Mitsubishi L200 2012 Workshop Manual

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Page 1

GROUP 00

GENERAL

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

00-1

Page 2

GROUP 00

GENERAL

CONTENTS

00-1

HOW TO USE THIS MANUAL. . . . . . 00-3

HOW TO USE TROUBLESHOOTING/

INSPECTION SERVICE POINTS. . . . 00-6

CONTENTS OF TROUBLESHOOTING . . . 00-6

DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 00-8

HOW TO USE THE INSPECTION PROCEDURES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9

CONNECTOR MEASUREMENT SERVICE POINTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12

CONNECTOR INSPECTION SERVICE POINTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13

INSPECTION SERVICE POINTS FOR A BLOWN

FUSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14

HOW TO COPE WITH INTERMITTENT

MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-14

HOW TO TREAT PAST TROUBLE . . . . . . 00-15

VEHICLE IDENTIFICATION . . . . . . . 00-15

MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-15

VEHICLE IDENTIFICATION NUMBER (CHASSIS

NUMBER) . . . . . . . . . . . . . . . . . . . . . . . . . . 00-18

VEHICLE INFORMATION CODE PLATE. . 00-19

VEHICLE IDENTIFICATION NUMBER (VIN) PLATE

<VEHICLES FOR RHD>. . . . . . . . . . . . . . . 00-19

MANUFACTURER PLATE . . . . . . . . . . . . . 00-20

ENGINE MODEL STAMPING. . . . . . . . . . . 00-20

GENERAL DATA AND SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-21

GENERAL DATA AND SPECIFICATIONS

<VEHICLES FOR EUROPE> . . . . . . . . . . . 00-21

GENERAL DATA AND SPECIFICATIONS <VEHICLES FOR RUSSIA (EASTERN EUROPE

COUNTRIES)> . . . . . . . . . . . . . . . . . . . . . . 00-32

GENERAL DATA AND SPECIFICATIONS

<VEHICLES FOR MOROCCO> . . . . . . . . . 00-35

PRECAUTIONS BEFORE SERVICE . 00-36

SERVICING COMMON RAIL ENGINE . . . . 00-36

CAUTIONS FOR AIR CONDITIONER STARITING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-36

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-37

SERVICING ELECTRICAL SYSTEM . . . . . 00-37

IN ORDER TO PREVENT VEHICLES FROM FIRE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-37

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-38

HOW TO PERFORM CHASSIS NUMBER (Chassis

No.) WRITING . . . . . . . . . . . . . . . . . . . . . . . 00-38

PRE-INSPECTION CONDITION . . . . . . . . . 00-42

ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 00-42

WHAT THE COMMON RAIL ENGINE LEARNS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-43

INJECTOR IDENTIFICATION CODE REGISTRATION

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-43

SMALL INJECTION QUANTITY LEARNING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-45

SUPPLY PUMP CORRECTION LEARNING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-45

INITIALISATION PROCEDURE FOR LEARNING VALUE IN DIESEL PARTICULATE FILTER (DPF)

SYSTEM <Euro5> . . . . . . . . . . . . . . . . . . . . 00-46

BATTERY CURRENT SENSOR CALIBRATION

<Euro5>. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-46

HOW TO USE THE THROTTLE CONTROLLER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-47

APPLICATION OF ANTI-CORROSION AGENTS AND

UNDERCOATS . . . . . . . . . . . . . . . . . . . . . . 00-47

VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-48

PRECAUTIONS FOR INSTALLATION OF ONVEHICLE RADIO TRANSMISSION EQUIPMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-48

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-48

Page 3

00-2

SRS SERVICE PRECAUTIONS . . . . 00-50 SUPPORT LOCATIONS FOR LIFTING AND

JACKING . . . . . . . . . . . . . . . . . . . . . . 00-54

Page 4

GENERAL

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspec tions, adjustments, and the removal and installation procedures for major components. For detailed infor mation concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to sepa rate manuals covering the engine and the transmission.

ON-VEHICLE SERVICE

"On-vehicle Service" is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.

INSPECTION

Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

DEFINITION OF TERMS

STANDARD VALUE

Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.

LIMIT

Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.

M1001000103302

REFERENCE VALUE

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be com pleted in a shorter time).

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that

must be avoided. The differences among DANGER,

WARNING, and CAUTION are as follows:

• If a DANGER is not followed, the result is severe

bodily harm or even death.

• If a WARNING is not followed, the result could be bodily injury.

• If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

INDICATION OF TIGHTENING TORQUE

Tightening torques (units: N⋅m) are set to take into account the central value and the allowable toler ance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques.

MODEL INDICATIONS

The following abbreviations are used in this manual for identification of model types. 2500:Indicates an engine with the 2,477mL <4D56>

diesel engine.

2WD:Indicates the 2-wheel drive vehicles. 4WD:Indicates the 4-wheel drive vehicles. A/C:Indicates the air conditioner. A/T:Indicates the automatic transmission. DOHC: Indicates an engine with the double over-

head camshaft.

M/T:Indicates the manual transmission.

00-3

Page 5

00-4

HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS

Indicates the

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

section title.

Indicates the group title.

GENERAL

Indicates the group number.

>>A<< >>B<<

35A-19

Indicates the page number.

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

Component diagram

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

Mark denotes nonreusable part.

Repair kit or parts sets are shown. (Only very frequently used parts are shown.)

Maintenance and servicing procedures

The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures.

Removal steps : The part designation number corresponds to the number in the illustration to indicate remov al steps.

Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disas sembly steps.

Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of re moval steps.

Reassembly steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if reassembly is possible in reverse order of dis assembly steps.

AC311238

Page 6

GENERAL

HOW TO USE THIS MANUAL

Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.). These are arranged together as major maintenance and service points and explained in detail.

<<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or reassembly.

00-5

BRAKE CALIPER ASSEMBLY

35A-21

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

Indicates (by symbols) where lubrication is necessary.

: Grease (Multi-purpose grease unless there is a brand or type specified) : Sealant or adhesive : Automatic transmission fluid, brake fluid, power steering fluid or air conditioning compressor oil : Engine oil or gear oil : Adhesive tape or butyl rubber tape

AC509265

Page 7

00-6

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS

CONTENTS OF TROUBLESHOOTING

M1001013300794

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) discon nected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

WARNING

Since the radiator fan rotates during CAN bus line diagnostics, make sure that no one is servicing the engine compartment before diagnosing the CAN bus line. Since the CAN communication stops when diagnosing the CAN bus line, the ETACS-ECU detects the time-out of the engine-ECU, and activates the radiator fan to prevent overheating as fail-safe.

Troubleshooting of electronic control systems for which the M.U.T.-III can be used follows the basic outline described below. Even in systems for which the M.U.T.-III cannot be used, some of these sys tems still follow this outline.

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.

Page 8

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Diagnosis method

GENERAL

Gathering information from the customer.

00-7

Reoccurs

CAN bus diagnosis*

Read the diagnosis code. Read the diagnosis code.

No diagnosis code or communication with M.U.T.-III not possible

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group).

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

Diagnosis code displayed. (Current trouble)*

Check trouble symptom.

CAN bus diagnosis chart*

After taking note of the malfunction code, erase the diagnosis code memory.

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code displayed.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group).

Diagnosis code displayed. (Current trouble)*

Does not reoccur

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

No diagnosis code.

INTERMITTENT MALFUNCTIONS*

No diagnosis code.

AC501888

• *1: For how to diagnose CAN bus lines, refer to GROUP 54C .

• *2: For the CAN bus diagnosis chart, refer to GROUP 54C .

• *3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem

currently exists or whether it existed before. The message for the former state identifies it as a "Active" and the message for the latter identifies it as a "Stored".

• *4: For how to treat past trouble, refer to P.00-15.

• *5: For how to cope with intermittent malfunctions, refer to P.00-14.

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms

5. DIAGNOSIS CODE PROCEDURES

Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to Use Inspection Procedures

P.00-9).

are shown.

6. TROUBLE SYMPTOM CHART

3. DIAGNOSIS FUNCTION

Details specific to individual systems are described.

4. DIAGNOSIS CODE CHART

Diagnosis codes and diagnostic items are shown.

If there are trouble symptoms even though the M.U.T.-III does not find any diagnosis codes, Inspec tion procedures for each trouble symptom will be found by means of this chart.

Page 9

00-8

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

7. SYMPTOM PROCEDURES

Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart (Refer to How to Use Inspection Procedures

P.00-9).

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have been provided in this chart as reference information.

9. ACTUATOR TEST TABLE

The Actuator Test item numbers, inspection items, and judgment values have been provided in this chart as reference information.

10. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspection items, and judgment values have been provided in this chart as reference information.

11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are described here.

HOW TO READ DIAGNOSIS CODE

CAUTION

Before connecting or disconnecting the M.U.T.III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

MB991910

MB991824

DIAGNOSIS FUNCTION

M1001013400865

The diagnosis function retrieves diagnosis code and service data by M.U.T.-III and enables the perform ance of the actuator test.

• DIAGNOSIS CODE

• Service data sent

• Actuator test

• Diagnosis deletion using M.U.T.-III

• Freeze frame data

• Status indication by diagnosis code

• ECU information display

NOTE: If a diagnosis code is set, the "status indication by diagnosis code" informs users whether a mechanical problem currently exists (current trouble) or whether it existed before but normal operation has been restored (past trouble).

MB991827

MB991824

MB991827

Diagnosis connector

MB991910

AC509179

AC501413

Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.

2. Start up the personal computer.

Page 10

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-9

3. Connect special tool M.U.T.-III USB cable MB991827 to V.C.I. (MB991824) and the personal computer.

4. Connect special tool M.U.T.-III main harness A (MB991910) to the V.C.I.

5. Connect the M.U.T.-III main harness A to the diagnosis connector of the vehicle.

6. Turn the V.C.I. power switch to the "ON" position.

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col our.

7. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

8. Read the diagnosis code.

NOTE: When storing the diagnosis code as reference information, the freeze frame data obtains the data when the diagnosis code is confirmed, and then stores the ECU status of that time. By analysing each data using M.U.T.-III, troubleshooting can be carried out efficiently.

9. Disconnecting the M.U.T.-III is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF) position.

ERASING DIAGNOSIS CODE

CAUTION

Before connecting or disconnecting the M.U.T.III, turn the ignition switch to the "LOCK" (OFF) position.

Connect the M.U.T.-III to the diagnosis connector, and erase the diagnosis code. The procedure is the same as "How to Read Diagnosis Code

HOW TO USE THE INSPECTION PROCEDURES

M1001013500345

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

Page 11

00-10

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Relevant circuit(s) of the component which the Code No. indicates are described.

Grey

AC301964

Page 12

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-11

Explains about the basic operation of the components.

Explains about technical details.

Describes the conditions for that diagnosis code being set.

Start of diagnosis procedure

Describes inspection procedure.

M.U.T.-III data list

Describes possible causes(s) for that diagnosis code.

CURRENT TROUBLE

Indicates that the status is "Active" and the trouble is currently present. Carry out troubleshooting as described in the applicable inspection procedure.

PAST TROUBLE

Indicates that the status is "Stored" and the trouble is historic. Since the trouble may still be present, set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", observe the applicable inspection procedure with particular emphasis on connector(s) and wiring harness.

AC313955

HARNESS CHECK

Check for an open or short circuit in the harness between the terminals which are faulty according to the connector measurements. Carry out this inspec

tion while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between the power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse

P.00-14."

MEASURES TO TAKE AFTER REPLACING THE ECU

If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection proce dure from the beginning.

Page 13

00-12

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR MEASUREMENT SERVICE POINTS

M1001013600386

CAUTION

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR CONNECTED <WATERPROOF CONNECTORS>

CAUTION

Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool extra fine probe (MB992006).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A FEMALE PIN>

CAUTION

• Use special tool inspection harness (MB991219). If the test bar is inserted forcibly, it will cause a poor contact.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

MB991219

Special tool

AC105597

Use the special tools such as test harness, harness connector or check harness.

IF INSPECTING WITH THE CONNECTOR CONNECTED <ORDINARY (NON-WATERPROOF) CONNECTORS>

MB992006

AC105598

AC105599

Use inspection harness (MB991219) of special tool harness set (MB991223).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A MALE PIN>

CAUTION

• Be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

AC105600

Touch the pin directly with the test bar.

Page 14

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-13

CONNECTOR INSPECTION SERVICE POINTS

M1001013700275

VISUAL INSPECTION

Connector disconnected or improperly connected

Stretched or broken wires

•

• Low contact pressure between male and female

terminals

• Low connection pressure due to rusted terminals or foreign matter lodged in terminals

CONNECTOR PIN INSPECTION

AC300898

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be per

fect even if the connector body is connected, and the pins may pull out of the reverse side of the connec

tor. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

Harness wire breakage at terminal section

Low contact pressure

Good

Bad

AC300896

Connector is disconnected or improperly connected

• Connector pins are pulled out

• Due to harness tension at terminal section

CONNECTOR ENGAGEMENT INSPECTION

MB991219

AC300899

Use special tool inspection harness (MB991219) (connector pin connection pressure inspection har ness of the inspection harness set) to inspect the engagement of the male pins and female pins. (Pin drawing force: 1 N or more)

Page 15

00-14

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

M1001013800250

CAUTION

A diagnosis code may be stored due to a blown fuse.

Battery

Fuse

Short-circuit Load switch

occurrence

section

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

M1001013900257

Load

AC300900

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0

Ω at this time, there is a short somewhere between these switches and the load. If the resistance is not 0

Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following.

• Harness being clamped by the vehicle body

• Damage to the outer casing of the harness due to

wear or heat

• Water getting into the connector or circuitry

• Human error (mistakenly shorting a circuit, etc.)

AC300901

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascer

tained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the cus

tomer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trou

ble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these con ditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which gen erates diagnosis codes or trouble symptoms).

Page 16

GENERAL

VEHICLE IDENTIFICATION

00-15

• Gently shake the connector up, down and to the left and right.

• Gently shake the wiring harness up, down and to the left and right.

• Gently rock each sensor and relay, etc. by hand.

• Gently shake the wiring harness at suspensions

and other moving parts.

NOTE: If determining the cause is difficult, the drive recorder function of the M.U.T.-III can also be used. (For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual).

VEHICLE IDENTIFICATION

MODELS

M1001000306510

VEHICLES FOR EUROPE

HOW TO TREAT PAST TROUBLE

M1001014100243

Since the trouble may still be present even the status is "Stored", set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", carry out the following procedure.

1. Establish from the customer whether a fuse or connector has been replaced or disconnected.

2. If yes, erase the diagnosis code, and then check that no diagnostic code is reset. If no diagnosis code is reset, the diagnosis is complete.

3. If no, follow the applicable Diagnostic Trouble Code Chart. Then check the wiring harness and connector, and refer to "How to Cope with Intermittent Malfunction

P.00-14 ."

