1) Undo the two clamps and then pull the cover
toward the clamps to remove it.

Z22621

3-16
 ENGINE

(2) Move the lock lever in the air cleaner ele-

ment case to the “UNLOCK” position.

Z21180

(3) Pull element straight down to remove.

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

(3) Install the cover on the case by inserting the

projections on the cover into the holes in
the case and then fasten the clamps.

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

INSPECTION AND CLEANING

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.

(1) Remove dust by blowing compressed air over

every surface of the air cleaner element from
its end fitted with the gasket .

Z21184

(2) Put a light on the gasket side of the air cleaner

element to check that there are no holes that
allow light to leak in the element. Also check
the gasket for cracks or other damage.

Z21185

(3) Clean the inside of the case and cover with a

clean cloth. Clean the sealing sections with
particular care.
(4) Replace the element with a new one if the
check reveals a defective cleaner element or
when the recommended replacement interval
expires.

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

Replacement intervals Every 40,000 km

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.

(4) Remove PCV O-ring from PCV cover. 㻰㼕㼍㼜㼔㼞㼍㼓㼙㻌

(5) Remove PCV shaft seal from PCV cover. 㼠㼔㼕㼚㻌㼒㼕㼘㼙
(Insert a suitable bar without an edge) 㻔㻿㼑㼙㼕㻌㼍㼞㼏㻌㼜㼍㼞㼠㻕 㻼㻯㼂㻌㻻㻙㼞㼕㼚㼓

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

(1) Check radiator and pressure cap for sealing

performance and mounting condition.
(2) Inspect hoses for looseness, deterioration,
damage causing leakage.
(3) Remove dust and foreign matter deposit from
radiator and intercooler front. 㻾㼍㼐㼕㼍㼠㼛㼞

㻾㼍㼐㼕㼍㼠㼛㼞㻌㼔㼛㼟㼑
㻟㻜㻟㻝㻝㻣

7. COOLANT

Replacement intervals 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.
• 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

WATER USED WITH COOLANT

Use soft water with any of the following properties
as coolant. Hard water from well or river, for
instance, will cause scale and rust. Do not use such
water.
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

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.

Figure the coolant mixing ratio based on the lowest

temperature for the area the vehicle will be operat-
ing in with the chart below.

The specified long life coolant mixture percentages

-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. 20 liters

quantity Without rear heater Approx. 16 liters

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.

(1) Place a can under the radiator drain cock to

receive the coolant.
(2) Open the reservoir tank lid and remove the cap
from the reservoir tank.
(3) Open the engine inspection lid (pressure cap
section).

U04800

(4) Release the lock and remove the pressure cap

of the surge tank by turning it counterclock-
wise.

U04801

3-23
 ENGINE

(5) Open the radiator drain cock to drain engine

coolant.
(6) After the coolant has been completely drained,
close radiator drain cock.

2.5 ± 0.5 N·m

Tightening torque
(0.25 ± 0.05 kgf·m)

Z22624

(7) Flush the cooling system.

Pour soft water (preferably after heating mod-
erately) through the pressure cap opening.
Refit the pressure cap tightly by turning it clock-
wise. Lower the cab.
Warm up the engine until the coolant tempera-
ture gauge needle moves to the middle of the
gauge (coolant temperature is 81°C or higher).
Depress the accelerator pedal and run the
engine slightly faster than the ordinary idling
speed.
Stop the engine after 10 minutes and then drain
out the engine coolant. Take great care as the
coolant is very hot.
Repeat the above procedure until the water is
free of dirt.

CAUTION
If the radiator tubing is clogged or coolant is
more contaminated than usual, have the vehicle
inspected.

(8) Make sure the radiator drain cock is securely

fitted.

(9) Pour coolant up to the top of the pressure cap

opening. Pour the coolant slowly to prevent air
from mixing with it.

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

(11) Fill the reservoir tank with the coolant to the

“FULL” line, then replace the cap.
(12) Keep the engine running at a speed slightly
higher than the specified idling speed to expel
air from the cooling system. Depress the accel-
erator pedal and run the engine slightly faster
than the ordinary idling speed. Press the rear
manual heater button to operate the rear
heater manually <Vehicles with rear heater>.
When the coolant temperature gauge needle U04799
approaches to the middle of the gauge, allow
the engine to idle for 10 more minutes then
stop it.
(13) When the engine has cooled, open the pres-
sure cap and, if the coolant level is too low, add
coolant until it reaches the top of the pressure
cap opening.
(14) Screw the pressure cap down tightly by turning
it clockwise and lock it.
Note: Be sure to screw the pressure cap tightly.
Otherwise, boiling water and steam under
high pressure will gush out if the engine over-
heats.
(15) Run the engine a few more minutes to make
sure that there are no coolant leaks.
(16) Make sure that the coolant level in the reservoir
tank is in the specified range. Add coolant if
necessary.

CLEANING THE RADIATOR CORE AND

INTERCOOLER
If the intercooler or front of the radiator core is
plugged with mud or dust, cooling efficiency will be
reduced leading to rust. Clean the intercooler and
radiator at regular intervals.

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.

(3) Turn on sonic belt tension gauge (special tool).

(4) Press “ (means “execute”)” key with no
belt type number entered.
(5) Set the sensitivity of its sensor microphone
when measuring the belt tension.
ON ( : means “low”): Measuring in noisy
environment, or out-
doors in heavy wind
ON ( : means “high”): Measuring in silent
environment, or mea- P102973E
suring a hard-to-
vibrate belt

(6) Enter the unit mass of the belt and push “

(means “execute”)”.

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

(8) Enter the number of ribs and push “

(means “execute”)”.

Measuring point on
Number of ribs
the belt
P1 7
P2 7

95138E

(9) Enter the length of span and push “

(means “execute”)”.

