Pajero Sport (3G) Manual

0-1
GROUP 0
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 0-2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-4
PRECAUTIONS BEFORE  SERVICING THE ELECTRICAL 
SERVICE . . . . . . . . . . . . . . . . . . . . . . 0-2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PROTECTING THE VEHICLE . . . . . . . . . . 0-2 APPLICATION OF ANTI-CORROSION 
AGENTS AND UNDERCOATS . . . . . . . . . . 0-4
DOING SERVICE WORK IN GROUPS 
OF TWO OR MORE MECHANICS . . . . . . . 0-2 PRE-INSPECTION CONDITION . . . . . . . . . 0-4
REMOVAL AND DISASSEMBLY . . . . . . . . 0-2 VEHICLE WASHING . . . . . . . . . . . . . . . . . . 0-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 0-3 MULTI USE TESTER (M.U.T.-III) 
SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 0-5
PARTS TO BE REPLACED . . . . . . . . . . . . 0-3
IN ORDER TO PREVENT 
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
VEHICLES FROM FIRE . . . . . . . . . . . . . . . 0-5
TUBES AND OTHER RUBBER PARTS . . . 0-3
ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 0-5
0-2 GENERAL
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

M6000000100026
This manual contains Pre-delivery inspection and Group 0 and 1 have the contents for all vehicle mod-
Periodic inspection and maintenance. els, and Group 2 has contents for the relevant vehi-
cle models.
PRECAUTIONS BEFORE SERVICE

PROTECTING THE VEHICLE REMOVAL AND DISASSEMBLY
M6001000100029 M6001000300023
AC305590 AC305591
If there is a likelihood of damaging interior or exterior When checking a malfunction, find the cause of the
parts during service operations, protect them with problem. If it is determined that removal and/or dis-
suitable covers (such as seat covers, fender covers, assembly is necessary, perform the work by following
etc.). the procedures contained in this manual.
DOING SERVICE WORK IN GROUPS OF

TWO OR MORE MECHANICS
M6001000200026
AC305592
If punch marks or mating marks are made to avoid

error in assembly and facilitate the assembly work,
AC305283 be sure to make them in locations which will have no
detrimental effect on performance and/or appear-
If the service work is to be done by two or more ance. If an area having many parts, similar parts,
mechanics working together, all the mechanics and/or parts which are symmetrical right and left is
involved should take safety into consideration while disassembled, be sure to arrange the parts so that
they work. they do not become mixed during the assembly proc-
ess.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which
are to be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to
use only the exact size specified.
GENERAL 0-3
SPECIAL TOOLS PARTS

M6001000400031 M6001000600024
AC305593 AC305284
If other tools are substituted for the special tools to When replacing parts, use MITSUBISHI MOTORS
do service of repair work, there is the danger that genuine parts.
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe- TUBES AND OTHER RUBBER PARTS
M6001000700021
cial tool whenever doing any work for which the use
of one is specified.
PARTS TO BE REPLACED
M6001000500027
AC305595
Be careful to avoid spilling any petrol, oil, etc.,

because if it adheres to any tubes or other rubber
parts, they might be adversely affected.
AC305594
If any of the following parts are removed, they must LUBRICANTS

M6001000800028
be replaced with new parts.
 Oil seals
 Gaskets (except rocker cover gasket)
 Packings
 O-rings
 Lock washers
 Split pins
 Self-locking nuts
AC305596
In accordance with the instructions in this manual,

apply the specified lubricants in the specified loca-
tions during assembly and installation.
0-4 GENERAL
BRAKE FLUID APPLICATION OF ANTI-CORROSION

M6001000900025
AGENTS AND UNDERCOATS
M6001001100022
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
M6001001200182
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
AC305285
tion can be carried out. If you see the words "Set the
Be careful to avoid spilling any brake fluid, because if vehicle to the pre-inspection condition". In this man-
it adheres to the vehicle body, the paint coat might be ual, it means to set the vehicle to the following condi-
discoloured. tion.
 Engine coolant temperature: 80 to 90C
SERVICING THE ELECTRICAL SYSTEM  Lamps, electric cooling fan and all accessories:
M6001001000081
OFF
CAUTION  M/T: Neutral
Before connecting or disconnecting the negative  A/T, CVT: P range
(-) cable, be sure to turn off the ignition switch
and the lighting switch. (If this is not done, there VEHICLE WASHING
is the possibility of semiconductor parts being M6001001300082
damaged.)
Approximately
40 cm or more
AC300832AC
ACX00880AD If high-pressure car-washing equipment or steam

car-washing equipment is used to wash the vehicle,
Before replacing a component related to the electri-
be sure to note the following information in order to
cal system and before undertaking any repair proce-
dures involving the electrical system, be sure to first avoid damage to plastic components, etc.
 Spray nozzle distance: Approximately 40 cm or
disconnect the negative (-) cable from the battery in
more
order to avoid damage caused by short-circuiting.
 Spray pressure: 3,900 kPa or less
 Spray temperature: 82C or less
 Time of concentrated spray to one point: within
30 sec.
GENERAL 0-5
MULTI USE TESTER (M.U.T.-III) SUB ENGINE OILS

M6001001600209
ASSEMBLY
M6001001900169 HEALTH WARNING
Refer to the "M.U.T.-III OPERATING INSTRUC- Prolonged and repeated contact with mineral oil will
TIONS" for instructions on handling the M.U.T.-III. result in the removal of natural fats from the skin,
CAUTION leading to dryness, irritation and dermatitis. In addi-
Turn the ignition switch to the LOCK (OFF) position, used engine oil contains potentially harmful con-
tion before connecting or disconnecting the taminants which may cause skin cancer. Adequate
M.U.T.-III. means of skin protection and washing facilities must
be provided.
Diagnosis connector
RECOMMENDED PRECAUTIONS
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
MB991910 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.
Other precautions:
 Avoid prolonged and repeated contact with oils,
particularly used engine oils.
MB991824  Wear protective clothing, including impervious
gloves where practicable.
 Avoid contaminating clothes, particularly under-
pants, 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
MB991827 AC505420AB oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from per-
Connect the M.U.T.-III to the diagnosis connector as
shown in the illustration. sonal clothing.
 Where there is a risk of eye contact, eye protec-
IN ORDER TO PREVENT VEHICLES tion should be worn, for example, chemical gog-
gles or face shields; in addition an eye wash
FROM FIRE facility should be provided.
M6001001500064
"Improper installation of electrical or fuel related parts  Obtain first aid treatment immediately for open
could cause a fire. In order to retain the high quality cuts and wounds.
and safety of the vehicle, it is important that any  Wash regularly with soap and water to ensure all
accessories that may be fitted or modifica- oil is removed, especially before meals (skin
tions/repairs that may be carried out which involve cleansers and nail brushes will help). After clean-
the electrical or fuel systems, must be carried out in ing, the application of preparations containing
accordance with MMC's information/Instructions". 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.
NOTES
1-1
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-16

14. TYRE AND SPARE TYRE 
PAINTWORK TERMS . . . . . . . . . . . . 1-5 PRESSURES . . . . . . . . . . . . . . . . . . . . . . . 1-16
15. SUSPENSION SYSTEM . . . . . . . . . . . . 1-16
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 16. STEERING LINKAGE 
1. CONNECTION OF DARK  AND SPLIT PINS. . . . . . . . . . . . . . . . . . . . . 1-16
CURRENT CONNECTOR . . . . . . . . . . . . . 1-6 17. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-17
BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 BEFORE ROAD TEST . . . . . . . . . . . . 1-17

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-8 18. SEAT ADJUSTERS AND 
3. WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 SEATBACK LATCHES . . . . . . . . . . . . . . . . 1-17
4. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-13 19. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-17
5. OPERATION OF DOOR LOCKING  20. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-17
SYSTEMS AND DOOR HINGES . . . . . . . . 1-13 21. INSTRUMENT PANEL CONTROLS . . . 1-17
6. OPERATION OF DOOR MIRRORS,  22. METERS, GAUGES, WARNING 
WINDOWS AND SUNROOF . . . . . . . . . . . 1-14 LAMPS AND INDICATION LAMPS . . . . . . . 1-17
23. AIR CONDITIONER, HEATER 
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-14 AND DEFROSTER SYSTEM . . . . . . . . . . . 1-17
7. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-14 24. WIPERS AND WASHERS. . . . . . . . . . . 1-18
8. BRAKE MASTER CYLINDER  25. OPERATION OF SERVICE BRAKES 
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-14 AND PARKING BRAKES . . . . . . . . . . . . . . 1-18
9. CLUTCH MASTER CYLINDER  26. CLUTCH OPERATION . . . . . . . . . . . . . 1-18
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-15 27. OPERATION OF SEAT BELTS, 
10. WASHER FLUID LEVEL. . . . . . . . . . . . 1-15 SHOULDER BELTS AND 
RETRACTORS . . . . . . . . . . . . . . . . . . . . . . 1-19
11. BATTERY CONDITION AND 
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-15
12. POWER STEERING FLUID LEVEL . . . 1-15
13. ELECTRICAL WIRING . . . . . . . . . . . . . 1-15
Continued on next page

1-2
ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-19 38. MANUAL TRANSMISSION AND 

28. ENGINE PERFORMANCE  TRANSFER (4WD) OIL LEVEL . . . . . . . . . . 1-22
AND EXHAUST GAS . . . . . . . . . . . . . . . . . 1-19 39. AUTOMATIC TRANSMISSION 
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-22
29. TRANSMISSION IN ALL RANGES. . . . 1-19
30. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-20 40. ENGINE, TRANSMISSION, 
STEERING GEAR BOX AND 
31. STEERING CONTROL . . . . . . . . . . . . . 1-20 DIFFERENTIAL FOR LEAKS . . . . . . . . . . . 1-22
32. VIBRATION AND RATTLES . . . . . . . . . 1-20 41. FRONT AND REAR 
33. ELECTRICAL EQUIPMENT . . . . . . . . . 1-20 DIFFERENTIAL OIL LEVELS . . . . . . . . . . . 1-23
42. HOSES, FLUID LINES AND 
AFTER ROAD TEST . . . . . . . . . . . . . 1-21 CONNECTIONS LOCATED 
34. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-21 UNDER VEHICLE . . . . . . . . . . . . . . . . . . . . 1-23
35. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-21
36. RADIATOR COOLANT LEVEL . . . . . . . 1-21
FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-24
43. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-24
37. HOSES, FLUID LINES AND 
CONNECTIONS LOCATED  44. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-24
UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . 1-21 45. EXTERIOR AND INTERIOR . . . . . . . . . 1-24
46. OWNER INSTRUCTIONS . . . . . . . . . . . 1-24
PRE-DELIVERY INSPECTION 1-3
NOTES CONCERNING ENTRIES

M6010100100132
This section describes the details and the inspection methods employed for the pre-delivery inspection of
vehicles. 
The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY
INSPECTION. 
Inspection methods are described following the TABLE OF PRE-DELIVERY INSPECTION.
NOTE: The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in
kilometres (miles), date of inspection, name of person conducting the inspection, and body colour must be
completed without fail.
NOTE: The spaces for place of inspection, and name of owner should be completed as required.
1-4 PRE-DELIVERY INSPECTION
TABLE OF PRE-DELIVERY INSPECTION
Model
Chassis number
Engine number Before Road Test
Distance Travelled km 17. Seat adjusters and seat back latches
Owner 18. Choke system and inhibitor switch
Date of inspection
19. Idle control knob
Place of inspection
20. Instrument panel controls
Inspector
21. Meters, gauges, warning lamps and indication lamps
Body colour
22. Air conditioning, heater and defroster systems
Symbols to be used 23. Wipers and washers
24. Operation of service brakes and parking brakes
Needs Needs
Good A T 25. Clutch operation
adjustment retightening
26. Operation of seat belts, shoulder belts and retractors
Needs
Needs
Needs replenishment Road Test
C L X replenishment
cleaning of lubricant,
of repair 27. Engine performance and exhaust gas
water, etc.
28. Transmission in all ranges
INSPECTION PROCEDURE
29. Brakes
First Step
30. Steering control
1. Connection of the dark current connector
31. Vibration and rattles
Body
32. Electrical equipment
2. Wrap film
3. Exterior
After Road Test
4. Operation of door locking systems and door hinges
33. Idle speed
5. Operation of door mirrors, windows and sunroof
34. Ignition timing
Under Hood
35. Radiator coolant level
6. Engine oil level
36. Hoses, fluid lines and connections located under hood
7. Brake master cylinder fluid level
37. Manual transmission and transfer (4WD) oil level
8. Clutch master cylinder fluid level
38. Automatic transmission fluid level
9. Washer fluid level
39. Engine, transmission, steering gear box and
10. Battery condition and connections differential for leaks
11. Power steering fluid level 40. Front and rear differential oil levels
12. Electrical wiring 41. Hoses, fluid lines and connections located under vehicle
Under Vehicle Final Steps
13. Tyre and spare tyre pressures 42. Headlamp aiming
14. Suspension system 43. Equipment
15. Steering linkage and split pins 44. Exterior and interior
16. Under body 45. Owner instructions
AC401525
AC306353
PAINTWORK TERMS
PAINTWORK TERMS
M6010200100098
Term Definition Remark

Blister A raised bubble in the paint (from the base
or the undercoat) caused by abnormal
moisture. The bubble may contain either
water or air.
Change in tone The colour tone of the painted surface is not Including wrong colour, discolouration
uniform. and decolouration.
Contact mark A mark on the painted surface as a result of
contact by hands or clothing at the time of
paint application.
Crack A crack in the painted surface. Cracks may be either shallow or deep.
Dirt in paintwork Rough surface resulting from foreign
material in the paint or from dust deposited
on wet paint during painting or storage.
Filed or ground Deep scratches in sheet metal surface,
traces resulting from improper use of buffer or
sander, are not completely covered, and are
visible through paint coating.
Orange peel The painted surface has the appearance of
an orange peel.
Peeling The paint flakes off (partly or over a wide The peeling may be minor, medium, or
area). major.
Pin holes Tiny holes in the painted surface.
Runs A visible trickle of dried paint on the surface. Either undercoat or top-coat.
Scratches Scratches on the painted surface.
Shrink The painted surface "shrinks", causing
wrinkles.
Smears Spots of soot or other material deposited on Including stains and water spots.
the painted surface.
Spray mist The painted surface includes fine particles of
other paint.
Uneven lustre The lustre of the painted surface is not
uniform.
Uneven metallic The metallic dispersion of the painted
dispersion surface is not uniform.
Visibly incomplete A part of the undercoating visible.
topcoating
FIRST STEP
FIRST STEP
1. CONNECTION OF DARK CURRENT Press down the storage connector. After the connec-
CONNECTOR tor has been pressed down once, never pull up it.
M6010300100493 CAUTION
<EXCEPT EV, PHEV> Never disconnect the negative terminal of the
CONNECTING PROCEDURE auxiliary battery even if a vehicle is stored for
long term.
CAUTION
Turn the ignition switch to the LOCK (OFF) posi- CONFIRMATION OF PRODUCTION DATE
tion before connecting storage connector. OF MAIN BATTERY
Storage connector Confirm the production date of the main battery to
check whether the elapsed period after the main bat-
tery has been produced exceeds an estimated trans-
portation period. If it exceeds, compensate the BMU
by referring to the Workshop Manual.
For example:
If the estimated transportation period is three months
and the production date of the main battery is April:
Relay box  Before July 31: Compensation is not necessary
AC700018AB because the elapsed period does not exceed
Press down the storage connector. three months
 After August 1: Compensation is necessary
<EV> because the elapsed period exceeds three
months
CONNECTING PROCEDURE
CAUTION
Turn the electric motor switch to the LOCK (OFF)
position before connecting storage connector. Left rear tyre
<LHD> Storage connector
Bar-code Production Date
Junction block
ACA02852 AB
<RHD>
Serial number
AKA00558 AC
1. Location of production date

 The production date is labelled on the rear side of
Storage connector the main battery, and can be identified through
Junction block ACA02853 AB the rear left wheelhouse.
2. Estimated vehicle transportation period
 Europe: Three months
FIRST STEP
<PHEV> CONFIRMATION OF PRODUCTION DATE

CONNECTING PROCEDURE OF MAIN BATTERY
Confirm the production date of the main battery to
CAUTION
check whether the elapsed period after the main bat-
Turn the electric motor switch to the LOCK (OFF)
tery has been produced exceeds an estimated trans-
position before connecting storage connector.
portation period. If it exceeds, compensate the BMU
Storage connector by referring to the Workshop Manual.
For example:
If the estimated transportation period is three months
and the production date of the main battery is April:
 Before July 31: Compensation is not necessary
because the elapsed period does not exceed
three months
 After August 1: Compensation is necessary
Relay box because the elapsed period exceeds three
AC700018AB months
Press down the storage connector. After the connec-
tor has been pressed down once, never pull up it. Vehicles front
CAUTION
Never disconnect the negative terminal of the
auxiliary battery even if a vehicle is stored for
long term. If you turn the electric motor switch
"ON" while the storage connector is discon-
nected, the warning message as "EV SYSTEM
SERVICE REQUIRED" with a warning icon
appears on the centre display.
Drive battery
Bar code Production date
EV SYSTEM
SERVICE REQUIRED Serial number Parts number
ACD03690AD
ACD03919
It is the normal behaviour and nothing wrong 1. Location of production date

with the vehicle. However, if you connect the  The production date is labelled on the rear side of
storage connector under this condition, the diag- the main battery, and can be identified through
nosis code will be set in the ECU. Consequently the rear left wheelhouse.
you need to delete it before delivering the vehicle 2. Estimated vehicle transportation period
to your customer. In order to avoid this unneces-  Europe: Three months
sary diagnosis code, please make sure that the
storage connector is connected only when the
electric motor switch is turned "OFF".
BODY
BODY
2. WRAP FILM
M6010400100241
AC305606
Vehicles may be shipped from the assembly plant to

the distributors with a white plastic film or coating
(wrap film) applied for the purpose of protecting the
painted exterior from environmental elements where
the assembly plant and point of embarkation is
located.
Distributors are required to remove the wrap film
immediately after receiving vehicles, which is neces-
sary for PDI operations. Please refer to the following
chart for the procedures.
REMOVAL PROCEDURE
Flow Chart of Wrap Film Removal
Wrap film removal Peel off from the corners of the wrap film. High temperature or
low temperature may cause wrap film to become brittle. For
easier removal, the recommended Wrap Film temperature is
below 40˚C. (i.e.: If the surface of the vehicle is hot, lower it to
40˚C or less by sprinkling water so the peeling off will be
easier.)
Rinse off debris such as sand and dust thoroughly. Then dry
Water washing the surface thoroughly.
If adhesive residue is left on the painted surface, wipe it off

with kerosene or white gasoline. If the residue is still visible,
Cleaning of border use a polishing compound for a fine finish. If you use such
solvents or compound, make sure to wipe it off.
Dispose removed film according to local

regulations. ACB04862 AB
BODY
The procedures to re-apply the wrap film
ACB04328
If there is an environment that the vehicles in stock

may be exposed to elements such as acid rain, dust
particles, it may be recommendable to re-apply the
wrap film for the purpose of protecting the painted
exterior from the environment. Please refer to the fol-
lowing chart for the procedures to re-apply the wrap
film.
Steps. Process Tips

1 Remove old wrap film Follow the "flow chart of removing the wrap film"
2 Prepare the surface to adhere the wrap Make sure there is no debris such as sand or dust. Dry
film the surface thoroughly. The temperature of the area to
apply the wrap film should be below 40C for workability.
3 Re-apply the wrap film The area to re-apply the wrap film is the same area
where the original wrap film was applied.
1. Begin adhering the wrap film from the low part of the
vehicle and move upward. Maintain some tension on
the wrap film so it will not get wrinkled or trap air
bubbles. Although air bubbles it self will not damage
the paint, you can avoid trapping air by adhering the
wrap film from the centre to the out side of the
vehicle. Use a tool such as a squeezer to adhere the
wrap film firmly to the vehicle.
2. For moving panels such as the hood and trunk lid, or
portion where parts such as windshield washer
nozzles are pointing out, cut the wrap film
accordingly, so it will adhere to the paint surface
firmly.
3. If the top side of the film (the side without the
adhesive) is left to contact the painted surface, it may
damage the paint surface. (for example, become
lusterless). The edges of the wrap film and
overlapping portions should be firmly adhered to
prevent entry of rain under the wrap film.
4. To prevent colour difference to be recognised
between the areas wrapped and unwrapped due to
exposure to sunlight etc. during storage, we
recommend the boundary of wrapped and
unwrapped areas be on a vertical location.
BODY
Steps. Process Tips

CAUTION
 Be careful not to damage the paint surface while cutting the wrap film.
 Once the wrap film is adhered to the vehicle, it should remain on the vehicle for no more than 6
months. If it is necessary, a new wrap film should be adhered to the vehicle following the steps
above, based on your inventory management schedule.
Guidelines to give you an estimate of the How to acquire the wrap film
labour costs It will be a direct transaction between O-WELL. Fill
Approximate labour time to adhere wrap film the necessary information, contact information;*1
and ordering quantity;*2 in the specified portion of
area to apply wrap film (m2) labour time (min) the document attached below and send to O-WELL
3.5 - 5.5 10 - 15 Corporation. The necessary information is stated in
the document attached below. O-WELL will give you
5.5 - 7.0 15 - 20
a quotation in return.
BODY
BODY
BODY
3. WHEEL 5. OPERATION OF DOOR LOCKING

M6010400500012
SYSTEMS AND DOOR HINGES
M6010400300137
ACD02910 Front
AC305608 AB
Vehicles may be shipped from the assembly plant to
the distributors with a plastic film or cover (non-adhe-
sive type) applied in order to avoid rust of the brake
disc. Distributors should remove the plastic film or
cover just before delivering the vehicle to your cus-
tomer. However, the plastic film should be removed
in five months after the vehicle is delivered to the dis-
tributor. The plastic cover can be kept for more than
five months.
CAUTION
Be careful not to damage the paint surface when AC210253AB
removing the plastic film or cover.
1. Open each door to check the release mechanism
4. EXTERIOR and ease of operation.
M6010400200301
2. Close the door to check the latch and striker.
1. Visually inspect the entire exterior.
(1) Paint condition 3. Open the door, operate the lock lever and close
the door to check the lock.
(2) Corrosion, scratches
4. Partially close the door to check the open-door
(3) Bent edges, dented panels
detent.
2. Coated surfaces maintenance 
5. Unlock each door with the key to check lock
Touch up minor paint chips and flaws.
operation.
(Refer to paintwork terms)
6. Verify that all doors can be locked by the lock
buttons.
NOTE: Adjust and lubricate the door latches, strikers
and locks as required.
UNDER HOOD
6. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF
M6010400400190
1. Door mirrors
Check that the mirror operate properly.
2. Door windows
Close all door windows to the fully closed position
to check ease of operation.
Child-protection knob
AC305610 AB
3. Power windows
7. Verify that the rear doors can't be opened by the Check that the door windows operate when the
inner door handle when the child protection knob respective switches are operated. Check that
at the end of the door is shifted to the "LOCK" when the lock switches are depressed, the
position with the inside lock plunger raised. respective door windows can no more be opened
or closed.
NOTE: Set the lock to the "FREE" position on child
protection of both rear doors. (For four door models) 4. Slide window
Close the slide window to the fully closed position
to check operation.
5. Sunroof
Close the sunroof to the fully closed position to
check operation.
UNDER HOOD
7. ENGINE OIL LEVEL 8. BRAKE MASTER CYLINDER FLUID
M6010500100293
LEVEL
M6010500200223
MAX
MIN
AC702169
Check that the oil level is between "MAX" and "MIN". AC702028
If it is at or below "MIN", add the necessary amount Check the fluid level.
of the specified engine oil referring to GROUP 2, If it is below the "MIN" mark, replenish fresh brake
Periodic Inspection and Maintenance. fluid up to the "MAX" mark.
Specified Brake Fluid: DOT3 or DOT4
UNDER HOOD
9. CLUTCH MASTER CYLINDER FLUID 12. POWER STEERING FLUID LEVEL

M6010500600072
LEVEL
M6010500300026
AC305616
AC305613
1. Check that the fluid level is between "MAX" and
Check the fluid level. "MIN".
If it is below the "MIN" mark, replenish fresh brake 2. If the fluid is added, start the engine and turn the
fluid up to the "MAX" mark. steering wheel from stop to stop several times to
Specified Brake Fluid: DOT3 or DOT4 expel air from the system.
Specified gear oil: Automatic transmission
10. WASHER FLUID LEVEL fluid DEXRON III or DEXRON II
M6010500400186
13. ELECTRICAL WIRING

M6010500700024
AC305614
Check the fluid level; if it is low, replenish the washer

fluid. AC305617
1. Windshield washer reservoir
1. Each electrical wiring harness and connector
2. Rear window washer reservoir
(1) Check each harness to be correctly routed
11. BATTERY CONDITION AND and securely clipped.
(2) Confirm that all connections are tight.
CONNECTIONS
M6010500500042 2. Ignition cable 
Be sure that all ignition cables are firmly attached
to the spark plugs, distributor cap (or crank angle
sensor) and ignition coil.
AC305615
Inspect the battery connections. Verify that they are

tightened.
NOTE: Do not wipe the lubricant from the battery
posts and cable clamps.
UNDER VEHICLE
UNDER VEHICLE
14. TYRE AND SPARE TYRE PRESSURES REMOVE FRONT SPRING RESTRAINTS
M6010600100041
CAUTION
It is very important that these restraints must be
removed during pre-delivery inspection. Failure
to do so could cause ride and handling com-
plaints.
Spring
restraints
AC305618
1. Tyre specification 
Check the correct tyre specification.
2. Tyre pressures 
Adjust each tyre pressure. AC305605
NOTE: Recommended pressure is shown on the With the vehicle correctly positioned on the
tyre pressure label. sub-frame contact points, and the suspension fully
3. Valve stem extensions  extended, remove the rubber restraints from the front
Verify that the valve stem extensions are installed springs.
where necessary.
4. Install the wheel covers, wheel rings and hub 16. STEERING LINKAGE AND SPLIT PINS
M6010600300023
caps.
5. On vehicles with TPMS, the 'Tyre Pressure
Monitoring System (TPMS)' needs to be activated
during the pre-delivery inspection of the vehicle 
(if applicable). During PDI each Tyre Pressure
Monitoring sensor in four tyres (with a tyre repair
kit) or five tyres (including a spare wheel) needs to
be activated with the trigger tool to enable the tyre
pressure monitoring function.
AC305604
15. SUSPENSION SYSTEM
M6010600200178
1. Steering linkage retaining nuts and split pins
Check visually and by feel that the steering
linkage retaining nuts are correctly tightened and
the split pins are correctly installed.
2. Tie rods and relay rod 
Check that the tie rods and relay rod of the
steering linkage are not bent and that the tie rod
end lock nuts are securely tightened.
3. Steering components
(1) Check that each of the steering components is
AC305609
tightened.
Check to be sure that each installation bolt and nut is (2) Check the tie rod end, nuts and split pins for
tightened. If split pins are used, make sure that they proper installation.
are properly installed.
(3) Check the condition of bellows-type dust
1. Lower arm, Upper arm seals.
2. Stabilizer bar
3. Strut assembly
BEFORE ROAD TEST
4. Split pins  17. UNDER BODY

Check the front axle nuts and rear wheel spindle M6010600400020
nuts for split pins. Check under body and under body coating for dam-
age.
BEFORE ROAD TEST

18. SEAT ADJUSTERS AND SEATBACK 22. METERS, GAUGES, WARNING
LATCHES LAMPS AND INDICATION LAMPS
M6010700100082 M6010700500024
AC305622 AC305624
Check the operation of the various parts of the seats. 1. Check the meters and gauges are functioning
1. Mechanical adjusters of the seats properly.
2. Operation of the latch for tilting the seatbacks 2. Check each indicator lamp and warning lamp
forward and backward. functions properly.
19. INHIBITOR SWITCH 23. AIR CONDITIONER, HEATER AND
M6010701100029
On models with an automatic transmission, be sure DEFROSTER SYSTEM
M6010700600128
the engine starts in both "P" and "N" position, and
Check the systems for proper operation.
does not start in other positions.
20. IDLE CONTROL KNOB

M6010700300020
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.
21. INSTRUMENT PANEL CONTROLS

M6010700400083
Check the operation of the following
1. Horn
AC305625
2. Headlamps
3. Exterior and interior lamps 1. Air conditioner
4. Instrument panel lamps (1) Operate the air conditioner system.
5. Instrument brightness control (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
(4) Operate the blower motor switch in all ranges.
BEFORE ROAD TEST
25. OPERATION OF SERVICE BRAKES

AND PARKING BRAKES
M6010700800382
Depress the brake pedal

with approximately 500
N force
AC305626
2. Heater and defroster

(1) After the engine has warmed up, turn on the AC305628 AB
heater.
(2) Operate the blower motor switch in all ranges. 1. Service brakes
(3) Move the control to "Defrost" position. (1) Check the clearance between the brake pedal
A: From front and side defroster and the floorboard when the brake pedal is
depressed.
B: From centre ventilators
C: From side ventilators
D: From under the instrument panel
E: From under the front seat (some models
only)
24. WIPERS AND WASHERS

M6010700700028
AC305629
(2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the
service brake, refer to GROUP 2, Periodic
Inspection and Maintenance.
2. Parking brake 
AC305627
Check the parking brake drag and lever travel.
NOTE: For inspection and adjustment of the park-
1. Front wiper and washer ing brake, refer to GROUP 2, Periodic Inspection
(1) Check operation of the front wipers in all and Maintenance.
ranges.
(2) Check the aim of the front washer stream. 26. CLUTCH OPERATION
M6010700900282
(3) Check the wiper blade-stop positions.
(4) Verify that the interval between cycles of
wiping is shifted when timer knob is turned to
any position.
(5) Verify that the front wipers function by
operating the washer switch.
2. Rear wiper and washer
(1) Check the operation of the rear wiper.
(2) Check the aim of the rear washer stream.
AC305630AC
(3) Check the wiper blade-stop positions.
1. Check the clutch operation in all driving ranges.
ROAD TEST
2. Check the pedal to floorboard clearance when the 27. OPERATION OF SEAT BELTS,
clutch is just disengaged. SHOULDER BELTS AND RETRACTORS
M6010701000022
AC305631
AC305632
3. Verify correct clutch pedal free play.
1. Verify that the seat belt warning lamp operates
NOTE: For inspection and adjustment of the
properly.
clutch pedal, refer to GROUP 2, Periodic Inspec-
tion and Maintenance. 2. Check all seat belts and harnesses to assure that
they connect and hold properly.
3. Lean forward to check that the shoulder
harnesses allow movement.
4. Check the condition of the belts and anchors.
5. Check for proper seat belt retraction.
ROAD TEST
28. ENGINE PERFORMANCE AND 29. TRANSMISSION IN ALL RANGES
M6010800200020
EXHAUST GAS
M6010800100023
AC305634
AC305633
1. Manual transmission 
1. Engine performance  Check the transmission in all forward ranges and
Check the engine for proper performance and in reverse.
accelerator pedal for smooth operation.
2. Exhaust system
(1) Check the exhaust system components for
gas leaks.
(2) Verify that no black smoking is emitted from
the end of the exhaust pipe (diesel-powered
vehicles).
ROAD TEST
31. STEERING CONTROL

M6010800400024
Button
AC305635 AB
AC305636
2. Automatic transmission
(1) Make sure shift indicator lines up properly in 1. Check for excessive play or looseness.
all ranges. 2. Check the steering wheel centre.
(2) Depress the accelerator completely to check
that the manual kickdown is operating 32. VIBRATION AND RATTLES
M6010800500021
correctly. 1. Locate squeaks, rattles and unusual vibrations.
(3) Stop the vehicle on a steep incline.  2. Verify that no noise occurs from the engine,
Put the automatic transmission in "P" position transmission, axle and body.
and slowly release the service brakes to see if
"P" position lock holds. If it does not hold, the 33. ELECTRICAL EQUIPMENT
transmission requires further service. M6010800600028
30. BRAKES
M6010800300027
1. Service Brake 
Put the vehicle in gear and apply the brakes while
the vehicle is in motion. Be sure brake operation
is smooth and positive.
2. Parking Brake
(1) Stop the vehicle on a steep incline. 
With the service brakes firmly applied, place AC305637
the transmission in "N" position, and set the
parking brakes. 1. Radio
(2) Slowly release the service brakes to see if the Tune the radio to a local broadcasting station and
parking brakes will hold. check the following:
(1) Operate the volume, tone, balance and fader
controls, etc.
(2) Pull out the pushbuttons, dial another station
and set each pushbuttons.
(3) Operate the AM/FM switch.
2. Tape player
Insert a cassette tape in the tape player and
check as follows:
(1) Check the operation of the tape feeder and
rewind.
(2) Check the ejection.
(3) Check the operation of volume, tone, balance
and fader controls, etc.
AFTER ROAD TEST
AFTER ROAD TEST

34. IDLE SPEED 37. HOSES, FLUID LINES AND
M6010900100172
Check the engine idle speed. CONNECTIONS LOCATED UNDER HOOD
M6010900400203
NOTE: For specific idle speed adjustment proce- CAUTION
dure, refer to GROUP 2, Periodic Inspection and Remember that the air conditioner system is
Maintenance. under pressure.
35. IGNITION TIMING
M6010900200179
AC305643
AC305641
1. Check all brake, fuel, power steering and air
conditioner lines and connections; verify proper
Check the ignition timing. Except MPI vehicles with routing, check connections for leaks, tighten loose
crankshaft-mounted crankshaft angle sensor. connector as required.
NOTE: For the inspection and adjustment of the igni- 2. Inspect routing and connections of all vacuum,
tion timing, refer to GROUP 2, Periodic Inspection and radiator and heater houses.
and Maintenance.
NOTE: Keep in mind that an oily residue around
an air conditioner connector does not necessarily
36. RADIATOR COOLANT LEVEL
M6010900300154 indicate a leak. Oil is used to lubricate fittings dur-
CAUTION ing assembly. Be sure lines are not twisted or
Do not remove the radiator cap while the cooling kinked.
system is under pressure. 
When removing the radiator cap, be careful of
steam and boiling water. Add coolant only to the
reserve tank if it is required.
AC305642
1. Check that the coolant level in the reserve tank is

at or above "LOW" mark at normal engine
operating temperature. And check cooling system
for leaks.
2. Check that the coolant concentration is 30% to
60%.
AFTER ROAD TEST
38. MANUAL TRANSMISSION AND 39. AUTOMATIC TRANSMISSION FLUID

TRANSFER (4WD) OIL LEVEL LEVEL
M6010900500330 M6010900600230
CAUTION
Gaskets (or packing) for the oil filler plug and the
drain plug are non-reusable parts. Always
replace them with new one, or oil leaks may be
caused.
Filler plug hole
Gasket
AC005861AD
1. Remove the dipstick and check the fluid level.

Filler plug 2. Fluid level is okay if it is in the specified range as
illustration at normal engine operating
Transmission oil
temperature.
AC700330AL
3. If the level is below the lower notch, replenish fluid
1. Remove the filler plug. until the level reaches the upper notch.
2. Check the oil level. If the oil level is at or slightly NOTE: For the specified automatic transmission
below the filler hole, it is in satisfactory condition. fluid, refer to GROUP 2, Periodic Inspection and
NOTE: For oil level, refer to GROUP 2, Periodic Maintenance.
3. If the level is low, replenish the transmission and
40. ENGINE, TRANSMISSION, STEERING
transfer case with fresh oil by using a lubricator. GEAR BOX AND DIFFERENTIAL FOR
NOTE: For the specified oil, refer to GROUP 2, LEAKS
M6010900700055
Periodic Inspection and Maintenance. Check the engine, transmission, steering gear box
4. Renew a gasket, because it is a non-reusable and differential for oil leaks.
part.
5. Install the filler plug with a new gasket, and tighten
it to the specified torque.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance.
AFTER ROAD TEST
41. FRONT AND REAR DIFFERENTIAL 42. HOSES, FLUID LINES AND
OIL LEVELS CONNECTIONS LOCATED UNDER
M6010900800427
VEHICLE
CAUTION M6010901000145
Gaskets (or packing) for the oil filler plug and the
drain plug are non-reusable parts. Always
replace them with new one, or oil leaks may be
caused.
1. Remove the filler plug.
2. Check the oil level. If the oil level is at or slightly
below the filler hole, it is in satisfactory condition.

TYPE 1 TYPE 2
AC305647
1. Check all hoses, fluid lines and connections for

Gear oil
Upper leaks.
limit
2. Check all hoses and fluid lines for proper routing
away from sharp edges and moving components.
Lower
limit
AC305646 AD
Type 1 only: Remove the filler plug, and check the

gear oil level.
NOTE: For oil level, refer to GROUP 2, Periodic
3. If the level is low, replenish the front and/or rear
differential with fresh oil by using a lubricator.
4. Renew a gasket, because it is a non-reusable
part.
5. Install the filler plug with a new gasket, and tighten
it to the specified torque.
FINAL STEPS
FINAL STEPS
43. HEADLAMP AIMING 45. EXTERIOR AND INTERIOR
M6011000100116 M6011000300262
Finally check and clean the exterior and interior.
1. Wash the vehicle to remove all traces of road
Screen grime and other dirt on the vehicle as a result of
Headlamp
new vehicle preparations.
2. Clean exterior and interior glass surface.
3. Remove all protective covers.
Level surface 4. Remove undercoat overspray, excess window
sealer, and excess weatherstrip adhesive.
AC305648 AB
5. Verify that the secondary key can not unlock the
glove box and tailgate/boot lid (if so equipped).
Check condition for headlamp aiming. 6. Remove shipping and inspection stickers.
NOTE: For headlamp aiming procedures, refer to the
Workshop Manual for that model. 46. OWNER INSTRUCTIONS
M6011000400054
44. EQUIPMENT 1. Verify that the owner's manual and service

M6011000200209 booklet is in the glove box.
2. Place the spare keys in envelope in the glove box
before delivery.
AC305649
Check the installation of the various equipment.

1. Trunk room floor mats
2. Spare tyre
3. Jack, jack handle and tool set
2-1
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
PERIODIC INSPECTION AND  REPLACE AIR CLEANER ELEMENT . . . . . 2-22

MAINTENANCE SCHEDULE . . . . . . 2-3 CHECK FLUID LEVEL IN 
BRAKE RESERVOIR AND 
CLUTCH RESERVOIR . . . . . . . . . . . . . . . . 2-23
OPERATIONS INSIDE THE 
ENGINE COMPARTMENT. . . . . . . . . 2-10 CHANGE BRAKE FLUID. . . . . . . . . . . . . . . 2-23
CHECK BATTERY CONDITION . . . . . . . . . 2-24
CHECK DRIVE BELT FOR 
CRACKS, FRAYING, WEAR,  REPLACE FUEL FILTER . . . . . . . . . . . . . . 2-25
AND ADJUST ITS TENSION . . . . . . . . . . . 2-10
CHECK VACUUM PUMP OIL  OPERATIONS UNDER 
HOSE FOR DAMAGE <4D5> . . . . . . . . . . . 2-14 THE VEHICLE. . . . . . . . . . . . . . . . . . . 2-29
CHECK INTAKE AIR HOSE  CHECK SUSPENSION SYSTEM 
AND TURBOCHARGER OIL  FOR DAMAGE AND LOOSENESS. . . . . . . 2-29
HOSE FOR DAMAGE 
CHECK SUSPENSION ARM 
(VEHICLES WITH TURBOCHARGER) . . . 2-14
BALL JOINTS FOR PLAY, AND 
REPLACE ENGINE TIMING BELT  DUST COVERS FOR DAMAGE . . . . . . . . . 2-30
(except vehicles with timing chain) . . . . . . . 2-15
CHECK STEERING LINKAGE 
CHECK OPERATION OF CRANKCASE  FOR DAMAGE AND 
EMISSION CONTROL SYSTEM . . . . . . . . 2-15 LOOSE CONNECTIONS 
REPLACE SPARK PLUGS . . . . . . . . . . . . . 2-15 (INCLUDING SEALS AND BOOTS) . . . . . . 2-30
CHECK VALVE CLEARANCE  LUBRICATE PROPELLER SHAFT 
(EXCEPT VEHICLES WITH  WITH GREASE FITTING 
AUTO-LASH ADJUSTER) . . . . . . . . . . . . . 2-16 (UNIVERSAL JOINTS 
CHECK RADIATOR HOSES  AND SLIDING SLEEVE) . . . . . . . . . . . . . . . 2-31
FOR DAMAGE AND  CHECK DRIVESHAFT BOOTS 
PROPER CONNECTION . . . . . . . . . . . . . . 2-19 FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-31
CHECK ENGINE COOLANT  CHECK MANUAL TRANSMISSION 
LEVEL IN RESERVOIR . . . . . . . . . . . . . . . 2-19 FOR OIL LEAKAGE 
CHANGE ENGINE COOLANT . . . . . . . . . . 2-19 (IN CASE OF LEAKAGE, 
CHECK THE OIL LEVEL) . . . . . . . . . . . . . . 2-31
CHECK AIR CLEANER ELEMENT 
FOR CLOGGING AND DAMAGE . . . . . . . . 2-22
Continued on next page

2-2
CHECK TRANSFER FOR OIL LEAKAGE  CHECK BRAKE SHOE LININGS 

(IN CASE OF LEAKAGE,  AND DRUMS FOR WEAR . . . . . . . . . . . . . 2-48
CHECK THE OIL LEVEL) . . . . . . . . . . . . . . 2-32 ADJUST THE CLEARANCE OF 
CHANGE GEAR OIL IN  THE BRAKE SHOE LININGS 
MANUAL TRANSMISSION. . . . . . . . . . . . . 2-32 <Electric parking brake> . . . . . . . . . . . . . . . 2-49
CHANGE GEAR OIL IN TRANSFER . . . . . 2-33 CHECK FUEL HOSES AND 
CHECK FRONT AND REAR  PIPES FOR LEAKAGE 
DIFFERENTIAL FOR OIL LEAKAGE  OR DETERIORATION. . . . . . . . . . . . . . . . . 2-49
(IN CASE OF LEAKAGE, 
CHECK THE OIL LEVEL) . . . . . . . . . . . . . . 2-34 OPERATIONS AFTER 
CHANGE GEAR OIL IN FRONT  ENGINE IS WARMED UP. . . . . . . . . . 2-50
AND REAR DIFFERENTIAL . . . . . . . . . . . . 2-36 CHECK AUTOMATIC TRANSMISSION 
CHECK EXHAUST PIPE  FOR FLUID LEAKAGE 
CONNECTIONS FOR GAS LEAKAGE,  (IN CASE OF LEAKAGE, 
AND CHECK PIPE INSTALLATION . . . . . . 2-37 CHECK THE FLUID LEVEL) . . . . . . . . . . . . 2-50
CHANGE AUTOMATIC 
OPERATIONS INSIDE  TRANSMISSION FLUID . . . . . . . . . . . . . . . 2-54
THE VEHICLE . . . . . . . . . . . . . . . . . . 2-37 CHANGE ENGINE OIL . . . . . . . . . . . . . . . . 2-56
CHECK BRAKE PEDAL AND  REPLACE ENGINE OIL FILTER . . . . . . . . . 2-59
CLUTCH PEDAL FOR FREE PLAY . . . . . . 2-37 CHECK ENGINE IDLING SPEED . . . . . . . . 2-60
CHECK PARKING BRAKE  CHECK CO CONCENTRATION 
LEVER STROKE AND PLAY  (PETROL-POWERED VEHICLES) . . . . . . . 2-61
<Lever type parking brake> . . . . . . . . . . . . 2-41
CHECK EXHAUST GAS 
REPLACE AIR PURIFIER FILTER . . . . . . . 2-42 RECIRCULATION (EGR) SYSTEM . . . . . . 2-61
OPERATIONS OUTSIDE  OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-64

THE VEHICLE . . . . . . . . . . . . . . . . . . 2-42 CHECK BODY CONDITION FOR 
CHECK WHEEL ALIGNMENT . . . . . . . . . . 2-42 DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
CHECK FRONT WHEEL  CHECK THE COMMON RAIL ENGINE 
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-44 (SMALL INJECTION 
CHECK BRAKE HOSES  QUANTITY LEARNING) . . . . . . . . . . . . . . . 2-64
AND PIPES FOR LEAKAGE. . . . . . . . . . . . 2-45 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 2-64
CHECK BRAKE PADS AND 
DISCS FOR WEAR. . . . . . . . . . . . . . . . . . . 2-46
PERIODIC INSPECTION AND MAINTENANCE 2-3
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

M6020100102894
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
VEHICLES FOR GENERAL EXPORT
Maintenance item Maintenance Maintenance interval
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
Check drive belt for cracks, fraying, wear, and Inspection Every 20,000 km or every 12 months
adjust its tension (P.2-10)
Check vacuum pump oil hose for 4D5 engine Inspection Every 20,000 km or every 12 months
damage (P.2-14)
Check intake air hose and turbocharger oil hose for Inspection Every 40,000 km or every 2 years 
damage (vehicles with turbocharger) (P.2-14) (Over 100,000 km, every 20,000 km for
turbocharger oil hose)
Replace engine timing belt [Including timing belt B] Replace Every 100,000 km
(except vehicles with timing chain) (P.2-15)
Check operation of crankcase emission control Inspection Every 40,000 km or every 2 years
system (P.2-15)
Replace spark plugs (P.2-15) Standard type Replace Every 40,000 km
Iridium-tipped Every 100,000 km
type
Check valve clearance*1 (except 4N1 engine Inspection Every 60,000 km
vehicles with auto-lash adjuster) 6B3 engine Inspection Every 40,000 km
(P.2-16) (intake side)
4D5 engine Inspection Every 40,000 km or every 2 years
(including noise check for every 20,000
km)
Check radiator hoses for damage and proper Inspection Every 40,000 km or every 2 years
connection (P.2-19)
Check engine coolant level in reservoir (P.2-19) Inspection Every 20,000 km or every 12 months
Change engine coolant (P.2-19) 4N1 and 6B3 Change First 160,000 km or 8 years, thereafter
engines every 100,000 km or 5 years
4D5 engine Every 40,000 km or every 2 years
Check air cleaner element for clogging and Inspection Normal Every 20,000 km or every 12
damage (P.2-22) usage months
Severe Every 10,000 km or every 6
usage months
2-4 PERIODIC INSPECTION AND MAINTENANCE

operation
Replace air cleaner element (P.2-22) Replace Normal Every 40,000 km or every 2
usage years
Severe More frequently
usage
Check fluid level in brake reservoir and clutch Inspection Every 10,000 km or every 6 months
reservoir (P.2-23)
Change brake fluid (P.2-23) Change Every 40,000 km or every 2 years
Check battery condition (P.2-24) Inspection Every 10,000 km or every 6 months
Replace fuel filter (P.2-25) Petrol-powered Replace Every 60,000 km or every 3 years
vehicles
Diesel-powered Replace Every 20,000 km or every 12 months
vehicles
OPERATIONS UNDER THE VEHICLE
Check suspension system for damage and Inspection Every 20,000 km or every 12 months
looseness (P.2-29)
Check suspension arm ball joints for play, and dust Inspection Every 20,000 km or every 12 months
covers for damage (P.2-30)
Check steering linkage for damage and loose Inspection Every 20,000 km or every 12 months
connections (including seals and boots) (P.2-30)
Lubricate propeller shaft with grease fitting (P.2-31) Lubrication Every 20,000 km or every 12 months
(universal joints and sliding sleeve)
Check driveshaft boots for damage (P.2-31) Inspection Normal Every 20,000 km or every 12
usage months
usage months
Check manual transmission for oil leakage Inspection Every 20,000 km or every 12 months
(In case of leakage, check the oil level) (P.2-31)
Check transfer for oil leakage Inspection Every 20,000 km or every 12 months
Change gear oil in manual transmission (P.2-32) Change Normal Every 100,000 km
usage
Severe Every 40,000 km
usage
Change gear oil in transfer (P.2-33) Change Normal Every 100,000 km
usage
usage
Check front and rear differential for oil leakage Inspection Every 20,000 km or every 12 months

operation
Change gear oil in front and rear Conventional Change Normal Every 80,000 km
differential (P.2-36) differential usage
usage
Hybrid type Change Normal Every 40,000 km
LSD usage
usage
Check exhaust pipe connections for gas leakage, Inspection Every 20,000 km or every 12 months
and check pipe installation (P.2-37)
OPERATIONS INSIDE THE VEHICLE
Check brake pedal and clutch pedal for free play Inspection Every 10,000 km or every 6 months
(P.2-37)
Check parking brake lever stroke and play (P.2-41) Inspection Every 20,000 km or every 12 months
Replace air purifier filter. (P.2-42) Replace Every 15,000 km or every 12 months
OPERATIONS OUTSIDE THE VEHICLE
Check wheel alignment (P.2-42) Inspection Every 20,000 km or every 12 months
Check front and rear wheel bearings for play Inspection Every 60,000 km or every 3 years
(P.2-44)
Check brake hoses and pipes for leakage (P.2-45) Inspection Every 20,000 km or every 12 months
Check brake pads and discs for wear (P.2-46) Inspection Normal Every 20,000 km or every 12
usage months
usage months
Check brake shoe linings and drums for wear Inspection Normal Every 40,000 km or every 2
(P.2-48) usage years
usage months
Adjust the clearance of the brake shoe linings Adjust Every 20,000 km or every 12 months
(vehicles with electric parking brake) (P.2-49)
Check fuel hoses and pipes for leakage or Inspection Every 40,000 km or every 2 years
deterioration (P.2-49)

operation
OPERATIONS AFTER ENGINE IS WARMED UP
Check automatic transmission for fluid leakage Inspection Every 20,000 km or every 12 months
Change automatic transmission fluid (P.2-54) Change Severe Every 100,000 km
usage
Change engine oil (P.2-56) Petrol-powered Change Normal Every 15,000 km or every 12
vehicle usage months
usage
Diesel-powered Change Normal Every 10,000 km or every 12
usage
Replace engine oil filter (P.2-59) Petrol-powered Replace Normal Every 15,000 km or every 12
usage
Diesel-powered Replace Normal Every 10,000 km or every 12
usage
Check engine idling speed (P.2-60) Inspection Every 20,000 km or every 12 months
Check CO concentration Inspection Every 20,000 km or every 12 months
(petrol-powered vehicles) (P.2-61)
Check exhaust gas recirculation 4D5 and 6B3 Inspection Every 20,000 km or every 12 months
(EGR) system (P.2-61) engines
OTHERS
Check body condition for damage (P.2-64) Inspection Every year
Check the common rail engine Inspection Every 20,000 km or every 12 months
(small injection quantity learning) (P.2-64)
Road test (P.2-64) Inspection Every 20,000 km or every 12 months
VEHICLES FOR EUROPE

operation
Check drive belt for cracks, fraying, wear, and Inspection Every 40,000 km or every 2 years
adjust its tension (P.2-10)
Check intake air hose and turbocharger oil hose Inspection Every 40,000 km or every 2 years
for damage (vehicles with turbocharger) (P.2-14)
Replace engine timing belt (P.2-15) Replace Every 100,000 km
Replace spark plugs (P.2-15) Iridium-tipped Replace Every 100,000 km
type
Check valve clearance*1 6B3 engine Inspection Every 40,000 km
(except vehicles with auto-lash 4N1 engine Inspection Every 60,000 km
adjuster) (P.2-16)
Check radiator hoses for Petrol-powered Inspection Every 40,000 km or every 2 years
damage and proper connection vehicles
(P.2-19) Diesel-powered Inspection Every 20,000 km or every 12 months
vehicles
Check engine coolant level in Petrol-powered Inspection Every 40,000 km or every 2 years
reservoir (P.2-19) vehicles
Diesel-powered Inspection Every 20,000 km or every 12 months
vehicles
Change engine coolant (P.2-19) Change First 200,000 km or 10 years, thereafter
every 120,000 km or 6 years
Check air cleaner element for clogging and Inspection Normal Every 20,000 km or every 12
damage (P.2-22) usage months
usage months
Replace air cleaner element (P.2-22) Replace Normal Every 60,000 km or every 3
usage years
usage
Check fluid level in brake reservoir and clutch Inspection Every 20,000 km or every 12 months
reservoir (P.2-23)
Change brake fluid (P.2-23) Change Every 40,000 km or every 2 years
Check battery condition (P.2-24) Inspection Every 20,000 km or every 12 months
Replace fuel filter (P.2-25) Petrol-powered Replace Every 160,000 km or every 10 years
vehicles
Diesel-powered Replace Every 40,000 km or every 2 years
vehicles

operation
Check suspension system for damage and Inspection Every 20,000 km or every 12 months
looseness (P.2-29)
Check suspension arm ball joints for play, and Inspection Every 20,000 km or every 12 months
dust covers for damage (P.2-30)
Check steering linkage for damage and loose Inspection Every 20,000 km or every 12 months
connections (including seals and boots) (P.2-30)
Lubricate propeller shaft with grease fitting Lubrication Every 20,000 km or every 12 months
(universal joints and sliding sleeve) (P.2-31)
Check driveshaft boots for damage (P.2-31) Inspection Normal Every 20,000 km or every 12
usage months
usage
Check manual transmission for oil leakage Inspection Every 20,000 km or every 12 months
Check transfer for oil leakage Inspection Every 20,000 km or every 12 months
Change gear oil in manual transmission (P.2-32) Change Normal Every 100,000 km
usage
usage
Change gear oil in transfer (P.2-33) Change Normal Every 100,000 km
usage
usage
Check front and rear differential for oil leakage Inspection Every 20,000 km or every 12 months
Change gear oil in front and rear differential Change Normal Every 80,000 km
(P.2-36) usage
usage
Check exhaust pipe connections for gas leakage, Inspection Every 40,000 km or every 2 years
and check pipe installation (P.2-37)
Check brake pedal and clutch pedal for free play Inspection Every 20,000 km or every 12 months
(P.2-37)
Check parking brake lever stroke and play Inspection Every 20,000 km or every 12 months
(P.2-41)
Replace air purifier filter. (P.2-42) Replace Normal Every 20,000 km or every 12
usage months
usage

operation
Check wheel alignment (P.2-42) Inspection Every 20,000 km or every 12 months
Check front and rear wheel bearings for play Inspection Every 60,000 km or every 3 years
(P.2-44)
Check brake hoses and pipes for leakage Inspection Every 20,000 km or every 12 months
(P.2-45)
Check brake pads and discs for wear (P.2-46) Inspection Normal Every 20,000 km or every 12
usage months
usage months
Check brake shoe linings and drums for wear Inspection Normal Every 40,000 km or every 2
(P.2-48) usage years
usage months
Adjust the clearance of the brake shoe linings Adjust Every 20,000 km or every 12 months
(vehicles with electric parking brake) (P.2-49)
Check fuel hoses and pipes for leakage or Inspection Every 40,000 km or every 2 years
deterioration (P.2-49)
Check automatic transmission for fluid leakage Inspection Every 20,000 km or every 12 months
Change automatic transmission fluid (P.2-54) Change Severe Every 100,000 km
usage
Change engine oil (P.2-56) Change Normal Every 20,000 km or every 12
usage months
usage
Replace engine oil filter (P.2-59) Replace Normal Every 20,000 km or every 12
usage months
usage
Check exhaust gas recirculation 6B3 engine Inspection Every 20,000 km or every 12 months
(EGR) system (P.2-61)
OTHERS
Check body condition for damage (P.2-64) Inspection Every year
Check the common rail engine Inspection Every 20,000 km or every 12 months
(small injection quantity learning) (P.2-64)
Road test (P.2-64) Inspection Every 20,000 km or every 12 months
NOTE: *1: If found any noise from the valve any time, please check valve clearance.
"Severe usage" specifications apply to only vehicles used under severe operating conditions.
Severe operating conditions include the following cases:
.
1. Driving in a dusty area or in an area in which the vehicle is likely to be exposed to salty air or brine.
2. Driving on rough roads, on submerged roads, or hilly areas.
3. Driving cold zones.
4. Engine idling for a long time or short-distance travel during cold weather.
5. Frequent, sudden application of brakes.
6. Towing of a trailer.
7. Use as a taxi or as a rent-a-car.
8. More than 50% of operation time in heavy city traffic in hot temperatures of 32C or higher.
9. More than 50% of operation time at speeds of 120 km/h or higher in hot temperatures of 30C or higher.
10. Operation under excessive load.

CHECK DRIVE BELT FOR CRACKS, Alternator drive belt
FRAYING, WEAR, AND ADJUST ITS auto-tensioner
TENSION
M6020202901395
.
DRIVE BELT CONDITION

Check the whole rounds of the V-belt for cracks, fray-
Indicator mark
ing and wear.
<6B3> ALTERNATOR AND OTHERS BELT

TENSION CHECK
CAUTION
Check the alternator and others belt tension after
turning the crankshaft clockwise one turn or MIN belt length MAX belt length
more.
A A
Indicator mark position AC904007AB
1. Make sure that the indicator mark is within the

area marked with A in the illustration.
2. If the mark is out of the area, replace the
alternator and others belt.
NOTE: The drive belt tension adjustment is not
necessary as alternator drive belt auto-tensioner
is adopted.
<4N1> ALTERNATOR DRIVE BELT TEN- Standard value <5-passenger seating>:

SION CHECK Item When When When
checked adjusted replaced
CAUTION
Check the drive belt tension after turning the Vibration 141  181 163  181 191  207
crankshaft clockwise one turn or more. frequency
Hz
Tension N 294  490 392  490 542  640
Deflection 9.9  13.5 9.9  11.5 8.0  9.2
mm
(Reference)
B
Indicator mark Standard value <7-passenger seating>:
Item When When When
checked adjusted replaced
ACE02203AB
Vibration 142  182 163  182 192  208
frequency Hz
Drive belt Tension N 294  490 392  490 542  640
auto-tensioner A Deflection 9.9  13.4 9.9  11.5 8.0  9.2
mm
(Reference)
.
Indicator mark <When the vibration frequency is

measured: Recommendation>
View B ACE02204AB
Belt tension meter set (MB992080)
1. Make sure that the indicator mark is within the
MB992081
2. If the mark is out of the area, replace the drive
belt.
necessary as the drive belt auto-tensioner is
adopted. MB992082
AC507219AB
POWER STEERING OIL PUMP AND A/C
COMPRESSOR DRIVE BELT TENSION 1. Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
CHECK AND ADJUSTMENT
.
(MB992081) of special tool belt tension meter set
DRIVE BELT TENSION CHECK (MB992080).
CAUTION 2. Press the "POWER" button to turn on the power
supply.
 When checking the drive belt tension, make
sure that the engine is cold. 3. Check how the belt tension meter is set.
 Check the drive belt tension after turning the 4. Press "Hz" button twice to change the display to
crankshaft clockwise one turn or more. the frequency display (Hz).
Check the drive belt tension in the following proce-
dure.
CAUTION 6. Press the "MEASURE" button.

 Do not let any contaminants such as water or 7. Gently tap the middle of the drive belt between the
oil get onto the microphone. pulleys (the place indicated by the arrow) with
 If strong gusts of wind blow against the your finger as shown in the illustration.
microphone or if there is loud sources of 8. Check that the vibration frequency of the drive
noise nearby, the values measured by the belt is within the standard value.
microphone may not correspond to actual NOTE: To take the measurement repeatedly, fillip
values. the drive belt again.
 If the microphone is touching the belt while 9. After the completion of the measurement, press
the measurement is being made, the values and hold the "POWER" button to turn off the
measured by the microphone may not corre- power supply.
spond to actual values.
 Do not take the measurement while the vehi- .
cle's engine is running.

<When tension is measured>
Power steering
Power steering
oil pump pulley
oil pump pulley
10 – 15 mm
Gently tap
with your finger
15˚
15˚
Belt tension
MB992080 gauge
A/C compressor
A/C compressor
pulley
pulley ACE02208AB
ACE02207AB
Use a belt tension gauge in the middle of the drive
5. Hold special tool MB992080 to the middle of the belt between the pulleys shown in the figure to check
drive belt between the pulleys (at the place that the drive belt tension is within the standard
indicated by arrow) where it does not contact the value.
drive belt (approximately 10  15 mm away from
the rear surface of the belt) so that it is .
perpendicular to the drive belt (within an angle of

 15).
<When deflection is measured> 5. Use the adjusting bolt to adjust the belt tension to
the standard values.
Power steering 6. Tighten the idler pulley nut.
oil pump pulley
Deflection Tightening torque: 50  2 Nm
7. Tighten the adjusting bolt.
Tightening torque: 5.5  1.5 Nm
CAUTION
When checking the belt tension, turn the crank-
shaft clockwise one turn or more.
8. Check the belt tension, and readjust if necessary.
9. When the belt tension is adjusted by measuring
Approximately
100 N
the deflection, adjust it with a tool for vibration
frequency measurement or tension measurement
afterward.
10.Install the air hose B.
<4D5> ALTERNATOR AND POWER

A/C compressor
pulley
STEERING OIL PUMP DRIVE BELT TEN-
ACE02209AB SION CHECK
Apply approximately 100 N of force to the middle of CAUTION
the drive belt between the pulleys (at the place indi-  When checking the drive belt tension, make
cated by the arrow) and check that the amount of sure that the engine is cold.
deflection is within the standard value.
 Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
DRIVE BELT TENSION ADJUSTMENT
If not within the standard value, adjust the belt ten-
A
sion by the following procedure.
1. Remove the air hose B.
Indicator mark
Auto-tensioner
AC501803 AE
Nut 1. Make sure that the indicator mark is within the

Bolt
ACE02210AB 2. If the mark is out of the area, replace the drive
belt.
2. Loosen the idler pulley nut.
3. Loosen the adjusting bolt. necessary as the drive belt auto-tensioner is
4. Temporarily tighten the idler pulley nut. adopted.
A/C COMPRESSOR DRIVE BELT TEN- 1. Apply approximately 100 N of force to the middle
SION CHECK of the A/C compressor drive belt between the
pulleys (at the place indicated by the arrow) and
NOTE: . check that the amount of deflection is within the
 An elastic stretch-type belt is used for the A/C standard value.
compressor drive belt, therefore, the tension
adjustment is not necessary. Standard value (Reference): 16.2 mm or less
 Perform the A/C compressor drive belt tension 2. If not within the standard value, replace the A/C
check according to the following procedures. compressor drive belt.
.
<When the tension is measured>

CHECK VACUUM PUMP OIL HOSE FOR
CAUTION
DAMAGE <4D5>
 When measuring the tension, make sure that M6020200400324
the engine is cold.
 Measure the tension after turning the crank-
shaft clockwise one turn or more. Vacuum pump
Belt tension
gauge
Oil hose
ACF03437AB
Crankshaft A/C compressor

1. Inspect the surface of hose for evidence of heat
pulley pulley ACE01742AB
and mechanical damage.
1. Use a belt tension gauge in the middle of the A/C CHECK INTAKE AIR HOSE AND
compressor drive belt between the pulleys shown
TURBOCHARGER OIL HOSE FOR
in the figure (at the place indicated by the arrow)
to check that the drive belt tension is within the DAMAGE
standard value. (VEHICLES WITH TURBOCHARGER)
M6020200500677
Standard value (Reference): 190  908 N
2. If not within the standard value, replace the A/C
compressor drive belt.
.
Turbocharger
<When the deflection is measured>
CAUTION
 When measuring the deflection, make sure
that the engine is cold.
 Measure the deflection after turning the
AC305652 AB
crankshaft clockwise one turn or more.
Approximately
1. Inspect the intake air hoses for cracks or dam-
100 N age.
Deflection 2. Inspect the turbocharger oil hoses for cracks or
damage.
Crankshaft A/C compressor

pulley pulley ACE01743AB
REPLACE ENGINE TIMING BELT  2. Remove the PCV valve from the rocker cover.
(except vehicles with timing chain) 3. Reinstall the PCV valve at the ventilation hose.
M6020200600607
4. Start the engine and run at idle.
For information concerning the replacement proce-
dures, refer to the Workshop Manual.
PCV valve
CHECK OPERATION OF CRANKCASE
EMISSION CONTROL SYSTEM
M6020200701038
.
BREATHER HOSE
Ventilation hose
AC305653 AB
5. Place finger at the opening of the PCV valve and

check that vacuum of the intake manifold is felt.
NOTE: At this moment, the plunger in the PCV
valve moves back and forth.
Breather hose 6. If vacuum is not felt, clean the PCV valve or
ACE01985 AB replace it.
.
1. Inspect the breather hose for cracks or damage.

PCV VALVE CHECK
2. Clean the inside of the breather hose if necessary.
3. Inspect the ventilation filter for clogging.
.
VENTILATION HOSE
PCV valve
1. Check entire circumference and length of hoses
using a mirror as required.
2. Check all clamps for tightness and the
connections for leakage.
3. Hoses should be replaced immediately if there is
AC305654 AB
any evidence of deterioration or damage.
. 1. Insert a thin rod into the PCV valve from the side
POSITIVE CRANKCASE VENTILATION shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
SYSTEM CHECK that the plunger moves.
2. If the plunger does not move, there is clogging in
PCV valve the PCV valve. In this case, clean or replace the
PCV valve.
REPLACE SPARK PLUGS

M6020200800838
After removing old spark plugs, install new ones and
tighten them at the specified torque.
ACE01986 AB
1. Remove the ventilation hose from the PCV

(Positive crankcase ventilation) valve.
CHECK VALVE CLEARANCE (EXCEPT 4. Valve clearance inspection and adjustment can be
VEHICLES WITH AUTO-LASH performed on rocker arms indicated by white
arrow mark when the No. 1 cylinder piston is at
ADJUSTER)
M6020202401390 the top dead centre on the compression stroke,
<6B3, Inlet valve> and on rocker arms indicated by black arrow mark
when the No. 4 cylinder piston is at the top dead
NOTE: Perform the valve clearance check and centre on the compression stroke.
adjustment at the engine cold state.
NOTE: If the rocker arm of No. 6 cylinder at the
NOTE: Valve clearance check and adjustment is inlet side is moved up and down and the rocker
unnecessary for exhaust side due to auto lash arm is moved, No. 1 cylinder is at top dead centre
adjuster installed. on compression stroke. If the rocker arm of No. 6
1. Remove all ignition coils. cylinder at the inlet side is moved up and down
2. Remove the rocker cover. and the rocker arm is not moved, No. 4 cylinder is
Power
at top dead centre on compression stroke.
Timing indicator
steering 5. Measure the valve clearance for inlet side.
pump
Notch pulley If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance
using a thickness gauge while turning the
adjusting screw.
Standard value (cold engine):
Alternator Inlet valve: 0.10 mm
pulley
Crankshaft pulley AK900838 AB
3. Turn the crankshaft clockwise until the notch on

the crankshaft pulley is lined up with the "T" mark
on the timing indicator.
Exhaust side
Right bank
AK603276
6. While holding the adjusting screw with a

screwdriver to prevent it from turning, tighten the
lock nut to the specified torque.
No. 1 No. 3 No. 5 Tightening torque: 9  1 Nm
Inlet side
7. Turn the crankshaft through 360 degree angle to
No. 2 No. 4 No. 6 line up the notch on the crankshaft pulley with the
"T" mark on the timing indicator.
8. Repeat steps 5 and 6 on other valves for
clearance adjustment.
9. Install the rocker cover.
10.Install the ignition coils.
Left bank Exhaust side

AK603275AF
<4N1> <Inlet side>

NOTE: The valve clearance check and adjustment
should be done when the engine is cold.
1. Remove the rocker cover. MB991477
CAUTION
The crankshaft should always be turned in a
clockwise direction.
Camshaft sprocket Thickness gauge

AK802488AB
<Exhaust side>
MB992046
Timing marks
AK802487AB
2. Align the camshaft sprocket timing marks and set

the No. 1 cylinder at top dead centre. Thickness gauge AK802489AB
Engine front 5. While holding the adjusting screw with a

lock nut to the specified torque using the special
tool, valve adjusting socket.
Special tool (valve adjusting socket):
Inlet side: MB991477
Exhaust side: MB992046
Tightening torque:
ACE02391AB Inlet side: 9.0  1.0 Nm
Exhaust side: 9.8  1.0 Nm
3. By using the thickness gauge, respectively
measure the clearance between the cam at the 6. Turn the crankshaft 360 clockwise to bring No. 4
portion marked with the arrow and the roller, as cylinder to the top dead centre position.
shown in the illustration. Engine front
Inlet valve: 0.08  0.03 mm
Exhaust valve: 0.16  0.03 mm
4. If the valve clearance is not as specified, loosen
using a thickness gauge between the cam and the
roller while turning the adjusting screw.
CAUTION ACE02391AC
Pay special attention that the tightening torque is
not beyond this valve. If the tightening torque is 7. Respectively measure the clearance at the
beyond the valve, the valve stem would possibly portion marked with the arrow, according to step
bend. 3.
8. If the clearance is not within the standard value,
repeat steps 4 and 5 above.
<4D5> CAUTION
NOTE: The valve clearance check and adjustment Pay special attention that the tightening torque is
should be done when the engine is cold. not beyond this valve. If the tightening torque is
beyond the valve, the valve stem would possibly
CAUTION
bend.
Leaked fuel on parts causes a decrease in func-
tion and burning. Therefore, Place waste to
absorb leaked fuel.
1. Remove the rocker cover.
CAUTION MB992046
The crankshaft should always be turned in a
clockwise direction.
Thickness gauge
Timing marks
Camshaft AK500381 AC
sprocket
4. While holding the adjusting screw with a
lock nut to the specified torque using a valve
adjusting socket (MB992046).
Tightening torque: 15  3 Nm
5. Turn the crankshaft 360 clockwise to bring No. 4
cylinder to the top dead centre position.
Timing marks Exhaust valve side
Crankshaft
pulley
AK500379 AB
2. Align the camshaft sprocket timing marks and set

Inlet valve side AK500380 AE
the No. 1 cylinder at top dead centre.
Exhaust valve side 6. Measure the valve clearances at the places
indicated by arrows in the illustration. If the
clearance is not within the standard value, repeat
steps 3 and 4 above.
Inlet valve side AK500380 AD
3. Measure the valve clearance.

If the valve clearance is not as specified, loosen
using a thickness gauge between the cam shaft
and the roller while turning the adjusting screw.
Inlet valve: 0.09 mm
Exhaust valve: 0.14 mm
CHECK RADIATOR HOSES FOR CHANGE ENGINE COOLANT

M6020201102515
DAMAGE AND PROPER CONNECTION
M6020200901366 <6B3>
1. Remove the under skid plate.
2. Remove the air cleaner assembly.
WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the radiator cap and
turn the radiator cap anti-clockwise a little to
let the pressure escape through the vinyl
ACE01987 AB tube. After relieving the steam pressure,
remove the radiator cap by slowly turning it
1. Check entire circumference and length of hoses, anti-clockwise.
using a mirror as required.
3. Drain the engine coolant from the radiator, heater
2. Check that hoses installed in grommets pass
core and engine after unplugging the radiator
through the centre of the grommets.
drain plug and removing the radiator cap.
3. Check all clamps for tightness and connections
4. Securely tighten the drain plug of the radiator.
for leakage.
<Left bank>
CHECK ENGINE COOLANT LEVEL IN
RESERVOIR
M6020201001311
29 ± 5 N·m
Power steering
oil pump
AC903246AB
<Right bank>
ACE01989
Check that the coolant level is between the "FULL"

and "LOW" lines when the engine is at the normal
operating temperature.
140 ± 5 N·m
Alternator
AC903247AB
5. Drain the engine coolant in the water jacket by

unplugging the cylinder block drain plug.
6. Remove the headlamp assembly RH.
7. Remove the condenser tank assembly and drain
the coolant.
8. Reinstall the condenser tank assembly.
9. Install the headlamp assembly RH.
10.Install the cylinder block drain plug and new 14.After repeatedly revving the engine up to 3,000
gasket, and then tighten the cylinder block drain r/min several times, then stop the engine.
plug to the specified torque. 15.Remove the radiator cap after the engine has
Tightening torque: become cold, and pour in coolant up to the brim.
<Left bank> 29  5 Nm Reinstall the cap.
<Right bank> 140  5 Nm CAUTION
CAUTION Do not overfill the condenser tank.
 Do not use alcohol or methanol anti-freeze or 16.Add engine coolant to the condenser tank
any engine coolants mixed with alcohol or between the "F" and "L" mark if necessary.
methanol anti-freeze. The use of an improper 17.Install the air cleaner assembly <4WD>.
anti-freeze can cause corrosion of the alumin-
18.Install the under skid plate.
ium components.
 Use the MITSUBISHI MOTORS GENUINE
<4N1>
SUPER LONG LIFE COOLANT PREMIUM with-
out adding water because the concentration 1. Remove the under skid plate.
is preadjusted to 50%. WARNING
MB991871 Place a shop towel over the radiator cap and
turn the radiator cap anti-clockwise a little to
let the pressure escape through the vinyl
tube. After relieving the steam pressure,
remove the radiator cap by slowly turning it
anti-clockwise.
2. Remove the radiator drain plug to drain the
AC503144AB
engine coolant.
11.Use special tool LLC changer (MB991871) to refill 3. Securely tighten the drain plug of the radiator.
the engine coolant up to the top of the radiator 4. Disconnect water hose I from the engine oil
port. cooler.
Recommended antifreeze: MITSUBISHI 5. Air-blow the system to drain the engine coolant
MOTORS GENUINE SUPER LONG LIFE through the radiator cap.
COOLANT PREMIUM or equivalent* 6. Connect water hose I from the engine oil cooler.
NOTE: *similar high quality ethylene glycol 7. Remove the thermostat.
based non-silicate, non-amine, non-nitrate
8. Air-blow the system to drain the engine coolant
and non-borate coolant with long life hybrid
through the radiator cap.
organic acid technology
Quantity (Includes volume inside condense 9. Install the thermostat.
tank): 9.0 L 10.Disconnect the radiator condenser tank hose the
NOTE: For how to use special tool MB991871, radiator.
refer to its manufacturer’s instructions. 11.Suspend the radiator condenser tank hose
12.Reinstall the radiator cap. downwards to drain the tank.
13.Start the engine and let it warm up until the 12.Connect the radiator condenser tank hose.
thermostat opens.
CAUTION CAUTION
 Do not use alcohol or methanol anti-freeze or Do not overfill the condenser tank.
any engine coolants mixed with alcohol or 18.Add engine coolant to the condenser tank
methanol anti-freeze. The use of an improper between the "F" and "L" mark if necessary.
anti-freeze can cause corrosion of the alumin-
19.Install the under skid plate.
ium components.
 Use the MITSUBISHI MOTORS GENUINE
<4D5>
SUPER LONG LIFE COOLANT PREMIUM with-
out adding water because the concentration 1. Remove the under skid plate.
is preadjusted to 50%. WARNING
MB991871 Place a shop towel over the cap and turn the
cap anti-clockwise a little to let the pressure
escape through the vinyl tube. After relieving
the steam pressure, remove the cap by
slowly turning it anti-clockwise.
2. Drain the engine coolant from the radiator, heater
core and engine after unplugging the radiator
AC503144AB
drain plug and removing the radiator cap.
13.Use special tool LLC changer (MB991871) to refill
the engine coolant up to the top of the radiator
port. Engine oil cooler
Recommended antifreeze: MITSUBISHI
MOTORS GENUINE SUPER LONG LIFE
COOLANT PREMIUM or equivalent*
NOTE: *similar high quality ethylene glycol Water hose
based non-silicate, non-amine, non-nitrate Alternator
and non-borate coolant with long life hybrid
organic acid technology AC503674AC
Quantity (Includes volume inside condense
3. Drain the engine coolant in the water jacket by
tank): 7.7 L
disconnect the engine oil cooler water hose.
NOTE: For how to use special tool MB991871,
4. Remove the headlamp assembly RH.
refer to its manufacturer’s instructions.
5. Remove the condenser tank assembly and drain
14.Reinstall the radiator cap.
the engine coolant.
15.Start the engine and let it warm up until the
6. Reinstall the condenser tank assembly.
thermostat opens.
7. Install the headlamp assembly RH.
16.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine. 8. Drain the engine coolant then clean the path of
the engine coolant by injecting water into the
17.Remove the radiator cap after the engine has
radiator from the radiator cap area.
become cold, and pour in coolant up to the brim.
Reinstall the cap. 9. Connect the engine oil cooler water hose.
10.Securely tighten the drain plug of the radiator.
CAUTION CHECK AIR CLEANER ELEMENT FOR

