2002 Mitsubishi Fuso FE639 FE640 FE649 FG639 FG649 Truck Service Manual

Covers FE639, FE640, FE649, FG639, FG649 models with detailed procedures for engine, transmission, axles, brakes, and more. Includes part numbers and diagrams.

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Document Details

Document Number / Seller:: 30467 / Ronald Owens
File Size:: 50.05 MB
File Type:: PDF
Language:: English
Pages:: 1559
Printable:: Yes
Category:: Truck
Last updated / verified: Dec 21, 2025

Models Covered & Key Technical Specifications

Mitsubishi Fuso FE639 FE640 FE649 FG639 FG649 Truck Service Manual: 2002 Covers FE639, FE640, FE649, FG639, FG649 models with procedures for engine, transmission, axles, brakes, and more. Ref: FEFGServiceManual.pdf

Engine Model: 4M50T2
Vehicle Type: Truck
Max. Power Output: 175 HP/2700 rpm (SAE Gross)
Total Displacement: 4.899 liters (299 cu. in.)
Compression Ratio: 17.5:1
Manual Year: 2002

Manual Description & Preview

Mitsubishi Fuso FE/FG Series Truck Service Manual: 2002

Repair-Classification: Service Manual / Repair-Classification: Engine / Service-Level: Detailed Repair & Maintenance Reference.

Technical Specifications Table

Service-Nexus	Parameters	Framework
Engine Model	4M50T2	Water-cooled, 4-cycle diesel
Max. Power Output	175 HP/2700 rpm (SAE Gross)	Direct injection
Total Displacement	4.899 L (299 cu. in.)	Double overhead camshaft
Compression Ratio	17.5:1	4-cylinder, in-line
Applicable Models	FE639, FE640, FE649, FG639, FG649	2002 Model Year
Manual Type	Service Manual	Documented Repair Procedures

Table of Contents Summary

The documentation is partitioned into:

Engine Specifications and Structure
Troubleshooting Guide
On-Vehicle Inspection and Adjustment
Removal and Installation Procedures
Rocker Cover, Assemblies, and Camshafts

Engine Specifications and Structure

This section details the engine's mechanical specifications, including bore, stroke, and valve mechanism. It provides diagrams for components like pistons, connecting rods, and crankshafts.

Troubleshooting Guide

Provides a systematic approach to diagnosing common engine problems, listing possible causes, symptoms, and recommended actions.

On-Vehicle Inspection and Adjustment

Covers essential checks and adjustments performed with the engine installed, such as compression testing and valve clearance adjustments.

Removal and Installation Procedures

Details the steps for removing and reinstalling the engine and related assemblies, including necessary special tools and tightening torques.

Rocker Cover, Assemblies, and Camshafts

This section outlines the disassembly, inspection, and reassembly of the rocker cover, rocker assemblies, and camshafts, including critical clearances and torque specifications.

This manual documents torque specifications for various components to ensure proper assembly and prevent structural misalignment.

FAQ

Calculate the **precise** pressure specifications for the FE639 front brake caliper?

6.9 to 8.8 N·m {5.1 to 6.5 ft.lbs, 0.7 to 0.9 kgf·m} is the specified torque for the front disc brake air bleeder.

What values ensure **proper** assembly sequence for the crankshaft and main bearings?

The upper main bearing 9 has an oil hole A for engine oil supply to the crankshaft 8 journal, and thrust plates 2 and 3 require specific thickness for end play specification.

Assess the **standard** service interval parameters for the air cleaner element?

Air cleaner element replacement is recommended every 5000 km/3000 miles, or when air cleaner element 3 is wet due to oil smoke or soot.

What components are **necessary** for the engine's valve mechanism?

Key components include valve keepers 1, upper retainer 2, outer valve spring 3, inner valve spring 4, valve stem seal 5, exhaust valve 6, inlet valve 7, and their respective guides and seats.

Confirm the **recommended** tool requirements for installing the idler gear bushing?

The recommended tool is the Idler Gear Bushing Puller (MH061779, Obtain Locally), with specific dimensions of φ 32 {φ 1.26 in.} for the tool and φ 35 {φ 1.38 in.} for the bushing.

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