Model code Engine model Transmission model Fuel supply system

KA4T NENMZL6 4D56 (2,477 mL)

DOHC DI-D (Direct Injection-

KB4T NENMZL6/R6 V5MB1 (Easy select 4WD,

Model code Engine model Transmission model Fuel supply system

KB4T NCNUZL6/R6 4D56 (2,477 mL)

GCNXZL6 V5MB1 (Super select

GCNXZPL6 4D56 (2,477 mL)

Diesel) engine with intercooled turbocharger

DOHC DI-D (Direct InjectionDiesel) engine with intercooled turbocharger

DOHC DI-D (Direct InjectionDiesel) high-power engine with intercooled turbocharger

R5MB1 (Rear wheel drive 2WD, 5M/T)

5M/T)

V5MB1 (Easy select 4WD, 5M/T)

4WD, 5M/T)

Common rail fuel injection (Electrical fuel injection)

Page 17

00-16

Model code Engine model Transmission model Fuel supply system

KA4T NJNUZL6 4D56 (2,477 mL)

HJNUZL6

HJRUZL6 R4A5A (Rear wheel drive

KB4T NJNUZL6/R6 V5MB1 (Easy select 4WD,

NJRUZL6 V4A5A (Easy select 4WD,

GJNXZL6 V5MB1 (Super select

GJRXZR6 V4A5A (Super select 4WD,

DOHC DI-D (Direct InjectionDiesel) engine with intercooled turbocharger

VEHICLE IDENTIFICATION

GENERAL

R5MB1 (Rear wheel drive 2WD, 5M/T)

2WD, 4A/T)

5M/T)

4A/T)

4WD, 5M/T)

4A/T)

Common rail fuel injection (Electrical fuel injection)

GJNXZPL6/R6 4D56 (2,477 mL)

DOHC DI-D (Direct Injection-

GJYXZPL6/R6 V5A5A (Super select 4WD,

VEHICLES FOR RUSSIA (EASTERN EUROPE COUNTRIES)

Model code Engine model Transmission model Fuel supply system

KB4T NJNUZL6Z 4D56 (2,477 mL)

GJNXZL6Z V5MB1 (Super select

GJRXZL6Z V4A5A (Super select 4WD,

MODEL CODE <VEHICLES FOR EUROPE AND RUSSIA (EASTERN EUROPE COUNTRIES)>

Diesel) high-power engine with intercooled turbocharger

DOHC DI-D (Direct InjectionDiesel) engine with intercooled turbocharger

1 2 3 4 5 6 7 8 9 10 11

No. Item Content

1 Development K L200

2 Drive system A 2WD

V5MB1 (Super select 4WD, 5M/T)

5A/T)

V5MB1 (Easy select 4WD, 5M/T)

4WD, 5M/T)

4A/T)

Common rail fuel injection (Electrical fuel injection)

AC407365

B 4WD

3 Engine type 4 2.5L diesel engine (4D56)

4 Sort T Truck

5 Vehicle width G Wide fender

H High rider

N Standard

6 Body style E Single cab

C Club cab

J Double cab

Page 18

GENERAL

VEHICLE IDENTIFICATION

No. Item Content

7 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

Y 5-speed automatic transmission

8 Vehicle grade M GL

U GLX

X GLS

9 Engine specification Z Common rail (intercooled turbocharger)

ZP Common rail (intercooled turbocharger high power engine)

10 Steering wheel location L Left hand

R Right hand

11 Destination 6 Vehicles for Europe

6Z Vehicles for Russia (Eastern Europe countries)

VEHICLES FOR MOROCCO

Model code Engine model Transmission model Fuel supply system

00-17

KA4T NENMZ6BA 4D56 (2,477 mL)

DOHC DI-D (Direct InjectionDiesel) engine with intercooled turbocharger

MODEL CODE <VEHICLES FOR MOROCCO>

12345678910

No. Item Content

1 Development K L200

2 Drive system A 2WD

3 Engine type 4 2.5L diesel engine (4D56)

4 Sort T Truck

5 Vehicle width N Standard

6 Body style E Single cab

7 Transmission type N 5-speed manual transmission

8 Vehicle grade M GL

R5MB1 (Rear wheel drive 2WD, 5M/T)

6BA

Common rail fuel injection (Electrical fuel injection)

ACA00801

9 Engine specification Z Common rail (intercooled turbocharger)

10 Destination 6BA Vehicles for Morocco

Page 19

00-18

GENERAL

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

M1001005602547

Frame

AC501503

1234567891011 1312

No. Item Content

1 Country M Thailand

2 Make M MITSUBISHI MOTORS (Thailand) Co., Ltd.

The vehicle identification number is stamped on the side wall of the frame near the rear wheel (right side).

00001

AC804908

3 Register C Europe (including Russia)

4 Body type E Single cab

C Club cab

J Double cab

5 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

Y 5-speed automatic transmission

6 Vehicle line K MITSUBISHI L200

7 Drive system A 2WD

B 4WD

8 Engine 4 2.5L diesel engine (4D56)

9 MMTh internal purpose 0 No meaning

10 Model year C 2012 year

11 Plants D Laemchabang-2 (Thailand motor vehicle works)

F Laemchabang-1 (Thailand motor vehicle works)

12 Emission step 0 Euro-4 <Vehicles for Morocco>, Euro-5

9 Euro-4 <Vehicles for Turkey>

Z Euro-3, Euro-4 <Vehicles for Russia (Eastern Europe countries) >

13 Serial number 00001 to 99999

Page 20

VEHICLE IDENTIFICATION

VEHICLE INFORMATION CODE PLATE

GENERAL

The vehicle identification number (VIN) is located on a plate attached to the left top side of the instrument panel.

00-19

M1001005402792

AC508917

The information code plate is riveted to the cowl top outer panel in the engine compartment.

MODEL

ENGINE

TRANS

AXLE

COLOR,TRIM

OPT

456

AC507828

No. Item Example Content

1 MODEL KB4T Vehicle model

GJRXZL6 Model series

2 ENGINE 4D56 Engine model

3 TRANS

AXLE

V4A5A 4100

Transmission model and final gear ratio

4 COLOUR W32 Body colour code

5 TRIM 10X Interior code

6 OPT S31 Option code

VEHICLE IDENTIFICATION NUMBER (VIN) PLATE <VEHICLES FOR RHD>

M1001005501945

1234567891011

AC804910

No. Item Content

1 Country M Thailand

2 Make M MITSUBISHI MOTORS

(Thailand) Co., Ltd.

3 Register C Europe

4 Body type E Single cab

C Club cab

J Double cab

5 Transmission

type

N 5-speed manual

transmission

R 4-speed automatic

transmission

Y 5-speed automatic

transmission

6 Vehicle line K MITSUBISHI L200

7 Drive system B 4WD

8 Engine 4 2.5L diesel engine (4D56)

9 MMTh internal

0 No meaning

purpose

10 Model year C 2012

11 Plants D Laemchabang-2 (Thailand

motor vehicle works)

F Laemchabang-1 (Thailand

motor vehicle works)

12 Emission step 0 Euro-5

AC507971

13 Serial number 00001 to 99999

Page 21

00-20

GENERAL

VEHICLE IDENTIFICATION

MANUFACTURER PLATE

M1001017600399

AC508918

The manufacturer plate is riveted to the cowl top outer panel in the engine compartment.

6 1 2

3 4 5

No. Content

4 Gross axle weight front

5 Gross axle weight rear

6 or 7 NTA No. (National type approval number)

ENGINE MODEL STAMPING

M1001005700861

Front suspension upper arm <left side>

The engine model is stamped on the cylinder block. This engine model numbers is as shown as follow.

Engine model Engine displacement

4D56 2,477 mL

AC507123

AC511709

No. Content

1 Chassis No. (Vehicle identification number)

2 Gross vehicle weight

3 Gross combination weight

The engine serial number is stamped near the engine model number.

Engine serial number AA0201 to YY9999

Page 22

GENERAL

GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS <VEHICLES FOR EUROPE>

M1001000906642

SINGLE CAB

00-21

1 2

Item KA4T KB4T

Vehicle dimension mm

Front track 1 1,505 1,505

Overall width 2 1,750 1,750

Front overhang 3 830 830

Wheel base 4 3,000 3,000

Rear overhang 5 1,210 1,210

Overall length 6 5,040 5,040

Ground clearance (unladen) 7 200 200

Overall height (unladen) 8 1,655 1,775

Rear track 9 1,500 1,500

Cargo bed interior length 10 2,220 2,220

34 5

NENMZL6 NENMZL6/NENMZR6

AC805672

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12 405 405

Cargo floor height (unladen) 13 715 845

Vehicle weight kgKerb

weight

Max. gross vehicle weight 2,630 2,850 <LHD>

Max. axle weight rating-front 1,030 1,260

Max. axle weight rating-rear 1,700 1,800

Max. towable weight

Max. trailer-nose weight 77 115

Max. gross combination weight 4,400 5,500 <LHD>

Without optional parts 1,565 1,780 <LHD>

1,770 <RHD>

With full optional parts 1,595 1,840 <LHD>

1,810 <RHD>

2,890 <RHD>

With brake 1,800 2,700

Without brake 750 750

5,540 <RHD>

Page 23

00-22

Item KA4T KB4T

Seating capacity (including a driver) 2 2

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

GENERAL DATA AND SPECIFICATIONS

GENERAL

NENMZL6 NENMZL6/NENMZR6

Type DOHC diesel

Intercooled, Turbocharger

Max. output kW/rpm (EEC net) 94/4,000 100/4,000

Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500 314/2,000

Transmission Model code R5MB1 V5MB1

Type 5M/T 5M/T

Drive system Rear wheel drive 2WD Easy select 4WD

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.1 6.3

Wheel 5.7 5.9

NOTE: .

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

DOHC diesel Intercooled, Turbocharger

CLUB CAB

1 2

4 6

AC805455

Page 24

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item KB4T

NCNUZL6/NCNUZR6 GCNXZL6

00-23

Vehicle dimension mm

Vehicle weight kgKerb

Front track 1 1,505 1,520

Overall width 2 1,750 1,815

Front overhang 3 795 795

Wheel base 4 3,000 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 200 205

Overall height (unladen) 8 1,775/1,790* 1,780

Rear track 9 1,500 1,515

Cargo bed interior length 10 1,805 1,805

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12 460 460

Cargo floor height (unladen) 13 855 860

weight

Max. gross vehicle weight 2,850 2,850

Max. axle weight rating-front 1,260 1,260

Without rear bumper 5 1,325 1,325

With rear bumper 1,400 1,400

Without rear bumper 6 5,120 5,120

With rear bumper 5,195 5,195

Without optional parts 1,800 1,815

With full optional parts 1,900 <LHD>

1,880 <RHD>

1,910

Max. axle weight rating-rear 1,800 1,800

Max. towable weight

Max. trailer-nose weight 115 115

Max. gross combination weight 5,500 5,500

Seating capacity (including a driver) 4 4

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

Type DOHC diesel

Max. output kW/rpm (EEC net) 100/4,000 100/4,000

Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000

Transmission Model code V5MB1 V5MB1

Type 5M/T 5M/T

Drive system Easy select 4WD Super select 4WD

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.3 6.3

With brake 2,700 2,700

Without brake 750 750

DOHC diesel Intercooled, Turbocharger

Intercooled,

Turbocharger

Wheel 5.9 5.9

Page 25

00-24

NOTE: .

•

*:Vehicles with rear body ground frame.

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

Item KB4T

Vehicle dimension mm

Front track 1 1,520

Overall width 2 1,815

Front overhang 3 795

Wheel base 4 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 205

Overall height (unladen) 8 1,780

Rear track 9 1,515

Without rear bumper 5 1,325

With rear bumper 1,400

Without rear bumper 6 5,120

With rear bumper 5,195

GENERAL DATA AND SPECIFICATIONS

GENERAL

GCNXZPL6

Cargo bed interior length 10 1,805

Cargo bed interior width 11 1,470

Cargo bed interior height 12 460

Cargo floor height (unladen) 13 860

Vehicle weight kgKerb

weight

Max. gross vehicle weight 2,850

Max. axle weight rating-front 1,260

Max. axle weight rating-rear 1,800

Max. towable weight

Max. trailer-nose weight 115

Max. gross combination weight 5,500

Seating capacity (including a driver) 4

Engine Model code 4D56

Total displacement mL 2,477

Type DOHC High-power diesel Intercooled,

Max. output kW/rpm (EEC net) 131/3,750

Without optional parts 1,825

With full optional parts 1,920

With brake 2,700

Without brake 750

Turbocharger

Max. torque N⋅m/rpm (EEC net) 400/2,000 − 2,850

Transmission Model code V5MB1

Type 5M/T

Drive system Super select 4WD

Page 26

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item KB4T

GCNXZPL6

Fuel system Fuel supply system Electrical fuel injection

Turning radius mBody 6.3

Wheel 5.9

NOTE: .

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

DOUBLE CAB

00-25

1 2

<2WD>

Item KA4T

Vehicle dimension mm

Front track 1 1,505 1,505

Overall width 2 1,750 1,750

Front overhang 3 830 795

Wheel base 4 3,000 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 200 200

Overall height (unladen) 8 1655 1,775

34 5

NJNUZL6 HJNUZL6

Without rear bumper 5 1,210/1,390* 1,210/1,390*

With rear bumper

Without rear bumper 6 5,040/5,220 5,005/5,185*

With rear bumper

−

1,285/1,465*

5,080/5,260*

AC809340

Rear track 9 1,500 1,500

Cargo bed interior length 10 1,325/1,505* 1,325/1,505*

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12 405/460* 405/460*

Cargo floor height (unladen) 13 715 845

Page 27

00-26

Item KA4T

GENERAL DATA AND SPECIFICATIONS

GENERAL

NJNUZL6 HJNUZL6

Vehicle weight kgKerb

weight

Max. gross vehicle weight 2,630 2,800

Max. axle weight rating-front 1,030 1,260

Max. axle weight rating-rear 1,700 1,800

Max. towable weight

Max. trailer-nose weight 75 112

Max. gross combination weight 4,400 5,465

Seating capacity (including a driver) 5 5

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

Type DOHC diesel

Max. output kW/rpm (EEC net) 94/4,000 100/4,000

Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500 314/2,000

Transmission Model code R5MB1 R5MB1

Type 5M/T 5M/T

Without optional parts 1,665 1,770

With full optional parts 1,735 1,900

With brake 1,800 2,700

Without brake 750 750

DOHC diesel Intercooled, Turbocharger

Intercooled,

Turbocharger

Drive system Rear wheel drive 2WD Rear wheel drive 2WD

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.1 6.3

Wheel 5.7 5.9

NOTE: .

•

*:Vehicles with long cargo bed.

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

Page 28

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item KA4T

HJRUZL6

00-27

Vehicle dimension mm

Vehicle weight kgKerb

Front track 1 1,505

Overall width 2 1,750

Front overhang 3 795

Wheel base 4 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 200

Overall height (unladen) 8 1,775

Rear track 9 1,500

Cargo bed interior length 10 1,325/1,505*

Cargo bed interior width 11 1,470

Cargo bed interior height 12 405/460*

Cargo floor height (unladen) 13 845

weight

Max. gross vehicle weight 2,800

Without rear bumper 5 1,210/1,390*

With rear bumper 1,285/1,465*

Without rear bumper 6 5,005/5,185*

With rear bumper 5,080/5,260*

Without optional parts 1,780

With full optional parts 1,910

Max. axle weight rating-front 1,260

Max. axle weight rating-rear 1,800

Max. towable weight

Max. trailer-nose weight 112

Max. gross combination weight 5,465

Seating capacity (including a driver) 5

Engine Model code 4D56

Total displacement mL 2,477

Type DOHC diesel Intercooled, Turbocharger

Max. output kW/rpm (EEC net) 100/4,000

Max. torque N⋅m/rpm (EEC net) 314/2,000

Transmission Model code R4A5A

Type 4A/T

Drive system Rear wheel drive 2WD

Fuel system Fuel supply system Electrical fuel injection

Turning radius mBody 6.3

Wheel 5.9

With brake 2,700

Without brake 750

Page 29

00-28

NOTE: .

•

*:Vehicles with long cargo bed.

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

<4WD>

Item KB4T

Vehicle dimension mm

Front track 1 1,505 1,505

Overall width 2 1,750 1,750

Front overhang 3 795 795

Wheel base 4 3,000 3,000

Rear overhang

Overall length

Without rear bumper 5 1,210/1,390* 1,210/1,390*

With rear bumper 1,285/1,465* 1,285/1,465*

Without rear bumper 6 5,005/5,185* 5,005/5,185*

With rear bumper 5,080/5,260* 5,080/5,260*

GENERAL DATA AND SPECIFICATIONS

GENERAL

NJNUZL6/NJNUZR6 NJRUZL6

Ground clearance (unladen) 7 200 200

Overall height (unladen) 8 1,775 1,775

Rear track 9 1,500 1,500

Cargo bed interior length 10 1,325/1,505* 1,325/1,505*

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12 405/460* 405/460*

Cargo floor height (unladen) 13 845 845

Vehicle weight kgKerb

weight

Max. gross vehicle weight 2,850 <LHD>

Max. axle weight rating-front 1,260 1,260

Max. axle weight rating-rear 1,800 1,800

Max. towable weight

Max. trailer-nose weight 115 115

Max. gross combination weight 5,500 <LHD>

Seating capacity (including a driver) 5 5

Without optional parts 1,870 <LHD>

1,850 <RHD>

With full optional parts 2,000 <LHD>

1,980 <RHD>

2,900 <RHD>

With brake 2,700 2,700

Without brake 750 750

5,550 <RHD>

1,880

2,010

2,850

5,500

Page 30

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item KB4T

NJNUZL6/NJNUZR6 NJRUZL6

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

Type DOHC diesel

Intercooled, Turbocharger

Max. output kW/rpm (EEC net) 100/4,000 100/4,000

Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000

Transmission Model code V5MB1 V4A5A

Type 5M/T 4A/T

Drive system Easy select 4WD Easy select 4WD

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.3 6.3

Wheel 5.9 5.9

NOTE: .

•

*:Vehicles with long cargo bed.

