Mitsubishi Fuso FH Series / FK617, FM617, FM657 — 2002 Truck Service & Repair Manual

Mitsubishi Fuso’s April 2001 service manual for the 2002 FH Series / FK617, FM617 and FM657 covers maintenance, diagnosis and repair of the documented diesel, driveline and chassis configurations. Section publication numbers include TWME0103-11 for Engine and TWME0103-54 for Electrical.

Search, Bookmarks and Wiring Detail

Finding procedures and circuit details: Most technical sections support PDF text search, but the reading-guide pages and air-conditioner content do not. Embedded bookmarks link to system groups and subtopics. Some wiring labels lack searchable text; small labels in dense schematics require zooming for clear reading.

One printable PDF contains 1,530 pages, including the foreword and 30 section-title pages. The reading guide, maintenance schedules, reference charts and air-conditioner section are included in that total.

Diesel, Driveline and Brake Work

These selected contents outline the main repair areas; additional topics include frame inspection and window-glass replacement.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head and valve work, piston and cylinder-sleeve service, timing gears and crankshaft inspection.

• Fuel and intake systems: Electronic governor and pre-stroke control diagnosis, injection timing, nozzle testing, turbocharger repair and intercooler service.

• Clutch and transmissions: Clutch hydraulic service, manual-gearbox disassembly and reassembly, splitter repair and automatic-transmission troubleshooting.

• Axles, suspension and steering: Propeller-shaft balancing, front-axle hub and kingpin service, rear-differential adjustment, front and rear leaf-spring repair and power-steering testing.

• Brakes and ABS: Separate air-over-hydraulic and full-air coverage, dual brake valve overhaul, automatic slack adjuster inspection and wheel-speed-sensor diagnosis.

• Electrical systems: Starting, charging and preheating circuit diagrams, connector configuration charts, component testing, and starter and alternator repair.

• Cab and climate control: Cab removal and tilt adjustment, air-conditioner diagnosis, compressor removal and magnetic-clutch service, plus heater controls, ducts and blower assemblies.

This manual is suited to truck technicians equipped for component overhaul, pressure testing and Multi-Use Tester II diagnosis.

Maintenance and Diesel Fault Diagnosis

Maintenance schedules and lubrication tables support service planning across the engine, drivetrain, suspension, steering and brakes. Exploded assembly views accompany component-specific tightening torques and wear limits.

The compression-test section relates test results to likely ring, sleeve, valve or head-gasket faults, supporting diagnosis before major disassembly.

Fuel controls: The MD-TICS injection pump and RED-III electronic governor sections cover current and stored fault codes, service data and sensor checks. The Fuel System (Flow of Fuel) diagram and ECU connection tables link fuel delivery with electrical diagnosis.

Pump removal, installation and timing are documented; internal injection-pump service is referred to MFTA. General Multi-Use Tester II operating instructions require its separate reference manual.

Cooling and lubrication: Procedures include cooling-system leak testing, water-pump and thermostat inspection, oil-pump service and oil-cooler work.

Transmission Variants and Brake Systems

The manual gearboxes have shaft, synchronizer and case procedures; the M8S2×5 adds splitter controls and a power cylinder. For automatics, FK617/FM617 coverage includes removal and installation; FM657 coverage adds ATEC self-diagnosis, stall tests and line-pressure tests.

Brake configurations: Hydraulic bleeding belongs to the air-over-hydraulic group. Full-air sections cover pneumatic valves and wheel brakes, with dual brake valve input/output characteristic curves for post-assembly checks. Center and wheel parking brakes have separate sections.

NABCO CN12 ABS coverage distinguishes 4S/3K and 4S/4K systems. Diagnosis includes warning-lamp codes and MUT-II actuator tests to investigate sensor, control-valve and harness faults.

Electrical Tracing, Steering and Cab Service

The Engine Starting Circuit and Battery Charging Circuit drawings identify connections between cab, chassis and engine harnesses. The FM657 automatic-transmission schematic adds ECU and vehicle-interface-module connections; connector views and component-location drawings support pin identification.

The cab group documents mounts and tilt linkage. Air-conditioner coverage extends to leak diagnosis, post-installation treatment and cooling-unit service; heater procedures include control-cable adjustment. Dimensioned armature-plate fixture drawings support preparation for magnetic-clutch work.

The steering section warns that prolonged full-lock operation can seize the power-steering pump. Mineral-oil contamination of the clutch hydraulics can swell rubber parts and cause faulty clutch operation.

Handling these commercial chassis weights safely requires adherence to the manufacturer’s lifting and stabilizing precautions before disassembly.

Selected Valve-Clearance and Crankshaft Data

For the covered 6D16 engines, the valve-clearance specification is 0.4 mm {0.016 in.} with the engine cold. The engine group pairs this with inspection and adjustment procedures.

Crankshaft inspection data distinguish a standard end play of 0.10–0.25 mm {0.0039–0.0098 in.} from the 0.4 mm {0.016 in.} service limit, alongside bearing-clearance and journal-condition checks.