Measuring point on
Length of span
the belt
P1 202 mm
P2 203 mm

(10) Set the sensor microphone of approx. 10 mm

above the belt, at the middle position between
pulleys.
(11) Tap the belt lightly with a grip of a screwdriver
to vibrate the belt.
(12) Measure the tension a few times and calculate
the average value.

Inspection Belt tension Frequency

point (N) (Hz)
P1 300 to 700 –
Stan-
dard New 560 ± 20 172 ± 5
value P2
Re-used 500 ± 20 162 ± 5

P119350E

3-27
 ENGINE

(13) The fan belt is automatically adjusted for

proper tension by the auto tensioner. So, check
the auto tensioner for correct operation.
(14) Confirm that the tension pulley moves smoothly
when each of the midpoints between pulleys of
the fan belt indicated by the arrows is pushed
with your palm or pull on it.

(15) Confirm that the belt is in correct alignment with

Incorrect position of belt
the tension pulley.
Tension pulley
Belt

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.

SECOND COMPRESSOR BELT INSPEC-

TION
(1) Give the belt a finger push at the arrow
between the compressor pulley and tension
pulley. The belt should slack to a proper extent.

(2) The belt is automatically tensioned and

requires no tension adjustment.
(3) Loosen the lock nut on the tension pulley, and
the pulley becomes free to turn and the belt
slackens.
(4) Adjust the belt tension by turning the pulley
with second compressor belt tension handle
(special tool). Then, tighten the lock nut to hold
the pulley.

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

BELT DAMAGE INSPECTION

(1) If a belt is cracked or otherwise damaged, have
it replaced. Belt replacement requires compo-
nent disassembly.

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.

(1) Using a wrench, by turning the automatic ten-

sioner in the direction of the arrow so as to 㻭㼡㼠㼛㼙㼍㼠㼕㼏
slacken the belt. 㼠㼑㼚㼟㼕㼛㼚㼑㼞
(2) Insert a screwdriver, or the like, into the hole in 㼃㼞㼑㼚㼏㼔
the automatic tensioner, and lock the automatic
tensioner in the “Stop” position. 㻰㼞㼕㼢㼑㼞
(3) Replace the belt.

P125684E

(4) Remove the upper bracket mounting bolt and

then remove the belt from the gap between the 㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞 㻮㼞㼍㼏㼗㼑㼠㻌㼙㼛㼡㼚㼠㼕㼚㼓㻌㼎㼛㼘㼠
alternator and the bracket.

㻮㼞㼍㼏㼗㼑㼠

㻮㼑㼘㼠
504538E

(5) After operating the automatic tensioner in the

direction of the arrow using a wrench, remove 㻭㼡㼠㼛㼙㼍㼠㼕㼏
the driver. 㼠㼑㼚㼟㼕㼛㼚㼑㼞
㼃㼞㼑㼚㼏㼔

㻰㼞㼕㼢㼑㼞

P125684E

3-30
 ENGINE

10. EXHAUST SYSTEM

Every 40,000 km or
Inspection intervals
every 12 months*1

*1: The exhaust system must be inspected

depending on either the odometer reading or
operating period (months), whichever occurs
first.

(1) Check the exhaust system for damage, corro-

sion and loose connection causing leakage.

Exhaust pipe

Tail pipe

Intermediate pipe Selective catalytic reduction muffler

Front pipe
Diesel particulate filter muffler

㻟㻜㻟㻝㻝㻤

3-31
 ENGINE

11. UREA LINE LEAKAGE & DAMAGE

Every 40,000 km or
Inspection intervals
every 24 months*1

*1: The urea line leakage & damage must be

inspected depending on either the odometer
reading or operating period (months), which-
ever occurs first.

(1) Check to confirm that there are not found any

white crystals or traces of AdBlue® leakage at the
connections of the urea lines to the urea tank,
urea dosing module, urea pump unit and urea
dosing nozzle.
(2) If any trace of AdBlue® leakage is found, wipe the
white crystals off with a cloth moistened with
AdBlue® and then check each connection for tight-
ening condition. Retighten any loose connections.
(3) Check the urea line connections at the urea
tank (urea pump unit) and urea dosing nozzle
for installation condition.

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 supply module

Urea line
Urea tank

Urea dosing module (injection valve) Selective catalytic reduction muffler

Diesel particulate filter muffler

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

*1: The DPF must be inspected depending on

either the odometer reading or operating period
(months), whichever occurs first.

(1) Check DPF muffler for damage and for leaks of

exhaust gases.
(2) Check mounting bolts and nuts for looseness.
(3) Check mounting brackets for damage.

13. DPF PRESSURE HOSE

DPF pressure hose

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

(1) Check the DPF pressure hoses for damage

and status.

14. ALTERNATOR TENSIONER

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

(1) Replace the alternator tensioner

(auto tensioner).
Alternator tensioner
45 ± 5.0 N·m
(auto tensioner) mounting
(4.6 ± 0.5 kgf·m)
bolt tightening torque

15. ALTERNATOR
Alternator
pulley

Inspection interval Every 12 months

(1) Remove the belt.
(2) Inspect the alternator pulley by slowly rotating it
counterclockwise to check if it is rough, catches
or does not rotate. 508345E
(3) Replace the alternator if the alternator pullet
rotates more than one rotation.

3-33
 ENGINE

16. FUEL LINE LEAKAGE & DAMAGE

Inspection Normal use Every 24 months

intervals Severe use type*1 Every 12 months
*1: 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).

(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

17. GLOW PLUG

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.

(1) Replace the glow plug.