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

DOHC diesel

Intercooled,

Turbocharger

00-29

Item KB4T

GJNXZL6 GJRXZR6

Vehicle dimension mm

Front track 1 1,520 1,520

Overall width 2 1,815 1,815

Front overhang 3 795 795

Wheel base 4 3,000 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 205 205

Overall height (unladen) 8 1,780 1,780

Rear track 9 1,515 1,515

Cargo bed interior length 10 1,325/1,505* 1,325/1,505*

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12 405/460* 405/460*

Cargo floor height (unladen) 13 850 850

Without rear bumper 5 1,210/1,390* 1,210/1,390*

With rear bumper 1,285/1,465* 1,285/1,465*

Without rear bumper 6 5,005/5,185* 5,005/5,185*

With rear bumper 5,080/5,260* 5,080/5,260*

Page 31

00-30

Item KB4T

GENERAL DATA AND SPECIFICATIONS

GENERAL

GJNXZL6 GJRXZR6

Vehicle weight kgKerb

weight

Max. gross vehicle weight 2,850 2,930

Max. axle weight rating-front 1,260 1,260

Max. axle weight rating-rear 1,800 1,800

Max. towable weight

Max. trailer-nose weight 115 115

Max. gross combination weight 5,500 5,580

Seating capacity (including a driver) 5 5

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

Type DOHC diesel

Max. output kW/rpm (EEC net) 100/4,000 100/4,000

Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000

Transmission Model code V5MB1 V4A5A

Type 5M/T 4A/T

Without optional parts 1,890 1,885

With full optional parts 2,030 2,030

With brake 2,700 2,700

Without brake 750 750

DOHC diesel Intercooled, Turbocharger

Intercooled,

Turbocharger

Drive system Super select 4WD Super select 4WD

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.3 6.3

Wheel 5.9 5.9

NOTE: .

•

*:Vehicles with long cargo bed.

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

Page 32

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item KB4T

GJNXZPL6/GJNXZPR6 GJYXZPL6/GJYXZPR6

00-31

Vehicle dimension mm

Vehicle weight kgKerb

Front track 1 1,520 1,520

Overall width 2 1,815 1,815

Front overhang 3 795 795

Wheel base 4 3,000 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 205 205

Overall height (unladen) 8 1,780 1,780

Rear track 9 1,515 1,515

Cargo bed interior length 10 1,325/1,505* 1,325/1,505*

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12 405/460* 405/460*

Cargo floor height (unladen) 13 850 850

weight

Without rear bumper 5 1,210/1,390* 1,210/1,390*

With rear bumper 1,285/1,465* 1,285/1,465*

Without rear bumper 6 5,005/5,185* 5,005/5,185*

With rear bumper 5,080/5,260* 5,080/5,260*

Without optional parts 1,900 <LHD>

1,885 <RHD>

With full optional parts 2,040 <LHD>

2,030 <RHD>

1,915 <LHD>

1,900 <RHD>

2,045

Max. gross vehicle weight 2,850 <LHD>

2,930 <RHD>

Max. axle weight rating-front 1,260 1,260

Max. axle weight rating-rear 1,800 1,800

Max. towable weight

Max. trailer-nose weight 115 115

Max. gross combination weight 5,500 <LHD>

Seating capacity (including a driver) 5 5

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

Type DOHC High-power

Max. output kW/rpm (EEC net) 131/3,750 131/3,750

Max. torque N⋅m/rpm (EEC net) 400/2,000 − 2,850 350/1,800 − 3,500

Transmission Model code V5MB1 V5A5A

Type 5M/T 5A/T

With brake 2,700 2,700

Without brake 750 750

5,580 <RHD>

diesel Intercooled, Turbocharger

2,850 <LHD>

2,945 <RHD>

5,500 <LHD>

5,595 <RHD>

DOHC High-power

diesel Intercooled,

Turbocharger

Drive system Super select 4WD Super select 4WD

Page 33

00-32

GENERAL DATA AND SPECIFICATIONS

GENERAL

Item KB4T

GJNXZPL6/GJNXZPR6 GJYXZPL6/GJYXZPR6

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.3 6.3

Wheel 5.9 5.9

NOTE: .

•

*:Vehicles with long cargo bed.

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

GENERAL DATA AND SPECIFICATIONS <VEHICLES FOR RUSSIA (EASTERN EUROPE COUNTRIES)>

M1001000906653

1 2

4 6

AC502186

Page 34

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item KB4T

NJNUZL6Z GJNXZL6Z

00-33

Vehicle dimension mm

Front track 1 1,505 1,520

Overall width 2 1,750 1,800

Front overhang 3 830 830

Wheel base 4 3,000 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 200 205

Overall height (unladen) 8 1,775 1,780

Rear track 9 1,500 1,515

Cargo bed interior length 10

Cargo bed interior width 11 1,470 1,470

Cargo bed interior height 12

Cargo floor height (unladen) 13 845 850

Vehicle weight kgKerb

weight

Without rear bumper 5

With rear bumper

Without rear bumper 6

With rear bumper

1,210/1,390*

1,285/1,465*

5,040/5,220*

5,115/5,295*

1,325/1,505*

405/460*

1,210/1,390*

1,285/1,465*

5,040/5,220*

5,115/5,295*

1,325/1,505*

405/460*

Without optional parts 1,860 1,880

With full optional parts 1,980 2,015

Max. gross vehicle weight 2,850 2,850

Max. axle weight rating-front 1,260 1,260

Max. axle weight rating-rear 1,800 1,800

Max. towable weight

With brake 2,700 2,700

Without brake 750 750

Max. trailer-nose weight 115 115

Max. gross combination weight 5,500 5,500

Seating capacity (including a driver) 5 5

Engine Model code 4D56 4D56

Total displacement mL 2,477 2,477

Type DOHC diesel

Intercooled, Turbocharger

DOHC diesel

Intercooled,

Turbocharger

Max. output kW/rpm (EEC net) 100/3,500 100/3,500

Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000

Transmission Model code V5MB1 V5MB1

Type 5M/T 5M/T

Drive system Easy select 4WD Super select 4WD

Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection

Turning radius mBody 6.3 6.3

Wheel 5.9 5.9

Page 35

00-34

GENERAL DATA AND SPECIFICATIONS

GENERAL

Item KB4T

GJRXZL6Z

Vehicle dimension mm

Front track 1 1,520

Overall width 2 1,800

Front overhang 3 830

Wheel base 4 3,000

Rear overhang

Overall length

Ground clearance (unladen) 7 205

Overall height (unladen) 8 1,780

Rear track 9 1,515

Cargo bed interior length 10

Cargo bed interior width 11 1,470

Cargo bed interior height 12

Cargo floor height (unladen) 13 850

Vehicle weight kgKerb

weight

Without rear bumper 5

With rear bumper

Without rear bumper 6

With rear bumper

1,210/1,390*

1,285/1,465*

5,040/5,220*

5,115/5,295*

1,325/1,505*

405/460*

Without optional parts 1,890

With full optional parts 2,025

Max. gross vehicle weight 2,850

Max. axle weight rating-front 1,260

Max. axle weight rating-rear 1,800

Max. towable weight

With brake 2,700

Without brake 750

Max. trailer-nose weight 115

Max. gross combination weight 5,500

Seating capacity (including a driver) 5

Engine Model code 4D56

Total displacement mL 2,477

Type DOHC diesel

Intercooled, Turbocharger

Max. output kW/rpm (EEC net) 100/3,500

Max. torque N⋅m/rpm (EEC net) 314/2,000

Transmission Model code V4A5A

Type 4A/T

Drive system Super select 4WD

Fuel system Fuel supply system Electrical fuel injection

Turning radius mBody 6.3

Wheel 5.9

Page 36

GENERAL

GENERAL DATA AND SPECIFICATIONS

NOTE: .

•

*1: Vehicle with extended cargo bed (optional)

•

Trailer specifications indicate the manufacturer’s recommendation.

•

When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum weights all the time.

GENERAL DATA AND SPECIFICATIONS <VEHICLES FOR MOROCCO>

M1001000906675

00-35

1 2

34 5

Item KA4T

NENMZ6BA

Vehicle dimension mmFront track 1 1,505

Overall width 2 1,750

Front overhang 3 830

Wheel base 4 3,000

Rear overhang 5

Overall length 6

1,210/1,385*

5,040/5,215*

Ground clearance (unladen) 7 200

Overall height (unladen) 8 1,655

Rear track 9 1,500

AC805672

Cargo bed interior length 10 2,220

Cargo bed interior width 11 1,470

Cargo bed interior height 12 405

Cargo floor height (unladen) 13 715

Vehicle weight kg Kerb weight Without optional parts 1,550

With full optional parts 1,600

Max. gross vehicle weight 2,630

Max. axle weight rating-front 1,030

Max. axle weight rating-rear 1,700

Seating capacity (including a driver) 2

Page 37

00-36

Item KA4T

Engine Model code 4D56

Total displacement mL 2,477

Type DOHC diesel

Max. output kW/rpm (EEC net) 94/4,000

Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500

Transmission Model code R5MB1

Type 5M/T

Drive system Rear wheel drive 2WD

Fuel system Fuel supply system Electrical fuel injection

Turning radius m Body 6.1

Wheel 5.7

NOTE: .

PRECAUTIONS BEFORE SERVICE

GENERAL

NENMZ6BA

Intercooled, Turbocharger

•

*1: Vehicles with rear step bumper assembly.

PRECAUTIONS BEFORE SERVICE

SERVICING COMMON RAIL ENGINE

DANGER

• The working near to a naked flame or

sparks must be avoided.

• Attention during engine running:

a. Do not work on the high pressure fuel

circuit.

b. Always remain out of the way of possi-

ble fuel jet that may result in serious injuries.

c. Do not place your hand near the high

pressure fuel circuit.

• Attention before service:

a. After turning the ignition switch to the

"LOCK" (OFF) position, wait for 30 seconds before starting any repair work.This period of time is required so that the high pressure fuel circuit pressure can get back to the atmospheric pressure.

b. After turning the ignition switch to the

"LOCK" (OFF) position, wait 10 minutes before disconnecting the fuel return pipe from diesel injectors.

M1001016400154

VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER STARTING

M1001011300077

CAUTION

Never start the engine with the refrigerant system empty as it will damage the A/C compressor.

Page 38

GENERAL

PRECAUTIONS BEFORE SERVICE

00-37

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRETENSIONER

M1001011601695

CAUTION

Items to review when servicing SRS:

1. Be sure to read GROUP 52B − Supplemental

Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.

2. Wait at least 60 seconds after disconnecting

the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Seri ous injury may result from unintended air bag deployment if work is done on the SRS sys tem immediately after the battery cable is disconnected.

3. Warning/Caution labels must be heeded when

servicing or handling SRS components. Warning labels can be found in the following locations. (Refer to WARNING/CAUTION LABELS

4. Always use the designated special tools and

test equipment.

5. Store components removed from the SRS in a

clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it.

6. Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module and clock spring).

7. Whenever you finish servicing the SRS, check

the SRS warning lamp operation to make sure that the system functions properly.

8. Be sure to deploy the air bag before dispos-

ing of the air bag module or disposing of a vehicle equipped with an air bag (Refer to GROUP 52B cedures).

Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag.

1. When removing or installing parts, do not

allow any impact or shock to the SRS compo nents.

2. If heat damage may occur during paint work,

remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, and the

− Air Bag Module Disposal Pro-

seat belt pre-tensioner.

• SRS-ECU, air bag modules, clock spring and impact sensors: 93

• Seat belt with pre-tensioner: 90°C or more

° C or more

SERVICING ELECTRICAL SYSTEM

M1001011900303

CAUTION

Before connecting or disconnecting the negative

−) cable, be sure to turn off the ignition switch

( and the lighting switch (If this is not done, there is the possibility of semiconductor parts being damaged).

AC300693

Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative ( order to avoid damage caused by short-circuiting.

−) cable from the battery in

IN ORDER TO PREVENT VEHICLES FROM FIRE

M1001011100147

"Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/ repairs that may be carried out which involve the electrical or fuel systems, must be carried out in accordance with MMC's information/Instructions".

Page 39

00-38

GENERAL

PRECAUTIONS BEFORE SERVICE

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

M1001012400215

Multi use tester (M.U.T.-III) sub assembly

Vehicle communication interface (V.C.I.)

MB991824

M.U.T.-III USB cable

MB991827

M.U.T.-III main harness A

CAUTION

Turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-III.

Diagnosis connector

MB991910

MB991824

MB991910

M.U.T.-III main harness B

Do not use

MB991911

M.U.T.-III measurement adapter

MB991825

M.U.T.-III trigger harness

MB991826

AC305090

Refer to the "M.U.T.-III OPERATION MANUAL" for instructions on handling the M.U.T.-III.

MB991827

MB991824

MB991827

Diagnosis connector

MB991910

AC509179

AC501413

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

HOW TO PERFORM CHASSIS NUMBER (CHASSIS NO.) WRITING

M1001015200715

Write the Chassis Number (Chassis No.) of immobiliser system as following procedure.

Page 40

GENERAL

PRECAUTIONS BEFORE SERVICE

00-39

The Chassis Number (Chassis No.) is stored in the engine-ECU or ETACS-ECU by the vehicle manufac ture. If the Chassis No. to be stored in the engineECU or ETACS-ECU is eliminated fraudulently, the engine warning lamp illuminates and Diagnostic Trouble Code (diagnosis code) No.P0630 (Chassis

SCREEN FLOW OF M.U.T.-III

System choice IMMOBILIZER

Special Function

Engine Key Code Reg. & Chassis No. Writing

Key Code Registration to Engine-ECU

Key Code Registration Completed

Engine Key Code Reg. & Chassis No. Writing

No. malfunction) is shown. When the engine-ECU or

ETACS-ECU is replaced, and entry of the Chassis No. necessary due to diagnosis code No. P0630 (Chassis No. malfunction). Enter the Chassis No. in accordance with the procedure as follows:

Coding

Chassis No. Writing

IMMOBILIZER & Chassis No. Writing

Writing confirmation

Chassis No. Writing

Chassis No. Information

Confirmation of Chassis No. writing execution

Chassis No. Writing

Chassis No. Writing Completed

Result of Chassis No. Writing

Chassis No. Writing Completed

Writing Result Display

AC510087

Page 41

00-40

GENERAL

PRECAUTIONS BEFORE SERVICE

CHASSIS NUMBER REGISTRATION PROCEDURE FOR ENGINE-ECU

CAUTION

• Check that diagnosis code No.P0603 (EEPROM malfunction) is not set. If diagnosis code No.P0603 (EEPROM malfunction) is set, entered Chassis No. cannot be stored. There fore, carry out troubleshooting and repair the malfunction when this code is set.

MB991824

•

Diagnosis connector

MB991910

Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.

2. Start up the personal computer.

3. Connect special tool M.U.T.-III USB cable (MB991827) to V.C.I. (MB991824) and the personal computer.

4. Connect special tool M.U.T.-III main harness A (MB991910) to the V.C.I.

5. Connect the M.U.T.-III main harness A to the diagnosis connector.

6. Turn the V.C.I. power switch to the "ON" position.

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col our.

7. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

MB991827

MB991824

MB991827

Diagnosis connector

MB991910

AC509179

AC501413

To prevent damage to M.U.T.-III, always turn the

ignition switch to the "LOCK" (OFF) position before connecting or disconnecting M.U.T.-III.

AC510062

8. Select "IMMOBILIZER" in the "System Select" tag. Select the model year and push the OK button (Check each model if there is an option). Select "Special Function" on the next screen, and select "Engine Key Code Reg. & Chassis No. Writing" on the further screen.

OK button

AC510063

9. Push the OK button after "Key Code Registration" is displayed.

Page 42

GENERAL

PRECAUTIONS BEFORE SERVICE

00-41

10.Push the OK button after "Completed. Press the OK button and move to Chassis No. writing function." is displayed.

***************** *****************

AC510064

11.Enter the Chassis No. of registering vehicle and push the OK button.

12.Push the OK button after "Chassis No. Writing will start. Are you sure?" is displayed.

13.Return to the previous screen and "In Progress" is displayed at the lower-left corner on the screen.

14.Push the OK button after "Completed." is displayed.

CHASSIS NUMBER REGISTRATION PROCEDURE FOR ETACS-ECU.

Diagnosis connector

MB991910

MB991824

MB991827

AC509179

IMMOBILIZER

Special Functio

Engine Key Code Reg. Chassis No. Writing

Item Current Before Writing

Chassis No.

Result of Writing

***************** *****************

AC510065

15.Chassis No. writing result is displayed.

