Pdi 5a4dz3 A 11 003 Eng

0-1
GROUP 0
GENERAL
CONTENTS
PRECAUTIONS BEFORE BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3

SERVICE . . . . . . . . . . . . . . . . . . . . . . 0-2 SERVICING THE ELECTRICAL SYSTEM . 0-4
PROTECTING THE VEHICLE . . . . . . . . . . 0-2 APPLICATION OF ANTI-CORROSION AGENTS
DOING SERVICE WORK IN GROUPS OF TWO AND UNDERCOATS . . . . . . . . . . . . . . . . . . 0-4
OR MORE MECHANICS . . . . . . . . . . . . . . 0-2 PRE-INSPECTION CONDITION . . . . . . . . . 0-4
REMOVAL AND DISASSEMBLY . . . . . . . . 0-2 VEHICLE WASHING . . . . . . . . . . . . . . . . . . 0-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 0-2 MULTI USE TESTER (M.U.T.-III) SUB
PARTS TO BE REPLACED . . . . . . . . . . . . 0-3 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 IN ORDER TO PREVENT VEHICLES FROM
FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
TUBES AND OTHER RUBBER PARTS . . . 0-3
ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 0-5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3
1-1
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
NOTES CONCERNING ENTRIES . . . 1-3 15. STEERING LINKAGE AND SPLIT

PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
PAINTWORK TERMS . . . . . . . . . . . . 1-5 16. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-11
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 BEFORE ROAD TEST . . . . . . . . . . . . 1-12

1. CONNECTION OF DARK CURRENT 17. SEAT ADJUSTERS AND SEAT BACK
CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 1-6 LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
18. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-12
BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 19. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-12
2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-6 20. INSTRUMENT PANEL CONTROLS . . . 1-12
3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-8 21. METERS, GAUGES, WARNING LAMPS
AND INDICATION LAMPS . . . . . . . . . . . . . 1-12
4. OPERATION OF DOOR LOCKING SYSTEMS
AND DOOR HINGES . . . . . . . . . . . . . . . . . 1-8 22. AIR CONDITIONER, HEATER AND
DEFROSTER SYSTEM. . . . . . . . . . . . . . . . 1-12
5. OPERATION OF DOOR MIRRORS,
WINDOWS AND SUNROOF . . . . . . . . . . . 1-8 23. WIPERS AND WASHERS. . . . . . . . . . . 1-13
24. OPERATION OF SERVICE BRAKES
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-9 AND PARKING BRAKES . . . . . . . . . . . . . . 1-13
25. CLUTCH OPERATION . . . . . . . . . . . . . 1-13
6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-9
7. BRAKE MASTER CYLINDER FLUID 26. OPERATION OF SEAT BELTS,
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 SHOULDER BELTS AND RETRACTORS . 1-14
8. CLUTCH MASTER CYLINDER FLUID

LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-14
9. WASHER FLUID LEVEL. . . . . . . . . . . . . 1-9 27. ENGINE PERFORMANCE AND
EXHAUST GAS . . . . . . . . . . . . . . . . . . . . . . 1-14
10. BATTERY CONDITION AND
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-9 28. TRANSMISSION IN ALL RANGES . . . . 1-14
11. POWER STEERING FLUID LEVEL . . . 1-10 29. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-15
12. ELECTRICAL WIRING . . . . . . . . . . . . . 1-10 30. STEERING CONTROL . . . . . . . . . . . . . 1-15
31. VIBRATION AND RATTLES . . . . . . . . . 1-15
UNDER VEHICLE . . . . . . . . . . . . . . . 1-10 32. ELECTRICAL EQUIPMENT . . . . . . . . . 1-15
13. TYRE AND SPARE TYRE
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . 1-10 Continued on next page
14. SUSPENSION SYSTEM. . . . . . . . . . . . 1-10
1-2
AFTER ROAD TEST . . . . . . . . . . . . . 1-16 40. FRONT AND REAR DIFFERENTIAL OIL
33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-16 LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-16 41. HOSES, FLUID LINES AND

CONNECTIONS LOCATED UNDER
35. RADIATOR COOLANT LEVEL . . . . . . . 1-16 VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
36. HOSES, FLUID LINES AND
CONNECTIONS LOCATED UNDER HOOD 1-16
FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-18
37. MANUAL TRANSMISSION AND
42. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-18
TRANSFER (4WD) OIL LEVEL . . . . . . . . . 1-16
43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-18
38. AUTOMATIC TRANSMISSION FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 44. EXTERIOR AND INTERIOR . . . . . . . . . 1-18
39. ENGINE, TRANSMISSION, STEERING 45. OWNER INSTRUCTIONS . . . . . . . . . . . 1-18
GEAR BOX AND DIFFERENTIAL FOR
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRE-DELIVERY INSPECTION
NOTES CONCERNING ENTRIES
1-3
M6010100100057
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: .
1. The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in kilo-
metres (miles), date of inspection, name of person conducting the inspection, and body colour must be
completed without fail.
2. 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
1-5
PAINTWORK TERMS
M6010200100032
Term Definition Remarks

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, discoloration and
uniform. decoloration.
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 The peeling may be minor, medium,
(partly or over a wide area). or 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
CONNECTOR
M6010300100073
Connecting Procedure
Junction block
Storage connector
AC311576AB
Press down the storage connector.
BODY
2. WRAP FILM
M6010400100025
AC305606
To protect the exterior finish of vehicles prior to

dealer delivery, a protective coating is used. The
coating is a thin white resin film. It is applied to all
painted exterior horizontal surfaces of the vehicle
and is held in place with a tacky adhesive backing.
BODY
1-7
Removal procedure
Peel off slowly from corners keeping parallel to the body. When
Wrap film removal the body temperature is high, lower it to 50ºC or less by
sprinkling water so that adhesive may not remain on the body.
Water washing
Wipe-off by kerosene or white gasoline, etc.

Cleaning of border
If it is considerably visible, use polishing compound.
Disposal of removed film: Burning is appropriate
AC306352 AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are There should be no leftover adhesive, swelling or
checked. discoloration of the paint film, or other defects.
4 Treatment of parts where film is to be Treat the defects on the parts where film is to be
reapplied. reapplied. If a solvent is used to remove leftover
adhesive, wipe off the solvent thoroughly.
5 Reapplication 1. Basically, the parts where the film is to be applied
should be the same as the film that is to be applied.
2. Apply the film from the lower portion of the body,
working upward progressively. Apply pressure using
a plastic squeegee or similar tool.
3. As necessary, cut the film at the various parts such as
windshield washer nozzles, hood and trunk lid.
CAUTION
1. Apply the film with the body at a temperature of 10 − 40°C. (Workability is good in this temperature
range.)
2. If the outside surface of the film (the side with no adhesive) is brought into direct contact with the
paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not
get folded under or otherwise make contact with the paint film.
3. Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort
should be made to prevent air bubbles from being trapped under the film by applying pressure
from the centre of the film outward toward the edges during application.
4. To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of
the film securely.
BODY
3. EXTERIOR 6. Verify that all doors can be locked by the lock

M6010400200334 buttons.
1. Visually inspect the entire exterior.
NOTE:
(1) Paint condition
Adjust and lubricate the door latches, strikers and
(2) Corrosion, scratches locks as required.
(3) Bent edges, dented panels
2. Coated surfaces maintenance
Touch up minor paint chips and flaws.
NOTE:
For terms of paintwork, refer to P.1-5.
4. OPERATION OF DOOR LOCKING

SYSTEMS AND DOOR HINGES
M6010400300029
Child-protection knob
AC305610 AB
7. Verify that the rear doors can't be opened by the

inner door handle when the child protection knob
at the end of the door is shifted to the "LOCK"
position with the inside lock plunger raised.
CAUTION
Set the lock to the "FREE" position on child pro-
Front
tection of both rear doors. (For four door models)
AC305608 AB
5. OPERATION OF DOOR MIRRORS,
WINDOWS AND SUNROOF
M6010400400220
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.
3. Power windows
AC210253AB Check that the door windows operate when the
respective switches are operated. Check that
1. Open each door to check the release mechanism when the lock switches are depressed, the
and ease of operation. respective door windows can no more be opened
2. Close the door to check the latch and striker. or closed.
3. Open the door, operate the lock lever and close 4. Slide window
the door to check the lock. Close the slide window to the fully closed position
4. Partially close the door to check the open-door to check operation.
detent. 5. Sunroof
5. Unlock each door with the key to check lock Close the sunroof to the fully closed position to
operation. check operation.
UNDER HOOD
1-9
UNDER HOOD
6. ENGINE OIL LEVEL 9. WASHER FLUID LEVEL
M6010500100022 M6010500400023
MAX
MIN
AC305611 AB AC305614
Check that the oil level is between "MAX" and "MIN". Check the fluid level; if it is low, replenish the washer
If it is at or below MIN, add the necessary amount of fluid at the up to MAX mark.
the specified engine oil referring to GROUP 2, Peri- 1. Windshield washer reservoir
odic Inspection and Maintenance P.2-3.
2. Rear window washer reservoir
7. BRAKE MASTER CYLINDER FLUID
LEVEL 10. BATTERY CONDITION AND
M6010500200041 CONNECTIONS
M6010500500020
AC305612
Check the fluid level. AC305615
If it is below the "MIN" mark, replenish fresh brake Inspect the battery connections. Verify that they are
fluid up to the "MAX" mark. tightened.
Specified Brake Fluid: DOT4+ NOTE:
Do not wipe the lubricant from the battery posts and
8. CLUTCH MASTER CYLINDER FLUID cable clamps.
LEVEL
M6010500300048
AC305613
Check the fluid level.