Glow plug tightening 8 to 10 N·m

torque (0.8 to 1.0 kgf·m)

3-35
 DRIVE LINE
18. CLUTCH CONTROL FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

19. TRANSMISSION GEAR OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

20. PROPELLER SHAFT BEARING KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

21. PROPELLER SHAFT CENTER BEARING

<EXCEPT DOUBLE ANTIVIBRATION TYPE> . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

22. PROPELLER SHAFT CENTER BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

23. PROPELLER SHAFT CENTER BEARING

<DOUBLE ANTIVIBRATION TYPE> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

24. PROPELLER SHAFT FLANGE YOKE BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

25. PROPELLER SHAFT (UNIVERSAL JOINT/SLIP JOINT) . . . . . . . . . . . . . . . . . 3-46

26. FRONT AND REAR WHEEL BEARING GREASE . . . . . . . . . . . . . . . . . . . . . . . 3-46

27. REAR AXLE DIFFERENTIAL GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

28. TIE ROD BALL JOINT DUST BOOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

29. TIE ROD ENDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

30. WHEEL NUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

31. DISC WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

32. TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

33. TIRE ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-37
 DRIVE LINE

18. CLUTCH CONTROL FLUID

Every 80,000 km or
Replacement intervals
every 24 months*1

*1: The clutch control fluid must be replaced

depending on either the odometer reading or
operating period (months), whichever occurs
first.

Recommended oil:
FUSO ATF SP III

Clutch control fluid quantity

Quantity required 2.0 liters

(1) Remove the drain plug to drain automatic

transmission fluid. Drainage can be made
quickly by removing the inspection plug.

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) Fill automatic transmission fluid until it over-

flows from the inspection plug hole.
(4) After filling, wait for 1 minute or more to check
the automatic transmission fluid level.

3-38
 DRIVE LINE

Connect FUSO Diagnostics.

(See Gr00 of the Service Manual.)

Adjust automatic transmission fluid temperature as fol-

lows.
• Adjust the automatic transmission fluid temperature to
approx. 50°C (45 to 55°C) with the vehicle stationary.

Fill the automatic transmission fluid in the hydraulic circuit

as follows.
• While depressing the brake pedal, shift the gearshift le-
ver between “R” and “D” positions for 3 times. (Hold the
lever for 3 to 5 seconds at each position.)
• Set the gearshift lever to “P” position.

Check the automatic transmission fluid level as follows.

• Stop the engine.
• Wait for 5 minutes. Remove the inspection plug and
check that the automatic transmission fluid is full to the
brim.

Automatic transmission Automatic transmission

fluid is full to the brim. fluid is not up to the brim.

Within 10 minutes after Through the inspection

stopping the engine, plug hole, fill the auto-
tighten the inspection matic transmission fluid
plug to the specified up to the brim.
torque.

Install the inspection

plug.

Initialize the DUONIC® system.

(See Gr22ED of the Service Manual.)

Operation finished.

3-39
 DRIVE LINE

(5) When the work is complete, tighten the inspec-

tion plug.
Inspection plug tightening 68.6 ± 14.7 N·m
torque (7.0 ± 1.5 kgf·m)

CAUTION
After filling automatic transmission fluid,
promptly install the inspection plug to prevent
dirt and dust from entering the clutch housing.

(6) When automatic transmission fluid has been

replaced, make initial setting of the DUONIC
system and perform a test drive. (See Gr22ED
of the Shop Manual.)

19. TRANSMISSION GEAR OIL

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:

Quantity required Approx. 3.5 liters

(1) Remove inspection plug and drain plug to let

the oil flow out.

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.

(2) The drain plug is fitted with a magnet. Wipe off

any metal particles sticking to the magnet.

3-40
 DRIVE LINE

(3) Replace the plug’s gasket with a new one, coat

the threads on the plug with sealant, and then
install and tighten the plug.

Sealant ThreeBond 1105

68.6 ± 14.7 N·m

Tightening torque
(7.0 ± 1.5 kgf·m)

(4) Add oil through the inspection plug hole until it

reaches the opening of the hole. After one
minute has passed, and check that the oil sur- Inspection plug hole
face reaches the opening of the hole.
(5) Replace the inspection plug’s gasket with a Oil surface
new one, coat the threads on the plug with
sealant, and then install and tighten the plug.

Sealant ThreeBond 1105

600504
68.6 ± 14.7 N·m
Tightening torque
(7.0 ± 1.5 kgf·m)

20. PROPELLER SHAFT BEARING KIT

Universal joint spider kit

Every 200,000 km or
Replace intervals
every 120 months*1

*1: The propeller shaft bearing kit must be

replaced depending on either the odometer
reading or operating period (months), which-
ever occurs first.

(1) Use the kits to replace the spider and needle

bearings.
P100333E

3-41
 DRIVE LINE

21. PROPELLER SHAFT CENTER BEARING

<EXCEPT DOUBLE ANTIVIBRATION TYPE>

Every 80,000 km or
Inspection intervals
every 24 months*1

*1: The propeller shaft center bearing must be

inspected depending on either the odometer
reading or operating period (months), which-
ever occurs first.

(1) Check the center bearing attaching bolts for

looseness.
Center bearing attaching 47 to 65 N·m
nut tightening torque (4.8 to 6.6 kgf·m)

(2) Check the center bearing if trace of grease

flowing out is evident. Check the center bearing
for wear, damage and play.

3-42
 DRIVE LINE

22. PROPELLER SHAFT CENTER BEARING

Every 80,000 km or
Greasing intervals
every 24 months*1

*1: The propeller shaft center bearing must be

greased depending on either the odometer
reading or operating period (months), which- 02800E
ever occurs first.

Recommended lubricant:
Heat-resisting grease
NLGI No. 3

(1) Pack grease in center bearing housing up to 70

to 100% (20 to 29 g) of space capacity.
(2) Apply grease to seal lips.

Note: The ball bearing portion of center bearing is

provided with an oil seal and requires no sup-
ply of grease.