16.Select "Chassis No. Information" on the "Coding" screen after the Chassis No. writing is completed, and check that the Chassis No. is changed.

17.Complete the M.U.T.-III.

18.Disconnecting the M.U.T.-III is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF) position.

MB991824

MB991827

Diagnosis connector

MB991910

AC501413

Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK" (OFF).

2. Start up the personal computer.

3. Connect M.U.T.-III USB cable (MB991827) to special tool Vehicle Communication Interface (V.C.I.) (MB991824) and the personal computer.

Page 43

00-42

PRECAUTIONS BEFORE SERVICE

4. Connect M.U.T.-III main harness A (MB991910) to the V.C.I.

5. Connect the M.U.T.-III main harness A to the diagnosis connector.

6. Turn the V.C.I. power switch to the "ON" position.

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col

our.

7. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

GENERAL

*****************

AC510067

13.Chassis No. writing result is displayed.

14.Select "Chassis No. Information" on the "Coding" screen after the Chassis No. writing is completed, and check that the Chassis No. is changed.

15.Resister the other ID code.(Refer to GROUP 54A, Immobilizer system

− On-vehicle service )

AC510062

8. Select "IMMOBILIZER" in the "System Select" tag. Select the model year and push the OK button (Check each model if there is an option).Select "Coding" on the next screen, and select "Chassis No. Writing" on the further screen.

*****************

OK button

AC510066

9. Enter the Chassis No. of registering vehicle and push the OK button.

10.Push the OK button after "Chassis No. Writing will start. Are you sure?" is displayed.

11.Return to the previous screen and "In Progress" is displayed at the lower-left corner on the screen.

12.Push the OK button after "Completed." is displayed.

PRE-INSPECTION CONDITION

M1001012100388

"Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspec

tion can be carried out. If you see the words "Set the vehicle to the pre-inspection condition" in this man

ual. It means to set the vehicle to the following condition.

• Engine coolant temperature 80 to 90°C

• Lamps, electric cooling fan and all accessories:

OFF

• M/T: Neutral

• A/T: P range

ENGINE OILS

M1001011200155

HEALTH WARNING

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addi

tion, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

RECOMMENDED PRECAUTIONS

The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions:

• Avoid prolonged and repeated contact with oils, particularly used engine oils.

Page 44

GENERAL

PRECAUTIONS BEFORE SERVICE

00-43

• Wear protective clothing, including impervious

• Obtain first aid treatment immediately for open

gloves where practicable.

• Avoid contaminating clothes, particularly under-

• Wash regularly with soap and water to ensure all

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 oilimpregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal cloth ing.

• Do not use petrol, kerosine, diesel fuel, gas oil,

• Use barrier creams, applying them before each

• Where there is a risk of eye contact, eye protec-

tion should be worn, for example, chemical goggles or face shields; in addition an eye wash

• If skin disorders develop, obtain medical advice

facility should be provided.

WHAT THE COMMON RAIL ENGINE LEARNS

After fuel-related parts are replaced, the common rail engine must register their identification codes with the engine-ECU and execute learning. The table below shows what should be registered and learned after each type of operation.

Registration and learning item Operation type

Injector replacement

Injector identification code registration applicable

Small injection quantity learning applicable

NOTE: When the engine-ECU is replaced, collect in advance the injector identification code from the cur rent engine-ECU. Doing it makes registration easy.

Correspondence table

cuts and wounds.

oil is removed, especially before meals (skin cleansers and nail brushes will help). After clean ing, the application of preparations containing lanolin to replace the natural skin oils is advised.

thinners or solvents for cleaning skin.

work period, to help the removal of oil from the skin after work.

without delay.

M1001012500018

Supply pump replacement

−

Engine-ECU replacement

applicable

Supply pump correction learning

−

REGISTRATION AND LEARNING PROCEDURE

Injector identification code registration

Refer to P.00-43, INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE.

Small injection quantity learning

Refer to P.00-45, SMALL INJECTION QUANTITY LEARNING PROCEDURE.

Supply pump correction learning

Refer to P.00-45, SUPPLY PUMP CORRECTION

applicable

LEARNING PROCEDURE.

INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE

CAUTION

1. If the injector identification code is not regis-

tered, the engine warning lamp goes on and diagnosis code No. P1626 is logged.

2. Failure to register the injector identification

code correctly will cause rough idling, abnor mal noise, and emission deterioration.

Identification code

PURPOSE

−

AK501491

M1001012600015

Because individual injectors have different injection characteristics, the engine-ECU corrects injection time for each cylinder to improve injection accuracy.

Page 45

00-44

)

GENERAL

PRECAUTIONS BEFORE SERVICE

For this reason, when the injector or engine-ECU is replaced, injector correction data must be registered afterwards in the engine-ECU using the Multi Use Tester III (M.U.T.-III). Correction data is converted into an identification code consisting of 30 alphanumeric characters and printed on the injector connector.

REGISTRATION PROCEDURE

1. When replacing the engine-ECU, connect the current engine-ECU to the body harness.

NOTE: This operation is purposed to read the injector identification code stored in the engine-ECU. Reading the identification code in this way before replacement can eliminate manual input of the identi fication code after replacement.

2. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

3. Turn the ignition switch to "ON" position.

4. Select SPECIAL FUNCTION from the function menu.

5. When the current engine-ECU is still mounted, read and register the injector identification code as follows:

(1) Select Read Injector ID Code (for engine-ECU

replacement) from the SPECIAL FUNCTION menu.

(2) Select Write and Save Injector ID Code from

the menu to read data from the current engineECU and save the data if it could be read

normally. (3) Mount the new engine-ECU on the vehicle. (4) Select SPECIAL FUNCTION from the function

menu. (5) Select Write Injector ID Code (for engine-ECU

replacement) from the SPECIAL FUNCTION

menu. (6) Select SAVED INJECTOR ID WRITING from

the Write Injector ID Code menu to write the

data, which was saved previously, to the

engine-ECU.

6. If the injector has been replaced or data has not been read from the current engine-ECU, register the injector identification code as follows:

(1) Select Write Injector ID Code from the

SPECIAL FUNCTION menu.

(2) If the injector was replaced, specify whether to

write to every cylinder or a specific cylinder.

Frame 1 (4 digits)

Frame 3 (4 digits)

Frame 5 (4 digits)

Frame 7 (4 digits)

Frame 2 (4 digits

Frame 4 (4 digits

Frame 6 (4 digits

Frame 8 (2 digits

AK501492

(3) Select the write mode from the menu, enter

the identification code printed on the injector, and execute writing.

CAUTION

Even if the number of the cylinder to be registered does not match the actual injector mounting location, registration ends normally. Specify the cylinder number correctly.

NOTE: The identification code is displayed in order of the frame numbers when it is read.

7. Makes sure that the engine warning lamp that is on changes to blinking, indicating the registration is complete.

NOTE: When the injector is replaced, executing the write operation also clears the values of small injec tion quantity learning.

8. Execute small injection quantity learning.

Refer to P.00-45, the SMALL INJECTION QUANTITY LEARNING PROCEDURE for the learning procedure.

9. Confirm that the engine warning lamp is off.

Confirm also that the diagnosis code is not stored.

Page 46

GENERAL

PRECAUTIONS BEFORE SERVICE

SMALL INJECTION QUANTITY LEARNING PROCEDURE

CAUTION

1. If small injection quantity learning has not

been executed, the engine warning lamp blinks.

2. When the requirements for learning are satis-

fied by operation after replacement of the engine-ECU, learning is automatically exe cuted even if no instruction is given from the M.U.T.-III. Accordingly, the malfunction indica tor lamp goes off. However, the learning thus executed is tentative and limited. Be sure to complete leaning using the M.U.T.-III.

PURPOSE

To keep emission and noise level at adequate levels, the engine-ECU must learn injector fuel injection in idle mode. During learning, the engine-ECU calculates actual injection from each cylinder based on changes in engine speeds and corrects pilot injection control. It then keeps records of this amount of correction as a learned value. For this reason, after the engine-ECU or injector is replaced, learning must be executed using the M.U.T.-III.

NOTE: Engine friction changes or injector deterioration over time may cause fluctuation in pilot injection. After use over time, it may prevent injection of an accurate amount of fuel according to the indication by the engine-ECU. This is why learning must be executed again periodically. For this reason, the engine-ECU periodically leans injection according to the cumulative mileage. Note that making the M.U.T.-III learn again resets the cumulative mileage.

NOTE: The engine sound may change or idling engine speeds may increase during injection learn ing. These are not abnormalities.

LEARNING PROCEDURE

1. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

2. Put the vehicle in the following idling stable conditions:

• Engine coolant temperature: 80 − 90°C

• Fuel temperature: 30 − 100°C

• Intake air temperature: −30 to 100°C

• Barometric pressure: 70 kPa or more

• Automatic transmission fluid temperature: 60°C

or higher

• Lamps, A/C condenser fan and all accessories: OFF

• Transmission: Neutral <M/T>, "P" range <A/T>

• Power steering: Static state

3. Select SPECIAL FUNCTION from the function menu.

4. Select LEARNING from the SPECIAL FUNCTION menu.

5. Select Item No. 1 Small injection quantity learning to execute learning.

CAUTION

If the vehicle conditions go out of the learning

conditions during idling, learning is interrupted.

To reexecute learning, the ignition switch

must once be turned off.

6. Continue idling for about 3 minutes before learning is completed.

7. Confirm that the engine warning lamp is off. If it still blinks, reexecute learning.

00-45

M1001014300322

SUPPLY PUMP CORRECTION LEARNING PROCEDURE

PURPOSE

The engine-ECU learns the relation between the suction control valve (linear solenoid valve) of the supply pump drive current and the fuel injection vol ume. The learning value is calculated from the suction control valve drive current and the rail pressure sen sor output voltage. When the supply pump is replaced, therefore, this learning must be executed.

Re-learning is executed when the engine is idling after the learning value in the engine-ECU has been reset by the M.U.T.-III.

LEARNING PROCEDURE

After the ignition switch is in "LOCK" (OFF) position,

connect the M.U.T.-III to the diagnosis connector.

1. Turn the ignition switch to "ON" position. (Do not start the engine.)

2. Select SPECIAL FUNCTION from the function menu.

M1001014400299

Page 47

00-46

GENERAL

PRECAUTIONS BEFORE SERVICE

3. Select INITIALIZATION from SPECIAL FUNCTION menu.

4. Select and initialize Item No. 21 Supply pump exchange service.

5. After initializing, run the engine at idle in the following conditions.

• Accelerator pedal: OFF

• Engine coolant temperature: 60°C or higher

• Fuel temperature: 30°C or higher

6. Confirm that the item No. 65 High pressure pump learned status on M.U.T.-III Service Data is "2".

NOTE: "2" indicates that the learning has completed.

INITIALIZATION PROCEDURE FOR LEARNING VALUE IN DIESEL PARTICULATE FILTER (DPF) SYSTEM <Euro5>

M1001015600069

PURPOSE

The engine-ECU stores the change of the DPF system caused by the various driving conditions as the learning value and uses it for assumption of the PM accumulated amount or for the acceptance/rejection criteria of the DPF system. For this reason, the learn ing value is necessary to be initialized when the parts related to the DPF system are replaced.

INITIALISATION PROCEDURE

1. After the ignition switch is in "LOCK" (OFF) position, connect M.U.T.-III with the diagnosis connector.

2. Ignition switch is in "ON" position.

3. Select the "SPECIAL FUNCTION" from the "FUNCTION MENU" on the M.U.T.-III.

4. Select the INITIALIZATION from the SPECIAL FUNCTION.

5. Select the item on the screen of the initialization for learning, and perform the initialization.

Service Item

No.

At replacing DPF 40 DPF exchange service

At replacing exhaust differential pressure sensor

At replacing catalytic converter

41 DPF differential

42 DPF system

Item

pressure sensor exchange service

malfunction service

BATTERY CURRENT SENSOR CALIBRATION <Euro5>

M1001018600240

PURPOSE

The engine-ECU carries out the electrical generation control according to the charge level of the battery, based on the battery current sensor signal. To improve the effect of reducing the fuel consumption by the electrical generation control, it is necessary to accurately detect the charge level of the battery. For this, if the following services are performed, carry out the battery current sensor calibration.

• Replacing the battery current sensor

• Replacing the engine-ECU

LEARNING PROCEDURE

1. After the ignition switch is in "LOCK" (OFF) position, disconnect the battery cable from the negative battery terminal.

Battery current sensor

AKB00261

2. Remove the battery current sensor from the battery cable (Do not disconnect the battery current sensor connector).

3. Connect the battery cable without the battery current sensor to the negative battery terminal.

Page 48

GENERAL

PRECAUTIONS BEFORE SERVICE

00-47

MB991824

MB991827

MB991910

Diagnosis connector

AC509179

9. Select "Battery current SNSR.calibration" from Learning Screen.

10.Start the calibration by pressing the "OK" button.

11.Confirm that the M.U.T.-III data list item No. 452 Battery current sensor calibration is "Completed".

12.After the ignition switch is in "LOCK" (OFF) position, disconnect the M.U.T.-III.

13.Install the battery current sensor.

HOW TO USE THE THROTTLE CONTROLLER

M1001009300036

As for a vehicle with the electronic control throttle

, engine operations such as racing can not be

valve performed from outside the vehicle. Thus, the throttle valve controller (MB991791) is provided as a special tool to enable the engine operation from outside the vehicle.

NOTE: *: A vehicle with the accelerator pedal position sensor (APS) installed to the accelerator pedal

THE THROTTLE CONTROLLER CONNECTION

MB991910

MB991824

MB991827

AC501413

4. Connect the M.U.T.-III to the diagnosis connector (But do not start the engine).

5. Turn the ignition switch to the ON position.

6. Select "MPI/GDI/DIESEL" from System select Screen of the M.U.T.-III.

7. Select "Special Function" from MPI/GDI/DIESEL Screen.

8. Select "Learning" from Special Function Screen.

APS harness side connector

MB991894

MB991791

AC103781

1. Disconnect the accelerator pedal position sensor (APS) connector installed to the accelerator pedal, and connect the 6-pin connector of throttle controller adaptor (MB991894) to the vehicle harness-side connector.

2. Connect the throttle controller (MB991791) to the 8-pin connector of throttle controller adaptor (MB991894).

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

M1001011000247

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.

Page 49

00-48

GENERAL

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

VEHICLE WASHING

M1001012000723

Approximately 40 cm or more

AC300832

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc.

• Spray nozzle distance: Approx. 40 cm or more

• Spray pressure: 3,900 kPa or less

• Spray temperature: 82°C or less

• Time of concentrated spray to one point: within

30 sec.

PRECAUTIONS FOR INSTALLATION OF ON-VEHICLE RADIO TRANSMISSION EQUIPMENT

M1001015500095

The computers (control unit) for various on-vehicle electronic equipment are provided with sufficient pro tective measures against external radio wave interference. However, because the on-vehicle radio transmission equipment may affect adversely the computers (control unit), pay attention to the follow ing precautions for installation.

• Install radio transmission equipment and antenna (including coaxial cables) 200 mm or more away from the computers (control unit) for on-vehicle electronic equipment.

• Because radio wave is radiated from the coaxial cables of the antenna for radio transmission equipment, do not route the cables in parallel with the vehicle wiring harness.

• Install only radio transmission equipment with the frequencies, output, and radio wave types described in the table.

FREQUENCY, OUTPUT, AND RADIO WAVE TYPE OF THE RADIO TRANSMISSION EQUIPMENT

Frequency (MHz)

Maximum output power

Modulation

(W)

3.5 50 CW, FM, AM,

SSB

144

430

1,260 2

•

Antenna attachment position

AC709451AB

Install the antenna for radio transmission equipment

only to the position shown in the figure.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The driver’s and passenger’s air bag and seat belt with pre-tensioner is designed to supplement the driver's and front passenger's seat belts to help reduce the risk or severity of injury to the driver and front passenger by activating and deploying both front air bags in certain frontal collisions. The side-air bag and the curtain air bag are activated when an impact exceeds the threshold upon a side collision, and inflates to protect the heads of the occupants in the front and rear seats.