If it is below the "MIN" mark, replenish fresh brake
fluid up to the "MAX" mark.
Specified Brake Fluid: DOT4+
UNDER VEHICLE
11. POWER STEERING FLUID LEVEL 12. ELECTRICAL WIRING

M6010500600027 M6010500700024
AC305616 AC305617
1. Check that the fluid level is between "MAX" and 1. Each electrical wiring harness and connector
"MIN". (1) Check each harness to be correctly routed
2. If the fluid is added, start the engine and turn the and securely clipped.
steering wheel from stop to stop several times to (2) Confirm that all connections are tight.
expel air from the system. 2. Ignition cable
Specified gear oil: Automatic transmission Be sure that all ignition cables are firmly attached
fluid DEXRON II to the spark plugs, distributor cap (or crank angle
sensor) and ignition coil.
UNDER VEHICLE
13. TYRE AND SPARE TYRE PRESSURES 14. SUSPENSION SYSTEM
M6010600100029 M6010600200026
AC305618 AC305609
1. Tyre specification Check to be sure that each installation bolt and nut is
Check the correct tyre specification. tightened. If split pins are used, make sure that they
are properly installed.
2. Tyre pressures
Adjust each tyre pressure. 1. Lower arm, Upper arm
2. Stabilizer bar
NOTE:
Recommended pressure is shown on the tyre pres- 3. Strut assembly
sure label.
3. Valve stem extensions
Verify that the valve stem extensions are installed
where necessary.
4. Install the wheel covers, wheel rings and hub
caps.
UNDER VEHICLE
1-11
REMOVE FRONT SPRING RESTRAINTS 15. STEERING LINKAGE AND SPLIT PINS
M6010600300023
Spring
restraints
AC305605
AC305604
With the vehicle correctly positioned on the
sub-frame contact points, and the suspension fully 1. Steering linkage retaining nuts and split pins
extended, remove the rubber restraints from the front Check visually and by feel that the steering
springs. linkage retaining nuts are correctly tightened and
the split pins are correctly installed.
CAUTION
It is very important that these restraints must be 2. Tie rods and relay rod
removed during predelivery-inspection. Failure Check that the tie rods and relay rod of the
to do so could cause ride and handling com- steering linkage are not bent and that the tie rod
plaints. end lock nuts are securely tightened.
3. Steering components
(1) Check that each of the steering components is
tightened.
(2) Check the tie rod end, nuts and split pins for
proper installation.
(3) Check the condition of bellows-type dust
seals.
4. Split pins
Check the front axle nuts and rear wheel spindle
nuts for split pins.
16. UNDER BODY

M6010600400020
Check under body and under body coating for dam-
age.
BEFORE ROAD TEST
BEFORE ROAD TEST

17. SEAT ADJUSTERS AND SEAT BACK 2. Check each indicator lamp and warning lamp
LATCHES functions properly.
M6010700100026
22. AIR CONDITIONER, HEATER AND
DEFROSTER SYSTEM
M6010700600021
Check the systems for proper operation.
AC305622
Check the operation of the various parts of the seats.
1. Mechanical adjusters of the seats
2. Operation of the latch for tilting the seatbacks
AC305625
forward and backward.
1. Air conditioner
18. INHIBITOR SWITCH
M6010701100029 (1) Operate the air conditioner system.
On models with an automatic transmission, be sure (2) Operate the air conditioner light.
the engine starts in both "P" and "N" position, and (3) Operate the control lever in all ranges.
does not start in other positions. (4) Operate the blower motor switch in all ranges.
19. IDLE CONTROL KNOB
M6010700300020
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.
20. INSTRUMENT PANEL CONTROLS

M6010700400027
Check the operation of the following
1. Horn
2. Head lamps
3. Exterior and interior lamps AC305626
4. Instrument panel lamps 2. Heater and defroster

5. Instrument brightness control (1) After the engine has warmed up, turn on the
heater.
21. METERS, GAUGES, WARNING
(2) Operate the blower motor switch in all ranges.
LAMPS AND INDICATION LAMPS (3) Move the control to "Defrost" position.
M6010700500024
A: From front and side defroster
B: From centre ventilators
C: From side ventilators
D: From under the instrument panel
E: From under the front seat (some models only)
AC305624
1. Check the meters and gauges are functioning

properly.
BEFORE ROAD TEST
1-13
23. WIPERS AND WASHERS
M6010700700028
AC305629
AC305627 (2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the
1. Front wiper and washer brake pedal free play, refer to GROUP 2, Peri-
(1) Check operation of the front wipers in all odic Inspection and Maintenance P.2-3.
ranges. 2. Parking brake
(2) Check the aim of the front washer stream. Check the parking brake drag and lever travel.
(3) Check the wiper blade-stop positions. NOTE: For inspection of the parking brake lever,
(4) Verify that the interval between cycles of refer to GROUP 2, Periodic Inspection and Main-
wiping is shifted when timer knob is turned to tenance P.2-3.
any position.
(5) Verify that the front wipers function by 25. CLUTCH OPERATION
operating the washer switch. M6010700900088
2. Rear wiper and washer

(1) Check the operation of the rear wiper.
(2) Check the aim of the rear washer stream.
(3) Check the wiper blade-stop positions.
24. OPERATION OF SERVICE BRAKES

AND PARKING BRAKES
M6010700800069
AC305630AC
1. Check the clutch operation in all driving ranges.

Depress the brake pedal
with approximately 500
2. Turn up the carpet, etc. under the clutch pedal.
N force Check the pedal-to-toeboard clearance when the
clutch is just disengaged.
Clearance to toeboard when clutch disen-
gaged:
Standard value: 30 mm or more
AC305628 AB
1. Service brakes
(1) Turn up the carpet, etc under the brake pedal.
Check the clearance between the brake pedal
and the toeboard when the brake pedal is
depressed. If the clearance does not meet the
specifications, check for air in the system,
brake fluid leakage, and/or a malfunction of
the pedal itself.
Clearance between the brake pedal and the AC305631
toeboard:
Standard value: 70 mm or more 3. Verify correct clutch pedal free play.
ROAD TEST
NOTE: 26. OPERATION OF SEAT BELTS,

For inspection and adjustment of the free play of SHOULDER BELTS AND RETRACTORS
the clutch pedal, refer to GROUP 2, Periodic M6010701000022
Inspection and Maintenance P.2-3.
AC305632
1. Verify that the seat belt warning lamp operates

properly.
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
27. ENGINE PERFORMANCE AND 28. 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
1-15
31. VIBRATION AND RATTLES
M6010800500021
1. Locate squeaks, rattles and unusual vibrations.
Button
2. Verify that no noise occurs from the engine,
transmission, axle and body.
32. ELECTRICAL EQUIPMENT

M6010800600028
AC305635 AB
2. Automatic transmission
(1) Make sure shift indicator lines up properly in
all ranges.
(2) Depress the accelerator completely to check
that the manual kickdown is operating
AC305637
correctly.
(3) Stop the vehicle on a steep incline. 1. Radio
Put the automatic transmission in "P" position
Tune the radio to a local broadcasting station and
and slowly release the service brakes to see if
check the following:
"P" position lock holds. If it does not hold, the
transmission requires further service. (1) Operate the volume, tone, balance and fader
controls, etc.
29. BRAKES (2) Pull out the pushbuttons, dial another station
M6010800300027 and set each pushbuttons.
1. Service Brake (3) Operate the AM/FM switch.
Put the vehicle in gear and apply the brakes while
2. Tape player
the vehicle is in motion. Be sure brake operation
is smooth and positive. Insert a cassette tape in the tape player and
2. Parking Brake check as follows:
(1) Stop the vehicle on a steep incline. (1) Check the operation of the tape feeder and
With the service brakes firmly applied, place rewind.
the transmission in "N" position, and set the (2) Check the ejection.
parking brakes. (3) Check the operation of volume, tone, balance
(2) Slowly release the service brakes to see if the and fader controls, etc.
parking brakes will hold.
30. STEERING CONTROL

M6010800400024
AC305636
1. Check for excessive play or looseness.

2. Check the steering wheel centre.
AFTER ROAD TEST
AFTER ROAD TEST

33. IDLE SPEED 36. HOSES, FLUID LINES AND
M6010900100064
Check the engine idle speed. CONNECTIONS LOCATED UNDER HOOD
M6010900400043
NOTE: For specific idle speed adjustment proce-
dure, refer to GROUP 2, Periodic Inspection and
Maintenance P.2-3.
34. IGNITION TIMING

M6010900200049
AC305643
1. Check all brake, fuel, power steering and air

conditioner lines and connections; verify proper
routing, check connections for leaks, tighten loose
connector as required.
AC305641
2. Inspect routing and connections of all vacuum,
Check the ignition timing. Except MPI vehicles with and radiator and heater houses.
crankshaft-mounted crankshaft angle sensor.
CAUTION
NOTE: For the inspection and adjustment of the igni- Remember that the air conditioner system is
tion timing, refer to GROUP 2, Periodic Inspection under pressure.
and Maintenance P.2-3.
NOTE:
Keep in mind that an oily residue around an air
35. RADIATOR COOLANT LEVEL
M6010900300046 conditioner connector does not necessarily indi-
cate a leak. Oil is used to lubricate fittings during
assembly. Be sure lines are not twisted or kinked.
37. MANUAL TRANSMISSION AND

TRANSFER (4WD) OIL LEVEL
M6010900500103
Filler plug hole

AC305642
1. Check that the coolant level in the reserve tank is 0 - 5 mm

at or above "LOW" mark at normal engine
operating temperature. And check cooling system
for leaks. Filler plug
2. Check that the coolant concentration is 30% to Transmission oil
AC311891AB
60%.
CAUTION 1. Remove the filler plug.
Do not remove the radiator cap while the cooling 2. Check that the oil level is with in 0 − 5 mm from
system is under pressure. the lower edge of the filler plug hole.
When removing the radiator cap, be careful of
3. If the level is low, replenish the transmission with
steam and boiling water. Add coolant only to the
fresh oil by using a lubricator.
reserve tank if it is required.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance P.2-3.
AFTER ROAD TEST
1-17
38. AUTOMATIC TRANSMISSION FLUID
•
TYPE 1 TYPE2
LEVEL
M6010900600070
8 mm Gear oil
Upper
limit
Lower
limit
AC305646 AB
Type 1 only: Remove the filler plug, and check the

AC005861AD
gear oil level. Check that gear oil level is not 8
mm below the bottom of filler plug hole.
1. Remove the dipstick and check the fluid level. 3. If the level is low, replenish the front and/or rear
2. Fluid level is okay if it is in the specified range as differential with fresh oil by using a lubricator.
illustration at normal engine operating NOTE:
temperature. For the specified oil, refer to GROUP 2, Periodic
3. If the level is below the lower notch, replenish fluid Inspection and Maintenance P.2-3.
until the level reaches the upper notch.
41. HOSES, FLUID LINES AND
Automatic transmission fluid: DIA QUEEN
ATF SP III CONNECTIONS LOCATED UNDER
VEHICLE
CAUTION M6010901000048
Do not overfill.
39. ENGINE, TRANSMISSION, STEERING

GEAR BOX AND DIFFERENTIAL FOR
LEAKS
M6010900700044
Check the engine, transmission, steering gear box
and differential for oil leaks.
40. FRONT AND REAR DIFFERENTIAL

AC305647
OIL LEVELS
M6010900800041 1. Check all hoses, fluid lines and connections for
1. Remove the filler plug. leaks.
2. Check the oil level. If the oil level is at or slightly 2. Check all hoses and fluid lines for proper routing
below the filler hole, it is in satisfactory condition. away from sharp edges and moving components.
FINAL STEPS
FINAL STEPS
42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR
M6011000100042 M6011000300295
Finally check and clean the exterior and interior.
1. Wash the vehicle to remove all traces of road
Screen
Headlamp
grime and other dirt on the vehicle as a result of
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 Work- 45. OWNER INSTRUCTIONS
shop Manual for that model. M6011000400043
1. Verify that the owner's manual and service
43. EQUIPMENT booklet is in the glove box.
M6011000200049 2. Place the spare keys in envelope in the glove box
before delivery.
AC305649
Check the installation of the various equipment.