3-43
 DRIVE LINE

23. PROPELLER SHAFT CENTER BEARING

<DOUBLE ANTIVIBRATION TYPE>

Inspection intervals Every 50,000 km

Replacement intervals Every 150,000 km

The first propeller shaft center bearing inspection

during the run-in period should be performed at the
first 2,000 km.

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.

(1) Move the propeller shaft up, down, left and

right at points near the center bearing to check
the propeller shaft center bearing.
(2) Check the center bearing for wear, damage
and play.
(3) Replace the propeller shaft center bearing.

3-44
 DRIVE LINE

24. PROPELLER SHAFT FLANGE YOKE BOLTS

Every 40,000 km or
Inspection intervals every 12 months*1

The first propeller shaft flange yoke bolts inspection

during the run-in period should be performed at the
first 2,000 km.

*1: The propeller shaft flange yoke bolts must be

inspected depending on either the odometer
reading or operating period (months), which-
ever occurs first.

(1) Check the flange yoke bolts for looseness.

Flange yoke bolt 100 to 120 N·m
tightening torque (10 to 12 kgf·m)

(2) Check the universal joint for play.

3-45
 DRIVE LINE

25. PROPELLER SHAFT

(UNIVERSAL JOINT/SLIP JOINT)

Every 40,000 km or
Greasing intervals
every 12 months*1

The first greasing of the propeller shaft (universal

75648
joint/slip joint) during the run-in period should be
performed at the first 2,000 km.

*1: The propeller shaft (universal joint/slip joint)

must be greased depending on either the
odometer reading or operating period
(months), whichever occurs first.

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.

26. FRONT AND REAR WHEEL BEARING <Front>

GREASE 㻴㼡㼎㻌㼎㼛㼘㼠

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

27. REAR AXLE DIFFERENTIAL GEAR OIL

Every 80,000 km or
Replacement intervals every 24 months*1

*1: The rear axle differential gear oil must be

replaced depending on either the odometer
reading or operating period (months), which-
ever occurs first.

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.

Oil quantity Approx. 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.

(1) Place a container under the drain plug .

(2) Remove drain plug and inspection plug and
drain out oil.

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

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) When all of the differential gear oil has drained

out, replace the drain plug gasket with a new
one and install the drain plug.
110 ± 10 N·m
Tightening torque
(11 ± 1 kgf·m)

3-47
 DRIVE LINE

(4) Replenish from inspection plug port up to

the brim .
(5) Attach inspection plug. Like with the drain plug,
replace the gasket of the inspection plug with a
new one.
110 ± 10 N·m
Tightening torque
(11 ± 1 kgf·m)

Z18456

28. TIE ROD BALL JOINT DUST BOOTS

Tie rod end

Every 40,000 km or
Inspection intervals
every 12 months*1

*1: The tie rod ball joint dust boots must be

inspected depending on either the odometer Ball joint dust cover
reading or operating period (months), which- 303122
ever occurs first.

(1) Check the ball joint dust boots for cracks and
wear.

29. TIE ROD ENDS

Tie rod end

Every 40,000 km or
Greasing intervals
every 12 months*1

*1: The tie rod ends must be greased depending

on either the odometer reading or operating
period (months), whichever occurs first. 303123

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

30. WHEEL NUT

Every 40,000 km or
Inspection intervals
every 12 months*1

*1: The wheel nut must be inspected depending on

either the odometer reading or operating period
(months), whichever occurs first.

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.

(1) Use a torque wrench to inspect wheel nuts for

looseness 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.
• 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.

<Single nut type>

Tighten the wheel nuts to the specified torque. Fol-
low the diagonal tightening sequence indicated in
the figure.

T77021

3-49
 DRIVE LINE

<Double nut type>

Retighten the wheel nuts using the following 2-pro-
cess procedure.
The wheel nuts for the right-side wheels should be
tightened in the direction A, and that for the left-side
wheels in the direction B.
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 First check and Then check and
torque. retighten the three retighten the
3) Tighten the loosened outer wheel nuts to the bolts shown. remaining
two bolts.
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-
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
㼆㻞㻞㻥㻣㻣
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.

31. DISC WHEEL

Every 40,000 km or
Inspection intervals every 12 months*1

*1: The disc wheel must be inspected depending

on either the odometer reading or operating
period (months), whichever occurs first.

(1) Check the disc wheels for cracks and other

damages.

3-50
 DRIVE LINE

32. TIRES

Every 40,000 km or
Inspection intervals every 12 months*1

*1: The tires must be inspected depending on

either the odometer reading or operating period
(months), whichever occurs first.

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.
(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 pres- Z21588
sure is slightly higher than the standard pres-
sure. 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 indi-
cating the standard inflation pressure. Keep the
tires inflated to the pressures shown on the label.
WARNING
• Excessively low or high tire pressures not
only give a poor ride. 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- T75454
sure.
• You need not increase tire pressure before
high-speed driving.

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.

3-51
 DRIVE LINE

(5) Never fail to install tire valve caps after check-

ing or adjusting the air pressure.

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

CHECKING FOR CRACKS, DAMAGE, AND

OBJECTS EMBEDDED IN TREAD
(1) 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.
(2) Check the tires for swelling and other deforma-
tion. Also, touch the tires with your hands to
check whether the rubber has been softened Z10805
by oil or chemicals. Inspect the spare tires as
well as those in use.

3-52
 DRIVE LINE

33. 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 40,000 km or
Tire rotation intervals every 12 months*1

*1: The tire must be rotated depending on either

the odometer reading or operating period
(months), whichever occurs first.

(1) 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

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

35. STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

36. STEERING SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3-55
 STEERING

34. POWER STEERING FLUID

Every 50,000 km or
Replacement intervals
every 12 months*1

*1: The power steering fluid must be replaced

depending on either the odometer reading or
operating period (months), whichever occurs
first.