M1001009801120

The Supplemental Restraint System (SRS) consists of air bag modules, SRS air bag control unit (SRSECU), front impact sensors, side impact sensor, SRS warning lamp, clock spring, passenger’s air bag cut off switch, passenger’s air bag cut off indicator lamp and seat belt with pre-tensioner. Front air bags are located in the centre of the steering wheel and above the glove box. Side-airbags are located inside the front seatback assemblies. The curtain air bag mod

ule is installed in the roof side sections (from the

Page 50

GENERAL

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

00-49

driver's and the passenger's front pillars to the rear pillars). Each air bag is made up of a folded air bag and an inflator unit. The SRS-ECU is mounted on the front of the floor console and has a front air bag saf ing G-sensor, front air bag analogue G-sensor. The front impact sensor is installed out side of the head

lamp support panel. The side impact sensor is installed in the lower parts of the centre pillars. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is

<A/T>

SRS warning lamp

<M/T>

SRS warning lamp

installed in the steering column. The passenger’s air bag cut off switch is located above inside the glove box. The passenger’s air bag cut off indicator lamp is

located above the centre upper panel. The seat belt pre-tensioner is built into the driver's and passen ger's front seat belt retractor. Only authorized service personnel should do work on or around the SRS components. Those service per sonnel should read this manual carefully before starting any such work.

Driver's air bag module

Clock spring

Passenger's air bag cut off indicator lamp

SRS-ECU

Passenger's (front) air bag module

Passenger's air bag cut off switch

SRS-ECU

Front impact sensor

Curtain air bag module

Side impact sensor

Seat belt pre-tensioner

Side-airbag module

AC900651

Page 51

00-50

SRS SERVICE PRECAUTIONS

DANGER

In order to avoid injury to yourself or others from accidental deployment of the air bag during servicing, read and carefully follow all the precautions and procedures described in this manual.

CAUTION

Do not use any electrical test equipment on or near SRS components, except those specified on .

CAUTION

Never attempt to repair the following components:

1. SRS-ECU

2. Front impact sensor

3. Clock spring

4. Driver's and passenger's (front) air bag mod-

ules

5. Seat belt with pre-tensioner

6. Side impact sensor

7. Front seatback assembly incorporating side-

airbag module

8. Curtain air bag module

NOTE: If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE pro cedures in this manual, starting at page .

GENERAL

M1001006001006

CAUTION

SRS-ECU connector

AC800836

Do not attempt to repair the wiring harness connectors of the SRS. If a defective wiring harness is found, repair or replace it by referring to the table below.

SRS-ECU terminal No. Destination of harness Remedy

1, 2 Instrument panel wiring harness →

Front wiring harness

→ Front impact

Correct or replace each wiring harness.

sensor (RH)

3, 4 Instrument panel wiring harness →

Front wiring harness

→ Front impact

Correct or replace each wiring harness.

sensor (LH)

8 Instrument panel wiring harness →

SRS warning lamp

9, 10 Instrument panel wiring harness →

Passenger's air bag cut off switch

→

Correct or replace the Instrument panel wiring harness.

Correct or replace the instrument panel wiring harness.

Passenger's (front) air bag module

11, 12 Instrument panel wiring harness →

Clock spring

→ Driver's air bag module

Correct or replace instrument panel wiring harness. Replace the clock spring.

13 Instrument panel wiring harness →

Junction block (fuse No.21)

Correct or replace the instrument panel wiring harness.

Page 52

GENERAL

SRS SERVICE PRECAUTIONS

SRS-ECU terminal No. Destination of harness Remedy

16 Instrument panel wiring harness →

Junction block (fuse No.15)

18 Instrument panel wiring harness →

Earth

20 Instrument panel wiring harness →

Diagnosis connector

27, 28 Instrument panel wiring harness →

Floor wiring harness tensioner (passenger’s side)

29, 30 Instrument panel wiring harness →

Floor wiring harness tensioner (driver’s side)

SRS-ECU terminal No. Destination of harness Remedy

→ Seat belt pre-

Correct or replace the instrument panel wiring harness.

Correct or replace each wiring harness.

00-51

1, 2 Floor wiring harness → Instrument

panel wiring harness harness

3, 4 Floor wiring harness → side-airbag

module (LH)

5, 6 Floor wiring harness → Seat belt pre-

tensioner (passenger’s side)

15, 16 Floor wiring harness → side impact

sensor (LH)

21, 22 Instrument panel wiring harness →

Passenger's air bag cut off switch Passenger's (front) air bag module

27, 28 Instrument panel wiring harness →

Clock spring

29, 30 Instrument panel wiring harness →

Front wiring harness sensor (LH)

35, 36 Instrument panel wiring harness →

Front wiring harness sensor (RH)

37 Instrument panel wiring harness →

Junction block (fuse No.15)

38 Instrument panel wiring harness →

Diagnosis connector

39 Instrument panel wiring harness →

SRS warning lamp

41 Instrument panel wiring harness →

Earth

43 Instrument panel wiring harness →

Junction block (fuse No.21)

→ curtain air bag module (LH)

→ Driver's air bag module

→ roof wiring

→

→ Front impact

Correct or replace each wiring harness.

Correct or replace the floor wiring harness.

Correct or replace the instrument panel wiring harness.

Correct or replace instrument panel wiring harness. Replace the clock spring.

Correct or replace each wiring harness.

Correct or replace the instrument panel wiring harness.

Page 53

00-52

SRS SERVICE PRECAUTIONS

GENERAL

SRS-ECU terminal No. Destination of harness Remedy

51, 52 Floor wiring harness → Seat belt pre-

tensioner (driver’s side)

Correct or replace the floor wiring harness.

53, 54 Floor wiring harness → side-airbag

module (RH)

55, 56 Floor wiring harness → Instrument

panel wiring harness harness

→ curtain air bag module (RH)

→ roof wiring

61, 62 Floor wiring harness → side impact

sensor (RH)

Correct or replace each wiring harness.

Correct or replace the floor wiring harness.

DANGER

Insulating tape

Battery

Battery cable

AC300580

After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. In addition, insulate the neg ative battery terminal with a tape. The condenser inside the SRS-ECU is designed to

retain enough voltage to deploy the air bag

Page 54

GENERAL

SRS SERVICE PRECAUTIONS

00-53

for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.

CAUTION

The SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, driver’s and passenger’s (front) air bag modules, clock spring, front impact sensor, seat belt with pre-tensioner before drying or baking the vehicle after painting.

• SRS-ECU, air bag modules, clock spring and impact sensors: 93

• Seat belt with pre-tensioner: 90°C or more

CAUTION

Whenever you finish servicing the SRS, always erase the diagnosis code and check warning lamp operation to make sure that the system functions properly.

CAUTION

° C or more

touched directly by the probe, the plating may break, which will cause drops in reliability.

SRS-harness connector

MB992006

SRS-ECU harness connector (rear side)

AC801105

If checks are carried out by using the SRS-ECU harness connector, observe the following proce dures: Insert the special tool extra fine probe (MB992006) into connector from harness side (rear side), and connect the tester to this probe. If any tool than special tool is used, damage to the harness and other components will result. Never insert the probe directly to the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are

Page 55

00-54

SUPPORT LOCATIONS FOR LIFTING AND JACKING

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000701160

SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

CAUTION

Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc.

AXLE STANDS <Front>

AC502650

<Rear>

AC502651

<Rear>

AC502647

GARAGE JACK

<Front>

crossmember

AC502069

<Rear>

AC502070

AC502553

Page 56

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-55

SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION

When service procedures require removing rear suspension, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.

<Front>

AC505968

<Rear>

AC502653

AC502572

Page 57

GROUP 00E

GENERAL

CONTENTS

00E-1

HOW TO READ WIRING DIAGRAMS 00E-2

COMPOSITION AND CONTENTS OF WIRING

DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2

HOW TO READ CONFIGURATION DIAGRAMS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2

HOW TO READ CIRCUIT DIAGRAMS . . . . 00E-4

MARKINGS FOR CONNECTOR AND EARTHING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-5

WIRE COLOUR CODES . . . . . . . . . . . . . . . 00E-7

ABBREVIATION SYMBOLS . . . . . . . . . . . . 00E-8

Page 58

00E-2

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

COMPOSITION AND CONTENTS OF WIRING DIAGRAMS

M1001012800150

In each section, all specifications are listed, including optional specifications. Accordingly, some specifications may not be applicable for individual vehicles.

Section Basic contents

Component locations

Configuration diagrams

Circuit diagrams Circuits from power source to earth are shown completely, classified according to

Locations are shown for each point of relays, ECUs, sensors, solenoid valves, inspection connectors, fusible links, fuses, etc. In the part’s lists, parts are listed in alphabetical order.

Connector locations and harness wiring configurations on actual vehicles are illustrated.

system. There is a main division into power source circuits and circuits classified by system.

• Junction block The entire circuit for the junction block is described, because only the part of the junction block needed is normally shown in each circuit diagram.

• Joint connectors The internal circuits for all joint connectors are described, because only the part needed is shown in each circuit diagram.

• Power source circuits Circuits from the battery to fusible link, fuse, ignition switch, etc are shown.

• Circuits classified by system For each system, the circuits are shown from fuse to earth, excluding the power source sections.

HOW TO READ CONFIGURATION DIAGRAMS

M1001006400227

The wiring harness diagrams clearly show the connector locations and harness routings at each site on actual vehicles.

Page 59

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Denotes connector No. The same connector No. is used throughout the circuit diagrams to facilitate connector location search. The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number. Numbers are usually assigned to part in clockwise order on the diagram.

Example: A-19

C: Instrument panel D: Floor and roof E: Door F: Frame

Denotes earth point. Same earth number is used throughout circuit diagrams to facilitate search of earth point. Refer to GROUP 70 COMPONENT LOCATIONS

- EARTH MOUNTING LOCATIONS for details of earth points.

Denotes harness name.

Number specific to connector (serial number) Connector location site symbol

A: Engine compartment B: Transmission

A-19

Front wiring harness (RH)

A-18

00E-3

Denotes a section covered by a corrugated tube.

The mark shows the standard mounting position of wiring harness.

Denotes the colour of the corrugated tube (If not specified, it is black.) R: Red Y: Yellow

The number of connector pins and the connector colour (except milk white)* are shown for ease of retrieval.

Example: (2-B)

Connector colour (milk white if no colour is indicated)

Number of connector pins

*: Typical connector colours B: Black BR: Brown Y: Yellow V: Violet L: Blue O: Orange G: Green GR: Grey R: Red None: Milk white

A-17

A-16

A-15

A-15 (2) Fog lamp (RH) A-16 (2-GR) Horn (LO) A-17 (2-B) Headlamp (RH) A-18 (2-B) Windshield washer motor A-19 (2-GR) Dual pressure switch

Indicates the device to which the connector is connected.

AC208446

Page 60

00E-4

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

HOW TO READ CIRCUIT DIAGRAMS

M1001006500194

The circuit of each system from the fuse (or fusible link) to earth is shown. The power source is shown at the top and the earth at the bottom to facilitate understanding of how the current flows. The circuit diagrams show the state when switches are not operated.

Indicates power source.

Indicates that terminal is connected via a plate in the relay box.

Each circuit diagram consists of block(s).

Indicates harness junction point numbers for another system. The number corresponds to the junction point number indicated on another circuit diagram.

Indicates the circuit name to be connected. The arrow indicates the current flow direction.

Indicates the power supply in the control unit. If no voltage is displayed, this indicates battery positive voltage.

An "X" at the end of a connector number indicates that the connector is connected to a centralized junction that is shown in the section "Centralized Junction."

Indicates that the diagram continues at which belongs to the block in the same circuit.

Indicates the connector symbol. Connectors in the circuit diagram are indicated in numerical order.

Indicates the operating conditions of the engine coolant switch, etc.

Indicates connector number. The same numbers are used in the wiring harness diagram. Connector and connector numbers are shown at the lower part of the page. Connector numbers not enclosed by frame indicate the device incorporated into wiring harness.

Indicates shield wire.

One-directional arrow indicates that current flows upwards.

Indicates input/output to/from control unit (current flow direction).

Input

Input/

Output

output

Indicates that the terminal is a spare one if the device (sensor in this case) is not provided.

Indicates a wiring connector which is inside the equipment and which is not shown in the wiring harness configuration diagram.

Example C-15-2

Indicates the connector number shown in the wiring harness configuration diagram.

Indicates a connector which is inside the equipment, numbered in order starting from 1.

Indicates that the diagram comes from which belongs to the block in the same circuit.

Indicates that these connectors are the same intermediate connectors.

Indicates terminal number.

In case two or more connectors are connected to the same device, markings indicating the same connector are connector by a broken line.

Bi-directional arrow indicates that current flows in both directions due to control by an ECU.

Indicates harness junction where wire diameter or colour changes.

Indicates intersections at which the lead wires are not connected.

Indicates intersections at which the lead wires are connected.

Indicates representative vehicle body earth point. (Same number as that of earth point in EARTHING LOCATION).

AC502479

Page 61

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

MARKINGS FOR CONNECTOR AND EARTHING

M1001007900162

00E-5

IGNITION SWITCH (IG1)

FUSIBLE

LINK

SOLENOID VALVE

ECU

INSPECTION CONNECTOR

SENSOR

MOTOR

AC208460

Page 62

00E-6

Male terminal

Male connector

Female terminal

Female connector

Device

Intermediate connector

Spare connector, check connector

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Item No. Connector/Earthing Symbol Contents

Connector and terminal marking

Male connecto

The male and female terminals are indicated as shown. The connector with male terminal(s) is called as male connector and indicated by two connector

ACX01252

contour lines, while the connector with female terminal(s) is called as female connector and indicated by

Male terminal

single connector contour line.

Connector symbol marking

ACX01251

ACX01253

Female connecto

ACX01255

Female terminal

ACX01256

ACX01254

The symbol indicates the connector is viewed as shown. At a device connection, the connector symbol on the device side is shown. For an

ACX01257

ACX01253

intermediate connector, the male connector symbol is shown. For spare connectors and check connectors, no device is connected, and so the harness-side connector symbol is shown for these connectors. However, a diagnosis connector

ACX01258

is exceptional.

ACX01256

ACX01816

Page 63

GENERAL <ELECTRICAL>

Direct connection type

Intermediate connector

Device earth

HOW TO READ WIRING DIAGRAMS

Item No. Connector/Earthing Symbol Contents

Connector connection marking

Connection between a device and the harness is either by direct insertion in the device (direct connection type) or by connection with a harness

ACX01260

Harness connection type

ACX01261

connector furnished on the device side (harness connection type). The two types are indicated as illustrated.

00E-7

Earth marking

ACX01262

ACX01263

ACX01264

Body earth

ACX01265

Earthing is either by body earth, device earth or control unit interior earth. These are indicated as illustrated.

AC208448

ACX01274

WIRE COLOUR CODE

Wire colours are identified by the following colour codes.

AC208449

arth in control unit

AC208450

M1001008000195

ACX01276

ACX01278

Page 64

00E-8

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Code Wire colour Code Wire colour Code Wire colour Code Wire colour

B Black L Blue PU Purple V Violet

BR Brown LG Light green R Red W White

G Green O Orange SB Sky blue Y Yellow

GR Grey P Pink SI Silver

− −

If a cable has two colours, the first of the two colour

Example:

<F> 1.25 G B

1234

code characters indicates the basic colour (colour of the cable coating) and the second indicates the marking colour.

ACX01279

No. Meaning

1 <F>: Flexible wire

<T>: Twisted wire

Wire size (mm2)*

3 Basic colour (colour of the cable coating)

4 Marking colour

NOTE: *: No code indicates 0.5 mm2. Cable colour code in parentheses indicates 0.3 mm

ABBREVIATION SYMBOLS

M1001008101593

The abbreviation symbols used in wiring diagrams are defined below.