1. Floor mats
2. Spare tyre
3. Jack, jack handle and tool set
0-2 GENERAL
PRECAUTIONS BEFORE SERVICE

PROTECTING THE VEHICLE
M6001000100029
AC305592
AC305590
If punch marks or mating marks are made to avoid
error in assembly and facilitate the assembly work,
If there is a likelihood of damaging interior or exterior be sure to make them in locations which will have no
parts during service operations, protect them with detrimental effect on performance and/or appear-
suitable covers (such as seat covers, fender covers, ance. If an area having many parts, similar parts,
etc.). and/or parts which are symmetrical right and left is
disassembled, be sure to arrange the parts so that
DOING SERVICE WORK IN GROUPS OF they do not become mixed during the assembly proc-
TWO OR MORE MECHANICS ess.
M6001000200026
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.
SPECIAL TOOLS
M6001000400031
AC305283
If the service work is to be done by two or more

mechanics working together, all the mechanics
involved should take safety into consideration while
they work.
REMOVAL AND DISASSEMBLY

M6001000300023
AC305593
If other tools are substituted for the special tools to

do service of repair work, there is the danger that
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe-
cial tool whenever doing any work for which the use
of one is specified.
AC305591
When checking a malfunction, find the cause of the

problem. If it is determined that removal and/or dis-
assembly is necessary, perform the work by following
the procedures contained in this manual.
GENERAL
0-3
PARTS TO BE REPLACED TUBES AND OTHER RUBBER PARTS
M6001000500027 M6001000700021
AC305594 AC305595
If any of the following parts are removed, they must Be careful to avoid spilling any petrol, oil, etc.,
be replaced with new parts. because if it adheres to any tubes or other rubber
• Oil seals parts, they might be adversely affected.
• Gaskets (except rocker cover gasket)
• Packings LUBRICANTS
M6001000800028
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
PARTS
M6001000600024
AC305596
In accordance with the instructions in this manual,

apply the specified lubricants in the specified loca-
tions during assembly and installation.
BRAKE FLUID
AC305284 M6001000900025
When replacing parts, use MITSUBISHI genuine

parts.
AC305285
Be careful to avoid spilling any brake fluid, because if

it adheres to the vehicle body, the paint coat might be
discoloured.
0-4 GENERAL
SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING

M6001001000025 M6001001300037
Approx.
40 cm
ACX00880AD ACX00881AE
Before replacing a component related to the electri- If high-pressure car-washing equipment or steam
cal system and before undertaking any repair proce- car-washing equipment is used to wash the vehicle,
dures involving the electrical system, be sure to first be sure to note the following information in order to
disconnect the negative (-) cable from the battery in avoid damage to plastic components, etc.
order to avoid damage caused by short-circuiting. • Spray nozzle distance: Approx. 40 cm or more
CAUTION • Spray pressure: 3,900 kPa or less
Before connecting or disconnecting the negative • Spray temperature: 82°C or less
(-) cable, be sure to turn off the ignition switch • Time of concentrated spray to one point: within
and the lighting switch. (If this is not done, there 30 sec.
is the possibility of semiconductor parts being
damaged.)
MULTI USE TESTER (M.U.T.-III) SUB
ASSEMBLY
APPLICATION OF ANTI-CORROSION M6001001800098
Refer to the "M.U.T.-III OPERATING INSTRUC-
AGENTS AND UNDERCOATS TIONS" for instructions on handling the M.U.T.-III.
M6001001100022
If oil or grease gets onto the oxygen sensor, it will AC302297
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
M6001001200029
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
16-pin
tion can be carried out. If you see the words "Set the
vehicle to the pre-inspection condition" in this man-
MB991910
ual, it means to set the vehicle to the following condi-
MB991824
tion.
• Engine coolant temperature: 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
• A/T: P range
MB991827 AC310120AB
Connect the M.U.T.-III to the diagnosis connector as

shown in the illustration.
CAUTION
Turn the ignition switch to the LOCK (OFF) posi-
tion before connecting or disconnecting the
M.U.T.-III.
GENERAL
0-5
IN ORDER TO PREVENT VEHICLES Other precautions:
FROM FIRE • Avoid prolonged and repeated contact with oils,
M6001001500020 particularly used engine oils.
"Improper installation of electrical or fuel related parts • Wear protective clothing, including impervious
could cause a fire. In order to retain the high quality gloves where practicable.
and safety of the vehicle, it is important that any • Avoid contaminating clothes, particularly under-
accessories that may be fitted or modifica- pants, with oil.
tions/repairs that may be carried out which involve • Do not put oily rags in pockets, the use of overalls
the electrical or fuel systems, MUST be carried out in without pockets will avoid this.
accordance with MMC's information/Instructions". • Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
ENGINE OILS cleaned regularly and kept separately from per-
M6001001600027
sonal clothing.
Health Warning • Where there is a risk of eye contact, eye protec-
Prolonged and repeated contact with mineral oil will tion should be worn, for example, chemical gog-
result in the removal of natural fats from the skin, gles or face shields; in addition an eye wash
leading to dryness, irritation and dermatitis. In addi- facility should be provided.
tion, used engine oil contains potentially harmful con- • Obtain First Aid treatment immediately for open
taminants which may cause skin cancer. Adequate cuts and wounds.
means of skin protection and washing facilities must • Wash regularly with soap and water to ensure all
be provided. oil is removed, especially before meals (skin
cleansers and nail brushes will help). After clean-
Recommended Precautions ing, the application of preparations containing
The most effective precaution is to adapt working lanolin to replace the natural skin oils is advised.
practices which prevent, as far as practicable, the • Do not use petrol, kerosine, diesel fuel, gas oil,
risk of skin contact with mineral oils, for example by thinners or solvents for cleaning skin.
using enclosed systems for handling used engine oil • Use barrier creams, applying them before each
and by degreasing components, where practicable, work period, to help the removal of oil from the
before handling them. skin after work.
• If skin disorders develop, obtain medical advice
without delay.
NOTES
2-1
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
PERIODIC INSPECTION AND OPERATIONS UNDER THE

MAINTENANCE SCHEDULE . . . . . . 2-3 VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 2-21
B1. CHECK SUSPENSION SYSTEM FOR
OPERATIONS INSIDE THE ENGINE DAMAGE AND LOOSENESS . . . . . . . . . . . 2-21
COMPARTMENT . . . . . . . . . . . . . . . . 2-6 B2. CHECK SUSPENSION ARM BALL JOINTS
A1. CHECK DRIVE BELT FOR CRACKS, FOR PLAY, AND DUST COVERS FOR
FRAYING, WEAR, AND ADJUST ITS DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 B3. CHECK DRIVESHAFT BOOTS FOR
A2. CHECK INTAKE AIR HOSE FOR DAMAGE DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
(VEHICLES WITH TURBOCHARGER) . . . 2-10 B4. CHECK STEERING LINKAGE FOR
A3. REPLACE ENGINE TIMING BELT DAMAGE AND LOOSE CONNECTIONS
<EXCEPT VEHICLES WITH TIMING CHAIN> 2-10 (Including seals and boots) . . . . . . . . . . . . . 2-22
A4. REPLACE SPARK PLUGS. . . . . . . . . . 2-10 B5. CHECK MANUAL TRANSMISSION FOR
OIL LEAKAGE (In case of leakage, check the
A5. CHECK VALVE CLEARANCE
oil level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
(EXCEPT VEHICLES WITH AUTO-LASH
ADJUSTER) . . . . . . . . . . . . . . . . . . . . . . . . 2-10 B6. CHANGE GEAR OIL IN MANUAL
TRANSMISSION
A6. CHECK RADIATOR HOSES FOR DAMAGE
(include Automated manual transmission) . 2-23
AND PROPER CONNECTION . . . . . . . . . . 2-14
B7. CHECK EXHAUST PIPE CONNECTIONS
A7. CHECK ENGINE COOLANT LEVEL IN
FOR GAS LEAKAGE, AND CHECK PIPE
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 2-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 2-23
A8. CHANGE ENGINE COOLANT . . . . . . . 2-15
A9. CHECK AIR CLEANER ELEMENT FOR OPERATIONS INSIDE THE
CLOGGING AND DAMAGE . . . . . . . . . . . . 2-17
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 2-24
A10. REPLACE AIR CLEANER ELEMENT 2-17
C1. CHECK BRAKE PEDAL AND CLUTCH
A11. CHECK FLUID LEVEL IN BRAKE PEDAL FOR FREE PLAY . . . . . . . . . . . . . . 2-24
RESERVOIR AND CLUTCH
C2. CHECK PARKING BRAKE LEVER
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 2-18
STROKE AND PLAY . . . . . . . . . . . . . . . . . . 2-24
A12. CHANGE BRAKE FLUID . . . . . . . . . . 2-18
C3. REPLACE AIR PURIFIER FILTER . . . . 2-25
A13. CHECK BATTERY CONDITION . . . . 2-19
A14. REPLACE FUEL FILTER . . . . . . . . . . 2-19 Continued on next page
2-2
OPERATIONS OUTSIDE THE OPERATIONS AFTER ENGINE IS

VEHICLE . . . . . . . . . . . . . . . . . . . . . . 2-26 WARMED UP . . . . . . . . . . . . . . . . . . . 2-30
D1. CHECK WHEEL ALIGNMENT . . . . . . . 2-26 E1. CHANGE ENGINE OIL . . . . . . . . . . . . . 2-30
D2. CHECK FRONT AND REAR WHEEL E2. REPLACE ENGINE OIL FILTER . . . . . 2-31
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-27
D3. CHECK BRAKE HOSES AND PIPES FOR OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-32
LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
F1. CHECK BODY CONDITION FOR
D4. CHECK BRAKE PADS AND DISCS FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
F2. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-32
D5. CHECK BRAKE SHOE LININGS AND
DRUMS FOR WEAR. . . . . . . . . . . . . . . . . . 2-29
D6. CHECK FUEL HOSES AND PIPES FOR
LEAKAGE OR DETERIORATION . . . . . . . 2-30
PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
2-3
M6020100101608
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
Maintenance item Maintenance Maintenance interval
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
A1 Check drive belt for cracks, fraying, wear, and adjust Inspection Every 20,000 km or every
its tension 12 months
A2 Check intake air hose for damage Inspection Every 40,000 km or every
(vehicles with turbocharger) 2 years
A3 Replace engine timing belt Replace Every 100,000 km
(except vehicles with timing chain)
A4 Replace spark plugs Standard type Replace Every 40,000 km
Iridium tipped Replace Every 100,000 km
type
A5 Check valve clearance Inspection Every 100,000 km
(except vehicles with auto-lash adjuster)
A6 Check radiator hoses for damage and proper Inspection Every 40,000 km or every
connection 2 years
A7 Check engine coolant level in reservoir Inspection Every 40,000 km or every
2 years
A8 Change engine coolant Change Every 60,000 km or every
4 years
A9 Check air cleaner element for clogging and damage Inspection Normal Every 20,000 km
usage
Severe Every 10,000 km
usage
A10 Replace air cleaner element Replace Normal Every 40,000 km or
usage every 3 years
Severe More frequently
usage
A11 Check fluid level in brake reservoir and clutch Inspection Every 20,000 km or every
reservoir 12 months
A12 Change brake fluid Change Every 40,000 km or every
2 years
A13 Check battery condition Inspection Every 20,000 km or every
12 months
A14 Replace fuel filter Replace Every 160,000 km or every 1
0 years
OPERATIONS UNDER THE VEHICLE
B1 Check suspension system for damage and looseness Inspection Every 40,000 km or every
2 years
B2 Check suspension arm ball joints for play, and dust Inspection Every 40,000 km or every
covers for damage 2 years
2-4 PERIODIC INSPECTION AND MAINTENANCE

operation
B3 Check driveshaft boots for damage Inspection Normal Every 40,000 km or
usage every 2 years
usage
B4 Check steering linkage for damage and loose Inspection Every 40,000 km or every
connections (including seals and boots) 2 years
B5 Check manual transmission for oil leakage Inspection Every 20,000 km or every
(In case of leakage, check the oil level) 12 months
B6 Change gear oil in manual transmission Change Normal Every 200,000 km
(include Automated manual transmission) usage
usage
B7 Check exhaust pipe connections for gas leakage, and Inspection Every 40,000 km or every
check pipe installation 2 years
OPERATIONS INSIDE THE VEHICLE
C1 Check brake pedal and clutch pedal for free play Inspection Every 20,000 km or every
12 months
C2 Check parking brake lever stroke and play Inspection Every 20,000 km or every
12 months
C3 Replace air purifier filter Replace Every 20,000 km or every
12 months
OPERATIONS OUTSIDE THE VEHICLE
D1 Check wheel alignment Inspection Every 20,000 km or every
12 months
D2 Check front and rear wheel bearings for play Inspection Every 60,000 km or every
3 years
D3 Check brake hoses and pipes for leakage Inspection Every 40,000 km or every
2 years
D4 Check brake pads and discs for wear Inspection Normal Every 20,000 km or
usage every 12 months
Severe Every 10,000 km or
D5 Check brake shoe linings and drums for wear Inspection Normal Every 40,000 km or
usage every 2 years
Severe Every 20,000 km or
D6 Check fuel hoses and pipes for leakage or Inspection Every 40,000 km or every
deterioration 2 years
2-5
operation
OPERATIONS AFTER ENGINE IS WARMED UP
E1 Change engine oil Vehicles Change Normal Every 20,000 km or
without a usage every 12 months
turbocharger Severe Every 10,000 km
usage
Vehicles with a Change Normal Every 10,000 km or
turbocharger usage every 6 months
usage
E2 Replace engine oil filter Vehicles Replace Normal Every 20,000 km or
without a usage every 12 months
turbocharger Severe Every 10,000 km
usage
Vehicles with a Replace Normal Every 10,000 km or
turbocharger usage every 6 months
usage
OTHERS
F1 Check body condition for damage Inspection Every year
F2 Road test Inspection Every 20,000 km or every
12 months
NOTE: "Severe usage" specifications apply to only vehicles used under severe operating conditions.
Severe operating conditions include the followings:
.
1. Driving in a dusty area.
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. When more than 50% of driving is in heavy city traffic and the ambient temperature is 32°C or more.
9. When more than 50% of driving is at 120 km/h or more and the ambient temperature is 30°C or more.

A1. CHECK DRIVE BELT FOR CRACKS, 2. Press the "POWER" button to turn on the power
FRAYING, WEAR, AND ADJUST ITS supply.
TENSION 3. Press number key 1. Check to ensure that "No.
M6020202900507 01" appears on the upper left of the display and
DRIVE BELT CONDITION that the following numeric values are displayed for
Check the whole rounds of the drive belt for cracks, individual items (M, W, and S):
fraying and wear. M 000.9 g/m
W 010.0 mm/R
DRIVE BELT TENSION
S 0100 mm
ALTERNATOR AND A/C DRIVE BELT
If numeric values have not been entered (new
TENSION CHECK <134, 135> tool), set them according to the belt specifications
Check the drive belt tension in the following proce- as shown below. Once you set them, you do not
dure. have to set them again. The settings remain
Standard value: undeleted even after battery replacement.
Item When When When NOTE: This operation is to temporarily set the
checked adjusted replaced preset data such as the belt specifications,
Vibration 142 − 174 151 − 167 196 − 218 because if the measurement is taken without input
frequency of the belt specifications, conversion to tension
Hz value (N) cannot be made, resulting in judgement
Tension N 392 − 588 441 − 539 784 − 980 of error.
Deflection 10.9 − 16.5 11.9 − 14.6 6.3 − 7.6 <Setting procedure>
mm (1) Press down the "MASS" button till the belt
(Reference) mass select display appears.
(2) Press the "UP" or "DOWN" button to select "01
<When the vibration frequency is 1.5GT 0.9" and press the "MEASURE" button
measured {Special tool (MB992080) is to decide it.
Check to ensure that "M 000.9 g/m" is
used}: Recommendation> displayed.
NOTE: The vibration frequency measuring method is (3) Press the "WIDTH" button to change to the
recommended for check and adjustment of the drive belt width input display.
belt tension. (4) Press number keys 0, 1, 0, and 0 sequentially,
Belt tension meter set (MB992080) and press the "SELECT" button to apply them.
Check to ensure that "W 010.0 mm/R"
MB992081 appears on the display.
(5) Press the "SPAN" button to change to the
span length input display.
(6) Press number keys 0, 1, 0, and 0 sequentially,
and press the "SELECT" button to apply them.
Check to ensure that "S 0100 mm" appears on
MB992082 the display.
AC507219AB
4. Press "Hz" button twice to change the display to
1. Connect the Special tool microphone assembly the frequency display (Hz).
(MB992082) to the Special tool belt tension meter
(MB992081) of the Special tool belt tension meter
set (MB992080).
2-7
CAUTION <When using the tension gauge>
• The temperature of the surface of the belt Alternator
should be as close as possible to normal tem- pulley
Tension
perature. gauge
• Do not let any contaminants such as water or
oil get onto the microphone. Water pump
pulley
• If strong gusts of wind blow against the
A/C compressor
microphone or if there is loud sources of pulley
noise nearby, the values measured by the
Crankshaft
microphone may not correspond to actual pulley
values. AK305688AB
• If the microphone is touching the belt while Use a belt tension gauge to check that the belt ten-
the measurement is being made, the values sion is within the standard value.
measured by the microphone may not corre-
spond to actual values. <Belt deflection check>
• Do not take the measurement while the vehi-
cle's engine is running. Alternator
pulley
Alternator Approximately
15˚ 100 N
15˚ pulley
Water pump
MB992080 pulley
(Microphone) Deflection
A/C compressor
10 – 15 mm pulley
Water pump
pulley Crankshaft
Crankshaft pulley AC807187 AB
pulley
Apply approx. 100 N of force to the middle of the
A/C compressor pulley AC700322 AB
drive belt between the pulleys (at the place indicated
5. Hold the microphone to the middle of the drive by the arrow) and check that the amount of deflection
belt between the pulleys (at the place indicated by is within the standard value.
the arrow), about 10 − 15 mm away from the rear
surface of the belt and so that it is perpendicular If not within the standard valve, adjust the belt ten-
to the belt (within an angle of ± 15 °). sion by the following procedure.
6. Press the "MEASURE" button. Adjusting bolt
7. Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
Alternator fixing nut
your finger as shown in the illustration, and check
that the vibration frequency of the belt is within the
standard value.
NOTE: To take the measurement repeatedly, fillip
the belt again. Nut for alternator
pivot bolt
8. After the completion of the measurement, press AC310987AB
and hold the "POWER" button to turn off the
power supply. 1. Loosen the nut of the nut for alternator pivot bolt.
2. Loosen the alternator fixing nut.
3. Use the adjusting bolt to adjust the belt tension
and belt deflection to the standard values.
4. Tighten the nut of the nut for alternator pivot bolt.
Tightening torque: 39.5 ± 4 N⋅m
5. Tighten the alternator fixing nut.
Tightening torque: 20 ± 2 N⋅m
6. Tighten the adjusting bolt. 2. Press the "POWER" button to turn on the power
Tightening torque: 5.0 ± 1.0 N⋅m supply.
7. Check the belt tension, and readjust if necessary. 3. Press number key 1. Check to ensure that "No.
01" appears on the upper left of the display and
8. When the belt tension is adjusted by measuring
that the following numeric values are displayed for
the deflection, adjust it with a tool for vibration
individual items (M, W, and S):
frequency measurement or tension measurement
afterward. M 000.9 g/m
W 010.0 mm/R
ALTERNATOR DRIVE BELT TENSION
S 0100 mm
CHECK <4G15>
If numeric values have not been entered (new
Check the drive belt tension in the following proce-
tool), set them according to the belt specifications
dure.
as shown below. Once you set them, you do not
Standard value: have to set them again. The settings remain
Item When When When undeleted even after battery replacement.
checked adjusted replaced
NOTE: This operation is to temporarily set the
Vibration 213 − 261 226 − 250 302 − 337 preset data such as the belt specifications,
frequency because if the measurement is taken without input
Hz of the belt specifications, conversion to tension
Tension N 392 − 588 441 − 539 785 − 981 value (N) cannot be made, resulting in judgement
of error.
Deflection 6.3 − 8.0 6.6 − 7.5 4.1 − 5.0
mm <Setting procedure>
(Reference) (1) Press down the "MASS" button till the belt
mass select display appears.
<When the vibration frequency is (2) Press the "UP" or "DOWN" button to select "01
measured {Special tool (MB992080) is 1.5GT 0.9" and press the "MEASURE" button
to decide it.
used}: Recommendation>
Check to ensure that "M 000.9 g/m" is
NOTE: The vibration frequency measuring method is displayed.
recommended for check and adjustment of the drive
(3) Press the "WIDTH" button to change to the
belt tension.
belt width input display.
Belt tension meter set (MB992080) (4) Press number keys 0, 1, 0, and 0 sequentially,
MB992081 Check to ensure that "W 010.0 mm/R"
appears on the display.
(5) Press the "SPAN" button to change to the
span length input display.
(6) Press number keys 0, 1, 0, and 0 sequentially,
MB992082
Check to ensure that "S 0100 mm" appears on
AC507219AB
the display.
1. Connect the Special tool microphone assembly 4. Press "Hz" button twice to change the display to
(MB992082) to the Special tool belt tension meter the frequency display (Hz).
(MB992081) of the Special tool belt tension meter
set (MB992080).
2-9
CAUTION <When using the tension gauge>
• The temperature of the surface of the belt Water pump
should be as close as possible to normal tem- pulley
perature.
• Do not let any contaminants such as water or
oil get onto the microphone. Tension
Gauge
• If strong gusts of wind blow against the
microphone or if there is loud sources of
noise nearby, the values measured by the Alternator
pulley
microphone may not correspond to actual Crankshaft
pulley
values. AK402045AC
• If the microphone is touching the belt while Use a belt tension gauge to check that the belt ten-
the measurement is being made, the values sion is within the standard value.
measured by the microphone may not corre-
spond to actual values. <Belt deflection check>
• Do not take the measurement while the vehi-
Water pump Deflection
cle's engine is running. pulley
Water pump 10 – 15 mm
pulley Approximately
100 N
15˚
15˚
MB992080
(Microphone) Alternator
Crankshaft pulley Crankshaft
Alternator pulley pulley
pulley AK402046AC
Apply approx. 100 N of force to the middle of the