Recommended fluid:
Automatic transmission fluid
DEXRON ll or DEXRON lII type

(1) Jack up the front wheels.

(2) Clean the port areas of feed tube to prevent
㻼㼛㼣㼑㼞㻌㼟㼠㼑㼑㼞㼕㼚㼓㻌㼓㼑㼍㼞㻌㼍㼟㼟㼑㼙㼎㼘㼥
ingress of dirt, dust, and other foreign matters
inside the power steering gear assembly.
(3) Loosen feed tube connected to the power
steering gear assembly.
(4) Repeatedly turn the steering wheel fully left
and right to drain the fluid from the power steer-
ing gear assembly. 㼀㼡㼎㼑
(5) Tighten the feed tube to specified torque. 92625E

Feed tube tightening 12 to 18 N·m

torque (1.2 to 1.8 kgf·m)

(6) Pour fluid into the power steering oil tank up to

the bottom of the strainer. 㻿㼠㼞㼍㼕㼚㼑㼞
(7) With the engine stopped, jack up the front
wheels.
(8) Repeatedly turn the steering wheel fully left 㻻㼕㼘㻌㼘㼑㼢㼑㼘㻌㼞㼍㼚㼓㼑
and right. When the fluid level has dropped,
add enough fluid to maintain the fluid level
within the specified range.
(9) Start the engine to idle.
(10) When the fluid level has dropped, stop the 㻮㼛㼠㼠㼛㼙㻌㼛㼒㻌㼟㼠㼞㼍㼕㼚㼑㼞 92564E
engine and add fluid.
(11) Restart the engine. While checking for a drop in
fluid level, repeatedly replenish the hydraulic
fluid until the fluid level is stabilized.
(12) 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.

3-56
 STEERING

(13) 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.
(14) Stop the engine and wait for approximately five
minutes.
(15) 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
steering system is completed.
(16) Repeat starting and stopping the engine sev-
eral times to remove small air bubbles left in
the power steering oil tank.
(17) If air bubbles are not removed completely, drive
the vehicle for a while, then check for abnormal
noise and oil level fluctuation.

35. STEERING SYSTEM

Every 40,000 km or
Inspection intervals
every 12 months*1

*1: The steering system must be inspected

depending on either the odometer reading or
operating period (months), whichever occurs
first.

LOOSENESS OF STEERING SYSTEM

(1) Check the steering system for looseness.

STEERING WHEEL LOOSENESS

(1) Try moving steering wheel up and down and
also right and left to check for excessive loose-
ness.

Note: Make sure the lock lever that is used for

steering wheel adjustment is securely locked.

U01510

3-57
 STEERING

STEERING WHEEL PLAY

Note: Be sure to check the steering wheel play with
the engine running and with the engine
turned off.

(1) Make sure the parking brake is securely

applied.
(2) If your vehicle is equipped with a manual trans-
mission, make sure that the gearshift lever is in
the neutral position. If your vehicle is equipped U01509
with the DUONIC system, make sure that the
gearshift lever is in the “P” position.
(3) Gently turn the steering wheel from its straight-
ahead (neutral) position to the point where you
first feel resistance in the clockwise direction
and to the point where you first feel resistance
in the counterclockwise direction. The distance
between the two points is the extent of steering
wheel play. Check the steering wheel play with
the engine running and with the engine turned
off.

Steering wheel When engine is

20 mm or less
play turned off
(on the periphery When engine is
of steering wheel) 5 to 50 mm
idling

STEERING WHEEL OPERATION

(1) While driving slowly, make sure that the steer-
ing wheel is free from shake and the vehicle
does not pull to one side.
(2) 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.

FLUID LEAKAGE FROM STEERING SYS-

TEM
(1) Check the power steering oil tank, power steer-
ing oil pump, power steering gear assembly,
and hose and pipe connections for fluid leak.
Check also the hoses for blister due to deterio-
ration, damage and crack.
(2) If any fluid leak is found, tighten the connection
or replace the faulty parts.

3-58
 STEERING

36. STEERING SHAFT

Greasing intervals Every 3 months

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

38. BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

39. PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

40. SERVICE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

3-61
 BRAKES

37. DISC AND PAD

<Front>
<VEHICLES WITH DISC BRAKES> Outer pad
(with pad wear indicator)
Inner pad
Piston

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

(1) Check the disc rotor for damage and wear.

(2) When a brake pad has worn down to a thick- Inspection hole
ness of approximately 4 mm, the pad wear indi-
cator contacts the disc rotor. A squeaking
sound is given off as the wheels rotate to indi-
cate the operator that the brake pads need
replacement.
(3) Through the inspection hole in the caliper,
measure the brake pad thickness.
Caliper Brake pad thickness
Thickness of out- Standard value Limit 06817
er/inner pad
14 mm 4 mm

(4) If the measured value is less than the limit,

replace all of the brake pads on that axle with a
new kit.

38. BRAKE FLUID

Replacement intervals Every 24 months

Recommended fluid:
Brake fluid SAE J1703
FMVSS No.116, DOT3

Note: With a manual transmission vehicles, the

brake fluid serves also as clutch fluid.

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.

Note: • 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) Remove the power fuse (F18) for the electronic

control unit of anti-lock brake system.

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

causing air to enter into the secondary system

F19
F20
F21
F22
F23
F24
F25
F26

F27
F28
F29
F30
F31
F32
F33
F34

(anti-lock brake system operating circuit).

608024

(2) In order to ensure that the vacuum booster func-

tions properly, start the engine and keep it run-
ning at idle until the replacement is completed.

