GROUP INDEX

(EURO 3)
MODIFICATION SUMMARY ............
Shop Manual ENGINE CONTROL SYSTEM ......... 13E
Supplement INTAKE AND EXHAUST.................. 15
diesel engine, chassis INTERIOR......................................... 52
and electrical ELECTRICAL ................................... 54

FOREWORD
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of
Mitsubishi Fuso FP.FV series trucks, and includes proce-
dures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with
no wastage.

As this Shop Manual is published as a supplement to the

following Shop Manuals, please see the followings for in-
formation not included in this manual.
• FP.FV (EURO 3) diesel engine .... Pub. No.00EHT0029
• FP.FV (EURO 3) chassis ............. Pub. No.00EHT0030
• FP.FV (EURO 3) electrical ........... Pub. No.00EHT0031

For more details, please consult your nearest authorized

Mitsubishi Fuso dealer or distributors.
Kindly note that the specifications and maintenance ser-
vice figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.

AUGUST 2013

Applicable models
FP.FV

©2013 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

MODIFICATION SUMMARY

1
MODIFICATION SUMMARY
1. Engine
This section describes only the difference from FP.FV (EURO 3) Shop Manual diesel engine. (Pub.No.00EHT0029).
Be sure to check the differences described in the following before servicing.
Service
Group Contents of different points
procedure
00 (1) Additions are made to POWER TRAIN TABLE.

Reduction &
Vehicle model Engine Clutch Transmission Propeller shaft Front axle Rear axle
Differential
FP51JGR4LNRA 6M70T4 C12W43P M130S2 × 5 P140(M) F900T R12T D12H

(2) The version of Multi-Use Tester is different.

Mark Tool name and shape Part No. Application
Multi-Use
Tester III
SOFTWARE FMS-E13-1 Data
DISC (Multi-Use transmission
Tester-III ver- between
sion) V.C.I and PC

13E (1) The description of intake air heater is added to the STRUCTURE AND OPERATION. See Gr13E.
(2) The following descriptions about intake air heater are added to the TROUBLESHOOTING.
• Multi-Use Tester Service Data
• Actuator Tests Using Multi-Use Tester
• Electronic Control Unit Input/Output Table
15 A type with an air heater has been added to INTAKE MANIFOLD. See Gr15.

2
2. Chassis
This section describes only the difference from FP.FV (EURO 3) Shop Manual chassis. (Pub.No.00EHT0030).
Be sure to check the differences described in the following before servicing.
Service
Group Contents of different points
procedure
00 The same as that in Gr00 of FP.FV (EURO 3) Shop Manual diesel engine.
22 A model with a transmission power take-off is added to M130S2 × 5 transmission. Same as before
The type of the transmission power take-off is the same as M130S6. except these ex-
The quantity of transmission gear oil for the model with a transmission power take-off is larger than plained here.
other models by one litter.
52 (1) Air suspension system for driver’s seat is different. See Gr52.
(2) Head lining is different.

3
3. Electrical
This section describes only the difference from FP.FV (EURO 3) Shop Manual electrical. (Pub.No.00EHT0031).
Be sure to check the differences described in the following before servicing.
Service
Group Contents of different points
procedure
54-00A The same as that in Gr00 of FP.FV (EURO 3) Shop Manual diesel engine. See Gr54-00A.
54-00C Engine electronic control unit (preheating function) is added. See Gr54-00C.
The following circuit is added for preheating and cold start function.
54-02 220 ENGINE PREHEATING AND COLD START CIRCUIT See Gr54-02.

The following circuit is changed for preheating and cold start function.
54-04 401 METER CLUSTER INTERNAL CIRCUIT See Gr54-04.

The following circuit is changed for preheating and cold start function.
54-08 880 ELECTRONICALLY CONTROLLED ENGINE SYSTEM See Gr54-08.

The following items are added for preheating and cold start function.
A06 Cold start switch
B05a Diode unit
54-10 See Gr54-10.
B59a Intake air heater drive relay
R04 Intake air heater
R26 Intake air heater relay
The following items are added for preheating and cold start function.
#005 Cold start switch
54-11 See Gr54-11.
#190 Intake air heater relay
#760 Intake air heater
The following inspection is added for preheating and cold start function.
54-13 See Gr54-13.
#995 INSPECTION OF PREHEATING SYSTEM

4
 GROUP 13E
ENGINE CONTROL SYSTEM

For other details except for the items described below, please see FP.FV (EURO 3) Shop Manual
diesel engine (Pub.No.00EHT0029).

STRUCTURE AND OPERATION

2. Electronic Control System .......................................................... 13E-2
3. Electronic Control Unit Connection Diagram .............................. 13E-4

TROUBLE SHOOTING
2. Multi-Use Tester Service Data ..................................................... 13E-6
3. Actuator Tests Using Multi-Use Tester ........................................ 13E-6
4. Electronic Control Unit Input/Output Table ................................. 13E-7

INSPECTION OF ELECTRICAL PARTS ................................ (See Gr54.)

13E-1
STRUCTURE AND OPERATION
2. Electronic Control System
2.1 System block diagram

Input signals Engine electronic control unit Output signals

Engine speed sensor Injector magnetic valve

Cylinder recognition sensor Fuel injection control MPROP1, 2 (rail pressure
control valve)
Water temperature sensor
Engine

Boost pressure sensor Fuel injection

Warm-up acceleration pressure control
Common rail pressure sensor function
Fuel temperature sensor Fuel injection quantity
Intake air temperature sensor Auxiliary brake control
function
Fuel injection timing
Idle-up function control
Starter switch
Accelerator pedal position sensor
Accelerator pedal switch Starter continuous Engine warning lamp
energization
Pulse divider (vehicle speed sensor) prevention function Intake air heater drive relay
Idling speed adjustment potentiometer (See Gr54.)
Cold start switch
Vehicle

Fuel injection rate adjustment resistor Intake air heater

Clutch switch
Transmission neutral switch Tachometer
Exhaust brake switch
Memory clear switch Fault diagnosis Safety relay
function
Diagnosis switch
Power take-off resistor Exhaust brake
Power take-off load sensor magnetic valve

Multi-Use Tester connector

: Electrical signal

13E-2
 13E
Engine speed sensor Sensing of engine speed
Cylinder recognition sensor Cylinder recognition
Water temperature sensor Sensing of coolant temperature
Boost pressure sensor Sensing of boost pressure
Common rail pressure sensor Sensing of common rail pressure
Fuel temperature sensor Sensing of fuel temperature
Intake air temperature sensor Sensing of intake air temperature
Senses that the engine is in starting condition with the starter switch in
Starter switch
START position.
Accelerator pedal position sensor Sensing of extent of accelerator pedal depression
Sensing of released/pressed condition of accelerator pedal (ON with
Accelerator pedal switch
pedal released)
Pulse divider (vehicle speed sensor) Sensing of vehicle speed
Idling speed adjustment potentiometer Acceleration of warm-up
Cold start switch Acceleration of warm-up
Fuel injection rate adjustment resistor Correction of fuel injection rate
Sensing of released/Pressed condition of clutch pedal (OFF with pedal
Clutch switch
released)
Transmission neutral switch Detection of transmission neutral condition
Exhaust brake switch Operation of auxiliary brake
Diagnosis switch Output of diagnosis codes
Memory clear switch Deletion of diagnosis codes; output of past diagnosis codes
Power take-off resistor Selection of power take-off map
Power take-off load sensor Sensing of extent of accelerator pedal depression
Control of fuel injection rate, fuel injection quantity, and fuel injection
Injector magnetic valve
timing
MPROP1, 2 (rail pressure control valve) Control of fuel injection pressure
Engine warning lamp Indication of system abnormalities
Intake air heater drive relay (Intake air heater) ON/OFF control of intake air heater
Tachometer Indication of engine speed (in meter cluster)
Exhaust brake magnetic valve ON/OFF control of Powertard magnetic valve
Safety relay Control of starter continuous energization prevention function
Multi-Use Tester connector Communication between Multi-Use Tester and common rail system

13E-3
STRUCTURE AND OPERATION
3. Electronic Control Unit Connection Diagram

13E-4
13E

13E-5
TROUBLESHOOTING
2. Multi-Use Tester Service Data
• The following service data become the addition.
• For other details except for the items described below, please see FP.FV (EURO 3) Shop Manual diesel engine
(Pub.No.00EHT0029).

No. Item Data Inspection condition Requirement

Cold start switch ON ON
7A Cold Start SW ON/OFF
Cold start switch OFF OFF
Immediately after starter switch turned
OFF to ON with engine coolant tem- ON
perature 0°C or less
86 Air Heater Relay ON/OFF Starter switch turned OFF to ON with
engine coolant temperature 0°C or OFF
more
[Actuator test] AF: Relay for Air Heater Relay
Starter switch ON with engine coolant
ON
temperature 0°C or less
87 Air Heater Indicator Lamp ON/OFF Starter switch ON with engine coolant
OFF
temperature 0°C or more
[Actuator test] B0: Air Heater Lamp

3. Actuator Tests Using Multi-Use Tester

• The following actuator test become the addition.
• For other details except for the items described below, please see FP.FV (EURO 3) Shop Manual diesel engine
(Pub.No.00EHT0029).

No. Item Explanation Confirmation method

Forcibly turns ON/OFF the Relay operating sound
intake air heater drive relay [Service data]
(automatically executed for 86: Air Heater Relay
15 seconds).
AF Relay for Air Heater Relay

Forcibly turns ON/OFF the Illumination of indicator

indicator lamp in the meter lamp
cluster (automatically exe- [Service data]
cuted for 15 seconds). 87: Air Heater Indicator
B0 Air Heater Lamp The intake air heater relay Lamp
and intake air heater drive
relay also operate.

13E-6
 13E
4. Electronic Control Unit Input/Output Table
• The following electronic control unit input and output item become the addition.
• For other details except for the items described below, please see FP.FV (EURO 3) Shop Manual diesel engine
(Pub.No.00EHT0029).

Input/
Hardware to be connected Terminal Voltage or waveform
Output
[Conditions]
• Vehicle-side harness left connected (measure from back
side of connector)
A7-Chassis • Perform Multi-Use Tester actuator test item No. AF
Intake air heater drive relay Output
ground “Relay for Air Heater Relay”.
[Normal status]
• Relay ON: 0 V
• Relay OFF: Equivalent to battery voltage
[Conditions]
• Vehicle-side harness left connected (measure from back
Ground ter-
Illumination of preheat indicator lamp Output side of connector)
minal A51
[Normal status]
• Indicator lamp illuminates.

13E-7
GROUP 15 INTAKE AND EXHAUST

INTAKE MANIFOLD............................................................................ 15-2

For other details except for the items described above, please see Shop Manual FP.FV (EURO
3) Pub.No.00EHT0029 GROUP 15 INTAKE AND EXHAUST.

15-1
INTAKE MANIFOLD
<with air heater>

Disassembly sequence
1 Eyebolt 6 Air inlet pipe 11 Gasket
2 Boost pressure sensor 7 Gasket
3 Intake air temperature sensor 8 Air heater
*a: Cylinder head (See Gr11.)
4 Plug 9 Gasket : Non-reusable parts
5 Bracket 10 Intake manifold

Assembly sequence
Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (intake manifold mounting)
Bolt (air inlet pipe mounting)
54 {5.5} –
Bolt (bracket mounting)
Nut (air inlet pipe mounting)
Eyebolt 21 {2.1} –
Bolt (boost pressure sensor mounting) 4 to 6 {0.4 to 0.6} –
Intake air temperature sensor 20 {2.0} –

15-2
 15
Inspection procedure
Inspection: Intake air temperature sensor
• Check that the sensor portion is free of soot, oily substance, etc.
• If not, clean the sensor portion as follows.
• Spray a cleaner on the sensor portion from 2 or 3 cm away.
Recommended cleaners:
Wako Chemical brake and parts cleaner from Wako Chemical
Trusco Nakayama brake and parts cleaner ALP-BP
Chemsearch Lexite LO
• In 20 to 30 seconds after spraying, wipe the sensor portion clear
of the sprayed cleaner using a soft waste cloth or the like.
CAUTION
• Be sure to wait for 20 or 30 seconds before wiping. It takes
the cleaner that long to dissolve foreign matter.

• If the sensor portion is fouled excessively, the positive crankcase

ventilation (PCV) may be faulty. Inspect the PCV valve and filter
to locate the cause and remove it.

15-3
 GROUP 52 INTERIOR

STRUCTURE AND OPERATION

1. Air Suspension Seat ..................................................................... 52-2

DRIVER SEAT
<AIR SPRING> .................................................................................. 52-4

HEAD LINING ..................................................................................... 52-6

For other detail except for the items described above, please see Shop Manual chassis FP.FV
(EURO 3) Pub.No.00EHT0030 GROUP 52 INTERIOR.

52-1
STRUCTURE AND OPERATION
1. Air Suspension Seat

• Air suspension is to maintain the height of the seat cushion constant, irrespective of the occupant’s weight; air
pressure is automatically introduced into the air sleeve by means of cam, mechanical valves, etc. to keep the seat
cushion at the constant height.
• When the function of air suspension is not required, the seat cushion can be freely locked at a desired height by
use of adjust lever.

52-2
 52
2.1 Movement of mechanical
valves
• The mechanical valves A, B have their
air passages opened and closed to the
movement of arm and cam.

2.2 Air suspension operation with

occupant in the seat
• When the link is pushed down by the
occupant’s weight, the arm rotates the
cam a little to open the air passages of
the mechanical valve.
• Air pressure is introduced into the air
sleeve to raise the link.

• When the link is raised, the cam is re-

stored to return the seat cushion to
home position.

52-3
DRIVER SEAT <AIR SPRING>
Removal sequence
1 Nylon tube
2 Seat (See later section.)
3 Air suspension

Installation sequence
Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (air suspension mounting) 34 to 50 {3.5 to 5.1} –
Nut (seat mounting) 10 to 15 {1.0 to 1.5} –

52-4
 52
M E M O

52-5
HEAD LINING
Area 1
Removal sequence
1 Lens
2 Personal lamp

Installation sequence
Follow the removal sequence in reverse.

Removal procedure
Removal: Lens

52-6
 52
Area 2
Removal sequence
1 Sun visor (left-hand)
2 Sun visor hook
3 Sun visor (right-hand)
4 Sun visor hook
5 Inside mirror

Installation sequence
Follow the removal sequence in reverse.

Installation procedure
Installation: Sun visor
• Install the sun visors with the “IN” mark toward the vehicle cen-
ter.

52-7
HEAD LINING
Area 3
Removal sequence
1 Coat hanger
2 End cover
3 Rail pin
4 Center curtain rail
5 Plug
6 Clips
7 Front head lining
8 Clips
(3 clips marked with )
9 Clip
10 Rear head lining
11 Overhead console frame

: Non-reusable parts

Installation sequence
Follow the removal sequence in reverse.

Removal procedure
Removal: Center curtain rail
• The rail pins (4 places) are threaded and can be screwed off in
the same way as a general screw.

52-8
 52
Installation procedure
Installation: Center curtain rail
• Install the center curtain rail in the illustrated direction.
• Before installation, align the locating hole in the center curtain
rail with the locating pin on the grommet.
• The rail pin can be fitted by simply pushing it in.

52-9
 GROUP54 ELECTRICAL

For other details except for the items described below, please see Shop Manual electrical FP.FV (EURO
3)(Pub.No.00EHT0031).

54-00C STRUCTURE AND OPERATION

1. Engine Electronic Control Unit (Preheating Function) ............. 54-00C-2

54-02 ENGINE STARTING, STOPPING AND

PREHEATING CIRCUIT
220 ENGINE PREHEATING AND COLD START CIRCUIT...............54-02-2

54-04 METER CIRCUIT

401 METER CLUSTER INTERNAL CIRCUIT ....................................54-04-2

54-08 ENGINE AND TRANSMISSION SIDE

ELECTRICAL CIRCUIT
880 ELECTRONICALLY CONTROLLED ENGINE SYSTEM ............54-08-2

54-10 ELECTRICAL EQUIPMENT INSTALLATION

POSITIONS
Cab side
A SWITCH AND SENSOR ..................................................................54-10-2
B RELAY, ELECTRONIC CONTROL UNIT AND FUSE.....................54-10-3
Engine and transmission
R ENGINE ............................................................................................54-10-5

54-11 INSPECTION OF ELECTRICAL EQUIPMENT

#001 to #179 SWITCH...........................................................................54-11-2
#180 to #249 RELAY.............................................................................54-11-2
#750 to #859 OTHER ............................................................................54-11-3

54-13 ON-VEHICLE INSPECTION AND ADJUSTMENT

#955 INSPECTION OF PREHEATING SYSTEM ..................................54-13-2
54-00C STRUCTURE AND OPERATION

54-00C-1
STRUCTURE AND OPERATION
1. Engine Electronic Control Unit (Preheating Function)
1.1 Outline
• This function is controlled by the engine electronic control unit. For other functions, see Gr13.

(1) System function schematic

Part name Major function and operation

Water temperature sensor Sensing of engine coolant temperature
Starter switch Operation of power supply and engine start
Cold start switch Acceleration of warm-up
Engine speed sensor Sensing of engine speed
Intake air heater drive relay Supply of power to intake air heater relay
Indication of preheating function operating (when the engine
Indicator lamp
coolant temperature is 0°C or less)

54-00C-2
 54-00C
1.2 Preheating function
• This preheating function aims to enhance the engine start up when the engine coolant is low in cold weather or
temperature.
(1) Pre-heat and After-heat
The preheating is operated with a pre-
heat before the engine starts and an af-
ter-heat after the engine starts. They are
controlled by the starter switch signal,
engine coolant temperature signal and
the engine speed signal.

(2) Operation mode

• When the engine coolant temperature
is 0°C or more.

• When the engine coolant temperature

is 0°C or less.

(3) Operation of cold start switch

• When the cold start switch is operated, the exhaust brake magnetic valve is activated to facilitate the preheating
control of the engine.

54-00C-3
1.3 Engine electronic control unit connection diagram

54-00C-4
54-02 ENGINE STARTING, STOPPING
AND PREHEATING CIRCUIT

54-02-1
 220 ENGINE PREHEATING AND COLD START CIRCUIT

54-02-2
54-04 METER CIRCUIT

54-04-1
 401 METER CLUSTER INTERNAL CIRCUIT

54-04-2
54-08 ENGINE AND TRANSMISSION
SIDE ELECTRICAL CIRCUIT

54-08-1
 880 ELECTRONICALLY CONTROLLED ENGINE SYSTEM

54-08-2
54-08

54-08-3
 880 ELECTRONICALLY CONTROLLED ENGINE SYSTEM

54-08-4
54-08

54-08-5
 880 ELECTRONICALLY CONTROLLED ENGINE SYSTEM

54-08-6
54-10 ELECTRICAL EQUIPMENT
INSTALLATION POSITIONS

54-10-1
 A SWITCH AND SENSOR
Cab side

54-10-2
B RELAY, ELECTRONIC CONTROL UNIT AND FUSE 54-10

54-10-3
 B RELAY, ELECTRONIC CONTROL UNIT AND FUSE

54-10-4
 R ENGINE 54-10
Engine and transmission

54-10-5
54-11 INSPECTION OF ELECTRICAL
EQUIPMENT

54-11-1
#001 to #179 SWITCH, #180 to #249 RELAY
#005 Inspection of cold start switch
• Perform the following checks, and if any fault is found, replace
the switch. (See Gr52.)
Continuity Operating
Switch position
terminal illumination
OFF 2–7, 5–6 –
ON 7–8 (+) 4–1 (–)

#190 Inspection of intake air heater relay

• Perform continuity check and operation check, and if any fault is
found, replace the relay.

54-11-2
#750 to #859 OTHER 54-11
#760 Inspection of intake air heater
• If any fault is found, replace the fuse.

54-11-3
54-13 ON-VEHICLE INSPECTION AND
ADJUSTMENT

54-13-1
#955 INSPECTION OF PREHEATING SYSTEM
1. Preparation for Inspection
Service standards
Location Maintenance item Standard value Limit Remedy
– Pre-heating time Coolant 0°C or more No pre-heating operation – Inspect
temperature
0°C or less About 28 seconds –
After-heating Coolant 0°C or more No after-heating operation –
time temperature
0°C or less About 30 seconds –
Indicator lamp Coolant 0°C or more No illumination –
ON time temperature
0°C or less About 5 to 20 seconds –

• Turn the starter switch to OFF.

• Connect a check lamp to the intake air heater.

• Remove the water temperature sensor from the engine, and

close the sensor mounting hole with the plug (M16 × 1.5 mm).
Removal and installation of the water temperature sensor. (See
Gr14.)
• Connect the extension harness between the water temperature
sensor and connector.
• Place the water temperature sensor in a container of water.
• Conduct the following test while charging the temperature of wa-
ter in the container. If anything abnormal is found, check relevant
components.

(1) Pre-heating time and indicator lamp ON time checking

Turn the starter switch to ON (without starting the engine), and
confirm that the pre-heating time and indicator lamp ON time at
each water temperature conform with the standard values.
• Measure the illuminating time of the check lamp to measure
the pre-heating time.
• Measure the meter cluster indicator lamp illuminating time to
measure the indicator lamp ON time.
(2) After-heating time checking
Start the engine, and measure how long the illumination of check
lamp lasts after the indicator lamp on the meter cluster goes out
to ensure that the after-heating time conforms with the standard
value.

54-13-2
 54-13
2. Inspection Based on Diagnosis Codes
• See Gr13E.

3. Multi-Use Tester Service Data

• See Gr13E.

4. Actuator Tests Performed Using Multi-Use Tester

• See Gr13E.

5. Inspection Performed at Electronic Control Unit Connectors

• See Gr13E.

54-13-3
 (EURO 3)

Supplement
diesel engine, chassis
and electrical

AUGUST 2013
60 (H)