AK600562AB
drive belt between the pulleys (at the place indicated
5. Hold the microphone to the middle of the drive by the arrow) and check that the amount of deflection
belt between the pulleys (at the place indicated by is within the standard value.
the arrow), about 10 − 15 mm away from the rear
surface of the belt and so that it is perpendicular
Locking bolt
to the belt (within an angle of ± 15 °).
6. Press the "MEASURE" button. Adjusting
7. Gently tap the middle of the belt between the bolt
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and check
that the vibration frequency of the belt is within the Nut
standard value.
NOTE: To take the measurement repeatedly, fillip
AC402698AC
the belt again.
If not within the standard value, adjust the belt ten-
8. After the completion of the measurement, press
sion by the following procedure.
and hold the "POWER" button to turn off the
power supply. 1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension
and belt deflection to the standard values.
4. Tighten the nut of the alternator pivot bolt.
5. Tighten the nut of the lock bolt.
6. Tighten the adjusting bolt.

Tightening torque: 5.0 ± 1.0 N⋅m Timing mark
CAUTION
When checking the belt tension, turn the crank-
shaft clockwise one turn or more.
7. Check the belt tension, and readjust if necessary.
8. When the belt tension is adjusted by measuring
the deflection, adjust it with a tool for vibration
frequency measurement or tension measurement AK604590AB
afterward.
3. Turn the crankshaft clockwise, and align the
A2. CHECK INTAKE AIR HOSE FOR timing mark on the exhaust camshaft sprocket
DAMAGE (VEHICLES WITH against the upper face of the cylinder head as
shown in Figure. Therefore No.1 cylinder goes to
TURBOCHARGER) the compression top dead centre.
M6020200500075
CAUTION
Turn the crankshaft always clockwise.
Air intake hose
Paint mark
Turbocharger 6.5 teeth

(65 degrees)
AC400556AB
Timing mark
Inspect the intake air hoses for cracks or damage.

AK604591AB
A3. REPLACE ENGINE TIMING BELT
<EXCEPT VEHICLES WITH TIMING 4. Apply the paint mark to the 6.5th tooth (65
degrees) anti-clockwise from the timing mark on
CHAIN> the exhaust camshaft sprocket.
M6020200600061
For information concerning the replacement proce-
dures, refer to the Workshop Manual.
A4. REPLACE SPARK PLUGS

M6020200800593
After removing old spark plugs, install new ones and
tighten them at the specified torque.
65˚
Paint mark
A5. CHECK VALVE CLEARANCE
(EXCEPT VEHICLES WITH AUTO-LASH
Timing mark
ADJUSTER) AK604592AB
M6020600900316
5. Turn the crankshaft clockwise 130 degrees, and
VALVE CLEARANCE CHECK AND
align the paint mark against the upper face of the
ADJUSTMENT <134> cylinder head as shown in Figure.
NOTE: Perform the valve clearance check and
adjustment at the engine cold state.
1. Remove all ignition coils.
2. Remove the cylinder head cover.
2-11
Exhaust valve side Exhaust valve side
No.3 No.2
No. 1 No. 3
Intake valve side AK305588AD Intake valve side AK305588 AF
6. Using a thickness gauge, measure the valve 9. Using a thickness gauge, measure the valve
clearance with the arrow shown in Figure. If clearance with the arrow shown in Figure. If
deviated from the standard value, make note for deviated from the standard value, make note for
the valve clearance. the valve clearance.
Standard value: Standard value:
Intake valve 0.22 ± 0.04 mm Intake valve 0.22 ± 0.04 mm
Exhaust valve 0.30 ± 0.04 mm Exhaust valve 0.30 ± 0.04 mm
Paint mark Paint mark
12 teeth
(120 degrees) 5.5 teeth Paint mark
(55 degrees)
Paint mark
Timing mark
AK604593AB AK604595AB
7. Apply the paint mark to the 12th tooth (120 10.Apply the paint mark to the 5.5th tooth (55
degrees) anti-clockwise from the paint mark. degrees) clockwise from the timing mark on the
exhaust camshaft sprocket.
Paint mark Timing mark
Timing mark
120˚ Paint mark

120˚ Paint mark
Paint mark
Paint mark
AK604594AB
AK604596AB
align the paint mark against the upper face of the 11.Turn the crankshaft clockwise 240 degrees, and
cylinder head as shown in Figure. align the paint mark against the upper face of the
cylinder head as shown in Figure.
Exhaust valve side A: thickness of newly installed valve tappet

No.1
B: thickness of removed valve tappet
C: measured valve clearance
Equation
Intake valve: A = B + (C − 0.22 mm)
Exhaust valve: A = B + (C − 0.30 mm)
NOTE: The valve tappet ranges 2.70 − 3.30 mm
No. 2 and has 31 types per 0.02 mm. The thickness
Intake valve side AK305588 AE below a decimal point is stamped on the reverse
side of the valve tappet.
12.Check the valve clearance with the arrow shown Example: In case of 2.90 mm, "90" is stamped.
in Figure. If deviated from the standard value, 16.Install the valve tappet selected through the
make note for the valve clearance. procedure 15, and put the camshaft in position.
13.If the valve clearance is deviated from the For the camshaft installation, refer to
standard value, remove the camshaft and the WORKSHOP MANUAL.
valve tappet. For the camshaft removal, refer to 17.Remove any liquid gasket remaining on the
WORKSHOP MANUAL. cylinder head cover, the timing chain case and the
Wall cylinder head.
thickness Cylinder head assembly
Timing A A
chain
case
assembly Section A - A
φ 4 mm
A A
AK304938 AB
14.Using a micrometer, measure the thickness of the AK700792 AC
removed valve tappet. 18.Apply a 4 mm bead of liquid gasket as illustrated.

Specified sealant:
Identification mark
LOCTITE 5970 or equivalent
CAUTION
The timing chain should be installed within 3
minutes of applying liquid gasket.
19.Install the cylinder head cover by tightening the
fittings to 9.0 ± 1.0 N⋅m.
20.Install the ignition coils.
AK305693 AB
15.Calculate the thickness of the newly installed

valve tappet through the following equation.
2-13
VALVE CLEARANCE CHECK AND
ADJUSTMENT <135> Timing mark
NOTE: Perform the valve clearance check and
adjustment at the engine cold state.
1. Remove all ignition coils.
2. Remove the cylinder head cover.
180˚
Timing mark
AK604598AB

put the timing mark on the exhaust camshaft
sprocket in position shown in Figure. Therefore,
No.4 cylinder goes to the compression top dead
centre.
AK604597AB Exhaust valve side
No. 2 No. 4
3. Turn the crankshaft clockwise, and align the
timing mark on the exhaust camshaft sprocket
against the upper face of the cylinder head as
shown in Figure. Therefore, No.1 cylinder goes to
the compression top dead centre.
CAUTION
Turn the crankshaft always clockwise. No. 3 No. 4
Intake valve side AK305589 AC
Exhaust valve side
No. 1 No. 3
6. Check the valve clearance with the arrow shown
in Figure. In the same procedure as 4.
7. If the valve clearance is deviated from the
standard value, remove the camshaft and the
valve tappet. For the camshaft removal, refer to
WORKSHOP MANUAL.
No. 1 No. 2 Wall

Intake valve side AK305589AB thickness
4. Using a thickness gauge, measure the valve

clearance with the arrow shown in Figure. If
deviated from the standard value, make note for
the valve clearance.
Standard value:
Intake valve 0.22 ± 0.04 mm
Exhaust valve 0.30 ± 0.04 mm AK304938 AB
8. Using a micrometer, measure the thickness of the

removed valve tappet.
A6. CHECK RADIATOR HOSES FOR

Identification mark DAMAGE AND PROPER CONNECTION
M6020200901043
< 134, 135 >
AK305693 AB
Radiator hose
9. Calculate the thickness of the newly installed
valve tappet through the following equation. AC310828AC
A: thickness of newly installed valve tappet

<4G15>
B: thickness of removed valve tappet
C: measured valve clearance
Equation
Intake valve: A = B + (C − 0.22 mm)
Exhaust valve: A = B + (C − 0.30 mm)
NOTE: The valve tappet ranges 2.70 − 3.30 mm
and has 31 types per 0.02 mm. The thickness Radiator hose
below a decimal point is stamped on the reverse AC404366 AB
side of the valve tappet.
Example: In case of 2.90 mm, "90" is stamped. 1. Check entire circumference and length of hoses,
10.Install the valve tappet selected through the using a mirror as required.
procedure 9, and put the camshaft in position. For 2. Check that hoses installed in grommets pass
the camshaft installation, refer to WORKSHOP through the centre of the grommets.
MANUAL. 3. Check all clamps for tightness and connections
11.Remove any liquid gasket remaining on the for leakage.
cylinder head cover, the timing chain case and the
cylinder head.
Cylinder head assembly
Timing A A
chain
case
assembly Section A - A
φ 4 mm
A A
AK700792 AC
12.Apply a 4 mm bead of liquid gasket as illustrated.