(3) Install one end of a vinyl pipe onto each air

bleeder. Place the loose end into a container.
(4) Loosen each bleeder screw, and depress and
release the brake pedal repetitively until brake
fluid is no longer discharged from the pipes. 㻭㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞
(5) While filling the brake fluid tank with new brake
fluid up to the "MAX" mark, cycle the brake pedal
repetitively until the old brake fluid being dis-
charged is replaced with new brake fluid. Tighten
each air bleeder to the specified torque. 㻭㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞 P58286E

3-63
 BRAKES

AIR BLEEDING OF BRAKE SYSTEM

(1) Remove the power fuse (F18) for the electronic
control unit of anti-lock brake system.

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

(2) In order to ensure that the vacuum booster

functions properly, start the engine and keep it
running at idle until the replacement is com-
pleted.
(3) Install one end of a vinyl pipe onto each air
bleeder. Place the loose end into a container.

㻭㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞

㻭㼕㼞㻌㼎㼘㼑㼑㼐㼑㼞 P58286E

(1) Air bleeding of primary brake system (normal

circuit)
1) Perform the air bleeding sequence described 㻞 㻝
below on each of the 4 wheels in the order of
the following table.
Order of air bleeding Brake system Wheel
1 Front right
Front
2 Front left 㻠 㻟
P58288
3 Rear right
Rear
4 Rear left

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

Loosen the air bleeder.

Slowly depress and release the brake pedal. Repeat this

several times until a sufficient amount of brake fluid is
discharged from the pipe.

Tighten the air bleeder.

Cycle the brake pedal several times, and finally depress

and hold it.

Loosen the air bleeder.

With the brake pedal still depressed, allow the brake fluid
to drain.

Air in brake fluid No air in brake fluid

Tighten the air bleeder to the specified torque.

Repeat the above procedures on all of the remaining

wheels.

With air bleeding completed on all wheels, install the pow-

er fuse for the anti-lock brake system electronic control
unit.

Air bleeding of the primary system (normal circuit) is com-

pleted.

3-65
 BRAKES

(2) Air bleeding of secondary brake system

(anti-lock brake system operating circuit)
1) Use the FUSO Diagnostics actuator test (man-
ual bleeding) for bleeding. (See 35EA "Actuator
Test Using FUSO Diagnostics"of the Service
Manual.)

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

39. PARKING BRAKE

Every 40,000 km or
Inspection intervals
every 12 months*1

*1: The parking brake must be inspected depend-

ing on either the odometer reading or operating
period (months), whichever occurs first.

PARKING BRAKE LEVER STROKE CHECK

(1) Make sure that the gearshift lever is in the neu-
tral position (on a manual transmission vehicle)
or that the gearshift lever is in the “P” position
(on a vehicle with a DUONIC system). Start the
engine and depress the brake pedal firmly so
that the vehicle cannot move.
(2) Starting with the parking brake lever in the fully
released position, pull the parking brake lever
with a force of 294 N (30 kgf) until it stops mov-
ing. Check whether the lever stroke (the dis-
tance moved by the lever) is within
specification. If the stroke is out of specifica-
tion, have the vehicle inspected.
Parking brake lever stroke 7 to 9 notches

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

40. SERVICE BRAKE SYSTEM

Every 40,000 km or
Inspection intervals
every 12 months*1

*1: The service brake system must be inspected

depending on either the odometer reading or
operating period (months), whichever occurs
first.

BRAKE SYSTEM DAMAGE Brake fluid

Vacuum
Front wheel Rear wheel
(1) Check the hoses and pipes for damage and booster tank
brake brake
looseness. Brake master
(2) Check the brake fluid leakage. Brake fluid cylinder Brake control
pressure sensor valve (rear)
<DUONIC®>
Hydraulic unit
Brake control valve
<DUONIC®>
䠖 Hose
䠖 Fluid line 303125

BRAKE PEDAL PLAY

(1) Confirm that the parking brake is securely
applied.
(2) Pump the brake pedal several times until you
feel a harder response from it than usual.
(3) 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
Pedal play
where resistance is felt (brake pedal play).
Check whether the distance is within specifica- 06539E
tion.

Brake pedal play

0.1 to 1.7 mm
(at center of pedal pad)

(4) If the brake pedal play is not as specified, have

the pedal inspected and adjusted.

3-69
 BRAKES

BRAKE PEDAL CLEARANCE

(1) With the engine idling, depress the brake pedal
by 490 N {50 kgf} and measure the pedal-to-
floor clearance.
Clearance between floor and
brake pedal (when depressed with 40 mm or more
a force of 490 N {50 kgf})

(2) If the measurement is out of the standard Height

value, adjust the installed height of the brake 06540E
pedal.

CHECK VALVE OPERATION

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.

(1) Start the engine and charge the vacuum tank

with vacuum.
(2) Stop the engine, and immediately remove the
clamp fixing the vacuum hose onto the vacuum
pipe, and hold the hose in your mouth.
(3) Blow into the hose. The check valve should be
closed, preventing the breath from passing it.
(4) Suck on the hose and depress the brake pedal.
The check valve should be opened immedi- 㻢㻜㻤㻜㻟㻝
ately, allowing air to pass.
(5) If any fault is encountered during the above
inspections, replace the vacuum hose with
check valve.

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.

(2) Using MUT-III, check the condition of the brake

control valve.

3-70
 SUSPENSION
41. SUSPENSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

42. IFS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

43. STABILIZER ROD BALL JOINT DUST BOOTS

<VEHICLES WITH STABILIZER> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

3-71
 SUSPENSION

41. SUSPENSION SYSTEM

䠘㻲㼞㼛㼚㼠䠚

Every 40,000 km or
Inspection intervals
every 12 months*1

The first suspension system inspection during the

run-in period should be performed at first 2,000 km. 㻿㼔㼛㼏㼗㻌㼍㼎㼟㼛㼞㼎㼑㼞

*1: The suspension system must be inspected 㻌䠘㻾㼑㼍㼞䠚

depending on either the odometer reading or 㻿㼔㼛㼏㼗㻌㼍㼎㼟㼛㼞㼎㼑㼞
operating period (months), whichever occurs
first.
㼁㻙㼎㼛㼘㼠
(1) Check the U-bolts for looseness.
Check at the first 1,000 km after removing and
retightening U-bolts nuts.
(2) Check the leaf spring, shock absorber for dam-
age. 㻸㼑㼍㼒㻌㼟㼜㼞㼕㼚㼓
㻟㻜㻟㻝㻞㻢

42. IFS SYSTEM

Every 40,000 km or
Inspection intervals
every 12 months*1

The first IFS system inspection during the run-in

period should be performed at first 2,000 km.

*1: The IFS system must be inspected depending

on either the odometer reading or operating
period (months), whichever occurs first.

Recommended lubricant :
Wheel bearing grease
NLGI No.2 (Li soap)

(1) Check the springs for cracks and damage. 㼁㼜㼜㼑㼞㻌㼍㼞㼙㻌㼎㼍㼘㼘㻌㼖㼛㼕㼚㼠

㼁㼜㼜㼑㼞㻌㼍㼞㼙
(2) Check both upper arm ball joints and lower arm 㼎㼡㼟㼔㼕㼚㼓㼟
ball joints for looseness. If any ball joint shows 㻷㼚㼡㼏㼗㼘㼑
looseness exceeding the standard value,
replace the affected ball joint assembly. 㻯㼛㼕㼘㻌㼟㼜㼞㼕㼚㼓
(3) Check the upper arm bushings for looseness.
Replace any bushing with looseness exceed-
ing the standard value. 㻿㼔㼛㼏㼗㻌㼍㼎㼟㼛㼞㼎㼑㼞
(4) Check the bump stoppers for height. If the 㻮㼡㼙㼜㻌㼟㼠㼛㼜㼜㼑㼞
height (total height including the plate height) is 㻸㼛㼣㼑㼞㻌㼍㼞㼙㻌㼎㼍㼘㼘㻌㼖㼛㼕㼚㼠
303127
smaller than the standard value, replace the
bump stopper.
(5) Check the rubber and plate portions of bump
stoppers for cracks.
(6) Check the dust boots of both upper arm ball
joints and lower arm ball joints for cracks or
other damage.
(7) Apply grease to the lip of the dust boots.

3-72
 SUSPENSION

43. STABILIZER ROD BALL JOINT DUST BOOTS

<VEHICLES WITH STABILIZER>

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

*1: The battery must be inspected depending on

either the odometer reading or operating period
(months), whichever occurs first.

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.

REMOVAL AND INSTALLATION OF BATTERY

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.

Note: The battery equalizer controls the electrical

balance between the 12-volt battery for
engine and the 24-volt battery for body so as
to protect the 12-volt battery for engine.
Y03316

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

(3) Remove the mounting nuts (marked with )

from the battery support . Both end of battery support
(4) Remove the battery support and J bolts , then
remove the batteries.
For the battery support, incline the J bolt and
pull out it from slotted holes .

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.

Use the steps below to connect the battery cables.

(1) Connect the (+) terminal of the 24-volt bat-

tery for the body .
(2) Connect the (+) terminal of the 12-volt bat-
tery for the engine .
(3) Connect the (-) terminal of the 24-volt battery
for the body .
(4) Connect the (-) terminal of the 12-volt battery
for the engine .
(5) Check that there is a gap of 15 mm or more
between any terminals to and the battery Y03320

support mounting nuts and J bolts .

(6) Make sure each battery terminal cap is
attached securely and terminals are not
exposed.
5 to 7 N·m
Tightening torque
(0.5 to 0.7 kgf·m)

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

BATTERY FLUID LEVEL CHECK

(1) Open the battery lid.
(2) Fluid level is adequate if it lies between the
“UPPER” and “LOWER” level lines on the side
of the battery case.
If inadequate, add battery fluid supplement or
distilled water until the fluid level reaches the
“UPPER” level line.
(3) If the battery has no level line displayed, the
normal range lies from 10 to 15 mm above the Z00409
plate.

(4) If the side of the battery case is not in your

direct view due to equipment or other things on Filler hole
the vehicle body, do the following:
• Remove the battery’s cap. Hand mirror
• Check the battery fluid level using an appro-
priate mirror like a hand mirror .
Battery fluid
• Check whether the battery fluid comes up to
the bottom of the sleeve of each filler hole.

DANGER U03112

BATTERY FLUID CONSISTS OF DILUTED

SULFURIC ACID, WHICH WILL DAMAGE
SKIN OR CLOTHING WHEREVER IT COMES
IN CONTACT. HANDLE IT VERY CAREFULLY.
IF IT GETS ON ANYONE, RINSE IT IMMEDI-
ATELY WITH COPIOUS AMOUNTS OF
WATER, THEN WASH IT THOROUGHLY
CLEAN WITH SOAP. IF YOU ACCIDENTALLY
GET BATTERY FLUID IN YOUR EYES, WASH
YOUR EYES WITH LOTS OF CLEAN WATER
THEN PROMPTLY SEE AN EYE DOCTOR FOR
TREATMENT.
USE PROTECTIVE GOGGLES AND RUBBER
GLOVES WHILE HANDLING BATTERY FLUID.

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

INSPECTION OF BATTERY FLUID SPECIFIC

GRAVITY
The battery condition can be confirmed by the spe-
cific gravity of the battery fluid.
Use a specific gravity meter to measure the battery
fluid specific gravity.
If the specific gravity falls below 1.220 (with battery
fluid temperature at 20°C), the battery must be
charged.
If the fluid is other than 20°C, calculate specific 76509
gravity 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

TERMINAL CONNECTION STATUS

(1) Inspect to confirm that battery cable is attached
securely to battery terminals.
(2) Clean terminals where there is dirt or corrosion.

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.

Note: There is a way to start the engine from the

battery of another vehicle, using a booster
cable, when the battery is dead.

3-80
 AIR CONDITIONER
45. AIR COMPRESSOR OIL LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82

46. AIR COMPRESSOR MAGNET CLUTCH BEARING . . . . . . . . . . . . . . . . . . . . . 3-82

47. AIR COMPRESSOR MAGNET CLUTCH GAP ADJUSTMENT . . . . . . . . . . . . . 3-82

48. AIR COMPRESSOR MAGNET CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . 3-83

49. AIR COMPRESSOR MAGNET CLUTCH CENTER BOLT . . . . . . . . . . . . . . . . . 3-83

3-81
 AIR CONDITIONER

45. AIR COMPRESSOR OIL LEAK

㻨㻱㼤㼏㼑㼜㼠㻌㻮㻱㻣㻠㻝㻶㻾㻹㻿㻰㻱㻮㻪

Inspection intervals Every 12 months

(1) Check the compressor proper for malfunction

and oil leakage.

㻨㻮㻱㻣㻠㻝㻶㻾㻹㻿㻰㻱㻮㻪

㻟㻜㻟㻝㻞㻥

46. AIR COMPRESSOR MAGNET CLUTCH

BEARING

Inspection intervals Every 12 months

(1) If the abnormal noise occurs, replace compres-

sor.

47. AIR COMPRESSOR MAGNET CLUTCH GAP

ADJUSTMENT 㻼㼡㼘㼘㼑㼥
㻭㼞㼙㼍㼠㼡㼞㼑 㻳㼍㼜
㼍㼟㼟㼑㼙㼎㼘㼥
㻮㼑㼍㼞㼕㼚㼓
㻯㼑㼚㼠㼑㼞
Inspection intervals Every 12 months 㼎㼛㼘㼠
㻯㼑㼚㼠㼑㼞㻌㼎㼛㼘㼠 㻭㼞㼙㼍㼠㼡㼞㼑
㼍㼟㼟㼑㼙㼎㼘㼥
(1) Turn on AC, check if the armature assembly of 㻼㼡㼘㼘㼑㼥 㻹㼍㼓㼚㼑㼠㼕㼏㻌㼏㼘㼡㼠㼏㼔
compressor clutch is engaged and rotates 㼏㼞㼛㼟㼟㻌㼟㼑㼏㼠㼕㼛㼚
303130
together.

3-82
 AIR CONDITIONER

48. AIR COMPRESSOR MAGNET CLUTCH

OPERATION 㻨㻱㼤㼏㼑㼜㼠㻌㻮㻱㻣㻠㻝㻶㻾㻹㻿㻰㻱㻮㻪

Inspection intervals Every 12 months

(1) Disconnect the magnetic clutch harness con-

nector and supply power from the positive ter-
minal of the battery to check if the magnetic
clutch operates normally. 㻨㻮㻱㻣㻠㻝㻶㻾㻹㻿㻰㻱㻮㻪
(2) Check for noise from compressor while operat-
ing AC.
(3) If there is any abnormal noise, replace the
compressor.

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.

49. AIR COMPRESSOR MAGNET CLUTCH

CENTER BOLT 㻼㼡㼘㼘㼑㼥
㻭㼞㼙㼍㼠㼡㼞㼑 㻳㼍㼜
㼍㼟㼟㼑㼙㼎㼘㼥
㻮㼑㼍㼞㼕㼚㼓
㻯㼑㼚㼠㼑㼞
Inspection intervals Every 12 months 㼎㼛㼘㼠
㻯㼑㼚㼠㼑㼞㻌㼎㼛㼘㼠 㻭㼞㼙㼍㼠㼡㼞㼑
㼍㼟㼟㼑㼙㼎㼘㼥
(1) If the center bolt does not rotate, replace the 㻼㼡㼘㼘㼑㼥 㻹㼍㼓㼚㼑㼠㼕㼏㻌㼏㼘㼡㼠㼏㼔
compressor. 㼏㼞㼛㼟㼟㻌㼟㼑㼏㼠㼕㼛㼚
303130
(2) If looseness occurs, replace the compressor.

3-83
 OTHERS
50. CHASSIS FRAME DAMAGE AND LOOSENESS . . . . . . . . . . . . . . . . . . . . . . . 3-86

51. CHASSIS PARTS

(ACCELERATOR LINK SHAFT, ACCELERATOR PEDAL,
TRANSMISSION CONTROL LINKAGE, GEAR SHIFT SELECT LEVER PIN,
PARKING BRAKE LEVER, BRAKE PEDAL LINK,
WHEEL BRAKE PARTS, DOOR LOCK, DOOR INSIDE AND
OUTSIDE HANDLES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3-85
 OTHERS

50. CHASSIS FRAME DAMAGE AND LOOSE-

NESS

Every 80,000 km or
Inspection intervals
every 24 months*1

*1: The chassis frame damage and looseness

must be inspected depending on either the
odometer reading or operating period
(months), whichever occurs first.

(1) Check the frame and cross member bolts and

rivets for cracks, damage and looseness.

51. CHASSIS PARTS

(ACCELERATOR LINK SHAFT, ACCELERA-
TOR PEDAL, TRANSMISSION CONTROL
LINKAGE, GEAR SHIFT SELECT LEVER
PIN, PARKING BRAKE LEVER, BRAKE
PEDAL LINK, WHEEL BRAKE PARTS,
DOOR LOCK, DOOR INSIDE AND OUTSIDE
HANDLES)

Every 80,000 km or
Greasing intervals
every 24 months*1

*1: The chassis parts must be greased depending

on either the odometer reading or operating
period (months), whichever occurs first.

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