1. FOR SYSTEM NAME

Abbreviation symbol

ABS Anti-skid braking system LHD Left hand drive vehicles

ASTC Active stability and traction control

CAN Controller area network PTC Positive temperature coefficient

ELC-4A/T Electronic controlled 4-speed

ELC-5A/T Electronic controlled 5-speed

J/B Junction block SRS Supplemental restraint system

J/C Joint connector USB Universal serial bus

Meaning Abbreviation

symbol

MMCS Mitsubishi multi-communication

system

RHD Right hand drive vehicles

automatic transmission

RV Recreation vehicle

automatic transmission

Meaning

system

Page 65

HOW TO READ WIRING DIAGRAMS

2. FOR COMBINATION METERS

GENERAL <ELECTRICAL>

00E-9

Abbreviation symbol

4WD 4-wheel drive indicator lamp GLOW Diesel preheat indicator lamp

A/T TEMP Automatic transmission fluid

ABS Anti-skid braking system warning

ASTC ASTC indicator lamp OD OFF Overdrive off indicator lamp

ASTC OFF ASTC OFF indicator lamp OIL Engine oil pressure warning lamp

BEAM High beam indicator lamp REAR DIFF

BRAKE Brake warning lamp REAR FOG Rear fog lamp indicator lamp

C/D LOCK Centre differential lock indicator

CHECK ENGINE

CHG Charging warning lamp SPEED Speedometer

CPU Central processing unit SRS Supplemental restraint system

CRUISE Cruise control indicator lamp T/GA Engine coolant temperature gauge

Meaning Abbreviation

symbol

LCD Liquid crystal display

temperature warning lamp

ODO Odometer

lamp

LOCK

REAR

lamp

Check engine warning lamp SEAT BELT Seat belt warning lamp

WHEEL

Meaning

Rear differential lock indicator lamp

Rear wheel indicator lamp

warning lamp

DOOR Door-ajar warning lamp TACHO Tachometer

DPF Diesel particulate filter warning lamp

F/GA Fuel gauge TRIP Tripmeter

FRONT FOG Front fog lamp indicator lamp TURN (LH) Turn-signal indicator lamp and

FRONT WHEEL

FUEL Low fuel warning lamp WATER

Front wheel indicator lamp TURN (RH)

SEPARATOR

hazard warning indicator lamp

Fuel filter warning lamp

3. FOR SWITCHES AND RELAYS

Name of switches and relays

Blower switch LO Blower operates at low speed

Cruise control switch ON/OFF Cruise control system ON/OFF

Abbreviation symbol

ML Blower operates at medium low speed

MH Blower operates at medium high speed

HI Blower operates at high speed

RES/ACC Set the vehicle speed

SET/CST

CANCEL Cancel the driving at a constant speed

Operation

Door lock actuator LOCK Door locked

UNLOCK Door unlocked

Page 66

00E-10

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Name of switches and relays

Headlamp levelling switch

Heated seat switch LO Normal heating

Ignition switch LOCK When turned to the LOCK position, no circuits will start

Inhibitor switch P Selector lever is at the P (PARKING) position

Abbreviation symbol

0, 1, 2, 3, 4 Lower the optical axis of the headlamp (LO) in steps at each

HI Rapid heating

ACC When turned to the ACC (ACCESSORY) or ON position, the

IG2 When at the ST (START) position, the power circuit will not start

IG1 Even when at the ST (START) position, the power circuit will start

ST Only when turned to the ST (START) position, the power circuit

R Selector lever is at the R (REVERSE) position

N Selector lever is at the N (NEUTRAL) position

D Selector lever is at the D (DRIVE) position

2 Selector lever is at the 2 (SECOND) position

Operation

position

power circuit will start

functioning

will start

L Selector lever is at the L (LOW) position

Lighting switch LO Low beams ON

HI High beams ON

PASS High beams ON

TAIL Tail, position, licence plate and illumination lamps ON

HEAD Headlamps ON

AUTO Headlamps or tail lamps automatically illuminate by sensing

ambient brightness.

FOG Front, rear fog lamps ON

Others ON Switched ON

OFF Switched OFF

Power window switch UP Window closes

DOWN Window opens

AUTO UP Window is easily closed with one action

AUTO DOWN Window is easily opened with one action

LOCK Prevents all switches other than the main switch from operating

the power windows

UNLOCK Every switch can open or close the respective window

Power seat switch FR Seat is moved forwards or seat back is stood upright

RR Seat is moved forwards or seat back is leaned backward

UP Seat cushion is tilted up

DOWN Seat cushion is tilted down

Page 67

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

00E-11

Name of switches and relays

Rear panel power window switch

Remote controlled mirror switch

Room lamp DOOR Room lamp ON when a door is open

Steering wheel audio remote control switch

Sunroof switch OPEN Sunroof slides to open

Turn-signal lamp switch

Windshield intermittent wiper interval adjusting knob

Windshield rain sensitive wiper function adjusting knob

Windshield wiper switch

Abbreviation symbol

UP Window closes

DOWN Window opens

FULL UP Window is easily closed with one action

FULL DOWN Window is easily opened with one action

LH LH mirror operates

RH RH mirror operates

MODE Switches the mode

CH UP Changes the radio frequency or the music number in the CD

CH DOWN

VOL UP Increases the sound volume

VOL DOWN Decreases the sound volume

CLOSE Sunroof slides to close

LH LH turn-signal lamps ON

RH RH turn-signal lamps ON

SLOW Pause time for intermittent operation lengthens

FAST Pause time for intermittent operation shortens

−

+ Raises the sensitivity of the lighting control sensor to the amount

MIST Windshield wiper operates once

AUTO The windshield wiper operates depending on the amount of

Operation

Lowers the sensitivity of the lighting control sensor to the amount of rainfall.

of rainfall.

rainfall.

INT Windshield wiper operates intermittently

LO Windshield wiper operates at low speed

HI Windshield wiper operates at high speed

4. FOR OTHERS

Abbreviation symbol

2WD 2 wheel-drive vehicles HI High

4WD 4 wheel-drive vehicles IC Integrated circuit

A/C Air conditioner ILL Illumination lamp

A/T Automatic transmission IND Indicator lamp

CPU Central processing unit LIN Local interconnect network

D.C Direct current LH Left hand

ECU Electronic control unit LO Low

Meaning Abbreviation

symbol

Meaning

Page 68

00E-12

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Abbreviation symbol

EEPROM Electrical erasable and

ETACS Electronic time and alarm control

EGR Exhaust gas recirculation RH Right hand

GND Earthing

Meaning Abbreviation

symbol

M/T Manual transmission

programmable read only memory

M.U.T. Multi-use tester

system

Meaning

Page 69

GROUP 11

ENGINE

CONTENTS

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

11-1

Page 70

GROUP 11A

ENGINE

MECHANICAL

CONTENTS

11A-1

GENERAL INFORMATION . . . . . . . . 11A-2

SERVICE SPECIFICATIONS. . . . . . . 11A-2

SEALANTS AND ADHESIVES . . . . . 11A-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4

ON-VEHICLE SERVICE. . . . . . . . . . . 11A-7

ALTERNATOR AND POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK AND ADJUSTMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7

A/C COMPRESSOR DRIVE BELT TENSION CHECK

AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 11A-7

AUTO-TENSIONER CHECK . . . . . . . . . . . 11A-9

VALVE CLEARANCE CHECK AND ADJUSTMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12

IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-13

COMPRESSION PRESSURE CHECK. . . . 11A-14

TIMING BELT B TENSION ADJUSTMENT 11A-15

CRANKSHAFT PULLEY . . . . . . . . . . 11A-17

CRANKSHAFT PULLEY REMOVAL AND

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11A-17

CAMSHAFT AND VALVE STEM SEAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-20

CAMSHAFT AND VALVE STEM SEAL REMOVAL

AND INSTALLATION . . . . . . . . . . . . . . . . . 11A-20

OIL PAN AND OIL STRAINER. . . . . . 11A-27

OIL PAN AND OIL STRAINER REMOVAL AND INSTALLATION <2WD (except high rider)> 11A-27

OIL PAN AND OIL STRAINER REMOVAL AND INSTALLATION <2WD (high rider) and 4WD>

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-30

OIL PAN AND OIL STRAINER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-32

CRANKSHAFT OIL SEAL . . . . . . . . . 11A-33

CRANKSHAFT OIL SEAL REMOVAL AND

INSTALLATION <M/T> . . . . . . . . . . . . . . . . 11A-33

CRANKSHAFT OIL SEAL REMOVAL AND

INSTALLATION <A/T> . . . . . . . . . . . . . . . . 11A-36

CYLINDER HEAD GASKET . . . . . . . . 11A-39

CYLINDER HEAD GASKET REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11A-39

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-43

TIMING BELT REMOVAL AND INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-43

VACUUM PUMP . . . . . . . . . . . . . . . . . 11A-50

VACUUM PUMP REMOVAL AND INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-50

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-52

ENGINE ASSEMBLY REMOVAL AND INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-52

Page 71

11A-2

ENGINE MECHANICAL

GENERAL INFORMATION

Item Euro 5 Except Euro 5

Total displacement mL 2,477

Bore × Stroke mm 91.1 × 95.0

Compression ratio 16.5 17

Combustion chamber Direct injection type

Camshaft arrangement DOHC

Number of valve Inlet 8

Exhaust 8

Valv e timi ng Inlet Opening BTDC 13° BTDC 20°

Closing ABDC 30° ABDC 40°

Exhaust Opening BBDC 38°

Closing ATD C 22°

Fuel system Common rail fuel injection

Rocker arm Double roller type

M1111000102222

SERVICE SPECIFICATIONS

Item Standard value Limit

A/C compressor drive belt tension (When checked)

A/C compressor drive belt tension (When adjusted)

A/C compressor drive belt tension (When replaced)

Alternator and power steering oil pump drive belt tension <Except Euro5>

Alternator and power steering oil pump drive belt tension <Euro5>

Vibration frequency Hz 222.5 − 251.0

Ten s i on N 363 − 462

Deflection mm (Reference) 6.8 − 8.0

Vibration frequency Hz 222.5 − 251.0

Ten s i on N 363 − 462

Deflection mm (Reference) 6.8 − 8.0

Vibration frequency Hz 259.8 − 300.0

Ten s i on N 495 − 660

Deflection mm (Reference) 5.1 − 6.4

Vibration frequency Hz (Reference)

Tension N (Reference) 196 − 392

Vibration frequency Hz (Reference)

Tension N (Reference) 196 − 392

107 − 151

87 − 123

−

M1111000302118

Valve clearance (at cold) [indicates clearance between cam and roller] mm

Intake valve 0.09

Exhaust valve 0.14

−

Page 72

ENGINE MECHANICAL

SEALANTS

Item Standard value Limit

Idle speed r/min Euro 5-M/T 600 ± 50

Euro 5-A/T 650 ± 50

−

11A-3

Except Euro 5-2WD-except high rider

Except Euro 5-high rider and 4WD

Compression pressure (at engine speed of 250 r/min) kPa

Compression pressure difference of all cylinder kPa

Timing belt B tension mm 4 − 5

Timing belt auto tensioner rod protrusion amount mm 2.3 − 7.6

Euro 5 2,400 Minimum

Except Euro 5 2,500 Minimum

650 ± 50

700 ± 50

−

1,650

1,750

Maximum 300

SEALANTS

M1111000500956

Item Specified Sealant Remark

Semi-circular packing 3M ATD Part No. 8660 or exact equivalent Semi-drying sealant

Front left camshaft bearing cap

Oil seal case assembly ThreeBond 1207F (Mitsubishi Genuine Part

No. 1000A992) or exact equivalent

Page 73

11A-4

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Use

MB992080

a: MB992081 b: MB992082

B992080

Belt tension meter set

a: Belt tension meter b: Microphone assembly

Drive belt tension check

M1111000602799

MB991955

a: MB991824 b: MB991827 c: MB991910 d: MB991911

MB991824

MB991827

MB991910

DO NOT USE

MB991911

e: MB991825 f: MB991826

M.U.T.-III sub assembly

a: Vehicle communication

interface (V.C.I.) b: M.U.T.-III USB cable c: M.U.T.-III main harness

A (Vehicles with CAN

communication system) d: M.U.T.-III main harness

B (Vehicles without CAN

communication system) e: M.U.T.-III adapter

harness f: M.U.T.-III trigger harness

CAUTION

For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly.

• Checking the idle speed

• Erasing diagnosis code

MB991825

MB991826

MB991955

MB992046 Valve adjusting socket Adjustment of valve clearance

MB992046

Page 74

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Use

MB991800 Pulley holder Holding the crankshaft pulley

MB991800

MB992100 Crank pulley holder • Holding the crankshaft pulley

• Crankshaft pulley removal

B992100

MB992099 Crank pulley puller Crankshaft pulley removal

B992099

11A-5

MD99877

D998713

MD998772 Valve spring compressor Compressing valve spring

MB991999 Valve stem seal installer Valve stem seal installation

MD998713 Camshaft oil seal installer Camshaft oil seal installation

MD998727 Oil pan FIPG cutter Oil pan removal

MB991883

D998727

MB991883 Flywheel stopper • Supporting the flywheel

assembly <M/T>

• Supporting the inertia ring assembly <A/T>

Page 75

11A-6

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Use

MB990767 Front hub and flange yoke

Holding the camshaft sprocket

holder

B990767

MD998719 Pin

D998719

MB992147 Oil seal installer Crankshaft rear oil seal

installation

D998383

D998382

MD998383 Crankshaft front oil seal

guide

Crankshaft front oil seal installation

MD998382 Crankshaft front oil seal

installer

MD998051 Cylinder head bolt wrench Removal and installation of

cylinder head bolt

MB991683 Sling chain set Removal and installation of

engine assembly

B991683

Page 76

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-7

ALTERNATOR AND POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK

M1111001200033

CAUTION

Check the drive belt tension after turning the crankshaft clockwise one turn or more.

Indicator mar

Auto tensioner

AC501803

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 drive belt. (Refer to

P.11A-17).

NOTE: The drive belt tension check is not necessary as auto tensioner is adopted.

A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

M1111001000363

Check the drive belt tension by the following procedures.

STANDARD VALUE:

Item When

checked

Vibration frequency Hz

222.5 −

251.0

Tension N 363 − 462 363 − 462 495 − 660

When adjusted

222.5 −

251.0

When replaced

259.8 −

300.0

WHEN THE VIBRATION FREQUENCY IS MEASURED (SPECIAL TOOL MB992080 IS USED): RECOMMENDATION

NOTE: The vibration frequency measuring method is recommended for check and adjustment of the drive belt tension.

Belt tension meter set (MB992080)

MB992081

MB992082

AC507219

1. Connect special tool microphone assembly (MB992082) to special tool belt tension meter (MB992081) of special tool belt tension meter set (MB992080).

2. Press the "POWER" button to turn on the power supply.

3. Press the numeral key of "1" and check that "No.1" appears on the upper left of the display.

NOTE: This operation is to temporarily set the preset data such as the belt specifications, because if the measurement is taken without input of the belt specifications, conversion to tension value (N) cannot be made, resulting in judgement of error.

4. Press "Hz" button twice to change the display to the frequency display (Hz).

Deflection mm (Reference)

6.8 − 8.0 6.8 − 8.0 5.1 − 6.4

Page 77

11A-8

)

ENGINE MECHANICAL

ON-VEHICLE SERVICE

CAUTION

• The temperature of the surface of the belt should be as close to normal temperature as possible.

• Do not let any contaminants such as water or oil get onto the microphone.

• If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not corre

spond to actual values.

• Do not take the measurement while the vehicle's engine is running.

10 – 15 mm

Tensioner pulley

15˚

MB992080 (Microphone

WHEN USING THE TENSION GAUGE

Tensioner pulley

Tension gauge

Crankshaft pulley

A/C compressor pulley

AC506003

Use a belt tension gauge in the middle of the belt between the pulleys shown in the figure (at the place indicated by the arrow) to check that the belt tension is within the standard value.

BELT DEFLECTION CHECK

Tensioner pulley

Approximately 100N

Crankshaft pulley

A/C compressor pulley

AC903689

5. Hold special tool MB992080 to the middle of the belt between the pulleys (at the place indicated by arrow) where it does not contact the belt (approximately 10

− 15 mm away from the rear surface of the belt) so that it is perpendicular to the belt (within an angle of

± 15 °).

6. Press the "MEASURE" button.

7. Gently tap the middle of the belt between the 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 standard value.

NOTE: To take the measurement repeatedly, fillip the belt again.

Deflection

Crankshaft pulley

A/C compressor pulley

AC506004

Apply approximately 100 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection. When the belt tension is adjusted by measuring the belt deflection, adjust it with a tool for vibration fre

quency measurement or tension measurement afterward.

BELT TENSION ADJUSTMENT

If not within the standard value, adjust the belt tension by the following procedure.

Adjusting bol

Tensioner pulley

Locking nut

AC505988

1. Loosen the locking nut of the tensioner pulley.

Page 78

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-9

2. Use the adjusting bolt to adjust the belt tension. The tension will increase when turning the adjusting bolt clockwise, and decrease when turning anti-clockwise.

3. Tighten the locking nut.

4. Tighten the adjusting bolt.

CAUTION

When checking the belt tension, turn the crankshaft clockwise one turn or more.

5. Check the belt tension, and readjust if necessary.

AUTO-TENSIONER CHECK

M1111003003216

OPERATION CHECK

1. Turn off the engine from the idle state then check to see that the drive belt is not protruding from the pulley width of the auto tensioner.