Specified sealant:
LOCTITE 5970 or equivalent
CAUTION
The timing chain should be installed within 3
minutes of applying liquid gasket.
13.Install the cylinder head cover by tightening the
fittings to 9.0 ± 1.0 N⋅m.
14.Install the ignition coils.
2-15
A7. CHECK ENGINE COOLANT LEVEL IN A8. CHANGE ENGINE COOLANT
M6020201101374
RESERVOIR
M6020201000987 <4G1>
< 134, 135 > WARNING
When removing the radiator cap, use care to
avoid contact with hot engine 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
Radiator condenser tank vinyl tube. After relieving the steam pres-
sure, remove the radiator cap by slowly turn-
ing it anti-clockwise.
AC310829AE
1. Drain the engine coolant from the radiator, heater
<4G15> core and engine after unplugging the radiator
drain plug and removing the radiator cap.
Water pump
Cylinder block inlet pipe
drain plug
Radiator condenser tank
AC404367AC
Check that the coolant level is between the "FULL"

and "LOW" lines when the engine is at the normal
AC402236AB
operating temperature.
2. Drain the engine coolant in the water jacket by
unplugging the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain
the engine coolant.
4. Drain the engine coolant then clean the path of
the engine coolant by injecting water into the
radiator from the radiator cap area.
Cylinder block
drain plug
AC104528AB
5. Apply the designated sealant to the screw area of

the cylinder block drain plug, and then tighten to
the standard torque.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent
6. Securely tighten the drain plug of the radiator.
7. Reinstall the radiator condenser tank.
CAUTION <Except for 4G1>

Do not use alcohol or methanol anti-freeze or any WARNING
engine coolant mixed with alcohol or methanol When removing the radiator cap, use care to
anti-freeze. The use of an improper anti-freeze avoid contact with hot engine coolant or
can cause corrosion of the aluminium compo- steam. Place a shop towel over the radiator
nents.
cap and turn the radiator cap anti-clockwise
a little to let the pressure escape through the
vinyl tube. After relieving the steam pres-
MB991871 sure, remove the radiator cap by slowly turn-
ing it anti-clockwise.
1. Drain the engine coolant from the radiator, heater
core and engine after unplugging the radiator
drain plug and removing the radiator cap.
Air hose
<134, 3A9>
AC804898AB
8. By referring to the section on engine coolant,

select an appropriate concentration for safe
operating temperature within the range of 45 to
60%. Use special tool LLC changer (MB991871)
to refill the engine coolant. A convenient mixture
is a 50% water and 50% antifreeze solution
(freezing point: −31°C).
Recommended antifreeze: High-quality ethyl- AC312142
ene glycol based coolant <135,4A9>
Quantity: 6.0 L
NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.
9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the
thermostat opens.
11.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has AC312143
become cold, and pour in engine coolant up to the
brim. Reinstall the radiator cap.
CAUTION
Do not overfill the radiator condenser tank. Cylinder block
drain plug
13.Remove the radiator condenser tank cap, and
refill the engine coolant up to the line "F" on the
cap level gauge.
Gasket
AC312144
AC312996AC
2. Drain the engine coolant in the water jacket by

unplugging the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain
the engine coolant.
2-17
4. Drain the engine coolant then clean the path of CAUTION
the engine coolant by injecting water into the Do not overfill the radiator condenser tank.
radiator from the radiator cap area.
13.Add engine coolant to the radiator condenser tank
5. Install a new cylinder block drain plug gasket and between the "F" and "L" mark if necessary.
then tighten the cylinder block drain plug to the
specified torque. A9. CHECK AIR CLEANER ELEMENT
Tightening torque: FOR CLOGGING AND DAMAGE
<134, 135> 26 ± 2 N⋅m M6020201200798
<3A9, 4A9> 25 ± 3 N⋅m
6. Securely tighten the drain plug of the radiator.
7. Reinstall the radiator condenser tank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolant mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium compo-
nents. AC311579
1. Check air cleaner element for clogging and

damage.
MB991871
2. Clean deposited dust from the element in the
following manner.
(1) Lightly tap the element against the top of a
bench.
(2) Blow compressed air from inside the element.
Air hose 3. Wipe off dust on the air cleaner interior.
AC804898AB
4. Install the air cleaner body.
8. By referring to the section on engine coolant,
select an appropriate concentration for safe A10. REPLACE AIR CLEANER ELEMENT
M6020201300944
operating temperature within the range of 45 to The air cleaner element will become dirty and loaded
60%. Use special tool LLC changer (MB991871) with dust during use, and the filtering effect will be
to refill the engine coolant. A convenient mixture substantially reduced. Replace it with a new one.
is a 50% water and 50% antifreeze solution
(freezing point: −31°C). Air cleaner element
Recommended antifreeze: High-quality ethyl-
ene glycol based coolant
Quantity:
<134, 3A9> 4.2 L
<135, 4A9> 4.6 L
NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.
9. Reinstall the radiator cap. AC311578AB
10.Start the engine and let it warm up until the

1. Unclasp the air cleaner cover clip.
thermostat opens.
2. Remove the air cleaner element and install a new
11.After repeatedly revving the engine up to 3,000
one.
r/min several times, then stop the engine.
3. Be sure to close the air cleaner cover completely
12.Remove the radiator cap after the engine has
when clamping it.
become cold, and pour in engine coolant up to the
brim. Reinstall the radiator cap.
A11. CHECK FLUID LEVEL IN BRAKE CAUTION

RESERVOIR AND CLUTCH RESERVOIR Use the specified brake fluid. Avoid using a mix-
M6020201400297 ture of the specified brake fluid and other fluid. If
brake fluid is exposed to the air, it will absorb
Reservoir tank
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 lit. or 0.5 lit. 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
AC312910AD vinyl tube, tighten the bleeder screw.
1. Check that the fluid level is between the "MAX" NOTE: This change from existing to fresh fluid
and "MIN" mark. can be judged by change in colour of fluid that
flows out.
2. If it is below the "MIN" marks, replenish with fresh
brake fluid up to the "MAX" mark.
A12. CHANGE BRAKE FLUID

M6020201601023
( ):R.H. drive vehicle AC305660 AB
4. Repeat above steps for other bleeder screws.

MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if
AC305659
bleeding is carried out by the following procedure,
1. Remove the cap of the bleeder screw, connect a bleeding of air from the brake pipeline will become
vinyl tube, and place its other end in a receptacle. easier. (When brake fluid is not contained in the mas-
2. Loosen the bleeder screw and depress the brake ter cylinder.)
pedal; supply new brake fluid when the level of 1. Fill the reserve tank with brake fluid.
the fluid within the reservoir tank decreases. 2. Keep the brake pedal depressed.
CAUTION
If the reservoir tank completely runs out of fluid
during operation, air will find way into the brake
line. Pay attention, therefore, to the fluid level
and replenish as necessary.
Specified brake fluid: DOT4+
Outlet
Outlet
AC312910AC
3. Have another person cover the master cylinder

outlet with a finger.
4. With the outlet still closed, release the brake
pedal.
5. Repeat steps (2) - (4) three or four times to fill the
inside of the master cylinder with brake fluid.
2-19
A13. CHECK BATTERY CONDITION A14. REPLACE FUEL FILTER
M6020201700674 M6020201901080
Thermometer Hydrometer 1. Reduce fuel line pressure.

Fuel main tube
Fuel vapour
control line tube
Battery fluid
AC504567AB Fuel return tube

<4G15>
AC400608AD
1. Inspect whether or not the battery fluid is between
the UPPER LEVEL and LOWER LEVEL marks. 2. Disconnect the fuel main tube, fuel return tube
CAUTION <4G15> and fuel vapour control line tube.
1. If the battery fluid is below the LOWER
LEVEL, the battery could explode in using. Fuel tank pump and
gauge mounting cap
2. If the battery fluid is over the UPPER LEVEL, MB991991
leakage could result.
2. Use a hydrometer and thermometer to check the
specific gravity of the battery fluid.
Standard value: 1.220 − 1.290 [20°C]
3. The specific gravity of the battery fluid varies with
the temperature, so use the following formula to
calculate the specific gravity for 20°C. Use the
calculated value to determine whether or not the AC313226AB
specific gravity is satisfactory.

3. Install the fuel tank cap wrench (special tool
D20 = (t - 20) × 0.0007 + Dt MB991991) as shown in the figure, and remove
D20: Specific gravity of the battery fluid cal- the fuel tank pump and gauge mounting cap.
culated for 20°C.
4. Remove the fuel tank pump and gauge assembly
Dt: Actually measured specific gravity
from the service hole.
t: Actually measured temperature
CAUTION
When withdrawing the fuel tank pump and gauge
assembly via the service hole, be careful not to
damage the gauge and the float.
Fuel tank pump and

gauge assembly
AC313782AB
5. Replace the fuel tank pump and gauge assembly

and the fuel tank pump gasket with new ones
respectively.
6. Install the fuel tank pump and gauge assembly to
the fuel tank through the service hole.
CAUTION (3) Remove the fuel tank cap wrench (special tool
When installing the fuel tank pump and gauge MB991991), and check that the mark on the
assembly from the service hole to the fuel tank, fuel tank pump and gauge mounting cap is
be careful not to damage the gauge of fuel tank within the area shown.
pump and gauge assembly and the float. Fuel return tube <4G15>,
fuel vapour control line tube
Fuel tank pump and or fuel main tube
gauge mounting cap Corresponding side
MB991991
3 mm
Quick connector
AC313166AE
CAUTION
AC313226AB After connecting the fuel return tube <4G15> fuel
vapour control line tube or fuel main tube,
7. Install the fuel tank cap wrench (special tool
slightly pull it to ensure that it is installed
MB991991) as shown in the figure.
securely. Also confirm that there is a play
8. Align the mating marks in the following procedure. approximately 3 mm.
6˚ Fuel main tube Fuel tank pump
and gauge assembly
connector
Mating marks
Fuel vapour
Fuel return tube
control line tube
<4G15>
AC313190AB AC400420AD
(1) Tighten the fuel tank pump and gauge

mounting cap to align the mating marks. 9. Connect the fuel tank pump and gauge assembly
(2) Use a torque wrench to ensure that the fuel connector, fuel main tube, fuel return tube
tank pump and gauge mounting cap is <4G15> and fuel vapour control line tube.
tightened to 60 N⋅m or more. 10.Install the service hole cover.
11.Return the centre carpet to the original state.
12.Install the rear seat assembly.
2-21
B1. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS
M6020300100063
FRONT SUSPENSION
Deterioration
and sagging
Noise and
oil leakage
Bends and
damage
Cracks, bends
and dents Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Deterioration
and sagging
Cracks, bends
and dents
AC313282AB
B2. CHECK SUSPENSION ARM BALL B4. CHECK STEERING LINKAGE FOR
JOINTS FOR PLAY, AND DUST COVERS DAMAGE AND LOOSE CONNECTIONS
FOR DAMAGE (Including seals and boots)
M6020300200532 M6020300500577
LOWER ARM BALL JOINT AXIAL PLAY

CHECK
Dust cover
AC305662
1. Move the steering wheel bit by bit to the left or

Lower arm
AC311581AB right, and check to be sure that there is no play or
looseness in the linkage coupling, that the
1. Raise the vehicle. installation is not loose, and that the rod or arm is
2. Remove the stabilizer bar from the lower arm not bent or damaged.
assembly.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly.
DUST COVERS FOR DAMAGE

1. Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.
2. If the dust cover is cracked or damaged, replace AC311580AB
the lower arm assembly.
2. Check to be sure that the seal and boot of the ball
NOTE: If the dust cover is cracked or damaged, it joint are correctly installed (in the correct
is possible that there may also be damage to the position), and that they are not damaged.
ball joint.
3. Check tie-rod end jam nut for looseness. If jam
B3. CHECK DRIVESHAFT BOOTS FOR nut is loose, adjust toe-in and then tighten jam nut
to the specified torque.
DAMAGE
M6020300400439 Tightening torque: 43 ± 7 N⋅m
AC305661
Check the driveshaft boots for damage.

2-23
B5. CHECK MANUAL TRANSMISSION <Right side view>
FOR OIL LEAKAGE
(In case of leakage, check the oil level)
M6020300600400
Check oil leakage

Check the transmission case for oil leakage visually
or by touching it with hand.
NOTE: An oil leakage is not detected, the oil level Drain plug
check is necessary.
AC311888AB
Check oil level 2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.
Filler plug hole Tightening torque: 43 ± 3 N⋅m
Lower edge of the 4. Fill the specified transmission oil until the level
filler plug hole comes to the lower portion of filler plug hole.
Transmission oil:
<F5MGA> DiaQueen NEW MULTI GEAR OIL
Filler plug API classification GL-3, SAE 75W-80 or
DiaQueen WIDE GEAR OIL G-1 or Cas-
Transmission oil AC711146 AE
trol/Burmah gear oil BOT328 (or exact equiv-
alents)
1. Remove the filler plug. <F5MGB, F6SGA> DiaQueen WIDE GEAR
2. Check that the oil level is within approximately 8 OIL G-1 or Castrol/Burmah gear oil BOT328
mm <F5MGA>, approximately 22 mm <F5MGB> (or exact equivalents)
or approximately 5mm <F6SGA> from the lower Quantity: 1.75L
edge of the filler plug hole.
5. Tighten the filler plug to the specified torque.
3. Check that the transmission oil is not noticeably
dirty, and that it has a suitable viscosity. Tightening torque: 43 ± 3 N⋅m
4. Tighten the filler plug to the specified torque. B7. CHECK EXHAUST PIPE
Tightening torque: 43 ± 3 N⋅m CONNECTIONS FOR GAS LEAKAGE,
B6. CHANGE GEAR OIL IN MANUAL AND CHECK PIPE INSTALLATION
M6020301200074
TRANSMISSION (include Automated 1. Confirm that the exhaust pipe does not interfere
manual transmission) with any body components.
M6020300800620
2. Check the exhaust pipe for damage by stones,
<Left side view> etc.
3. Start the engine and check for gas leaks from the
exhaust pipe connections.
Filler plug
AC311889AB
1. Remove the filler plug.


C1. CHECK BRAKE PEDAL AND CLUTCH 2. If the clutch pedal lateral play and the distance
PEDAL FOR FREE PLAY between the clutch pedal and the toeboard when
M6020400100781 the clutch is disengaged do not agree with the
BRAKE PEDAL FREE PLAY standard values, it is probably the result of either
air in the hydraulic system or a faulty master
NOTE: The brake pedal assembly cannot be
cylinder, release cylinder or clutch. Bleed the air,
adjusted structurally and so the brake pedal clevis
and inspect the master cylinder, release cylinder
pin play nor the brake pedal free play is not set.
or clutch.
Brake pedal lateral play
C2. CHECK PARKING BRAKE LEVER
STROKE AND PLAY
M6020400200700
1. Pull the parking brake lever with a force of
approximately 200 N and count the number of
notches.
Standard value: 5 − 7 notches
B CAUTION
AC311382 AC
The 196 N force of the parking brake lever must
1. Measure the brake pedal lateral play. be strictly observed.
Standard value (B): 1.5 mm or less 2. If the parking brake lever stroke is not the
2. If the brake pedal lateral play and the distance standard value, adjust as described below.
between the brake pedal and the toeboard when (1) Remove the rear cup holder.
the brake is disengaged do not agree with the
standard values, it is probably the result of either
air in the hydraulic system or a faulty master
cylinder, release cylinder or brake. Bleed the air,
and inspect the master cylinder, release cylinder
or brake.
CLUTCH PEDAL FREE PLAY

Adjusting nut
NOTE: The clutch pedal assembly cannot be
adjusted structurally and so the clutch pedal clevis AC311502 AB
pin play nor the clutch pedal free play is not set. (2) Loosen the adjusting nut to the end of the
Clutch pedal lateral play cable rod in order to allow slack in the cables.
(3) For vehicles with rear drum brakes, with the
engine idling, forcefully depress the brake
pedal five or six times and confirm that the
pedal stroke stops changing.
NOTE: If the pedal stroke stops changing, the
automatic-adjustment mechanism is function-
ing normally, and the clearance between the
B shoe and drum is correct
AC311382 AB
1. Measure the clutch pedal lateral play.

Standard value(B): 1.5 mm or less
2-25
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
Pin rear brakes may drag.
(6) After the parking brake lever stroke is
adjusted, raise the rear of the vehicle. Release
the parking brake, turn the rear wheels to
Parking brake confirm that the rear brakes are not dragging.
lever
(7) Install the rear cup holder.
AC311503AB
(4) For vehicles with rear disc brakes, check that

C3. REPLACE AIR PURIFIER FILTER
M6020400300064
the parking brake lever on the caliper side is
touching the parking brake lever bracket.
NOTE: If the parking brake lever is not touch-
ing the parking brake lever bracket, the parking
brake cable might be stuck or routed incor-
rectly, or there might be a problem with the
Air purifier
automatic adjustment mechanism inside the filter
rear brake calipers. Therefore, it is necessary
to check the parking brake cable and to disas- Cover
semble and inspect the rear brake calipers.
AC313204AC
(5) Adjust the parking brake lever stroke to the
Remove the cover from the lower side of the front
standard value by turning the adjusting nut.
passenger to extract the air purifier filter.
After the adjustment, ensure that there is no
free play between the adjusting nut and the
parking brake lever.

D1. CHECK WHEEL ALIGNMENT Standard value:
M6020500101071
FRONT WHEEL ALIGNMENT Item Specifications

Measure wheel alignment with alignment equipment Inner wheels 36°40' ± 1°30' (Left/right
on a level surface. The front suspension, steering deviation within 2°00’)
system, wheels, and tires should be serviced to nor- Outer wheels 32°50'
mal condition before measuring wheel alignment. (for reference)
Toe-in
Standard value:
TOE-OUT ANGLE ON TURNS
At the centre of tyre tread: 0 ± 2 mm To check the steering linkage, especially after the
Toe angle (per wheel): 0°00’ ± 06’ vehicle has been involved in an accident or if an acci-
dent is presumed, it is advisable to check the toe-out
Lock nut Clip angle on turns in addition to the wheel alignment.
Conduct this test on the left turn as well as on the
right turn.
Standard value:
Item Specifications
Toe-out angle on turns (inner 21°21'
wheel when outer wheel at 20°)
AC312518AC CAMBER, CASTER AND KINGPIN

1. Adjust the toe-in by undoing the clip and lock nut, INCLINATION
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions). MB991004
NOTE: The toe will move out as the left turnbuckle
is turned toward the front of the vehicle and the
right turnbuckle is turned toward the rear of the
vehicle.
2. Install the clip and tighten the lock nut to the
specified torque.
AC001079 AB
3. Confirm that the toe-in is at the standard value.
Standard value:
Item Specifications
Standard High-ground
suspension clearance
suspension
Camber −0°30' ± 0° −0°15' ± 0°
30'* 30'*
Caster 2°40' ± 0° 30'* 2°30' ± 0° 30'*
AC306798
Kingpin inclination 13°20' ± 0° 13°00' ± 0° 30'
4. Use a turning radius gauge to check that the 30'
steering angle is at the standard value. NOTE: *: Difference between right and left wheels
must be 30' or less.
NOTE: Camber and caster are preset at the factory
and cannot be adjusted.
2-27
NOTE: For vehicles with aluminium wheels, attach
the camber/caster/kingpin gauge to the driveshaft by
using special tool wheel alignment gauge attachment
(MB991004). Tighten the special tool to the same
torque 236 ± 19 N⋅m as the driveshaft nut.
CAUTION
To prevent the wheel bearing from damage, never
subject the wheel bearings to the vehicle load
when the drive shaft nuts are loosened.
AC209503AC
REAR WHEEL ALIGNMENT
The rear suspension, wheels, and tyres should be 3. Attach a dial gauge as shown in the illustration,
serviced to the normal condition prior to wheel align- and then measure the axial play while moving the
ment measurement. hub in the axial direction.
Limit: 0.05 mm
Toe-in 4. If axial play exceeds the limit, replace the front
Standard value: hub assembly.
At the centre of tyre tread:
<Standard suspension> 3 ± 3.5 mm <Rear wheel>
<High−ground clearance suspension> 2.5 ± 3.5 1. For vehicles with drum brake, remove the brake
mm drum.
Camber 2. For vehicles with disc brake, remove the caliper
assembly, and suspend the caliper assembly with
Standard value: −1°00’ ± 0° 45’ a wire and remove the brake disc.
(Left/right deviation within 30’)
Vehicles with
rear drum brake
Compensator
AC208743 AC
AC102503AD
Vehicles with
NOTE: For vehicles with aluminium wheel, we rec- disc brake
ommend that a compensator be used to measure the
camber.
NOTE: Camber is preset at the factory and cannot
be adjusted.
D2. CHECK FRONT AND REAR WHEEL

BEARINGS FOR PLAY
M6020500900320
<Front wheel> AC311430 AB
1. Remove the disc brake caliper and suspend it 3. Check the bearing's axial play. Place a dial gauge
with a wire. against the hub surface; then move the hub in the
2. Remove the brake disc from the front hub. axial direction and check whether or not there is
axial play.
Limit: 0.05 mm
4. If the play exceeds the limit, replace the rear hub
assembly.
D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300113
Brake booster
Hydraulic unit
Rear disc brake
AC403774AB
Front disc brake
1. Check entire circumference and length of hoses
and pipes.
2. Check all clamps for tightness and connections
for leakage.
D4. CHECK BRAKE PADS AND DISCS

FOR WEAR
M6020500400723
ACX00668AF
3. Using a micrometer, measure disc thickness at

eight positions, approximately 45° apart and 10
mm in from the outer edge of the disc.
Standard value:
<Front> 24.0 mm (except 4G15), 25.8 mm
(4G15)
AC102396AF
<Rear> 10.0 mm
Limit:
1. Check the brake pad thickness through the caliper <Front> 21.5 mm (except 4G15), 23.5 mm
body check port. (4G15)
Standard value: <Rear> 8.0 mm
<Front> 11.2 mm (except 4G15), 10.5 mm 4. If the disc thickness is less than the limits, replace
(4G15) it with a new one.
<Rear> 10.0 mm
Limit: 1.5 mm
2. When the thickness is less than the limit, always
replace the pads at an axle set.
2-29
BRAKE DISC RUN-OUT CHECK Standard value (A):
1. Remove the brake assembly, and then hold it with <Leading> 4.6 mm
wire. <Trailing> 3.3 mm
Limit (A): 0.5 mm
2. Temporarily install the disc with the hub nut.
3. If the thickness of the brake lining is below the
limit, replace the shoe and lining assemblies on
both sides of the vehicle. Never replace only one
side.
BRAKE DRUM INSIDE DIAMETER CHECK

1. Remove the brake drum.
ACX00669AF
3. Place a dial gauge approximately 5 mm from the A

outer circumference of the brake disc, and
measure the run-out of the disc.
Limit:
<Front> 0.06 mm
<Rear> 0.10 mm AC000893AD
D5. CHECK BRAKE SHOE LININGS AND 2. Measure the inside diameter of the brake drum in
DRUMS FOR WEAR two places or more.
M6020500500173
Standard value: 203.0 mm
BRAKE LINING THICKNESS CHECK Limit: 204.4 mm
1. Remove the brake drum. 3. If the inside diameter exceeds the limit, or if it is
excessively worn or one side, replace the brake
drum.
ACX00708AE
2. Measure the thickness of the brake lining at

several places.
D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION

M6020500600114
Fuel tank pump and gauge assembly
Fuel vapour canister
Fuel delivery pipe
Fuel tank assembly

Fuel line pipes
AC404209AC
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.

E1. CHANGE ENGINE OIL
M6020600301317
<134, 135>
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80°C to 90°C.
2. Stop the engine and remove the engine oil filler
cap.
3. Remove the engine oil pan drain plug to drain
engine oil.
AC701360
CAUTION
Use care as oil could be hot. 5. Refill with specified quantity of engine oil.
4. Install a new engine oil pan drain plug gasket and Specified Engine Oil:
then tighten the engine oil pan drain plug to the MB229.1 or higher
specified torque. Total quantity (Includes volume inside oil fil-
Tightening torque: 55 ± 5 N⋅m ter):
<134> 3.2L
<135> 4.2L
6. Install the engine oil filler cap.
7. Start the engine and run it for a few minutes.
8. Stop the engine and check the oil level.
2-31
<4G15> E2. REPLACE ENGINE OIL FILTER
M6020600401080
2. Remove the engine oil filler cap.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
3. Remove the drain plug to drain oil.
CAUTION CAUTION
Use care as oil could be hot. Use care as oil could be hot.
Engine oil <134, 135>
pan drain Commercially-
Engine oil pan plug gasket
drain plug available tool
Engine oil A/C compressor

pan side
AC402262AD
AC312138AC
4. Install a new drain plug gasket so that it faces in

<4G15>
the direction shown in the illustration, and then
tighten the drain plug to the specified torque.
MB991396 or
commercially-
available tool
AC612987AJ
4. Use the commercially-available tool to remove the

engine oil filter.
5. Clean the filter bracket side mounting surface.
AC405038
5. Refill with specified quantity of engine oil.

Specified Engine Oil
• ACEA classification: "For service
A1/B1, A3/B3, A3/B4 or A5/B5"
• API classification: "For service SG" or
higher
Total quantity (Includes volume inside oil filter
and oil cooler): 3.7 L O-ring
6. Install the engine oil filler cap. AC103250AD
7. Start the engine and run it for a few minutes. 6. Apply a small amount of engine oil to the O-ring of
8. Stop the engine and check the oil level. the new oil filter.
OTHERS
7. Where the oil filter O-ring touches the oil pan 8. Install the drain plug and refill the engine oil.
flange, tighten the oil filter to the specified torque 9. Race the engine 2-3 times, and check to be sure
using the commercially-available tool. that no engine oil leaks from installation section of
Engine Number Tightening torque the oil filter.
134, 135 MR984204 Approximately 3/4 turn
(11 ± 1 N⋅m)
4G15 MD136466, Approximately 3/4 turn
MD322508 (17 ± 3 N⋅m)
MD356000 Approximately 3/4 turn
(14 ± 2 N⋅m)
OTHERS
F1. CHECK BODY CONDITION FOR F2. ROAD TEST
M6020700200615
DAMAGE Drive the vehicle and check for conditions.
M6020700100027
1. Check underbody coating for damage. 1. Check free play of steering wheel.
2. Check body painting for damage. 2. Check efficiency of service brakes and parking
brakes system.
3. Check driveability of engine.
4. Check condition of instruments, gauges
indicators, exterior lamps, heater and ventilators.
5. Check abnormal noise of each part.
6. Check the tyres for wear and for the correct air
pressure.

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0-1

PRECAUTIONS BEFORE BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3

NOTES CONCERNING ENTRIES . . . 1-3 15. STEERING LINKAGE AND SPLIT

FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 BEFORE ROAD TEST . . . . . . . . . . . . 1-12

8. CLUTCH MASTER CYLINDER FLUID

34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-16 41. HOSES, FLUID LINES AND

TABLE OF PRE-DELIVERY INSPECTION

Term Definition Remarks

Press down the storage connector.

To protect the exterior finish of vehicles prior to

Wipe-off by kerosene or white gasoline, etc.

Disposal of removed film: Burning is appropriate

3. EXTERIOR 6. Verify that all doors can be locked by the lock

4. OPERATION OF DOOR LOCKING

7. Verify that the rear doors can't be opened by the

Check the fluid level.

11. POWER STEERING FLUID LEVEL 12. ELECTRICAL WIRING

16. UNDER BODY

BEFORE ROAD TEST

20. INSTRUMENT PANEL CONTROLS

4. Instrument panel lamps 2. Heater and defroster

1. Check the meters and gauges are functioning

AC305627 (2) Verify correct brake pedal free play.

2. Rear wiper and washer

24. OPERATION OF SERVICE BRAKES

1. Check the clutch operation in all driving ranges.

NOTE: 26. OPERATION OF SEAT BELTS,

1. Verify that the seat belt warning lamp operates

32. ELECTRICAL EQUIPMENT

30. STEERING CONTROL

1. Check for excessive play or looseness.

AFTER ROAD TEST

34. IGNITION TIMING

1. Check all brake, fuel, power steering and air

37. MANUAL TRANSMISSION AND

Filler plug hole

1. Check that the coolant level in the reserve tank is 0 - 5 mm

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

39. ENGINE, TRANSMISSION, STEERING

40. FRONT AND REAR DIFFERENTIAL

Check the installation of the various equipment.

PRECAUTIONS BEFORE SERVICE

If the service work is to be done by two or more

REMOVAL AND DISASSEMBLY

If other tools are substituted for the special tools to

When checking a malfunction, find the cause of the

In accordance with the instructions in this manual,

When replacing parts, use MITSUBISHI genuine

Be careful to avoid spilling any brake fluid, because if

SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING

cause a drop in the performance of the sensor.

Connect the M.U.T.-III to the diagnosis connector as

PERIODIC INSPECTION AND OPERATIONS UNDER THE

OPERATIONS OUTSIDE THE OPERATIONS AFTER ENGINE IS

Maintenance item Maintenance Maintenance interval

OPERATIONS INSIDE THE ENGINE COMPARTMENT

Apply approx. 100 N of force to the middle of the

6. Tighten the adjusting bolt.

Turbocharger 6.5 teeth