Do not use alcohol or methanol anti-freeze or any CLOGGING AND DAMAGE
engine coolants mixed with alcohol or methanol M6020201201058
anti-freeze. The use of an improper anti-freeze

can cause corrosion of the aluminium compo-
nents.
MB991871
AC502427
1. Check air cleaner element for clogging and

damage.
AC503144AB
2. Clean deposited dust from the element in the
11.Use special tool LLC changer (MB991871) to refill following manner.
the engine coolant up to the top of the radiator (1) Lightly tap the element against the top of a
port. bench.
Recommended antifreeze: MITSUBISHI (2) Blow compressed air from inside the element.
MOTORS GENUINE SUPER LONG LIFE 3. Wipe off dust on the air cleaner interior.
COOLANT or equivalent 4. Install the air cleaner body.
Quantity (Includes volume inside condense
tank): 8.2 L REPLACE AIR CLEANER ELEMENT
NOTE: For how to use special tool MB991871, M6020201301215
refer to its manufacturer’s instructions. The air cleaner element will become dirty and loaded
with dust during use, and the filtering effect will be
12.Reinstall the radiator cap.
substantially reduced. Replace it with a new one.
13.Start the engine and let it warm up until the
thermostat opens.
14.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
15.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
Do not overfill the condenser tank.
ACE01988
16.Add engine coolant to the condenser tank
between the "F" and "L" mark if necessary. 1. Unclasp the air cleaner cover clip.
17.Install the under skid plate. 2. Remove the air cleaner element and install a new
one.
3. Be sure to close the air cleaner cover completely
when clamping it.
CHECK FLUID LEVEL IN BRAKE CAUTION

RESERVOIR AND CLUTCH RESERVOIR If the reservoir tank completely runs out of fluid
M6020203000541 during operation, air will find way into the brake
<BRAKE> line. Pay attention, therefore, to the fluid level
and replenish as necessary.
2. Loosen the bleeder screw and depress the brake
pedal; supply new brake fluid when the level of
the fluid within the reservoir tank decreases.
Specified brake fluid: DOT3 or DOT4
CAUTION
Use the specified brake fluid. Avoid using a mix-
ACE01990 AB ture of the specified brake fluid and other fluid. If
brake fluid is exposed to the air, it will absorb
<CLUTCH> moisture; as water is absorbed from the atmos-
phere, the boiling point of the brake fluid will
decrease and the braking performance will be
seriously impaired. For this reason use a hermet-
ically sealed 1 L or 0.5 L brake fluid container.
Firmly close the cap of the brake fluid container
after use.
3. When fresh fluid has come to flow out from the
vinyl tube, tighten the bleeder screw.
ACE01991 AB
NOTE: This change from existing to fresh fluid
1. Check that the fluid level is between the "MAX" can be judged by change in colour of fluid that
and "MIN" mark. flows out.
2. If it is below the "MIN" marks, replenish with fresh
brake fluid up to the "MAX" mark. 4 2
Specified brake fluid: DOT 3 or DOT 4
CHANGE BRAKE FLUID

M6020201601432
CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix
the specified brake fluid with other fluid as it will 3 1
influence the braking performance significantly. ACF01563 AB
4. Repeat above steps for other bleeder screws.
AC305659
1. Remove the cap of the bleeder screw, connect a

vinyl tube, and place its other end in a receptacle.
CHECK BATTERY CONDITION 2. Use a specific gravity meter and a thermometer to

M6020203100582 measure the specific gravity.
FLUID LEVEL AND SPECIFIC GRAVITY Standard value: 1.220  1.290 (electrolyte
CHECK temperature 20C)
CAUTION The specific gravity of the battery electrolyte
 If the battery is used with the electrolyte level changes according to the temperature, so the spe-
below the LOWER LEVEL indicator, there is cific gravity when the electrolyte is at a temperature
the danger that explosions may occur, so add of 20C can be calculated using the following for-
water to the battery until the electrolyte level mula. Use the converted value to judge whether the
is between the LOWER LEVEL and UPPER electrolyte is okay or not.
LEVEL indications. D20 = (t  20)  0.0007 + Dt
 If too much water is added to make the level
D20: Specific gravity converted to a value for
rise above the UPPER LEVEL indication, the
electrolyte may leak out, so adjust so that the electrolyte temperature of 20C
electrolyte level is between the LOWER t: Electrolyte temperature at the time of
LEVEL and UPPER LEVEL indications. measurement
Dt: Actual specific gravity
OK
Thermometer
Specific
gravity meter
AC102027AB
1. Check that the battery electrolyte level is between

the UPPER LEVEL and LOWER LEVEL
indications.
REPLACE FUEL FILTER

M6020201901819
<4N1, 4D5>
Post-installation Operation
 Evacuation of Air from Fuel Line.
N 2
N 3
ACE01405AB
Fuel filter removal steps Fuel filter removal steps

<<A>> >>A<< 1. Fuel filter cap 2. Fuel filter and O-ring
3. O-ring
REMOVAL SERVICE POINTS FUEL PUMP AND GAUGE ASSEMBLY

.
<<A>> FUEL FILTER CAP REMOVAL REMOVAL AND INSTALLATION <6B3>

1. Reduce Pressurized Fuel Lines.
1. Loosen the drain plug to drain the fuel. Then,
tighten the drain plug. 2. Remove the second seat assembly, rear scuff
plate (LH) and turn up the floor carpet.
Floor inspection lid
Fastener
nut
ACB01912 AB
AC800981AB
2. Insert a flat-tipped screwdriver into the groove of
the fastener nut. 3. Remove the floor inspection lid.
3. Loosen the fastener nut using the flat-tipped Fuel Fuel pump
screwdriver until it can be loosened by hand. high-pressure and gauge
hose assembly
connector
INSTALLATION SERVICE POINTS
.
>>A<< FUEL FILTER CAP INSTALLATION Vapour

hose
AC806807AC
4. Disconnect the fuel pump and gauge assembly

connector and the fuel high-pressure hose.
ACE01406
1. Install the fuel filter cap by aligning the marks on

the fuel filter cap and the fuel filter case.
Mark
AC806808 AC
OPEN
5. Remove the fuel pump and gauge assembly

mounting nuts.
ACE01407AB
2. Securely tighten the fastener nut until the mark is

in the position shown in the figure (until it clicks in
place).
CAUTION 9. Tighten the fuel pump and gauge assembly

Pay attention not to damage the fuel gauge unit mounting nuts to the specified torque.
and float of the fuel pump and gauge assembly Tightening torque: 2.5  0.5 Nm
when removing the fuel pump and gauge assem-
CAUTION
bly from the fuel tank.
After connecting the fuel high-pressure hose,
6. Remove the retainer plate and the fuel pump and slightly pull it to ensure that it is installed
gauge assembly from service hole. securely. Also confirm that there is a play
NOTE: When disassembling and reassembling approximately 3 mm.
the fuel pump and gauge assembly, refer to the 10.Connect the fuel pump and gauge assembly
next section "DISASSEMBLY AND REASSEM- connector and the fuel high-pressure hose.
BLY <6B3>".
11.Install the floor inspection lid.
7. Replace the fuel pump and gauge assembly
12.Return the floor carpet to the original condition.
packing with a new one.
13.Install the rear scuff plate (LH) and second seat
CAUTION assembly.
 Pay attention not to damage the fuel gauge
unit and the float of the fuel pump and gauge
assembly when installing it to the fuel tank.
 When installing the fuel pump and gauge
assembly to the fuel tank, check that the fuel
gauge unit moving area moves smoothly.
8. Install the fuel pump and gauge assembly and the
retainer plate from service hole.
DISASSEMBLY AND REASSEMBLY <6B3>

FUEL PUMP AND GAUGE ASSEMBLY
14
4 N
N 15 8 N
11 N
9 N 12 N
1
13 N
10
7
3
6N
N 2
ACF00384 AB
Disassembly steps Disassembly steps

1. Fuel gauge unit >>A<< 12. O-ring
2. Clip 13. Spacer
3. Sub tank assembly 14. Bracket
4. Spring 15. Fuel flange and filter assembly
5. Fuel pump wiring harness
6. Fuel filter REASSEMBLY SERVICE POINT
7. Fuel pump assembly .
>>A<< 8. O-ring >>A<< O-RING INSTALLATION

9. Spacer To avoid twisting and damage, apply gasoline before
10. Fuel pressure regulator installation of the O-ring.
>>A<< 11. O-ring

CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS
M6020300100847
1. Check each portion of suspension for damage 2. Check each installation bolt and nut for looseness
visually. by spanner or similar tool.
FRONT SUSPENSION
Deterioration
and sagging
Noise and
oil leakage
Cracks, bends
and dents
Bends and
damage
Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Bends and
damage
Deterioration
and sagging
Cracks, bends
and dents
AC801750 AB
CHECK SUSPENSION ARM BALL JOINTS 4. If the upper arm ball joint cover is cracked or
FOR PLAY, AND DUST COVERS FOR damaged, replace the upper arm ball joint
assembly.
DAMAGE
M6020300200651 NOTE: If the upper arm ball joint cover is cracked
or damaged, it is possible that there may also be
.
BALL JOINTS FOR PLAY

damage to the ball joint.
CHECK STEERING LINKAGE FOR

DAMAGE AND LOOSE CONNECTIONS
(INCLUDING SEALS AND BOOTS)
M6020300500704
AC502481
1. With the vehicle unladen, check the top end of

tyre for the amount of movement.
2. Remove the stabilizer link from the lower arm.
3. Jack up the lower arm and move the bottom of
AC305662
tyre to check the amount of movement.
1. Move the steering wheel bit by bit to the left or
.
DUST COVERS FOR DAMAGE right, and check to be sure that there is no play or
looseness in the linkage coupling, that the
installation is not loose, and that the rod or arm is
not bent or damaged.
AC508161AB
1. Press the lower arm ball joint cover with your

finger to check that there are no cracks or AC508162AB
damage in the lower arm ball joint cover.
2. If the lower arm ball joint cover is cracked or 2. Check to be sure that the seal and boot of the ball
damaged, replace the lower arm ball joint joint are correctly installed (in the correct
assembly. position), and that they are not damaged.
NOTE: If the lower arm ball joint cover is cracked 3. Check tie-rod end lock nut for looseness. If lock
or damaged, it is possible that there may also be nut is loose, adjust toe-in and then tighten lock nut
damage to the ball joint. to the specified torque.
3. Press the upper arm ball joint cover with your Tightening torque: 93  15 Nm
finger to check that there are no cracks or
damage in the upper arm ball joint cover.
LUBRICATE PROPELLER SHAFT WITH TRANSMISSION OIL LEVEL CHECK

GREASE FITTING (UNIVERSAL JOINTS <R5MB1, V5MB1>
AND SLIDING SLEEVE) Filler plug
M6020301300093
Drain plug
AC502641AF
<R6M5A, V6M5A>
AC503034AB
Fill the multi-purpose grease fitting of the propeller

shaft joints.
Filler plug
CHECK DRIVESHAFT BOOTS FOR
DAMAGE
M6020300400622
Drain plug ACE01621AB
Filler plug hole
Gasket
Filler plug
AC305661
Transmission oil
Check the driveshaft boots for damage. AC700330AL
CHECK MANUAL TRANSMISSION FOR 1. Remove the filler plug and gasket.
OIL LEAKAGE 2. Check that the oil level is up to the lower edge of
the filler plug hole.
(IN CASE OF LEAKAGE, CHECK THE OIL
3. Check that the oil is not noticeably dirty.
LEVEL)
M6020302300706 4. Install the filler plug and new gasket, then tighten
.
them to the specified torque.
CHECK OIL LEAKAGE
Tightening torque:
Check the transmission case for oil leakage visually 37  11 Nm <R5MB1, V5MB1>
or by touching it with hand. 32  2 Nm <R6M5A, V6M5A>
NOTE: If an oil leakage is not detected, the oil level
check is necessary.
CHECK TRANSFER FOR OIL LEAKAGE 4. Install the filler plug and new gasket, then tighten
(IN CASE OF LEAKAGE, CHECK THE OIL them to the specified torque.
LEVEL) Tightening torque:
M6020302400662 32  2 Nm <V5MB1>
37  11 Nm <V6M5A, V5AWF, V8AWG>
.
CHECK OIL LEAKAGE

Check the transfer case for oil leakage visually or by
touching it with hand. CHANGE GEAR OIL IN MANUAL
NOTE: If an oil leakage is not detected, the oil level TRANSMISSION
M6020300801377
check is necessary.
<R5MB1, V5MB1>
TRANSFER OIL LEVEL CHECK <R5MB1, V5MB1>
Filler plug
<V5MB1>
Filler plug Drain plug
Drain plug
AC502641AF
AC502640AD
Filler plug hole

<V6M5A>
Gasket
Filler plug
Transmission oil
AC700330AL
Filler plug
Drain plug ACE01619AB 1. Remove the filler plug and gasket.
2. Remove the drain plug and gasket, and then drain
Filler plug hole
the oil.
3. Install the drain plug and new gasket, then tighten
Gasket
4. Fill with gear oil MITSUBISHI MOTORS
GENUINE MTF API classification GL-3 SAE
Filler plug
75W-85 until the level comes to the lower portion
Transfer oil of filler plug hole.
AC700330AM
Quantity:
1. Remove the filler plug and gasket. 2.3 L <R5MB1>
2. Check that the oil level is up to the lower edge of 3.4 L <V5MB1>
the filler plug hole. 5. Install the filler plug and new gasket, then tighten
3. Check that the oil is not noticeably dirty. them to the specified torque.
<R6M5A, V6M5A> CHANGE GEAR OIL IN TRANSFER

M6020302600860
<R6M5A, V6M5A> <V5MB1>
<V5MB1>
Filler plug
Filler plug
Drain plug
AC502640AD
Filler plug hole
Gasket
Filler plug hole
Gasket
Filler plug
Transmission oil
AC700330AL
Filler plug
Transfer oil
1. Remove the filler plug and gasket. AC700330AM
2. Remove the drain plug and gasket, and then drain
the oil. 1. Remove the filler plug and gasket.
3. Install the drain plug and new gasket, then tighten 2. Remove the drain plug and gasket, and then drain
them to the specified torque. the oil.
Tightening torque: 32  2 Nm 3. Install the drain plug and new gasket, then tighten
4. Fill with gear oil MITSUBISHI MOTORS
GENUINE NEW MULTI GEAR OIL ECO API
classification GL-4, SAE 75W-80 until the level 4. Fill with gear oil MITSUBISHI MOTORS
comes to the lower portion of filler plug hole. GENUINE MTF API classification GL-3 SAE
Quantity: 2.2 L 75W-85 or MITSUBISHI MOTORS GENUINE
Multi Gear Oil API classification GL-4 SAE
5. Install the filler plug and new gasket, then tighten 75W-85 until the level comes to the lower portion
them to the specified torque. of filler plug hole.
Tightening torque: 32  2 Nm Quantity: 2.5 L
5. Install the filler plug and new gasket, then tighten
<V6M5A, V5AWF, V8AWG> CHECK FRONT AND REAR

<V6M5A> DIFFERENTIAL FOR OIL LEAKAGE
(IN CASE OF LEAKAGE, CHECK THE OIL
LEVEL)
M6020301000672
CHECK OIL LEAKAGE

.
Check the area around the differential for oil leakage

visually or by touching it with hand.
Filler plug NOTE: If an oil leakage is detected, the oil level
Drain plug ACE01619AB check is necessary.
CHECK OIL LEVEL

Filler plug hole FRONT DIFFERENTIAL
Gasket
Filler plug
Filler plug
Transfer oil
AC700330AM
1. Remove the filler plug and gasket.

2. Remove the drain plug and gasket, and then drain Drain plug ACE02535AB
the oil.
1. Remove the under cover, filler plug and gasket.
3. Install the drain plug and new gasket, then tighten
Tightening torque: 37  11 Nm Filler plug hole
4. Fill with gear oil MITSUBISHI MOTORS Gear oil Gasket

GENUINE NEW MULTI GEAR OIL ECO API
classification GL-4, SAE 75W-80 until the level
Upper
comes to the lower portion of filler plug hole. limit
Quantity: 1.34 L Lower Oil filler plug
limit
5. Install the filler plug and new gasket, then tighten 8 mm
them to the specified torque. AC700330 BS
Tightening torque: 37  11 Nm 2. Check that the oil level is in between the upper
limit (bottom of the filler plug hole) and the lower
limit as shown.
3. If the oil level is not in between the upper limit and
the lower limit, refill the specified oil to the bottom
of the oil filler plug hole.
Specified gear oil:
Mitsubishi Motors Genuine Super Hypoid
Gear Oil ECOLOGY API GL-5 SAE 80
4. Install the filler plug and new gasket, and tighten
to the specified torque.
5. Install the under cover.
REAR DIFFERENTIAL Vehicle is standing on wheels

.
Vehicle is lifted (not standing on wheels)
Filler plug
and gasket
Filler plug
and gasket ACE02541AC
ACE02541AC 1. Remove the filler plug and gasket.
Inspection tool
Inspection tool Oil level
A A
Oil level
Bottom edge of
the filler plug hole
Bottom edge
of the filler ACF02558 AB
plug hole
ACF00651AB 2. Insert an inspection tool as shown so that it
touches the bottom of the filler plug. The
2. Insert an inspection tool as shown so that it inspection tool: 10 mm-diameter L shaped bar
touches the bottom of the filler plug. The (e.g. 10 mm-diameter angled hexagon wrench).
inspection tool: 10 mm-diameter L shaped bar
3. Remove the inspection tool, and then check that
(e.g. 10 mm-diameter angled hexagon wrench).
dimension A (between the bottom edge and the
3. Remove the inspection tool, and then check that oil level) conforms to the table below.
dimension A (between the bottom edge and the
oil level) conforms to the table below. Item Dimension A
Item Dimension A Size and number of M10  10 Within 30 mm

the nuts securing M10  12 Within 38 mm
Size and number of M10  10 Within 19 mm the differential
the nuts securing M10  12 Within 27 mm carrier assembly
the differential
carrier assembly 4. Install the filler plug and new gasket, then tighten
.
CHANGE GEAR OIL IN FRONT AND Rear differential

REAR DIFFERENTIAL .
Vehicle is lifted (not standing on wheels)

M6020301100958
Front differential
Filler plug
Drain plug
and gasket
Filler plug
and gasket
ACE02541AB

1. Remove the under cover, filler plug and gasket. 2. Remove the drain plug and gasket, and drain the
2. Remove the drain plug and gasket, to drain the oil.
oil. 3. Tighten the drain plug and new gasket, to the
3. Install the drain plug and new gasket, and tighten specified torque.
to the specified torque. Tightening torque: 60  10 Nm
Inspection tool
Filler plug hole A
Oil level
Gasket
Bottom edge
of the filler
Filler plug plug hole
ACF00651AB
Gear oil
AC700330BR
4. Fill the Mitsubishi Motors Genuine Super Hypoid
4. Add the oil until the level comes to the lower Gear Oil ECOLOGY API GL-5 SAE 80 until the
portion of the filler plug hole. level satisfies the specification.
Specified gear oil: Item Dimension A
Mitsubishi Motors Genuine Super Hypoid Gear Size and number of M10  10 Within 19 mm
Oil ECOLOGY API GL-5 SAE 80 the nuts securing M10  12 Within 27 mm
Amount to use: 1.2 L the differential
5. Install the filler plug and new gasket, and tighten carrier assembly
to the specified torque. Specified gear oil:
Tightening torque: 50  10 Nm Mitsubishi Motors Genuine Super Hypoid Gear
6. Install the under cover. Oil ECOLOGY API GL-5 SAE 80
Amount to use: 2.1 L
.
Vehicle is standing on wheels 4. Fill the Mitsubishi Motors Genuine Super Hypoid
Gear Oil ECOLOGY API GL-5 SAE 80 until the
level satisfies the specification.
Item Dimension A
Size and number of M10  10 Within 30 mm
Drain plug the nuts securing M10  12 Within 38 mm
and gasket the differential
carrier assembly
Filler plug
and gasket Specified gear oil:
Mitsubishi Motors Genuine Super Hypoid Gear
ACE02541AB
Oil ECOLOGY API GL-5 SAE 80
1. Remove the filler plug and gasket. Amount to use: 2.1 L
2. Remove the drain plug and gasket, and drain the 5. Install the filler plug and new gasket, then tighten
oil. them to the specified torque.
3. Tighten the drain plug and new gasket, to the Tightening torque: 50  10 Nm
specified torque.
Tightening torque: 60  10 Nm CHECK EXHAUST PIPE CONNECTIONS
FOR GAS LEAKAGE, AND CHECK PIPE
INSTALLATION
M6020301200966
Inspection tool 1. Confirm that the exhaust pipe does not interfere
Oil level
A with any body components.
2. Check the exhaust pipe for damage by stones,
etc.
Bottom edge of 3. Start the engine and check for gas leaks from the
the filler plug hole exhaust pipe connections.
ACF02558 AB

CHECK BRAKE PEDAL AND CLUTCH BRAKE PEDAL FREE PLAY
PEDAL FOR FREE PLAY
M6020400101557
BRAKE PEDAL CHECK AND ADJUST-

MENT
.
CAUTION
Do not apply grease or lubricant to the switch
and the switch installation section to avoid mal-
function of the switch. In addition, do not use C
gloves which have grease on them. ACE01167AC
.
1. Turn the ignition switch to the "LOCK" (OFF)

position, depress the brake pedal two or three
times. After eliminating the vacuum in the brake
booster, press the pedal down by hand, and
confirm that the amount of movement before
resistance is met (free play) is within the standard
value range.
Standard value (C): 3  8 mm
2. If the brake pedal play is not within the standard (3) Loosen the lock nut of operating rod, then turn
value, check the following, and adjust or replace if the serrated section of operating rod using the
necessary: pliers to adjust the brake pedal height to the
 Excessive play between the brake pedal and the standard value.
clevis pin, or between the clevis pin and the Tightening torque: 26  4 Nm
brake booster operating rod
NOTE: After adjust the brake pedal height,
 Brake pedal height
tighten the lock nut of operating rod with hold-
 Installation position of the stop lamp switch, etc.
ing the serrated section of operating rod by
.
using the pliers.
BRAKE PEDAL HEIGHT
Stop lamp switch
Pedal
stopper
Pedal pad
A
Retainer
ACE01777AB
ACE01776AB
(4) Press in the stop lamp switch until the thread
1. Check that shown distance "A" meets the section of stop lamp switch comes in contact
standard value. with the pedal stopper. Then, secure the stop
Standard value (A): 208.6  214.6 mm lamp switch by turning it clockwise by
(From the surface of retainer to the face of approximately 1/8 turn. While doing this, pull
pedal pad) and hold the brake pedal by hand.
(5) Check that the clearance between the stop
2. When the brake pedal height is not within the lamp switch and the pedal stopper is as shown
standard value, adjust the brake pedal in the in the figure.
following procedure.
Standard value (B): 0.5  1.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it CAUTION
anti-clockwise by approximately 1/8 turn. Make sure that the stop lamp is not illuminated
when the brake pedal is not depressed.
(6) Connect the stop lamp switch connector.
.
Lock nut
(26 ± 4 N·m)
AC706513AC
CLEARANCE BETWEEN BRAKE PEDAL CLUTCH PEDAL CHECK AND ADJUST-

AND RETAINER MENT
1. Turn up the carpet, etc. under the brake pedal. 1. Turn back the carpet etc. under the clutch pedal.
Clutch pedal clevis pin playAC709695
Clutch pedal
Stopper
A
ACE02958 AC
Pedal pad
2. Measure the clutch pedal clevis pin play (A). If the
play is outside the standard value, go to Step 3.
Standard value (A): 1  3 mm
3. Remove the clutch switch and clutch interlock
Silencer E switch.
Melting sheets
CAUTION
Dash panel
D Do not push in the master cylinder pushrod at
ACE02990AC
this time, otherwise the clutch will not operate
2. Pierce a needle or similar material to the silencer properly.
and melting sheets, and measure the thickness of
"D" shown in the figure.
3. Start the engine, depress the brake pedal with
approximately 500 N of force, and measure the Pushrod
distance "E" between the silencer and brake Clutch pedal
pedal shown in the figure.
4. Check that the total value of "D" and "E"
measured in the previous items 2 and 3 is within Setting nut
the standard value. 13 ± 2 N·m
AC712193 AC
Standard value (D + E):
70 mm or more <4D5>, 65 mm or more 4. If the clutch pedal height is not within the standard
<4N1>, 80 mm or more <6B3> value, loosen the setting nut of pushrod, then turn
(From the surface of dash panel to the face the pushrod to adjust the clutch pedal height to
of pedal pad) the standard value.
5. If the clearance is outside the standard value,
check for air trapped in the brake line, thickness of
the disc brake pad, clearance between the lining
and the drum and dragging in the parking brake.
And then adjust and replace defective parts as
required.
6. Return the carpet etc. to its original position.
AC610163 AC709695
Clutch pedal free play
Dash panel
Clutch pedal
B
Stopper Stopper
Released
Depressed D
ACE02960AB ACE02958 AB
AC611454 AC611454
Dash panel Dash panel
Stopper Stopper
C C
ACE02959AB ACE02959AB
5. Check that the height (B) as well as the clearance 9. After the adjustments, confirm that the clutch
(C) between the clutch pedal and stopper when pedal free play (measured at the face of the pedal
the clutch is disengaged are within the standard pad) and the distance between the clutch pedal
value. (the face of the pedal pad) and the floorboard
Standard value (B): when the clutch is disengaged are within the
<L.H. drive vehicles> 117  122 mm standard value ranges.
<R.H. drive vehicles> 133.5  139 mm Standard value (D): 4  13 mm
Standard value (C): Standard value (C):
<L.H. drive vehicles> 30 mm or more <L.H. drive vehicles> 30 mm or more
<R.H. drive vehicles> 35 mm or more <R.H. drive vehicles> 35 mm or more
6. If the clutch pedal play and height as well as the 10.If the measured free play and distance do not
clearance between the clutch pedal and stopper agree with the standard value ranges, it is
when the clutch is disengaged are not within the probably the result of either air in the hydraulic
standard value, the air intrusion into the hydraulic system or a faulty master cylinder or clutch. Bleed
system may have occurred, or either the clutch the air, or disassemble and inspect the master
master cylinder or the clutch release cylinder may cylinder or clutch.
have an abnormality. In this case, perform air 11.Reinstall the carpet, etc.
bleeding, or check the clutch master cylinder or
the clutch release cylinder, and replace if
necessary.
7. Install the clutch switch and clutch interlock
switch.
8. If the clutch pedal clevis pin play is not within the
standard value, loosen the setting nut and move
the pushrod to adjust.
CHECK PARKING BRAKE LEVER 4. Repeatedly depress the brake pedal until the
STROKE AND PLAY  pedal stroke no longer changes with the engine
running.
<Lever type parking brake>
M6020400201219 NOTE: If the pedal stroke stops changing, the
automatic-adjustment mechanism is functioning
.
STROKE CHECK
normally, and the clearance between the shoe
Pull and drum is correct.
5. Turn the ignition switch to "OFF" position, and
stop the engine.
Spring balance CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
Approximately 6. Turn the adjuster to adjust the parking brake lever
40 mm ACX00701AF stroke to the standard value. After adjusting,
Attach the spring scale to the centre of the parking check that there is no space between the adjuster
brake lever grip. Then, check that the stroke is within and the parking brake lever. Check that the
the standard value when the parking brake lever is adjuster is secured with the adjuster holder.
pulled to the vertical direction of the lever with a force 7. After adjusting the parking brake lever stroke, jack
of approximately 200 N. up the rear end of the vehicle, and then release
Standard value: 8  9 notches the parking brake and turn the rear wheels to
check that the rear brakes are not dragging.
8. Install the rear floor console assembly.
.
STROKE ADJUSTMENT  .
<Vehicles with rear drum brake> STROKE ADJUSTMENT 

If the parking brake lever stroke is out of the standard <Vehicles with rear disc brake>
range, adjust as described below: If the parking brake lever stroke is out of the standard
1. Remove the rear floor console assembly. range, adjust as described below:
1. Remove the rear floor console assembly.
Cable rod
Adjuster
Cable rod
Adjuster
ACE02344AC
ACE02344AC
2. Loosen the adjuster to move it to the cable rod
end so that the cable will be free. 2. Loosen the adjuster to move it to the cable rod
3. Turn the ignition switch to "ON" position, and start end so that the cable will be free.
the engine. 3. Raise the vehicle, and remove the rear wheels.
REPLACE AIR PURIFIER FILTER

M6020400300622
1. Remove the glove box.
Adjuster
assembly
Brake disc
AC604649AC
Heater side cover

4. Remove the adjustment hole plug of the rear
brake disc, and then use a flat-tipped screwdriver ACE01676 AB
to turn the adjuster in the direction of the arrow
(the direction which expands the shoe) so that the 2. Remove the heater side cover.
disc will not rotate. 3. Replace the clean air filter.
5. Return the adjuster eight notches in the direction NOTE: The arrow on the clean air filter should
opposite to the direction of the arrow. face downwards.
CAUTION <Front view>
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
6. Turn the adjuster to adjust the parking brake lever AIR
FLOW
stroke to the standard value. After adjusting,
check that there is no space between the adjuster
and the parking brake lever. Check that the Install with the arrow
adjuster is secured with the adjuster holder. facing down.
ACE01951AB
7. After adjusting the parking brake lever stroke, jack
up the rear end of the vehicle, and then release 4. Install the glove box.
the parking brake and turn the rear wheels to
check that the rear brakes are not dragging.
8. Install the rear floor console assembly.

CHECK WHEEL ALIGNMENT Measure wheel alignment with alignment equipment
M6020500101617 on a level surface. The front suspension, steering
FRONT WHEEL ALIGNMENT CHECK AND system, wheels, and tyres should be serviced to nor-
ADJUSTMENT mal condition before measuring wheel alignment.
.
CAUTION
TOE-IN
When the suspension is adjusted, the calibration
of steering wheel sensor must be performed. Standard value:
<Vehicles with ASTC> At the centre of tyre tread: 0  5 mm
Toe-angle (per wheel): 000'  012'
CAMBER, CASTER AND KINGPIN

INCLINATION
Clip
Lock nut Compensator
AC502611AB
1. Adjust the toe-in by undoing the clip and lock nut,

ACX00712AC
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions). Standard value:
NOTE: The toe will move out as the left turnbuckle
is turned toward the front of the vehicle and the Camber 000'  030'*
right turnbuckle is turned toward the rear of the Caster 416'  100'*
vehicle. Kingpin inclination 1246'
2. Install the clip and tighten the lock nut to the
NOTE: *: Difference between right and left wheels
specified torque.
must be 030' or less.
3. Confirm that the toe-in is at the standard value. CAMBER AND CASTER REFERENCE
TABLE
.
HOW TO READ THIS TABLE (EXAMPLE)
B A
AC000756AB
4. Place the front wheel on a turning radius gauge Lower arm

mounting bolt
and measure the steering angle. AC407369AD
Item Standard value If the camber difference 035' and the caster differ-
ence is 017' by comparing the measurement value
Inner wheel 3650'  200'* with the standard value, rotate the front adjusting
Outer wheel 3240' cam by 1.5 graduations to the "B" direction and the
(reference value) rear adjusting cam by 2.5 graduations to the "A"
direction.
NOTE: *: Difference between right and left wheels
must be 200’ or less.
5. If the steering angle is not within the standard
value, adjust the toe-in.
.
Front side
adjust bolt scale
Direction A
6'
'
2'
7'
˚2
˚4
˚3
˚1
–1
–0
–0
–0
0˚
7'
˚1
+4
+0
2'
˚3
+3
+0
6'
˚4
+2
+0
'
˚2
+1
+1
Rear side
adjust bolt scale
Direction A Direction B
+4 +3 +2 +1 0 –1 –2 –3 –4
–0
˚3
5'
–1
–0
˚2
6'
–2
–0
˚1
8'
–3
–0
˚1
0'
–4
0˚
+0
+0
+0
+0
: Caster angle
˚3
˚2
˚1
˚1
: Camber angle
5'
6'
8'
0'
Direction B AC407327AD
NOTE: Solid lines show caster, broken lines show 3. If axial play exceeds the limit, disassemble the
camber. front hub assembly and check the parts.
4. After checking, install the brake disc and the
CHECK FRONT WHEEL BEARINGS FOR caliper assembly.
PLAY
M6020500200473
<REAR WHEEL>
<FRONT WHEEL> .
1. Remove the caliper assembly and brake disc, and AXLE SHAFT AXIAL PLAY CHECK
retain the caliper assembly with a wire and the like
to prevent from falling.
AC004839 AB
1. Measure the axle shaft axial play by using a dial

indicator.
Standard value: 0  0.30 mm
AC602402AB
2. If not within specifications, replace the axle shaft
2. Attach a dial gauge as shown in the illustration, assembly.
and then measure the axial play while moving the
hub in the axial direction.
Limit: 0 mm
CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300748
Brake booster
Brake fluid reservoir
Hydraulic unit
(integrated with
ABS-ECU or
ASTC-ECU)
<Vehicles with rear disc brake>
Master cylinder
Rear disc brake
<Vehicles with rear drum brake>

Front disc brake
Rear drum brake

ACF01555AB
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
CHECK BRAKE PADS AND DISCS FOR BRAKE DISC CHECK

WEAR .
BRAKE DISC THICKNESS CHECK

M6020500401306
BRAKE PAD CHECK 1. Remove contaminants or corrosion from the brake

disc surface.
CAUTION
If there is a significant difference in thickness
between the brake pads at right and left, check Approx. 10 mm
the sliding area and the run-out of the brake disc.
<Front (1-piston)>
ACX00668AH
2. Use a micrometer to measure the brake disc

thickness at minimum eight points which are 10
mm inward from its circumference.
<Front (2-piston)>
Standard value:
28.0 mm <Front>
18.0 mm <Rear>
Limit:
26.4 mm <Front>
16.4 mm <Rear>
3. If the brake disc thickness is worn beyond the limit
value at more than one point, replace the brake
disc and check its run-out.
ACF04709AB .
BRAKE DISC THICKNESS UNEVENNESS

<Rear> CHECK AND CORRECTION
1. Remove contaminants or corrosion from the brake
disc surface.
Approx. 10 mm
AC808013AB
1. Visually check the thickness of brake pad from the

inspection hole of the caliper body.
Standard value: ACX00668AH
10.0 mm <Front (1-piston)>, 
12.0 mm <Front (2-piston)> 2. Use a micrometer to measure the brake disc
10.0 mm <Rear> thickness at minimum eight points which are 10
Limit: 2.0 mm mm inward from its circumference. Then record
2. If the brake pad thickness is less than the limit the measurements.
value, replace the brake pad.
3. If the brake disc thickness unevenness (the BRAKE DISC RUN-OUT CHECK AND
difference between the maximum and minimum CORRECTION
values measured above) is 0.015 mm or less, it is
1. Check for wheel bearing looseness in the axial
within the standard value.
direction.
4. If the brake disc thickness unevenness exceeds
2. If the axial play is within the limit value, secure the
the standard value, grind it according to the
brake disc by tightening the nut (M121.5) evenly
procedure below while it is mounted on the
to the specified torque (100 Nm). If the axial play
vehicle.
still exceeds the limit value, replace the wheel
NOTE: If it is suspected that the brake disc thick- bearing. Then secure the brake disc by tightening
ness will become less than the limit value after the the nut (M121.5) evenly to the specified torque
grinding, replace the brake disc and check its (100 Nm).
run-out.
(1) Check for wheel bearing looseness in the axial Approx. 5 mm
direction.
CAUTION

M12 Flat washer
ACX00669AG
3. Place a dial gauge ca. 5 mm inward from the

circumference of the brake disc to measure its
run-out.
Limit:
0.06 mm <Front>, 0.06 mm <Rear>
4. If the brake disc run-out exceeds the limit value,
rephase the brake disc to the hub so that the
M12 Flat washer
minimum brake disc run-out is obtained.
AC006226 AE
 Insert M12 plain washer and then install the

adapter as shown before grinding. Failure to
use the M12 plain washer will cause the brake
disc to be deformed and ground incorrectly.
 To grind the brake disc, ensure that all the
nuts (M12 X 1.5) are tightened evenly and in a
diagonal sequence to the specified torque
(100 Nm). Failure to use all the nuts
(M121.5), excessive or uneven tightening
torque will cause the brake disc to deform or
judder.
(2) Correct the brake disc uneven thickness by
grinding it while in place on the vehicle.
.
CAUTION CHECK BRAKE SHOE LININGS AND


DRUMS FOR WEAR

M6020500501024
M12 Flat washer

BRAKE LINING THICKNESS CHECK
.
CAUTION
 Whenever the shoe and lining assembly is
replaced, replace both RH and LH assemblies
as a set to prevent the car from pulling to one
side when braking.
 If there is a significant difference in the thick-
ness of the shoe and lining assemblies on the
left and right sides, check the sliding condi-
tion of the piston.
1. Remove the brake drum.
M12 Flat washer
AC006226 AE
 Insert M12 plain washer and then install the

adapter as shown before grinding. Failure to
ACX00708AB
use the M12 plain washer will cause the brake
disc to be deformed and ground incorrectly. 2. Measure the thickness of the brake lining at the
 To grind the brake disc, ensure that all the area with the worst wear.
nuts (M12 X 1.5) are tightened evenly and in a <Vehicles with rear drum brake>
diagonal sequence to the specified torque Standard value: 5.0 mm
(100 Nm). Failure to use all the nuts Limit: 1.0 mm
(M121.5), excessive or uneven tightening
torque will cause the brake disc to deform or <Vehicles with rear disc brake>
judder. Standard value: 2.5 mm
Limit: 1.0 mm
5. If the brake disc run-out exceeds the limit value
after rephasing, grind the disc while in place on 3. Replace the shoe and lining assembly if the brake
the vehicle so that the brake disc run-out is within lining thickness is less than the limit or if it is not
the limit value. worn evenly. For installation procedures for the
shoe and lining assembly.
NOTE: If it is suspected that the brake disc thick-
ness will be below the limit value, replace the
brake disc. Then rephase the brake disc so that
the minimum brake disc run-out is obtained, or
grind the disc while in place on the vehicle so that
its run-out is below the limit value.
BRAKE DRUM INSIDE DIAMETER CHECK

.
1. Remove the brake drum.
Adjuster
assembly
Brake disc
AC604649AC
2. Remove the adjustment hole plug of the rear

AC000893 brake disc, and then use a flat-tipped screwdriver
to turn the adjuster in the direction of the arrow
2. Measure the inside diameter of the brake drum at (the direction which expands the shoe) so that the
two or more locations. disc will not rotate.
<Vehicles with rear drum brake> 3. Return the adjuster eight notches in the direction
Standard value: 295 mm opposite to the direction of the arrow.
Limit: 297 mm 4. Turn the rear wheels to check that the rear brakes
<Vehicles with rear disc brake> are not dragging.
Standard value: 190.0 mm 5. Pull up the electric parking brake switch to apply
Limit: 191.0 mm the parking brake.
3. Replace the brake drums, shoe and lining Check that the brake warning lamp in the
assembly when wear exceeds the limit value or is combination meter comes on.
badly imbalanced.
6. Push down the electric parking brake switch to
release the parking brake.
ADJUST THE CLEARANCE OF THE
BRAKE SHOE LININGS  Check that the brake warning lamp in the
combination meter goes out.
<Electric parking brake>
M6020501000018
1. Use the M.U.T.-III to release the parking brake CHECK FUEL HOSES AND PIPES FOR
cables fully according to the procedure below: LEAKAGE OR DETERIORATION
M6020500600772
(1) Move the selector lever to the P position.
1. Check entire circumference and length of hoses
(2) Connect the M.U.T.-III and turn ON the ignition and pipes.
switch.
2. Check all clamps for tightness and connections
(3) Check the following actuator test. for leakage.
 Item No. 2: Full release control

CHECK AUTOMATIC TRANSMISSION 4. Remove the drain plug (overflow plug) and check
FOR FLUID LEAKAGE (IN CASE OF whether a drop of A/T fluid comes out of the drain
hole. If not, remove the filler plug and refill the A/T
LEAKAGE, CHECK THE FLUID LEVEL)
M6020600100796 fluid through the filler plug opening. After the A/T
FLUID LEAK CHECK fluid comes out, tighten the drain plug by hand.
After cleaning the lower side of transmission, check 5. Apply the parking brake, and start the engine.
visually or by touching that there is no oozing or leak-
ing of fluid from the transmission. CAUTION
Depending on ambient temperature, the A/T fluid
FLUID LEVEL CHECK <R8AWG, V8AWG> temperature may exceed the upper threshold
(43C <6B3>, 46C <4N1>) prematurely. So,
CAUTION speedy operations must be ensured.
During the fluid level check, the fluid temperature 6. Depress the brake pedal, move the selector lever
must be between 40 and 43C <6B3> or between from the P to D range, and then move it to every
43 and 46C <4N1>. If the temperature is outside position by holding 2 seconds or more at each
this range, set the fluid temperature to the suita- range. Repeat this cycle twice, and then return
ble temperature, and then check the fluid level. the lever to the P range.
.
<WHEN THE M.U.T.-III IS USED> 7. Check that the fluid temperature is between 40
and 43C <6B3> or between 43 and 46C <4N1>.
1. Park the vehicle on a flat place, and move the
selector lever to the P range. NOTE: When the ambient temperature is low
2. Connect the M.U.T.-III. (10C or lower), move the selector lever to the P
range, warm up the engine for 15 minutes with the
3. Use the M.U.T.-III Data list item No.7: A/T fluid engine speed of 2,000 to 2,500 r/min. Then, the
temperature (oil pan) to check that the A/T fluid fluid temperature becomes approximately 40C.
temperature is less than the lower threshold (40C In such case, after the fluid temperature
<6B3>, 43C <4N1>). If not, wait until it reaches increased, leave the engine idling for 5 minutes,
40C <6B3>, 43C <4N1> or less. and then check the fluid level.
8. Remove the drain plug (overflow plug) and check
whether a drop of A/T fluid comes out of the drain
hole.
9. <When the fluid is drained>
Wait until the fluid becomes oil drops.
Overflow plug <When the fluid is not drained>
gasket
Remove the filler plug, and pour in the fluid
Drain plug through the filler plug hole until the fluid comes out
(overflow plug) ACF01275AB
of the drain plug (overflow plug) hole. Wait until
the fluid becomes oil drops.
10.Tighten the drain plug (overflow plug) with a new
gasket to the specified torque.
11.Tighten the filler plug with a new O-ring to the
O-ring specified torque.
Filler plug ACF01274AB

.
<WHEN THE M.U.T.-III IS NOT USED> Multi information A/T fluid temperature
1. Park the vehicle on a flat place, and move the display warning mark
selector lever to the P range.
Overflow plug ACF01253AB

gasket
6. Move the selector lever (N  D  N) within 1.5
Drain plug
seconds, and continue the operation until the A/T
fluid temperature warning mark is shown on the
multi-information display. After the A/T fluid
temperature warning mark is shown, check that
the fluid temperature is within the specified range
(Refer to NOTE). Then move the selector lever
back to the P range. The A/T fluid temperature
warning mark should go out within a few seconds.
O-ring
NOTE: .
 The status of A/T fluid temperature warning
mark shows if the fluid temperature is suitable
Filler plug ACF01274AB for the fluid level check.
 The warning mark is not displayed: The
2. Remove the drain plug (overflow plug) and check fluid temperature is 40C <6B3>, 43C
whether a drop of A/T fluid comes out of the drain <4N1> or less, thus checking is impossi-
hole. If not, remove the filler plug and refill the A/T ble.
fluid through the filler plug opening. After the A/T  The warning mark is displayed: The fluid
fluid comes out, tighten the drain plug by hand. temperature is between 40 and 43C
<6B3> or between 43 and 46C <4N1>,
thus checking is possible.
 Warning mark is blinking*: The fluid tem-
perature is 43C <6B3>, 46C <4N1> or
higher, thus checking is impossible.
*
: It will blink at the cycle of ON for five sec-
onds and OFF for one second, and the
Diagnosis connector
buzzer will sound every approximately five
seconds. Note that only the buzzer sounds
ACE02027AB
every five seconds without blinking.
3. Earth the diagnosis connector terminal No. 1.  When the ambient temperature is low (10C or
lower), move the selector lever to the P range,
4. Apply the parking brake, and start the engine.
warm up the engine for 15 minutes with the
5. Depress the brake pedal, move the selector lever engine speed of 2,000 to 2,500 r/min. Then,
from the P to D range, and then move it to every the fluid temperature becomes approximately
position by holding 2 seconds or more at each 40C. In such case, after the fluid temperature
range. Repeat this cycle twice, and then return increased, leave the engine idling for 5 min-
the lever to the P range. utes, and then check the fluid level.
CAUTION
Depending on ambient temperature, the A/T fluid
temperature may exceed the upper threshold
(43C <6B3>, 46C <4N1>) prematurely. So,
speedy operations must be ensured.
<WHEN THE M.U.T.-III IS USED>

1. Connect the M.U.T.-III.
2. Pull the parking brake lever, and start the engine.
3. Depress the brake pedal, move the selector lever
from the P to D range, and then move it to every
position by holding 2 seconds or more at each
Overflow plug range. Repeat this cycle twice, and then return
gasket
the lever to the P range.
Drain plug
(overflow plug) 4. Using the M.U.T.-III, check that the fluid
ACF01275AB
temperature is between 42 to 47C.
NOTE: When the ambient temperature is low
(10C or lower), move the selector lever to the P
range, warm up the engine for 15 minutes with the
engine speed of 2,000 to 2,500 r/min. Then, the
fluid temperature becomes approximately 40C.
O-ring In such case, after the fluid temperature
increased, leave the engine idling for 5 minutes,
and then check the fluid level.
Filler plug <2WD>
ACF01274AB
7. Remove the drain plug (overflow plug), and check

whether a drop of the A/T fluid comes out of the
rain hole.
Wait until the A/T fluid drops. Filler plug
<When the fluid is not drained>

ACE02024 AB
Remove the filler plug, and pour in the fluid
through the filler plug hole until the fluid comes out <4WD>
of the drain plug (overflow plug) hole. Wait until
the A/T fluid drops.
9. Tighten the drain plug (overflow plug) with a new
gasket to the specified torque.
10.Tighten the filler plug with a new O-ring to the
specified torque.
Tightening torque: 39  15 Nm Filler plug
ACE02025 AB
FLUID LEVEL CHECK <R5AWF, V5AWF>

CAUTION Overflow plug
During the fluid level check, the fluid temperature
must be between 42 and 47C. If the temperature
is outside this range, set the fluid temperature to
the suitable temperature, and then check the
fluid level.
.
Drain plug
ACE02026 AB
5. Remove the filler plug and the overflow plug, and

drain the fluid from the overflow plug hole.
6. <When the fluid is drained> A/T fluid temperature

Wait until the fluid becomes oil drops, and then warning lamp
tighten the overflow plug with a new gasket and
the filler plug with a new O-ring to the specified
torque.
<When the fluid is not drained>
Pour in the fluid through the filler plug hole until
the fluid is drained from the overflow plug hole.
Wait until the fluid becomes oil drops, and then ACE01954AC
the filler plug with a new O-ring to the specified 4. Move the selector lever (N  D  N) within 1.5
torque. seconds, and continue the operation until the A/T
Tightening torque: fluid temperature warning lamp illuminates. After
20  2 Nm (overflow plug) the A/T fluid temperature warning lamp
39  15 Nm (filler plug) illuminated, return the selector lever to the P
range. The warning lamp goes out within a few
.
seconds.
<WHEN THE M.U.T.-III IS NOT USED> NOTE: .
 The status of A/T fluid temperature warning
lamp shows if the fluid temperature is suitable
for the fluid level check.
 Warning lamp is off: The fluid temperature
is 42C or less, thus checking is impossi-
ble.
 Warning lamp is on: The fluid temperature
Diagnosis connector
is between 42 to 47C, thus checking is
possible.
 Warning lamp is blinking: The fluid temper-
ACE02027AB
ature is 47C or higher, thus checking is
1. Earth the diagnosis connector terminal No. 1. impossible.
2. Pull the parking brake lever, and start the engine.  When the ambient temperature is low (10C or
lower), move the selector lever to the P range,
3. Depress the brake pedal, move the selector lever
warm up the engine for 15 minutes with the
from the P to D range, and then move it to every
engine speed of 2,000 to 2,500 r/min. Then,
position by holding 2 seconds or more at each
the fluid temperature becomes approximately
range. Repeat this cycle twice, and then return
40C. In such case, after the fluid temperature
the lever to the P range.
increased, leave the engine idling for 5 min-
utes, and then check the fluid level.
<2WD> CHANGE AUTOMATIC TRANSMISSION

FLUID
M6020600201020
SPECIFICATIONS
Automatic Quantity Remark
transmission fluid
Filler plug MITSUBISHI 10.9 L R5AWF and
MOTORS GENUINE V5AWF
ATF-PA
ACE02024 AB
MITSUBISHI 10.4 - 12.8 L R8AWG and
<4WD> MOTORS GENUINE V8AWG
ATF-MA1
<R8AWG, V8AWG>
If there is an ATF changer, use it. If there is no ATF
changer, replace the fluid as described below.
NOTE:
<6B3>
Filler plug
ACE02025 AB
Overflow plug
ACF02565AB
<4N1>
Drain plug
ACE02026 AB
5. Remove the filler plug and the overflow plug, and

drain the fluid from the overflow plug hole.
Wait until the fluid becomes oil drops, and then
the filler plug with a new O-ring to the specified ACF02566AB
torque.
If you use an ATF changer, disconnect the A/T fluid
<When the fluid is not drained> cooler hose at the position shown. Then connect the
Fill the fluid from the filler plug until the fluid is ATF changer between them.
drained from the overflow plug hole, and wait until
the fluid becomes oil drops. Then, tighten the
overflow plug with a new gasket and the filler plug
with a new O-ring to the specified torque.
Tightening torque:
20  2 Nm (overflow plug)
39  15 Nm (filler plug)
3. Using the hexagon wrench (5 mm), install the

overflow tube and tighten it to the specified
torque.
4. Pour in the fluid through the filler plug hole until
O-ring the fluid is drained from the overflow plug hole.
Wait until the fluid becomes oil drops, and then
tighten the overflow plug with a new gasket to the
Filler plug
specified torque.
ACF01274AB
Tightening torque:
5. Tighten the filler plug with a new O-ring to the
specified torque.
6. Check the fluid level.
Overflow plug 7. During the fluid level check, check the drained
gasket fluid for contamination. If the fluid is contaminated,
Drain plug perform steps 1 to 6 again.
<R5AWF, V5AWF>
1. Remove the filler plug and the drain plug If there is an ATF changer, use it. If there is no ATF
(overflow plug). changer, replace the fluid as described below.
NOTE:
Oil return hose
Overflow tube
Oil return tube
ACF01276AB ACE03177AB
2. Using the hexagon wrench (5 mm), remove the If you use an ATF changer, disconnect the oil return
overflow tube and then drain fluid from the drain hose from the oil return tube. Then connect the ATF
plug (overflow plug) hole. changer between them.
Discharge volume: Approx. 1.8 L
CAUTION 5. Check the fluid level.

When draining the fluid from the drain plug hole, 6. During the fluid level check, check the drained
use a plate to prevent the fluid from dripping on fluid for contamination. If the fluid is contaminated,
the centre member assembly. perform steps 1 to 5 again.
<2WD>
CHANGE ENGINE OIL
M6020600302321
<6B3>
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 C
to 90 C.
Filler plug
2. Remove the engine oil filler cap.
3. Remove the under skid plate and engine room
ACE02024 AB
under cover front.
<4WD> WARNING
Use care as engine oil could be hot.
4. Remove the engine oil pan drain plug to drain
engine oil.
<6B3>
Filler plug
ACE02025 AB
Overflow plug
AC902837AD
5. Install a new engine oil pan drain plug gasket, and

then tighten the engine oil pan drain plug to the
specified torque.
Drain plug Tightening torque: 39  5 Nm
ACE02026 AB
6. Install the under skid plate and engine room under
1. Remove the filler plug and the drain plug, and cover front.
drain the fluid from the drain plug hole. 7. Refill with specified quantity of engine oil.
Discharge volume: Approx. 3.0 L Specified Engine Oil
 ACEA classification: "For service A1/B1,
2. Install the drain plug with a new gasket in
A3/B3, A3/B4 or A5/B5"
between, and tighten it to the specified torque.
 ILSAC classification: ILSAC certificated
Tightening torque: 20  2 Nm oil
3. Remove the overflow plug.  API classification: "For service SG or
4. Pour in the fluid through the filler plug hole until higher"
the fluid is drained from the overflow plug hole. Total quantity (Includes volume inside
Wait until the fluid becomes oil drops, and then engine oil filter): 4.3 L
the filler plug with a new O-ring to the specified
torque.
Tightening torque:
20  2 Nm (overflow plug)
39  15 Nm (filler plug)
NOTE: 7. Refill with specified quantity of oil.

Specified Engine Oil
A3/B3, A3/B4 or A5/B5"
 API classification: "For service CD or
higher"
Total quantity (Includes volume inside oil fil-
ter and oil cooler): 7.4L
NOTE:
ACA00609AB
Select engine oil of the proper SAE viscosity

number according to the atmospheric tempera-
ture.
SAE 0W-30, 5W-30, and 5W-40 engine oils can
only be used if they meet ACEA A3/B3, A3/B4 or
A5/B5 and API SG (or higher) specification.
8. Install the engine oil filler cap.
9. Check engine oil level. AC903479

<4N1-Vehicles without diesel particulate number according to the atmospheric tempera-
filter (DPF)> ture.
1. Start the engine and allow it to warm up until the 8. Install the oil filler cap.
temperature of the coolant reaches 80 C to 90 9. Check oil level.
C.
2. Remove the oil filler cap. <4N1-Vehicles with diesel particulate 
3. Remove the under skid plate and engine room filter (DPF)>
under cover front. 1. Start the engine and allow it to warm up until the
WARNING temperature of the coolant reaches 80 C to 90
Use care as oil could be hot. C.
4. Remove the oil drain plug to drain oil. 2. Remove the oil filler cap.
3. Remove the under skid plate and engine room
under cover front.
WARNING
Use care as oil could be hot.
4. Remove the oil drain plug to drain oil.
ACE01737AB
5. Install a new oil drain plug gasket, and then

tighten the drain plug to the specified torque.
6. Install the under skid plate and engine room under ACE01737AB
cover front.
tighten the drain plug to the specified torque.
6. Install the under skid plate and engine room under <4D5>
cover front. 1. Start the engine and allow it to warm up until the
7. Refill with specified quantity of oil. temperature of the coolant reaches 80 C to 90
Specified Engine Oil C.
 ACEA classification: "For service C1, C2, 2. Remove the oil filler cap.
C3 or C4" 3. Remove the under skid plate and engine room
 JASO classification: "For service DL-1" under cover front.
Total quantity (Includes volume inside oil fil-
ter and oil cooler): WARNING
 <Except vehicles for Russia> 7.4L Use care as oil could be hot.
 <Vehicles for Russia> 8.4L 4. Remove the oil drain plug to drain oil.
NOTE:
<Except vehicles for
Australia and New Zealand>
ACE01736AB
ACA00381AF

<Vehicles for Australia and New Zealand> tighten the drain plug to the specified torque.
6. Install the under skid plate and engine room under
cover front.
7. Refill with specified quantity of oil.
Specified Engine Oil
A3/B3, A3/B4 or A5/B5"
ACE02877AB
 API classification: "For service CD or
Select engine oil of the proper SAE viscosity higher"
number according to the atmospheric tempera- Total quantity (Includes volume inside oil fil-
ture. ter and oil cooler): 6.4L
8. Install the oil filler cap. NOTE:
9. Check oil level indicate below maximum marking.
10.Warm up engine for 10 minutes and wait for
further 10 minutes.
11.Check that the oil level is between maximum
marking and minimum marking.
12.If no, add the oil until the oil level gauge indicates
between maximum marking and minimum
marking.
AC903479

number according to the atmospheric tempera-
ture.
8. Install the oil filler cap.
9. Check oil level.
REPLACE ENGINE OIL FILTER <4N1>

M6020600401604
1. Remove the oil drain plug to drain engine oil.
<4G6, 6B3>
MB991396 or
commercially-
MB991396, available tool
MB991828 or
commercially-
available tool
AC904112 AB
AC904112 AC 2. Use special tool oil filter wrench (MB991396) or

commercially-available tool to remove the oil filter.
2. Use special tool oil filter wrench (MB991396, 3. Clean the oil filter installing surface on the cylinder
MB991828) or commercially-available tool to block side.
remove the oil filter.
3. Clean the oil filter installing surface on the cylinder (Engine oil)
block side.
Gasket
(Engine oil)
Gasket
AC904113 AC
4. Apply a small amount of engine oil to the new oil

AC904113 AC filter gasket.
5. For the specified tightening torque, refer to the
4. Apply a small amount of engine oil to the new oil caution label attached on the oil filter.
filter gasket.
6. Tighten the oil filter until the gasket contacts with
5. For the specified tightening torque, refer to the the installation surface.
caution label attached on the oil filter.
7. In the same manner as removal, use special tool
6. Tighten the oil filter until the gasket contacts with oil filter wrench (MB991396) or
the installation surface. commercially-available tool to tighten the oil filter
7. In the same manner as removal, use special tool to the specified torque.
oil filter wrench (MB991396, MB991828) or 8. Install the oil drain plug and refill the engine oil.
commercially-available tool to tighten the oil filter
9. Rev the engine a few times, and check to be sure
that no engine oil leaks from the installation
8. Install the oil drain plug and refill the engine oil. section of the oil filter.
9. Rev the engine a few times, and check to be sure
section of the oil filter.
<4D5> CHECK ENGINE IDLING SPEED

M6020601301149
<6B3>
2. Remove the bracket for the battery wiring harness
to ensure working space to gain access to the oil 1. Before inspection, set the vehicle to the
filter. pre-inspection condition.
position and then connect the M.U.T.-III to the
diagnosis connector.
MH061590 or No.1 ignition coil
commercially-
available tool
ACX00395AM
3. Use special tool oil filter wrench (MH061590) or Ignition coil pick-up loop
commercially-available tool to remove the oil filter. ACF01013 AB
4. Remove the oil filter through the right wheel
house. 3. Set the timing light to the timing pick-up loop
(white) of No. 1 ignition coil.
5. Clean the oil filter installing surface on the cylinder
block side. 4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
(Engine oil) Standard value: approximately 10 BTDC
Gasket NOTE: The ignition timing may fluctuate within
7. This is normal.
NOTE: In higher altitude, the ignition timing is
more advanced than the standard value by
approximately 5.
NOTE: Wait till approximately 1 minute passes
after the engine started, and check the ignition
AC904113 AC
timing when the engine stabilized.
6. Apply a small amount of engine oil to the new oil 6. Check the idle speed.
filter gasket. Standard value: 650  100 r/min
7. For the specified tightening torque, refer to the NOTE: The idle speed is controlled automatically
caution label attached on the oil filter. by the idle speed control system.
8. Tighten the oil filter until the gasket contacts with NOTE: When using the M.U.T.-III, select item No.
the installation surface. 2 and take a reading of the idle speed.
9. In the same manner as removal, use special tool 7. If the idle speed is outside the standard value,
oil filter wrench (MH061590) or inspect the MPI system.
commercially-available tool to tighten the oil filter
8. Remove the timing light.
10.Install the oil drain plug and refill the engine oil.
position and then disconnect the M.U.T.-III.
11.Rev the engine a few times, and check to be sure
section of the oil filter.
<4N1, 4D5> 6. Run the engine at 2,000  3,000 r/min for 2

1. Set the vehicle to the pre-inspection condition. minutes.
2. Turn the ignition switch to the "LOCK" (OFF) 7. Set the CO, HC tester.
position and then connect the M.U.T.-III to the 8. Check the CO contents and the HC contents at
diagnosis connector. idle.
3. Start the engine, and let it run at idle. Standard value
4. Check the idle speed. Select the item No. 2 of the CO contents: 0.3 % or less
Data List, Engine Revolution, and take a reading HC contents: 200 ppm or less
of the idle speed. 9. If there is a deviation from the standard value,
Standard value: 650  50 r/min inspect the MPI system.
5. If the idle speed is not within the standard value, 10.Remove the HC, CO tester and timing light.
inspect the diesel system. 11.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-III.
CHECK CO CONCENTRATION
(PETROL-POWERED VEHICLES) CHECK EXHAUST GAS RECIRCULATION
M6020601001223 (EGR) SYSTEM
<6B3> M6020600801204
1. Before inspection, set the vehicle to the <6B3>

pre-inspection condition.
.
CHECKING THE OPERATION SOUND

position and then connect the M.U.T.-III to the
diagnosis connector.
No.1 ignition coil
Exhaust gas
recirculation
valve
ACF00778AB
Ignition coil pick-up loop 1. Check that the operation sound of the stepper
ACF01013 AB motor can be heard from the exhaust gas
recirculation valve when the ignition switch is
3. Set the timing light to the timing pick-up loop turned ON (without starting the engine).
(white) of No. 1 ignition coil.
2. If the operation sound cannot be heard, inspect
4. Start the engine and let it run at idle. the drive circuit of the stepper motor.
5. Check that ignition timing is at the standard value. NOTE: If the circuit is normal, either the stepper
Standard value: approximately 10 BTDC motor or the engine-ECU may have failed.
NOTE: The ignition timing may fluctuate within .
7. This is normal.

NOTE: In higher altitude, the ignition timing is
more advanced than the standard value by
approximately 5.
NOTE: Wait till approximately 1 minute passes
after the engine started, and check the ignition
timing when the engine stabilized.
CHECKING THE COIL RESISTANCE 4. Connect terminals No. 1 and No. 3 to the negative
() terminal of the battery, in order to test whether
the stepper motor vibrates (with a slight shudder),
indicating that the stepper motor is operating.
CAUTION
Connecting battery voltage to the exhaust gas
1 2 3 recirculation valve for a long term could damage
4 5 6
the coil.
1 2 3 Equipment side
4 5 6 connector
AK200805 AC
1 2 3
1. Remove the exhaust gas recirculation valve. 4 5 6
2. Measure the resistance between terminal No. 2 Battery
and either terminal No. 1 or terminal No. 3 of the
connector at the exhaust gas recirculation valve.
Standard value: 20  24  (at 20C)
3. Measure the resistance between terminal No. 5 MB991658 ACC07469 AC
and either terminal No. 6 or terminal No. 4 of the

5. Connect the positive (+) terminal of the battery to
connector at the exhaust gas recirculation valve.
terminal No. 5.
Standard value: 20  24  (at 20C)
6. Connect terminals No. 4 and No. 6 to the negative
4. If the voltage deviates from the standard value, () terminal of the battery, in order to test whether
replace the exhaust gas recirculation valve. the stepper motor vibrates (with a slight shudder),
NOTE: For removal and installation of the exhaust indicating that the stepper motor is operating.
gas recirculation valve. 7. If a vibration can be felt during the test, the
.
stepper motor is normal.
OPERATION CHECK 8. Install the exhaust gas recirculation valve.
1. Remove the exhaust gas recirculation valve. .
2. Attach a special tool test harness (MB991658) to CLEANING THE EXHAUST GAS
the connector at the exhaust gas recirculation RECIRCULATION VALVE
valve.
CAUTION
MB991658 Do not use a solvent or detergent, which could
enter the motor and cause it to malfunction.
1. Remove the exhaust gas recirculation valve and
check that the exhaust gas recirculation valve is
not stuck or clogged with carbon deposits. Use a
wire brush to clean the valve if necessary.
1 2 3 2. Install the exhaust gas recirculation valve.
4 5 6
Battery
Equipment side
connector ACC07468 AC
CAUTION
Connecting battery voltage to the exhaust gas
recirculation valve for a long term could damage
the coil.
3. Connect the positive (+) terminal of the battery to
terminal No. 2.
<4D5> 3. A tester is to be connected between the terminal

.
No.1 and No. 2.
CHECK ON OPERATING SOUND 4. Connect the terminal (+) of the power supply with
NOTE: Carry out this check after checking that the the terminal No. 6 of the exhaust gas recirculation
diagnosis code is not set. If the diagnosis code is set, valve connector, and connect the terminal () of
the exhaust gas recirculation valve (DC motor) could the power supply with the terminal No. 4. Confirm
possibly not be checked correctly. the exhaust gas recirculation valve is opened.
NOTE: At this time, the power supply voltage is to
be 5 V. When the valve is not opened, increase
the voltage 1 V by 1 V. For each voltage, current is
to be applied within 5 seconds. Once the valve is
opened, the voltage is not to be increased any
more.
Exhaust gas 5. Confirm the voltage is changed between the
recirculation valve terminal No. 1 and No. 2 together with the exhaust
(in which exhaust gas
recirculation valve position sensor built) gas recirculation valve opening movement.
AK802306AC
6. By the voltage changed, the DC is recognised as
1. Start up the engine and run on at idle speed to being normal.
allow the engine coolant temperature to reach at 7. Use a new gasket and tighten the installation bolt
least 70C. to the tightening torque.
2. When turning the ignition switch to the LOCK Tightening torque: 48  6 Nm
(OFF) position and stopping the engine, check
that the operating sound "clicking noise" is heard .
from the exhaust gas recirculation valve three CLEANING THE EXHAUST GAS
times. RECIRCULATION VALVE
3. If the operating sound is not heard, check the CAUTION
drive circuit of the DC motor. Do not use a solvent or detergent, which could
NOTE: If the circuit is normal and the operating enter the motor and cause it to malfunction.
sound is not heard, it could possibly be caused by 1. Remove the exhaust gas recirculation valve and
the failed exhaust gas recirculation. check that the exhaust gas recirculation valve is
not stuck or clogged with carbon deposits. Use a
wire brush to clean the valve if necessary.
.
OPERATION CHECK
2. Using a new gasket, install the exhaust gas
1. Remove the exhaust gas recirculation valve.
recirculation valve by tightening its mounting bolts
5V
1 2 3
4 5 6
5V
AK701971AB
2. Connect the terminal (+) of the sensor power

supply (5 V) with the terminal No. 3 of the exhaust
gas recirculation valve connector, and connect the
terminal () of the sensor power supply (5 V) with
the terminal No. 2.
OTHERS
OTHERS
CHECK BODY CONDITION FOR DAMAGE LEARNING PROCEDURE
M6020700100470
1. Check underbody coating for damage. CAUTION
To prevent damage to M.U.T.-III, always turn the
2. Check body painting for damage.
ignition switch to the "LOCK" (OFF) position
CHECK THE COMMON RAIL ENGINE <except vehicles with KOS> (or put the power
supply mode is OFF <vehicles with KOS>) before
(SMALL INJECTION QUANTITY connecting or disconnecting M.U.T.-III.
LEARNING) 1. After the ignition switch is in the "LOCK" (OFF)
M6020700400341
position <except vehicles with KOS> (or put the
SMALL INJECTION QUANTITY LEARN- power supply mode is OFF <vehicles with KOS>),
ING PROCEDURE <Diesel> connect the M.U.T.-III to the diagnosis connector.
CAUTION 2. Put the vehicle in the following idling stable
1. If small injection quantity learning has not conditions:
been executed, the engine warning lamp  Engine coolant temperature: 76  100C
blinks.  Fuel temperature: 30  100C
2. When the requirements for learning are satis-  Intake air temperature: 30 to 100C
fied by operation after replacement of the  Barometric pressure: 70 kPa or more
engine-ECU, learning is automatically exe-  Lamps, radiator fan and all accessories: OFF
cuted even if no instruction is given from the  Transmission: Neutral
M.U.T.-III. Accordingly, the malfunction indica-  Power steering: Static state
tor lamp goes off. However, the learning thus 3. Select "MPI/GDI/DIESEL" from System select
executed is tentative and limited. Be sure to Screen of the M.U.T.-III.
complete leaning using the M.U.T.-III. 4. Select "Special Function" from MPI/GDI/DIESEL
Screen.
PURPOSE 5. Select "Learning" from Special Function Screen.
To keep emission and noise level at adequate levels,
6. Select Item No. 1 "Small Injection qt. Learning"
the engine-ECU must learn injector fuel injection in
from the Learning Screen to execute learning.
idle mode.
During learning, the engine-ECU calculates actual CAUTION
injection from each cylinder based on changes in If the vehicle conditions go out of the learning
engine speeds and corrects pilot injection control. It conditions during idling, learning is interrupted.
then keeps records of this amount of correction as a To reexecute learning, the ignition switch must
learned value. once be turned off.
For this reason, after the engine-ECU or injector is 7. Continue idling for about 3 minutes before
replaced, learning must be executed using the learning is completed.
M.U.T.-III. 8. Confirm that the engine warning lamp is off. If it
NOTE: Engine friction changes or injector deteriora- still blinks, reexecute learning.
tion over time may cause fluctuation in pilot injection.
After use over time, it may prevent injection of an ROAD TEST
M6020700200831
accurate amount of fuel according to the indication
Drive the vehicle and check for conditions.
by the engine-ECU. This is why learning must be
1. Check free play of steering wheel.
executed again periodically.
For this reason, the engine-ECU periodically leans 2. Check efficiency of service brakes and parking
injection according to the cumulative mileage. brakes system.
Note that making the M.U.T.-III learn again resets the 3. Check driveability of engine/motor.
cumulative mileage. 4. Check condition of instruments, gauges
NOTE: The engine sound may change or idling indicators, exterior lamps, heater and ventilators.
engine speeds may increase during injection learn- 5. Check abnormal noise of each part.
ing. These are not abnormalities. 6. Check the tyres for wear and for the correct air
pressure.

Pajero Sport (3G) Manual

Uploaded by

Copyright:

Available Formats

Pajero Sport (3G) Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pajero Sport (3G) Manual

Uploaded by

Copyright:

Available Formats

0-1

HOW TO USE THIS MANUAL. . . . . . 0-2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

HOW TO USE THIS MANUAL

PRECAUTIONS BEFORE SERVICE

DOING SERVICE WORK IN GROUPS OF

If punch marks or mating marks are made to avoid

SPECIAL TOOLS PARTS

Be careful to avoid spilling any petrol, oil, etc.,

If any of the following parts are removed, they must LUBRICANTS

In accordance with the instructions in this manual,

BRAKE FLUID APPLICATION OF ANTI-CORROSION

ACX00880AD If high-pressure car-washing equipment or steam

MULTI USE TESTER (M.U.T.-III) SUB ENGINE OILS

NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-16

BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 BEFORE ROAD TEST . . . . . . . . . . . . 1-17

Continued on next page

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-19 38. MANUAL TRANSMISSION AND 

NOTES CONCERNING ENTRIES

TABLE OF PRE-DELIVERY INSPECTION

Term Definition Remark

<LHD> Storage connector

Bar-code Production Date

1. Location of production date

<PHEV> CONFIRMATION OF PRODUCTION DATE

Bar code Production date

It is the normal behaviour and nothing wrong 1. Location of production date

Vehicles may be shipped from the assembly plant to

Flow Chart of Wrap Film Removal

If adhesive residue is left on the painted surface, wipe it off

Dispose removed film according to local

The procedures to re-apply the wrap film

If there is an environment that the vehicles in stock

Steps. Process Tips

Steps. Process Tips

3. WHEEL 5. OPERATION OF DOOR LOCKING

6. OPERATION OF DOOR MIRRORS,

9. CLUTCH MASTER CYLINDER FLUID 12. POWER STEERING FLUID LEVEL

13. ELECTRICAL WIRING

Check the fluid level; if it is low, replenish the washer

Inspect the battery connections. Verify that they are

4. Split pins  17. UNDER BODY

BEFORE ROAD TEST

20. IDLE CONTROL KNOB

21. INSTRUMENT PANEL CONTROLS

25. OPERATION OF SERVICE BRAKES

Depress the brake pedal

2. Heater and defroster

24. WIPERS AND WASHERS

(2) Verify correct brake pedal free play.

31. STEERING CONTROL

AFTER ROAD TEST

1. Check that the coolant level in the reserve tank is

38. MANUAL TRANSMISSION AND 39. AUTOMATIC TRANSMISSION FLUID

Filler plug hole

1. Remove the dipstick and check the fluid level.

1. Check all hoses, fluid lines and connections for

Type 1 only: Remove the filler plug, and check the

44. EQUIPMENT 1. Verify that the owner's manual and service