2. Remove the drive belt (Refer to P.11A-17).

AC501804

Auto tensioner

AC507703

3. Install the tool to the auto tensioner, and check that no binding is present by turning the auto tensioner in the left and right directions.

4. If there are any problems in the procedure 1 or 3, replace the auto tensioner (Refer to

5. Install the drive belt (Refer to P.11A-17).

P.11A-43).

FUNCTION CHECK

You can verify if the auto tensioner is defective or not by checking the drive belt tension.

When the vibration frequency is measured (Special tool MB992080 is used): Recommendation

1. Check the drive belt tension (Refer to P.11A-7).

2. Measure the drive belt tension vibration frequency by the following procedures:

Belt tension meter set (MB992080)

MB992081

MB992082

AC507219

(1) Connect special tool microphone assembly

(MB992082) to special tool belt tension meter (MB992081) of special tool belt tension meter set (MB992080).

(2) Press the "POWER" button to turn on the

power supply.

(3) Press the numeral key of "1" and check that

"No.1" appears on the upper left of the display.

(4) Press "Hz" button twice to change the display

to the frequency display (Hz).

Page 79

11A-10

)

ENGINE MECHANICAL

ON-VEHICLE SERVICE

CAUTION

• The temperature of the surface of the belt should be as close to normal temperature as possible.

• Do not allow any contaminants such as water or oil to get onto the microphone.

• If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not corre

spond to actual values.

• Do not take the measurement while the vehicle's engine is running.

Power steering oil pump pulley

Gentry tap with your finger

Water pump pulley

<Euro5>

15˚

MB992080 (Microphone

15˚

10 – 15 mm

AC805802

10 – 15 mm

15˚

Gentry tap with your finger

15˚

MB992080 (Microphone)

Alternator pulley

Power steering oil pump pulley

AC805654

(5) Hold special tool MB992080 to the middle of

the belt between the pulleys (at the place indicated by arrow) where it does not contact the belt (approximately 10

− 15 mm away from the rear surface of the belt) so that it is perpendicular to the belt (within an angle of 15

°).

(6) Press the "MEASURE" button.

Page 80

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-11

(7) Gently tap the middle of the belt between the

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 standard value.

Standard value (Reference):

<Except Euro5> 107 − 151 Hz <Euro5> 87 − 123 Hz

NOTE: To take the measurement repeatedly, fillip the belt again.

3. If not within the standard value, replace the auto tensioner (Refer to

P.11A-43).

When using the tension gauge

1. Check the drive belt tension (Refer to P.11A-7).

Power steering oil pump pulley

Water pump pulley

<Euro5>

Belt tension gauge

AC805803

Belt tension gauge

Alternator pulley

Power steering oil pump pulley

AC805655

2. Use a belt tension gauge in the middle of the belt between the pulleys shown in the figure (at the place indicated by the arrow) to check that the belt tension is within the standard value.

Standard value (Reference): 196 − 392 N

3. If not within the standard value, replace the auto tensioner (Refer to

P.11A-43).

Page 81

11A-12

ENGINE MECHANICAL

ON-VEHICLE SERVICE

VALVE CLEARANCE CHECK AND ADJUSTMENT

M1111001502096

NOTE: The valve clearance check and adjustment should be done when the engine is cold.

1. Remove the engine air intake pipe.

2. Remove the inlet manifold.

3. Remove the injection pipe.

CAUTION

Leaked fuel on parts causes a decrease in function and burning. Therefore, Place waste to absorb leaked fuel.

4. Remove the timing belt cover.

5. Remove the rocker cover.

Timing marks

Camshaft sprocket

7. Measure the valve clearance.

If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a thickness gauge between the cam shaft and the roller while turning the adjusting screw.

Standard value (cold engine): Inlet valve: 0.09 mm Exhaust valve: 0.14 mm

MB992046

Thickness gauge

AK500381

8. While holding the adjusting screw with a screwdriver to prevent it from turning, tighten the lock nut to the specified torque using a valve adjusting socket. (MB992046)

Tightening torque: 15 ± 3 N⋅m

Timing marks

Crank shaft pulley

AK500379

6. Align the camshaft sprocket timing marks and set the No. 1 cylinder at top dead centre.

CAUTION

The crankshaft should always be turned in a clockwise direction.

Exhaust valve side

CAUTION

Pay special attention that the tightening torque is not beyond this valve. If the tightening torque is beyond the valve, the valve stem would possibly bend.

9. Turn the crankshaft 360° clockwise to bring No. 4 cylinder to the top dead centre position.

Exhaust valve side

Inlet valve side

AK500380AE

10.Measure the valve clearances at the places indicated by arrows in the illustration. If the clearance is not within the standard value, repeat steps 7 and 8 above.

Inlet valve side

AK500380AD

Page 82

ENGINE MECHANICAL

ON-VEHICLE SERVICE

AK202860AB

10 mm

Semicircular packing

Cylinder head

AK304411

11.Apply specified sealant to the section of the semicircular packing shown in the illustration.

Specified sealant: 3M ATD Part No. 8660 or equivalent

12.Install the rocker cover.

13.Install the timing belt cover.

14.Install the injection pipe, the injection pipe to the specified torque.

Tightening torque: 35 ± 5 N⋅m

11A-13

CAUTION

• The reinstallation histories of the removed injection pipe are up to five times. To count how many times the injection pipe is rein stalled, record the number of the reinstallation histories on the service booklet by adding this latest number of the histories, which is usually "1", to the previous one. Use a new injection pipe when the total reinstalla tion history numbers reach five times, or when the injector or common rail is replaced. In this case, record " a new injector pipe, the number of the reinstallation histories is zero" on the service booklet.

• When the injection pipe is reinstalled, confirm there is no foreign material on the seal sur face or in the pipe and then install it not to deviate from the axis, fitting the seal surface.

15.Install the inlet manifold.

NOTE: Install a new gasket

16.Install the engine air intake pipe.

17.After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

18.Start the engine, and let it run at idle.

19.Select SPECIAL FUNCTION from the function menu.

20.Select FUEL LEAKAGE CHECK from SPECIAL FUNCTION menu to execute the test.

NOTE: During the test, the engine speed and the fuel pressure is 2, 000 r/min and 180Mpa for 20 seconds respectively.

21.Confirm there is no fuel leak from the joint for the injection pipe.

IDLE SPEED CHECK

M1111003503277

1. Set the vehicle to the pre-inspection condition.

Page 83

11A-14

ENGINE MECHANICAL

ON-VEHICLE SERVICE

MB991824

MB991827

MB991910

Diagnosis connector

5. If the idle speed is not within the standard value, inspect the diesel system (Refer to GROUP 13A Troubleshooting Code

P.13A-429).

− Inspection Chart for Diagnosis

COMPRESSION PRESSURE CHECK

M1111002604058

1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition.

2. Remove the engine air intake pipe.

3. Remove the inlet manifold.

4. Remove all of the glow plugs.

Crank angle sensor connector

AK500382

−

MB991910

MB991824

MB991827

AK600277

2. Turn the ignition switch to "LOOK" (OFF) position, and connect the diagnosis connector to the M.U.T.-III.

3. Start the engine, and let it run at idle.

4. Check the idle speed.

Standard value: 600 ± 50 r/min <Euro 5-M/T> 650 ± 50 r/min <Euro 5-A/T> 650 ± 50 r/min <Except Euro 5-2WD-except

high rider> 700 ± 50 r/min <Except Euro 5-high rider and

4WD>

5. Disconnect the crank angle sensor connector.

NOTE: Doing this will prevent carrying out fuel injection.

6. Cover the glow plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

CAUTION

• Keep away from the glow plug hole when cranking.

•

If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from glow plug hole, which is dangerous.

Compression gauge

AK500383

7. Set compression gauge to one of the glow plug holes.

8. Crank the engine and measure the compression pressure.

Page 84

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-15

Standard value (at engine speed of 250 r/

min): 2,400 kPa <Euro 5> 2,500 kPa <Except Euro 5>

Limit (at engine speed of 250 r/min): Minimum 1,650 kPa <Euro 5> Minimum 1,750 kPa <Except Euro 5>

9. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Maximum 300 kPa

10.If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the glow plug hole, and repeat the operations in steps (8) and (9).

(1) If the compression increases after oil is added,

the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is

added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

11.Connect the crank angle sensor connector.

12.Install the glow plugs.

Tightening torque: 17 ± 2 N⋅m

13.Install the inlet manifold.

NOTE: Install a new gasket.

14.Install the engine air intake pipe.

MB991824

MB991827

MB991824

MB991910

Diagnosis connector

MB991910

Diagnosis connector

MB991827

AK600277

15.Use the M.U.T.-III to erase the diagnosis codes.

NOTE: This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

TIMING BELT B TENSION ADJUSTMENT

M1111004900031

1. Remove timing belt upper cover.

2. Turn the crankshaft in the clockwise direction and check the timing belt around its entire circumference for abnormalities.

Page 85

11A-16

ENGINE MECHANICAL

ON-VEHICLE SERVICE

Timing marks

Camshaft sprocket

Timing marks

Crank shaft pulley

AK500379

3. Align the timing marks on the sprockets with the timing mark on the front upper case.

CAUTION

When aligning the timing mark, be sure not to turn the crankshaft in the anti-clockwise direc

tion as this can cause improper belt tension.

4. Remove the access cover.

Pivot side bolt

Slot side bolt

AK500385

5. Loosen the tensioner pivot side bolt 1 turn and slot side nut 1 or 2 turns.

NOTE: These works will allow the tensioner spring to tension timing belt B automatically.

6. First tighten tensioner slot side nut, and then tighten pivot side bolt to the specified torque.

Tightening torque: Pivot side bolt 23 ± 3 N⋅m Slot side bolt 20 ± 4 N⋅m

Access cover

AK500384

Access cover

AK500386AB

7. Install the access cover.

8. Install the timing belt upper cover.

Page 86

ENGINE MECHANICAL

CRANKSHAFT PULLEY

11A-17

REMOVAL AND INSTALLATION

Pre-removal Operation

• Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover P.51-32).

M1112001602814

Post-installation Operation

• Alternator and Power Steering Oil Pump Drive Belt Tension Check (Refer to P.11A-7).

• A/C Compressor Drive Belt Tension Check and Adjustment (Refer to P.11A-7).

• Under Skid Plate and Engine Room Under Cover Installation (Refer to GROUP 51 − Under Cover P.51-32).

<<A>> <>

265 N·m to 0 N·m to 275 N·m

(Engine oil)

Removal steps

1. A/C compressor drive belt

2. Alternator and power steering oil pump drive belt

<<C>> >>A<< <<C>> >>A<< <<C>> >>A<<

AC501821

Removal steps (Continued)

3. Crankshaft pulley bolt

4. Crankshaft pulley washer

5. Crankshaft pulley

Page 87

11A-18

REMOVAL SERVICE POINTS

<<A>> A/C COMPRESSOR DRIVE BELT REMOVAL

Adjusting bol

Tensioner pulley

Locking nut

ENGINE MECHANICAL

CRANKSHAFT PULLEY

<<C>> CRANKSHAFT PULLEY BOLT/ CRANKSHAFT PULLEY WASHER/CRANKSHAFT PULLEY REMOVAL

MB992100

Crankshaft pulley

MB991800

AC505988

1. Loosen the locking nut of the tensioner pulley.

CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.

2. Rotate the adjusting bolt to the anti-clockwise direction (to the left), and remove the drive belt.

<> ALTERNATOR AND POWER STEERING OIL PUMP DRIVE BELT REMOVAL

AC501823

L-shaped hexagon wrench

Auto tensioner

AC507702

The following operations will be needed due to the introduction of the serpentine drive system with the auto tensioner.

1. Set the tool to the pulley bolt of auto tensioner, and then turn the auto tensioner clockwise.

CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.

AC501824

1. Use the following special tools to hold the crankshaft pulley.

• Pulley holder (MB991800)

• Crank pulley holder (MB992100)

2. Loosen the crankshaft pulley bolt and remove the crankshaft pulley washer and crankshaft pulley.

3. If the crankshaft pulley cannot be removed from the crankshaft, follow the procedure below.

(1) Install the crankshaft pulley bolt and

crankshaft pulley washer to the crankshaft pulley. At this time, the crankshaft pulley bolt must be loosened by 3 to 4 turns from the completely tightened state.

MB992099

MB992100

AC501870

(2) Using the special tools below, remove the

crankshaft pulley.

• Crank pulley puller (MB992099)

• Crank pulley holder (MB992100)

2. Insert an L-shaped hexagon wrench, etc. into the hole to fix and then remove the drive belt.

Page 88

ENGINE MECHANICAL

CRANKSHAFT PULLEY

11A-19

INSTALLATION SERVICE POINT

>>A<< CRANKSHAFT PULLEY/CRANKSHAFT PULLEY WASHER/CRANKSHAFT PULLEY BOLT INSTALLATION

Engine front

Crankshaft pulley bolt

Clean

(Engine oil)

Clean

1. Clean the screw hole of the crankshaft, the crankshaft pulley, the crankshaft pulley bolt and the crankshaft pulley washer.

: Clean : Apply engine oil : Degrease

Crankshaft pulley washer

Crankshaft pulley

Clean

Degrease

Crankshaf

AC501871

2. Install the crankshaft pulley.

3. Apply an appropriate quantity of new engine oil to the thread of crankshaft pulley bolt.

MB992100

Crankshaft pulley

MB991800

AC501824

4. In the same way as for removing, using the special tools below, support the crankshaft pulley.

• Pulley holder (MB991800)

• Crank pulley holder (MB992100)

5. Tighten the crankshaft pulley bolt according to the procedure below.

(1) Tighten the crankshaft pulley bolt to the

specified torque.

Tightening torque: 265 N⋅m

(2) Loosen the crankshaft pulley bolt fully. (3) Tighten the crankshaft pulley bolt to the

specified torque again.

Tightening torque: 275 N⋅m

Page 89

11A-20

ENGINE MECHANICAL

CAMSHAFT AND VALVE STEM SEAL

REMOVAL AND INSTALLATION

M1112006602262

CAUTION

* Remove and assemble the marked parts in each cylinder unit.

Pre-removal and Post-installation Operation

• Inlet Manifold Removal and Installation (Refer to GROUP 15

− Inlet Manifold P.15-15).

11 ± 1 N·m

20 ± 1 N·m

Apply engine oil to all moving parts before installation.

22 23

18 ± 2 N·m

26* 27*

29*

25*

11 ± 1 N·m

797

25*

21 20 22 23

18 ± 2 N·m

26*

27*

29*

88 ± 10 N·m

<<A>> >>K<<

>>J<<

<> >>I<<

>>I<< >>I<<

<> >>I<<

10 ± 2 N·m

Inlet camshaft removal steps

Timing belt (Refer to P.11A-43).

•

Rocker cover (Refer to GROUP

•

13A

− Fuel Injector P.13A-598).

Valve clearance check and

•

adjustment (Refer to

1. Camshaft sprocket

2. Timing belt rear cover

3. Camshaft oil seal

4. Front left camshaft bearing cap

5. Inlet oil pipe assembly

6. O-ring

7. Left camshaft bearing cap

P.11A-12).

>>H<< >>G<< >>G<< >>G<< >>G<< >>G<< >>G<<

AC501908

Inlet camshaft removal steps

8. Inlet camshaft assembly

9. Snap ring

10. Wave washer

11. Sub gear

12. C-spring

13. Dowel pin

14. Inlet camshaft

Page 90

ENGINE MECHANICAL

CAMSHAFT AND VALVE STEM SEAL

11A-21

<> >>F<<

>>F<< >>F<<

<> >>F<<

>>E<<

<<A>> >>K<<

>>J<<

<> >>I<<

>>I<< >>I<<

<> >>I<<

>>H<<

<> >>F<<

>>F<< >>F<<

<> >>F<<

>>E<< >>D<< >>D<< >>D<<

>>C<<

<<C>> >>B<<

>>A<<

Exhaust camshaft removal steps

Rocker cover (Refer to GROUP

•

13A

− Fuel Injector P.13A-598).

Valve clearance check and

•

adjustment (Refer to

P.11A-12).

15. Front right camshaft bearing cap

16. Exhaust oil pipe assembly

17. O-ring

18. Right camshaft bearing cap

19. Exhaust camshaft assembly

Valve stem seal removal steps

Timing belt (Refer to P.11A-43).

•

Rocker cover (Refer to GROUP

•

13A

− Fuel Injector P.13A-598).

Valve clearance check and

•

adjustment (Refer to

P.11A-12).

