00-1

GENERAL




CONTENTS 00109001516
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2

Scope of Maintenance, Repair and Servicing
Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Indication of Tightening Torque . . . . . . . . . . . . . . . . 2
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Explanation of Manual Contents . . . . . . . . . . . . . . . 4
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . 16
Vehicle Information Code Plate . . . . . . . . . . . . . . . 16
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 19
MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . 20
HOW TO USE TROUBLESHOOTING/
INSPECTION SERVICE POINTS . . . . . . . . . . . . . 6
Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6
Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How to Use the Inspection Procedures . . . . . . . . 9
Connector Measurement Service Points . . . . . . . 10
Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection Service Points for a Blown Fuse . . . 12
Points to Note for Intermittent Malfunctions . . . . 12
PRECAUTIONS BEFORE SERVICE . . . . . . . 21
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SRS Service Precautions . . . . . . . . . . . . . . . . . . . . 26
SUPPORT LOCATIONS FOR LIFTING AND
JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Support Positions for a Garage Jack and Axle
Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Support Positions for a Single-Post Lift or
Double-Post Lift and H-BAR Lift . . . . . . . . . . . . . . 29
TREATMENT BEFORE/AFTER THE FORDING
A STREAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection and Service before Fording a Stream
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection and Service after Fording a Stream
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STANDARD PARTS-TIGHTENING-TORQUE
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30





00-2 GENERAL How to Use This Manual
HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR
AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
00100010418
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the value to which the part or assembly is
corrected and adjusted. It is given by tolerance.
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components.
For detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
LIMIT
Shows the standard for judging the quality of a
part or assembly on inspection and means the
maximum or minimum value within which the part
or assembly must be kept functionally or in strength.
It is a value established outside the range of
standard value.
after they have
please refer to
engine and the
been removed from the vehicle,
separate manuals covering the
transmission.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
ON-VEHICLE SERVICE
On-vehicle Service is procedures for performing
inspections and adjustments of particularly
important locations with regard to the construction
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage,
etc.) must also be performed.
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of
maintenance and servicing procedures in order to
avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of
component or vehicle function or performance, etc.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well. INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a
basic value with a tolerance of 10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1)
(2)
(3)
The tolerance of the basic value is within 10%.
Special bolts or the like are in use.
Special tightening methods are used.
00-3 GENERAL How to Use This Manual
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.

M/T: Indicates the manual transmission, or models equipped with the manual transmission.
SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such
an engine.
MPI: Indicates the multipoint injection, or engines equipped with the multipoint injection.
DIESEL: Indicates a diesel engine, or models equipped with such an engine.
4WD: Indicates the 4 wheel-drive vehicles.














00-4 GENERAL How to Use This Manual
EXPLANATION OF MANUAL CONTENTS

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lubrica- : Grease
tion and for application of sealants and adhe- (multipurpose grease unless there is
sives is provided, by using symbols, in the dia- a brand or type specified)
gram of component parts or on the page follow-
ing the component parts page, and explained. : Sealant or adhesive

: Brake fluid or automatic transmission fluid

: Engine oil, gear oil or air conditioner
compressor oil

: Adhesive tape or butyl rubber tape



























Classifications of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
]A} : Indicates that there are essential points for removal or disassembly.
}A] : Indicates that there are essential points for installation or reassembly.















Maintenance and Servicing Procedures
The numbers provided within the diagram indi- Installation steps:
cate the sequence for maintenance and servic- Specified in case installation is impossible
ing procedures. in reverse order of removal steps. Omitted
Removal steps: if installation is possible in reverse order of
The part designation number corresponds removal steps.
to the number in the illustration to indicate Reassembly steps:
removal steps. Specified in case reassembly is impossible
Disassembly steps: in reverse order of disassembly steps.
The part designation number corresponds Omitted if reassemby is possible in reverse
to the number in the illustration to indicate order of disassembly steps.
disassembly steps.























Indicates (by symbols) where lubrica-
tion is necessary.





A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.












Indicates procedures to be performed
before the work in that section is started,
and procedures to be performed after
the work in that section is finished.








Component Diagram


00-5 GENERAL How to Use This Manual
denotes non-re-
Repair kit or set parts
Operating procedures, cau-
indicates that there is
indicates terminals to
ented) indicating the locations of



The title of the page (following
the page on which the diagram

of component parts is pres-




lubrication and sealing proce-

dures.





between the termi-


y voltage is applied.


a continuity
nals.

which batter













usab
le part.







Denotes tightening torque.
For bolts and nuts which do not
have a tightening torque listed,
refer to the Standard Parts-
tightening-torque Table.













are shown. (Only very
equently used parts
are shown.)




fr









tions, etc. on removal, installa-

tion, disassembly and reas-

sembly are described.



Indicates the
page number.

Indicates the
group num-
ber.


Indicates the
section title.

Indicates the
group title.


00-6 GENERAL How to Use Troubleshooting/Inspection Service Points
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS 00100020220
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems
still follow this outline.
TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
The troubleshooting sections follow the basic diagnosis flow which
flow is different from that given below, or if additional explanation
is given below. If the diagnosis
is required, the details of such
differences or additions will also be listed.
Diagnosis method
ode
code
he
the diagnosis code
ouble symptom.
gnosis codes.
Refer to the INSPECTION CHART FOR DIAGNOSIS INTERMITTENT MALFUNCTIONS (Re
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS
If verification of the trouble symptoms is difficult, procedures for checking operation and
trouble symptoms are shown.
verifying
3. DIAGNOSIS FUNCTION
Details which are different from those in the Diagnosis Function section on the next page are listed.
Gathering information
from the customer.




Check trouble symptom.


Reoccurs

Does not reoccur.

Read the diagnosis c Read the diagnosis code

No diagnosis code
or communication
with MUT-II not

Diagnosis code Diagnosis code
displayed. displayed.



No diagnosis

possible


Refer to the INS PECTION

After taking note of t


CHART FOR TROUBLE
SYMPTOMS (Refer to
applicable group.)

malfunction code, erase


memory



Recheck tr



Read the dia


Diagnosis code
displayed.
No diagnosis
code





fer to P.00-12.)
CODES (Refer to applicable group.)



00-7 GENERAL How to Use Troubleshooting/Inspection Service Points
4.

5.
INSPECTION CHART FOR DIAGNOSIS CODES

INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how
to read the inspection procedures.)
6. INSPECTION CHART FOR TROUBLE SYMPTOMS
If there are trouble symptoms even though the results of inspection using the MUT-II show that all
diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means
of this chart.
7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM
Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection
Chart for Trouble Symptoms. (Refer to P.00-9 for how to read the inspection procedures.)
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgement values have been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspection items and standard values have been provided
in this chart as reference information.
10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE
When there are inspection procedures using an oscilloscope, these are listed here.
DIAGNOSIS FUNCTION
METHOD OF READING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and take a
reading of the diagnosis codes.
Caution
Turn off the ignition switch before connecting or
disconnecting the MUT-II.












MB991502


On
f



On
f





00-8 GENERAL How to Use Troubleshooting/Inspection Service Points
WHEN USING THE WARNING LAMP
1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
Turn on the ignition switch.
Read out a diagnosis code by observing how the warning
lamp flashes.
2.
3.
Applicable systems
Indication of diagnosis code by warning lamp
METHOD OF ERASING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and erase the diagnosis
Caution
Turn off the ignition switch before connecting or disconnecting the
WHEN NOT USING THE MUT-II
code.
MUT-II.
1.
2.
Turn the ignition switch to OFF.
After disconnecting the battery cable from the battery () terminal for 10 seconds or more, reconnect
the cable.
After the engine has warmed up, run it at idle for about 15 minutes. 3.
When the diagnosis code No.24 is output When no diagnosis code is output*

0.5 s
1.5 s 0.5 s
Of
Pause Tens Place Units
time 3 s signal division signal
2 s


0.5 s



Of

System name Warning lamp name
MPI Engine warning lamp
Auto-cruise Auto-cruise control indicator
ABS ABS warning lamp



Diagnosis connector








MB991529
00-9
GENERAL How to Use Troubleshooting/Inspection Service Points
HOW TO USE THE INSPECTION PROCEDURES
The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.
CHECKING PROCEDURE 4
Indicator does not turn on or off even if control Probable cause
udgement conditions.
on
MUT-II Data list
OK: Voltage changes between approx. 0V approx.
easured at a particular
NG
connector.
oints.)
he wiring diagram in the
Indicates the OK judgement conditions.
NG
Repair
s.)
he wiring diagram in the
After carrying out connector inspection, always be sure to
serted incorrectly and the
s, so check the harness.
HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, Check harness between power supply and terminal xx also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to Inspection Service Points for a Blown
Fuse.
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.

1. Comments on the diagnosis code or trouble

symptom above.




mode switch is pressed.
2. Indicates inspectio n carried out using the
Indicator switch should not be illuminated is
MUT-II.
illuminated. Indicates the opera tion and inspection proce-

dures.
In the above cases, the ECS switch circuit is defective or the indicator Indicates the OK j

circuit is defective.


3. Detailed inspecti procedures (methods)
such as compone nt inspection and circuit

inspection are listed o n a separate page, and

OK are given here for refe rence.

17 Control mode selection switch



2.5V approx. 5V when the switch is operated.

NG

ECU switch component inspection (Refer to P.3-44.)
OK
4. Indicates voltage and resistance to be m

(Refer to Connector Measurement Service P
The connector position can be located in t
OK electrical wiring manual by means of this sym




bol.
Measure at switch connector A-44

Disconnect the connector, and measure at the harness
side.
Voltage between terminal 6 earth and terminal 8
earth
Indicates operation and inspection procedures
and inspection conditions.

, inspection terminals



OK: Approx. 5V

OK


Check the following connector. A-44

OK

Check trouble symptom.


Replace the ECS-ECU.


5. Inspect the contact condition at each connect
(Refer to Connector Inspection Service Point
The connector position can be located in t
electrical wiring manual by means of this sym
Caution

reconnect the connector as it was before
or terminal.


bol.


.


6. Confirm that there are trouble symptoms. If t
disappeared, the connector may have been in
trouble symptom may have disappeared during
If it seems that trouble symptoms still remain, pro
instructions.
rouble symptoms have
inspection.
ceed to the next page of



7. If trouble symptoms still remain up to this stage, there is a p
open or short circuit in the harness between the connector
Alternatively, the cause may be a defective ECU, so try repla
if the trouble symptom disappears.
ossibility that there is an
cing the ECU and check









00-10 GENERAL How to Use Troubleshooting/Inspection Service Points
CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to OFF when connecting disconnecting
the connectors, and turn the ignition switch to ON when
measuring if there are no instructions to be contrary.
IF INSPECTING WITH THE CONNECTOR CONNECTED
(WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Waterproof Connectors
Be sure to use the special tool (harness connector). Never
insert a test bar from the harness side, because to do so
will reduce the waterproof performance and result in corrosion.
Ordinary (non-waterproof) Connectors
Check by inserting the test bar from the harness side. Note
that if the connector (control unit, etc.) is too small to permit
insertion of the test bar, it should not be forced; use a special
tool (the extra-thin probe in the harness set for checking
for this purpose.
IF INSPECTING WITH THE CONNECTOR DISCONNECTED
<When Inspecting a Female Pin>
Use the special tool (inspection harness for connector pin
contact pressure in the harness set for inspection).
The inspection harness for connector pin contact pressure
should be used. the test bar should never be forcibly inserted,
as it may cause a defective contact.
<When Inspecting a Male Pin>
Touch the pin directly with the test bar.
Caution
At this time, be careful not to short the connector pins
with the test bars. To do so may damage the circuits
inside the ECU.








Inspection harness
for connector pin
contact pressure


Extra-thin probe






Test bar
Connector

Harness connector







00-11 GENERAL How to Use Troubleshooting/Inspection Service Points
CONNECTOR INSPECTION
VISUAL INSPECTION
Connector disconnected or improperly
connected





Connector is disconnected or improperly connected
Connector pins are pulled out
Due to harness tension at terminal section
Low contact pressure between male and female terminals
Low connection pressure due to rusted terminals or foreign
matter lodged in terminals
Defective connector contact
Harness wire breakage
t terminal section
Low contact pressure
CONNECTOR PIN INSPECTION
If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be perfect even
if the connector body is connected, and the pins may pull
out of the reverse side of the connector. Therefore, gently
pull the harnesses one by one to make sure that no pins
pull out of the connector.
CONNECTOR ENGAGEMENT INSPECTION
Use the special tool (connector pin connection pressure
inspection harness of the inspection harness set) to inspect
the engagement of the male pins and females pins. (Pin
drawing force : 1 N or more)


MB991219



























a





00-12 GENERAL How to Use Troubleshooting/Inspection Service Points
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 fi at this time, there
is a short somewhere between these switches and the load.
If the resistance is not 0 fi, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
The main causes of a short circuit are the following.


Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to wear
or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)


POINTS TO NOTE FOR INTERMITTENT
MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
Gently shake the connector up, down and to the left and
right.
Gently shake the wiring harness up, down and to the
left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions and other
moving parts.



NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.








0 fi


Battery



Fuse


Connector
Load inspection
switch


Load



00-13 GENERAL Treatment Before/After Fording a Stream
TREATMENT BEFORE/AFTER FORDING A STREAM
INSPECTION AND SERVICE BEFORE FORDING A STREAM
00100060062
Vehicles which are driven through water, or which
may possibly be driven through water, should be
subjected to the following inspections and
maintenance procedures in advance.
Seal the speedometer cable with a
water-resistant grease or tape.
Inspect the dust boot and breather hose for
cracks or damage, and replace them if cracks
or damage are found.


Joint assembly











Clutch
release
cylinder



00-14 GENERAL Treatment Before/After Fording of Stream
Apply grease to the lubricating points of the
front suspension, steering linkage and propeller
shaft.
Upper arm


Pitman arm









Tie rod










Tie rod ends




00-15 GENERAL Treatment Before/After Fording of Stream
INSPECTION AND SERVICE AFTER FORDING A STREAM
After fording a stream, check the following points.
If abnormal condition is evident, clean, replace or
lubricate.
Apply grease to the lubricating points of the
front suspension, steering linkage and propeller
shaft.
Check all boots and breather hoses for cracks
and damage.
Check for water, mud, sand, etc. in the rear
brake drum, clutch housing, starter motor, brake
pipe and fuel pipe.
Check for water in the fluid or oil inside the
front differential, rear differential, transmission
and transfer.








00-16 GENERAL Vehicle Identification
VEHICLE IDENTIFICATION
VEHICLE INFORMATION CODE PLATE
LOCATION
Vehicle information code plate is riveted onto the headlamp
support panel in the engine compartment.
00100540177
CODE PLATE DESCRIPTION
The plate shows model code,
model, and body colour code.
engine model, transmission
3

5
For monotone colour vehicles, the body colour code shall
be indicated. For two-tone colour vehicles, each colour code
only shall be indicated in series.
No. Item Contents
1

MODEL

K96WGNHER6

K96WG: Vehicle model
NHER6: Model series
2 ENGINE 6G72 Engine model
3 EXT B60B Exterior code
4

TRANS
AXLE

V5MT1
4636

V5MT1: Transmission
code
4636: Rear differential
reduction
5

COLOR
INT OPT

B60 41H 03V

B60: Body colour code
41H: Interior code
03V: Equipment code



1
2

4




00-17 GENERAL Vehicle Identification
MODELS 00100550132
MODEL CODE 00100040400
No. Items Contents
1 Vehicle line K: Challenger
2 Drive system 9: 4WD
3

Engine system

4: 2,477 mL Diesel engine
6: 2,972 mL Petrol engine
4 Group W: Wagon
5 Vehicle width G: Wide fender
6 Transmission type N: 5-speed manual transmission
7

Vehicle grade

U: GLX
H: GLS
8

Specified engine feature

E: MPI
F: I/C T/C








1 2 3 4 5 6 7 8 9 10

Model code Engine model Transmission model Fuel supply system
K96WG

NHEL6 6G72-SOHC
(2,972 mL)

V5MT1(4WD-5M/T)

MPI

NHER6
K94W

NUFL6 4D56
(2,477 mL)

Fuel injection

NUFR6
K94WG

NHFL6
NHFR6




00-18 GENERAL Vehicle Identification
CHASSIS NUMBER 00100560142
The chassis number is stamped on the side wall of the frame
near the rear wheel (R.H.).
No. Items Contents
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3

Destination

A Right hand drive
B Left hand drive
4 Body style 0 4 door tailgate
5 Transmission type N 5-speed manual transmission
6 Vehicle line K Pajero sport
7 Body type 9 4WD
8

Engine type

4 4D56: 2,477 mL diesel engine
6 6G72: 2,972 mL petrol engine
9 Body style 0 Frame
10 Model year X 1999








1 2 3 4 5 6 7 8 9 1011 12


No. Items Contents
9

Steering wheel location

L: Left hand
R: Right hand
10 Destination 8: For Europe




00-19 GENERAL Vehicle Identification
ENGINE MODEL NUMBER
1. The engine model number is stamped at the cylinder
block as shown in the following.
2. The engine serial number is stamped near the engine
model number.
<4D56>




Front of
engine

Engine serial number AA0201 to YY9999
Engine model Engine displacement mL
6G72 2,972
4D56 2,477
<6G72>




Front of
engine

No. Items Contents
11 Plant Y,P Ooe Plant of Nagoya Motor Vehicle Works
12 Serial number


00-20 GENERAL Major Specifications
MAJOR SPECIFICATIONS 00100090382
3
11
10
9
7 8 5

2
4

1
6
Items

K96WGNHE
L6/R6
K94WNUF
L6/R6
K94WGNHF
L6/R6
Vehicle dimensions
mm

Overall length 1 4,545 4,545 4,545
Overall width 2 1,775 1,695 1,775
Overall height (unladen) 3 1,730 1,720 1,730
Wheelbase 4 2,725 2,725 2,725
Tread-front 5 1,465 1,420 1,465
Tread-rear 6 1,480 1,435 1,480
Overhang-front 7 765 765 765
Overhang-rear 8 1,055 1,055 1,055
Ground clearance (unladen) 9 215 205 215
Angle of approach degress 10 37 36 37
Angle of departure degress 11 26 25 26
Vehicle weight kg

Kerb weight 1,845 1,825 1,895
Max. gross vehicle weight rating 2,510 2,510 2,510
Max. axle weight rating-front 1,110 1,110 1,145
Max. axle weight rating-rear 1,400 1,400 1,365
Max. trailer weight

With brake 2,800 2,800 2,800
Without
brake
750

750

750

Max. trailer-nose weight 115 115 115
Seating capacity 5 5 5
Engine

Model No. 6G72 4D56 4D56
Total displacement mL 2,972 2,477 2,477
Transmission

Model No. V5MT1 V5MT1 V5MT1
Type

5-speed
manual
5-speed
manual
5-speed
manual
Fuel system Fuel supply system MPI Fuel injection Fuel injection
00-21 GENERAL Precautions Before Service
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
00100050410
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
Always use the designated special tools and test equipment. (2)
(3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
Never attempt to disassembly or repair the SRS components, (SRS-ECU, air bag module and
clock spring, front impact sensor). If faulty, replace it.
Warning labels must be heeded when servicing or handling SRS components. Warning labels
are located in the following locations.
(4)
(5)









Hood
Sun visor
Glove box
SRS-ECU
Steering wheel
Air bag module
Clock spring
Instrument panel
Frame
(6) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upward.
Do not place anything on top of it.
Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle
equipped with an air bag. (Refer to GROUP 52B Air Bag Module Disposal Procedures.)
(7)
(8) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on places where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.


Approx
40 cm




00-22 GENERAL Precautions Before Service
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
() cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative () cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
Pre-inspection condition refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words Set the vehicle to the
pre-inspection condition. in this manual, it means to set the
vehicle to the following condition.



Engine coolant temperature: 8090C
Lamps, electric cooling fan and all accessories: OFF
M/T: Neutral
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to note the
following information in order to avoid damage to plastic
components, etc.




Spray
Spray
Spray
nozzle distance: Approx. 40 cm or more
pressure: 3,900 kPa or less
temperature: 82C or less
Time of concentrated spray to one point: within 30 sec.



.






00-23 GENERAL Precautions Before Service
MUT-II
Refer to the MUT-II REFERENCE MANUAL or MUT-II
OPERATING INSTRUCTIONS for instructions on handling
the MUT-II.
Connect the MUT-II to the diagnosis
in the illustration.
Caution
Connection and disconnection of
always be made with the ignition
position.
connector as shown
the MUT-II should
switch in the OFF
IN ORDER TO PREVENT VEHICLES FROM FIRE
Improper installation of electrical or fuel related parts could
cause a fire. In order to retain the high quality and safety
of the vehicle, it is important that any accessories that may
be fitted or modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be carried out
in accordance with MMC's information/Instructions.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats from the skin, leading to dryness,
irritation and dermatitits. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing facilities
must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices
which prevent, as far as practicable, the risk of skin contact
with mineral oils, for example by using enclosed systems
for handling used engine oil and by degreasing components,
where practicable, before handling them.


MUT-II
sub-assembly




ROM pack

00-24 GENERAL Precautions Before Service
Other precautions:
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious gloves
where practicable.
Avoid contaminating clothes, particularly underpants, with
oil.
Do not put oily rags in pockets, the use of overalls without
pockets will avoid this.
Do not wear heavily soiled clothing and oil-impregnated
foot-wear. Overalls must be cleaned regularly and kept
separately from personal clothing.
Where there is a risk of eye contact, eye protection should
be worn, for example, chemical goggles or face shields;
in addition an eye wash facility should be provided.
Obtain First Aid treatment immediately for open cuts and
wounds.
Wash regularly with soap and water to ensure all oil is
removed, especially before meals (skin cleansers and
nail brushes will help). After cleaning, the application of
preparations containing lanolin to replace the natural skin
oils is advised.
Do not use petrol, kerosine, diesel fuel, gas oil, thinners
or solvents for cleaning skin.
Use barrier creams, applying them before each work
period, to help the removal of oil from the skin after work.
If skin disorders develop, obtain medical advice without
delay.











00-25 GENERAL Supplemental Restraint System (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 00100590110
To improve safety, the SRS is available as optional
part.
The SRS consists of two air bag modules, SRS
air bag control unit (SRS-ECU), front impact
sensors, SRS warning lamp and clock spring. One
air bag is located in the centre of the steering wheel
and another above the glove box. Each air bag
has a folded air bag and an inflator unit. The control
unit under the floor console monitors the system
and has a safing G-sensor and an analog G-sensor.
The front impact sensors are installed in the fender
shield panel. The warning lamp on the instrument
panel indicates the operational status of the SRS.
The clock spring is installed in the steering column.
Only authorized service personnel should do work
on or around the SRS components. Those service
personnel should read this manual carefully before
starting any such work. Extreme care must be used
when servicing the SRS to avoid injury to the service
personnel (by inadvertent deployment of the air
bags) or the driver (by
inoperative).
rendering the SRS
SRS warning lamp
Clock spring

Air bag module
(Driver's side)
Front impact sensor (L.H.)
Diagnosis
connector
Front impact sensor (R.H.)
Air bag module
(Front passenger's side)
SRS-ECU




00-26 GENERAL Supplemental Restraint System (SRS)
SRS SERVICE PRECAUTIONS 00100600110
SRS air bag control unit (SRS-ECU)
Front impact sensor
Clock Spring
Air Bag Module
1. In order to avoid injury to yourself or others
from accidental deployment of the air bag during
servicing, read and carefully follow all the
precautions and procedures described in this
manual.
Do not use any electrical test equipment on
or near SRS components, except those
specified on GROUP 52B.




If any of these components are diagnosed as
faulty, they should only be replaced, in 2.
accordance with the INDIVIDUAL COM-
PONENTS SERVICE procedures in this manual
on GROUP 52B. 3. Never Attempt
Components:
to Repair the Following
4. After disconnecting the battery cable, wait 60 seconds
or more before proceeding with the following work.
The SRS system is designed to retain enough voltage
to deploy the air bag for a short time even after the
battery has been disconnected, so serious injury may
result from unintended air bag deployment if work
is done on the SRS system immediately after the
battery cables are disconnected.
5. Do not attempt to repair the wiring harness connectors
of the SRS. If any of the connectors are diagnosed as
faulty, replace the wiring harness. If the wires are
diagnosed as faulty, replace or repair the wiring harness
according to the following table.


SRS-ECU connector


Insulating tape
Battery


00-27 GENERAL Supplemental Restraint System (SRS)
NOTE
*: The sensor cable is available as service part.
6. SRS components should not be subjected to heat over 93C, so remove the SRS-ECU, air bag
module, clock spring and front impact sensors before drying or baking the vehicle after painting.
7. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to GROUP 52B.)
Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
8.
9.
SRS-ECU
terminal No.

Harness connector
(No. of terminals,
colour)
Destination of harness

Corrective action

1 to 4 21 pins, yellow


5 Body wiring harness Clock spring Air bag
module (Driver's side)

Correct or replace each
wiring harness. Replace
clock spring. 6
7 Body wiring harness Air bag module (Front
passenger's side)

Correct or replace each
wiring harness.
8
9,10
11

Body wiring harness Diagnosis connector

Correct or replace each
wiring harness.
12, 17

Body wiring harness Front wiring
harnessFront impact sensor (L.H.)

Sensor cable* installation
procedures (Refer to
P.52B-38.)
13 Body wiring harness Junction block (fuse No.2) Correct or replace each
wiring harness.
14 Body wiring harness Junction block (fuse No.4)
15 Body wiring harness SRS warning lamp
16
18, 19

Body wiring harness Front wiring
harnessFront impact sensor (R.H.)

Sensor cable* installation
procedures (Refer to
P.52B-38.)
20 Body wiring harness Earth

Correct or replace body
wiring harness.
21



































GARAGE JACK


00-28 GENERAL Support Locations for Lifting and Jacking
SUPPORT LOCATIONS FOR LIFTING AND JACKING
Caution
Do not support the vehicles at locations other than specified supporting points. If do so, this
will cause damage, etc.
00100070096
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

AXLE STANDS




00-29 GENERAL Support Locations for Lifting and Jacking
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT AND
H-BAR LIFT
Caution
When service procedures require removing rear
suspension, spare tyre and rear bumper, place
anchor vehicle to hoist to prevent tipping of
centre of gravity changes.
additional weight on

DOUBLE-POST LIFT
rear end of vehicle or
SINGLE-POST LIFT
H-BAR LIFT


00-30 GENERAL Standard Parts-tightening-torque Table
STANDARD PARTS-TIGHTENING-TORQUE TABLE 00100110033
Each torque value in the table is a standard value
for tightening under the following conditions.
(1) Bolts, nuts and washers are all made of steel
and plated with zinc.
(2) The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
(1)
(2)
(3)
If
If
If
toothed washers are inserted.
plastic parts are fastened.
bolts are tightened to plastic or die-cast
inserted nuts.
(4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Flange bolt and nut tightening torque
Thread size Torque Nm
Bolt nominal
diameter (mm)
Pitch (mm)

Head mark 4

Head mark 7

Head mark 8

M6 1.0 4.9 9.8 12
M8 1.25 13 24 28
M10 1.25 26 49 57
M10 1.5 24 44 54
M12 1.25 46 93 103
M12 1.75 42 81 96
Thread size Torque Nm
Bolt nominal
diameter (mm)
Pitch (mm)

Head mark 4

Head mark 7

Head mark 8

M5 0.8 2.5 4.9 5.9
M6 1.0 4.9 8.8 9.8
M8 1.25 12 22 25
M10 1.25 24 44 52
M12 1.25 41 81 96
M14 1.5 72 137 157
M16 1.5 111 206 235
M18 1.5 167 304 343
M20 1.5 226 412 481
M22 1.5 304 559 647
M24 1.5 392 735 853