1. Camshaft sprocket

2. Timing belt rear cover

3. Camshaft oil seal

4. Front left camshaft bearing cap

5. Inlet oil pipe assembly

6. O-ring

7. Left camshaft bearing cap

8. Inlet camshaft assembly

15. Front right camshaft bearing cap

16. Exhaust oil pipe assembly

17. O-ring

18. Right camshaft bearing cap

19. Exhaust camshaft assembly

20. Rocker arm assembly

21. Nut

22. Adjusting screw

23. Pivot bolt

24. Stem end cap

25. Valve spring retainer lock

26. Valve spring retainer

27. Valv e spr ing

28. Valve stem seal

29. Valve spring seat

1. Use the following special tools to hold the camshaft sprocket.

• Front hub and flange yoke holder (MB990767)

• Pin (MD998719)

2. Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket.

<> FRONT LEFT CAMSHAFT BEARING CAP/ LEFT CAMSHAFT BEARING CAP/FRONT RIGHT CAMSHAFT BEARING CAP/RIGHT CAMSHAFT BEARING CAP REMOVAL

Engine front

Front right camshaft bearing cap

Right camshaft bearing cap

1 1

Front left camshaft bearing cap

Left camshaft bearing cap

9 9

5 5

AC501909

Loosen the mounting bolts of the front camshaft bearing cap and camshaft bearing cap in the order shown in the figure. Then, remove the front camshaft bearing cap and camshaft bearing caps.

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT SPROCKET REMOVAL

MD998719

MB990767

AC507554

Page 91

11A-22

ENGINE MECHANICAL

CAMSHAFT AND VALVE STEM SEAL

<<C>> VALVE SPRING RETAINER LOCK REMOVAL

CAUTION

When removing valve spring retainer lock, leave the piston of each cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylin der if the piston is not properly in the TDC position.

MD998772

AC501910

Use special tool valve spring compressor (MD998772) to compress the valve spring and then remove the valve spring retainer lock.

>>B<< VALVE SPRING RETAINER LOCK INSTALLATION

MD998772

AC501910

Use special tool valve spring compressor (MD998772) to compress the valve spring and then install the valve spring retainer lock in the same man ner as removal.

>>C<< STEM END CAP INSTALLATION

Inlet valve or exhaust valve

Stem end cap

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION

1. Apply a small amount of engine oil to the valve stem seal.

CAUTION

• Do not re-use the valve stem seal.

•

Special tool valve stem seal installer (MB991999) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.

MB991999

Valve

Valve stem seal

Valve guide

AC308654

2. Use the special tool valve stem seal installer (MB991999) to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

AC501911

Install the stem end cap. Make sure that the stem end cap is in close contact with the stem end faces of the inlet and exhaust valve.

>>D<< ADJUSTING SCREW/NUT/ROCKER ARM ASSEMBLY INSTALLATION

Rocker arm assembly

Adjusting screw

Nut

5.5

–

AC501912

6.5 mm

1. Screw the adjusting screw into the rocker arm assembly, and then temporarily assemble using a nut so that the adjusting screw protrusion becomes the dimension shown in the figure.

2. Apply the engine oil to the sliding surface of the parts below.

Page 92

ENGINE MECHANICAL

CAMSHAFT AND VALVE STEM SEAL

11A-23

• Roller and valve-side sliding area of the rocker arm assembly

• Concave spherical surface of pivot bolt or spherical surface of adjusting screw

Stem end cap

Rocker arm assembly

Pivot bolt

AC501913

3. Place the rocker arm assembly onto the pivot bolt and the stem end cap as shown in the figure.

>>E<< EXHAUST CAMSHAFT ASSEMBLY INSTALLATION

1. Apply the engine oil to the cam face, journal section, thrust face, and gear teeth face of exhaust camshaft.

Exhaust camshaft

Timing mark

AC501914

Engine front

Front right camshaft bearing cap

Right camshaft bearing cap

AC501915

3. Tighten the mounting bolts of the right camshaft bearing cap and front right camshaft bearing cap to the specified torque in the order shown in the figure. Then, fix the right camshaft bearing cap, exhaust oil pipe assembly, and front right camshaft bearing cap to the cylinder head.

Tightening torque:

11 ± 1 N⋅m (Right camshaft bearing cap mount-

ing bolts)

20 ± 1 N⋅m (Front right camshaft bearing cap

mounting bolts)

2. Set the timing mark of the exhaust camshaft in the position shown in the figure.

>>F<< RIGHT CAMSHAFT BEARING CAP/ORING/EXHAUST OIL PIPE ASSEMBLY/FRONT RIGHT CAMSHAFT BEARING CAP INSTALLATION

1. Place the right camshaft bearing cap onto the camshaft journal section.

2. Apply the engine oil to the O-ring section of exhaust oil pipe assembly, and insert the tip of exhaust oil pipe assembly into the cylinder head. Then, place the pipe section onto the right camshaft bearing cap.

>>G<< INLET CAMSHAFT/DOWEL PIN/CSPRING/SUB GEAR/WAVE WASHER/SNAP RING INSTALLATION

Inlet camshaft

AC501916

1. Fix the inlet camshaft hexagonal area using a vice or other devices.

Page 93

11A-24

ENGINE MECHANICAL

CAMSHAFT AND VALVE STEM SEAL

2.3 – 2.8 mm

Dowel pin

Sub gear

Dowel pin

Inlet camshaft

2.3 – 2.8 mm

AC501917

2. Press fit the dowel pin into the inlet camshaft and sub gear so that the dimension becomes as shown in the figure.

C-spring

Dowel pin

>>H<< INLET CAMSHAFT ASSEMBLY INSTALLATION

Inlet camshaft

AC501919

1. Fix the hexagonal area of inlet camshaft assembly using a vice or other devices.

CAUTION

Avoid turning the sub gear than necessary.

Hole of sub gear (M8)

Thread hole of camshaft (M6)

Screwdriver

Inlet camshaft

AC501918

3. After contacting the C-spring with the dowel pin as shown in the figure, set to the inlet camshaft.

Dowel pin

Inlet camshaft

C-spring

AC501918

4. Set the sub gear to the inlet camshaft so that the sub gear dowel pin is inside the A range between the C-spring and inlet camshaft dowel pin as shown in the figure.

5. Assemble the wave washer and the snap ring to the inlet camshaft.

Flange bolts (M6

× 20)

AC501920

2. Set the flange bolts (M6 x 20) to 2 locations of sub gear. Then, using a screwdriver, turn the sub gear clockwise until the sub gear hole (M8) and the threaded hole (M6) of inlet camshaft gear match as shown in the figure.

Bolt (M6

× 20)

AC501921

3. Temporarily fix the sub gear using the bolt (M6 x

20). At this time, screw in until the bolt head is in contact with the sub gear.

4. Remove the 2 flange bolts (M6 x 20) installed in the step 2.

Page 94

ENGINE MECHANICAL

)

CAMSHAFT AND VALVE STEM SEAL

11A-25

5. Remove from the vice or other devices the inlet camshaft assembly to which the sub gear being temporarily fixed. Then, apply the engine oil to the cam face, journal section, thrust face, and gear teeth face of inlet camshaft assembly.

Exhaust camshaft

Timing mark

Inlet camshaf

AC501922

6. Set the timing mark of the inlet camshaft assembly and exhaust camshaft in the position shown in the illustration.

>>I<< LEFT CAMSHAFT BEARING CAP/O-RING/ INLET OIL PIPE ASSEMBLY/FRONT LEFT CAMSHAFT BEARING CAP INSTALLATION

1. Place the left camshaft bearing cap onto the camshaft journal.

2. Apply the engine oil to the O-ring of the inlet oil pipe assembly, and insert the tip of the inlet oil pipe assembly into the cylinder head. Then, place the pipe onto the left camshaft bearing cap.

CAUTION

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

NOTE: Install the front left camshaft bearing cap immediately after applying sealant.

Engine front

Front left camshaft bearing cap

Left camshaft bearing cap

AC501924

4. Tighten the mounting bolts of the left camshaft bearing cap and front left camshaft bearing cap to the specified torque in the order shown in the figure. Then, fix the left camshaft bearing cap, inlet oil pipe assembly, and front left camshaft bearing cap to the cylinder head.

Tightening torque:

11 ± 1 N⋅m (Left camshaft bearing cap mount-

ing bolts)

20 ± 1 N⋅m (Front left camshaft bearing cap

mounting bolts)

Cylinder head assembly

Front left camshaft bearing cap

3. Apply specified sealant to the matching area of

AC501923

the cylinder head assembly and the front left camshaft bearing cap as shown, and install the left camshaft bearing cap to the cylinder head assembly.

Specified sealant: 3M ATD Part No.8660

5. Remove the bolt (M6 x 20) used to temporarily fix the sub gear of inlet camshaft assembly.

>>J<< CAMSHAFT OIL SEAL INSTALLATION

Camshaft oil sea

(Engine oil

MD998713

AC102323

1. Apply engine oil to the entire inner diameter of the oil seal lip.

Page 95

11A-26

ENGINE MECHANICAL

CAMSHAFT AND VALVE STEM SEAL

2. Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seal as shown.

>>K<< CAMSHAFT SPROCKET INSTALLATION

MD998719

MB990767

AC507554

1. Use the following special tool as during removal to hold the camshaft sprocket.

• Front hub and flange yoke holder (MB990767)

• Pin (MD998719)

2. Tighten the camshaft sprocket mounting bolt to the specified torque.

Tightening torque: 88 ± 10 N⋅m

Page 96

ENGINE MECHANICAL

OIL PAN AND OIL STRAINER

11A-27

OIL PAN AND OIL STRAINER

REMOVAL AND INSTALLATION <2WD (EXCEPT HIGH RIDER)>

M1112008301004

CAUTION

At the time of factory shipment or when the engine is overhauled, liquid gasket is used for the engine oil pan gasket. Use the replacement engine oil pan gasket since the sealed surface may interfere with surrounding parts, causing engine oil leak when the engine oil pan is installed on the vehicle using the liquid gasket.

Pre-removal Operation

• Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover P.51-32).

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement

P.12-4).

19 ± 3 N·m

Post-installation Operation

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle Service, Engine Oil Replacement

• Engine Room Under Cover Installation (Refer to GROUP 51

− Under Cover P.51-32).

P.12-4).

48 ± 6 N·m

(Engine oil)

19 ± 3 N·m

39 ± 5 N·m

9.0 ± 3.0 N·m

Removal steps

1. Engine oil level gauge and guide assembly

2. O-ring

3. Bell housing cover

19 ± 3 N·m

>>B<<

9.0 ± 1.0 N·m

11 ± 1 N·m

AC506493

Removal steps (Continued)

4. Engine oil pan drain plug

5. Engine oil pan drain plug gasket

Page 97

11A-28

<<A>>

<>

<> <> <<C>>

>>A<< >>A<< >>A<< >>A<<

Removal steps (Continued)

Steering column assembly and

•

steering shaft joint assembly connection Power steering gear & link

•

assembly mounting bolt Return tube clamp

•

Pressure tube clamp

•

6. Engine oil pan and engine oil pan strainer assembly

7. Engine oil pan

8. Engine oil pan gasket

9. Engine oil pan strainer

10. Engine oil pan strainer gasket

11. Stiffener

ENGINE MECHANICAL

OIL PAN AND OIL STRAINER

REMOVAL SERVICE POINTS

<<A>> STEERING COLUMN ASSEMBLY AND STEERING SHAFT JOINT ASSEMBLY DISCON NECTION

Steering colum assembly and steering shaft joint assembly connecting bolt

<<C>> ENGINE OIL PAN AND ENGINE OIL PAN STRAINER ASSEMBLY REMOVAL

1. Remove the engine oil pan mounting bolts.

CAUTION

Do not use special tool oil pan FIPG cutter (MD998727) in area A of the engine oil pan. Using the special tool (MD998727) in area A may cause deformation of the cylinder block case assembly front lower because the cylinder block case assembly front lower is made of aluminium.

MD998727

AC504256A

MD998727

18 ± 2 N·m

Front suspensio upper arm (LH)

AC600311

Disconnect the steering column assembly and the steering shaft joint assembly. (Refer to GROUP 37 Steering Column Shaft Assembly

P.37-18).

−

<> POWER STEERING GEAR & LINK ASSEMBLY MOUNTING BOLT/RETURN TUBE CLAMP/PRESSURE TUBE CLAMP REMOVAL

AC502231

Remove the mounting bolts of the power steering gear & link assembly and of the tube clamps, and hung the power steering gear & link assembly using a wire or other similar material. (Refer to GROUP 37

− Power Steering Gear Box and Linkage P.37-22, and Power Steering Hoses P.37-40).

AC104547

2. Tap special tool (MD998727) into the range B between the cylinder block assembly and the engine oil pan, and then slide the tool sideways.

NOTE: If any surrounding parts interfere with the removal, there is no need to use the special tool.

3. With the engine oil pan separated from the cylinder block assembly, remove the engine oil pan strainer mounting bolts, and then remove the engine oil pan together with the engine oil pan strainer.

INSTALLATION SERVICE POINTS

>>A<< ENGINE OIL PAN STRAINER GASKET/ ENGINE OIL PAN STRAINER/ENGINE OIL PAN GASKET/ENGINE OIL PAN INSTALLATION

1. Remove sealant from the engine oil pan and cylinder block assembly surfaces.

Page 98

ENGINE MECHANICAL

OIL PAN AND OIL STRAINER

11A-29

2. Place the engine oil pan strainer into the engine oil pan. Then, insert the engine oil pan and engine oil pan gasket into the clearance between the cylinder block assembly and the power steering gear & link assembly.

3. Set the engine oil pan strainer gasket and the engine oil pan strainer in the engine oil pan to the cylinder block assembly, and tighten the engine oil pan strainer mounting bolts to the specified torque.

Tightening torque: 19 ± 3 N⋅m

4. Set the engine oil pan gasket and engine oil pan to the cylinder block assembly, and tighten the engine oil pan mounting bolts to the specified torque.

Tightening torque: 9.0 ± 3.0 N⋅m

>>B<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Engine oil pan sid

AC102325

Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.

Page 99

11A-30

ENGINE MECHANICAL

OIL PAN AND OIL STRAINER

REMOVAL AND INSTALLATION <2WD (HIGH RIDER) AND 4WD>

M1112008301015

CAUTION

At the time of factory shipment or when the engine is overhauled, liquid gasket is used for the engine oil pan gasket. Use the replacement engine oil pan gasket since the sealed surface may interfere with surrounding parts, causing oil leak when the engine oil pan is installed on the vehicle using the liquid gasket.

Pre-removal Operation

• Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 51

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle Service, Engine Oil Replacement

• Differential Gear Oil Draining (Refer to GROUP 26 − Onvehicle Service, Gear Oil Replacement

• Front Differential Carrier Assembly Removal (Refer to GROUP 26

P.26-33) <4WD>.

• Power Steering Gear Box and Linkage Assembly Removal (Refer to GROUP 37 Box and Linkage

− Differential Carrier and Freewheel Clutch

P.37-22).

− Under Cover P.51-32).

P.12-4).

P.26-11) <4WD>.

− Power Steering Gear

Post-installation Operation

• Power Steering Gear Box and Linkage Assembly Installation (Refer to GROUP 37 − Power Steering Gear Box and Linkage

• Front Differential Carrier Assembly Installation (Refer to GROUP 26

P.26-33) <4WD>.

• Differential Gear Oil Refilling (Refer to GROUP 26 − Onvehicle Service, Gear Oil Replacement

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle Service, Engine Oil Replacement

• Under Skid Plate and Engine Room Under Cover Installation (Refer to GROUP 51 − Under Cover P.51-32).

P.37-22).

− Differential Carrier and Freewheel Clutch

P.26-11) <4WD>.

P.12-4).

Page 100

ENGINE MECHANICAL

OIL PAN AND OIL STRAINER

11A-31

48 ± 6 N·m

>>C<<

<<A>> >>B<<

>>A<<

19 ± 3 N·m

9.0 ± 3.0 N·m

Removal steps

1. Engine oil level gauge and guide assembly

2. O-ring

3. Bell housing cover

4. Engine oil pan drain plug

5. Engine oil pan drain plug gasket

6. Engine oil pan

7. Engine oil pan gasket

8. Engine oil pan strainer

(Engine oil)

9.0 ± 1.0 N·m

11 ± 1 N·m

19 ± 3 N·m

39 ± 5 N·m

AC506494

Removal steps (Continued)

9. Engine oil pan strainer gasket

10. Stiffener

REMOVAL SERVICE POINT

<<A>> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.

Mitsubishi L200 2012 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual