Mitsubishi PAJERO IV Service Manual

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Page 1

GROUP 0

GENERAL

CONTENTS

0-1

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

PRECAUTIONS BEFORE SERVICE. 0-2

PROTECTING THE VEHICLE . . . . . . . . . . 0-2

DOING SERVICE WORK IN GROUPS OF TWO

OR MORE MECHANICS . . . . . . . . . . . . . . 0-2

REMOVAL AND DISASSEMBLY . . . . . . . . 0-2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 0-3

PARTS TO BE REPLACED . . . . . . . . . . . . 0-3

PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

TUBES AND OTHER RUBBER PARTS . . . 0-3

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3

SERVICING THE ELECTRICAL SYSTEM . 0-4

APPLICATION OF ANTI-CORROSION AGENTS

AND UNDERCOATS . . . . . . . . . . . . . . . . . . 0-4

PRE-INSPECTION CONDITION . . . . . . . . . 0-4

VEHICLE WASHING . . . . . . . . . . . . . . . . . . 0-4

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

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

IN ORDER TO PREVENT VEHICLES

FROM FIRE . . . . . . . . . . . . . . . . . . . . . . . . . 0-5

ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 0-5

Page 2

0-2

HOW TO USE THIS MANUAL

This manual contains Pre-delivery inspection and Periodic inspection and maintenance.

PRECAUTIONS BEFORE SERVICE

GENERAL

M6000000100026

Group 0 and 1 have the contents for all vehicle models, and Group 2 has contents for the relevant vehicle models.

PROTECTING THE VEHICLE

M6001000100029

AC305590

If there is a likelihood of damaging interior or exterior parts during service operations, protect them with suitable covers (such as seat covers, fender covers, etc.).

DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS

M6001000200026

REMOVAL AND DISASSEMBLY

M6001000300023

AC305591

When checking a malfunction, find the cause of the problem. If it is determined that removal and/or dis assembly is necessary, perform the work by following the procedures contained in this manual.

AC305283

If the service work is to be done by two or more mechanics working together, all the mechanics involved should take safety into consideration while they work.

AC305592

If punch marks or mating marks are made to avoid error in assembly and facilitate the assembly work, be sure to make them in locations which will have no detrimental effect on performance and/or appear

ance. If an area having many parts, similar parts, and/or parts which are symmetrical right and left is disassembled, be sure to arrange the parts so that they do not become mixed during the assembly proc ess.

1. Arrange the parts removed in the proper order.

2. Determine which parts are to be reused and which

are to be replaced.

3. If bolts, nuts, etc., are to be replaced, be sure to

use only the exact size specified.

Page 3

GENERAL

PRECAUTIONS BEFORE SERVICE

0-3

SPECIAL TOOLS

M6001000400031

AC305593

If other tools are substituted for the special tools to do service of repair work, there is the danger that vehicle parts might be damaged, or the technician might be injured; therefore, be sure to use the spe

cial tool whenever doing any work for which the use of one is specified.

PARTS TO BE REPLACED

M6001000500027

When replacing parts, use MITSUBISHI genuine parts.

TUBES AND OTHER RUBBER PARTS

M6001000700021

AC305595

Be careful to avoid spilling any petrol, oil, etc., because if it adheres to any tubes or other rubber parts, they might be adversely affected.

LUBRICANTS

M6001000800028

AC305594

If any of the following parts are removed, they must be replaced with new parts.

• Oil seals

• Gaskets (except rocker cover gasket)

• Packings

• O-rings

• Lock washers

• Split pins

• Self-locking nuts

PARTS

M6001000600024

AC305596

In accordance with the instructions in this manual, apply the specified lubricants in the specified loca

tions during assembly and installation.

BRAKE FLUID

M6001000900025

AC305285

Be careful to avoid spilling any brake fluid, because if it adheres to the vehicle body, the paint coat might be discoloured.

AC305284

Page 4

0-4

GENERAL

PRECAUTIONS BEFORE SERVICE

SERVICING THE ELECTRICAL SYSTEM

M6001001000081

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.)

ACX00880

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

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

M6001001100022

If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITION

M6001001200041

"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

VEHICLE WASHING

M6001001300123

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: Approximately 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.

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

M6001001900169

Refer to the "M.U.T.-III OPERATING INSTRUCTIONS" for instructions on handling the M.U.T.-III.

CAUTION

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

Diagnosis connector

MB991910

MB991824

MB991827

AC505420

Page 5

GENERAL

PRECAUTIONS BEFORE SERVICE

0-5

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

IN ORDER TO PREVENT VEHICLES FROM FIRE

M6001001500064

"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 modifica tions/repairs that may be carried out which involve the electrical or fuel systems, must be carried out in accordance with MMC's information/Instructions".

ENGINE OILS

M6001001600061

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.

• Wear protective clothing, including impervious gloves where practicable.

• Avoid contaminating clothes, particularly underpants, with oil.

• Do not put oily rags in pockets, the use of overalls without pockets will avoid this.

• Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from per sonal clothing.

• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

• Obtain first aid treatment immediately for open cuts and wounds.

• Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After clean ing, the application of preparations containing lanolin to replace the natural skin oils is advised.

• Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.

• Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work.

• If skin disorders develop, obtain medical advice without delay.

Page 6

NOTES

Page 7

GROUP 1

PRE-DELIVERY

INSPECTION

CONTENTS

1-1

NOTES CONCERNING ENTRIES . . . 1-3

PAINTWORK TERMS . . . . . . . . . . . . 1-5

FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6

1. CONNECTION OF DARK CURRENT

CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 1-6

BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-6

3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-7

4. OPERATION OF DOOR LOCKING SYSTEMS

AND DOOR HINGES . . . . . . . . . . . . . . . . . 1-8

5. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF . . . . . . . . . . . 1-8

UNDER HOOD . . . . . . . . . . . . . . . . . . 1-9

6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-9

7. BRAKE MASTER CYLINDER FLUID LEVEL 1-9

8. CLUTCH MASTER CYLINDER FLUID LEVEL 1-9

9. WASHER FLUID LEVEL. . . . . . . . . . . . . 1-9

10. BATTERY CONDITION AND

CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-9

11. POWER STEERING FLUID LEVEL . . . 1-9

12. ELECTRICAL WIRING . . . . . . . . . . . . . 1-10

UNDER VEHICLE . . . . . . . . . . . . . . . 1-10

13. TYRE AND SPARE TYRE PRESSURES 1-10

14. SUSPENSION SYSTEM. . . . . . . . . . . . 1-10

15. STEERING LINKAGE AND SPLIT PINS 1-11

16. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-11

BEFORE ROAD TEST . . . . . . . . . . . . 1-11

17. SEAT ADJUSTERS AND SEATBACK

LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

18. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-11

19. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-11

20. INSTRUMENT PANEL CONTROLS . . . 1-12

21. METERS, GAUGES, WARNING LAMPS

AND INDICATION LAMPS . . . . . . . . . . . . . 1-12

22. AIR CONDITIONER, HEATER AND

DEFROSTER SYSTEM. . . . . . . . . . . . . . . . 1-12

23. WIPERS AND WASHERS. . . . . . . . . . . 1-12

24. OPERATION OF SERVICE BRAKES AND

PARKING BRAKES. . . . . . . . . . . . . . . . . . . 1-13

25. CLUTCH OPERATION . . . . . . . . . . . . . 1-13

26. OPERATION OF SEAT BELTS, SHOULDER

BELTS AND RETRACTORS . . . . . . . . . . . . 1-13

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-14

27. ENGINE PERFORMANCE AND EXHAUST

GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

28. TRANSMISSION IN ALL RANGES . . . . 1-14

29. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-14

30. STEERING CONTROL . . . . . . . . . . . . . 1-14

31. VIBRATION AND RATTLES . . . . . . . . . 1-15

32. ELECTRICAL EQUIPMENT . . . . . . . . . 1-15

Continued on next page

Page 8

1-2

AFTER ROAD TEST . . . . . . . . . . . . . 1-15

33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-15

34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-15

35. RADIATOR COOLANT LEVEL . . . . . . . 1-15

36. HOSES, FLUID LINES AND CONNECTIONS

LOCATED UNDER HOOD . . . . . . . . . . . . . 1-16

37. MANUAL TRANSMISSION AND TRANSFER

(4WD) OIL LEVEL. . . . . . . . . . . . . . . . . . . . 1-16

38. AUTOMATIC TRANSMISSION FLUID

LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

39. ENGINE, TRANSMISSION, STEERING GEAR BOX AND DIFFERENTIAL FOR LEAKS 1-16

40. FRONT AND REAR DIFFERENTIAL OIL

LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

41. HOSES, FLUID LINES AND CONNECTIONS

LOCATED UNDER VEHICLE . . . . . . . . . . . 1-17

FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-17

42. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-17

43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-17

44. EXTERIOR AND INTERIOR . . . . . . . . . 1-17

45. OWNER INSTRUCTIONS . . . . . . . . . . . 1-17

Page 9

PRE-DELIVERY INSPECTION

NOTES CONCERNING ENTRIES

1-3

NOTES CONCERNING ENTRIES

M6010100100132

This section describes the details and the inspection methods employed for the pre-delivery inspection of vehicles. The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY INSPECTION. Inspection methods are described following the TABLE OF PRE-DELIVERY INSPECTION.

NOTE: The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in kilometres (miles), date of inspection, name of person conducting the inspection, and body colour must be completed without fail.

NOTE: The spaces for place of inspection, and name of owner should be completed as required.

Page 10

1-4

PRE-DELIVERY INSPECTION

NOTES CONCERNING ENTRIES

TABLE OF PRE-DELIVERY INSPECTION

Model Chassis number Engine number Distance Travelled km Owner Date of inspection Place of inspection Inspector Body colour

Symbols to be used

Good A T

Needs cleaning

INSPECTION PROCEDURE

First Step

1. Connection of the dark current connector

Body

2. Wrap film

3. Exterior

4. Operation of door locking systems and door hinges

5. Operation of door mirrors, windows and sunroof

Under Hood

6. Engine oil level

7. Brake master cylinder fluid level

8. Clutch master cylinder fluid level

9. Washer fluid level

10. Battery condition and connections

11. Power steering fluid level

12. Electrical wiring

Under Vehicle

13. Tyre and spare tyre pressures

14. Suspension system

15. Steering linkage and split pins

16. Under body

Needs adjustment

Needs replenishment

L X C

of lubricant, water, etc.

Needs retightening

Needs replenishment of repair

Before Road Test

17. Seat adjusters and seat back latches

18. Choke system and inhibitor switch

19. Idle control knob

20. Instrument panel controls

21. Meters, gauges, warning lamps and indication lamps

22. Air conditioning, heater and defroster systems

23. Wipers and washers

24. Operation of service brakes and parking brakes

25. Clutch operation

26. Operation of seat belts, shoulder belts and retractors

Road Test

27. Engine performance and exhaust gas

28. Transmission in all ranges

29. Brakes

30. Steering control

31. Vibration and rattles

32. Electrical equipment

After Road Test

33. Idle speed

34. Ignition timing

35. Radiator coolant level

36. Hoses, fluid lines and connections located under hood

37. Manual transmission and transfer (4WD) oil level

38. Automatic transmission fluid level

39. Engine, transmission, steering gear box and differential for leaks

40. Front and rear differential oil levels

41. Hoses, fluid lines and connections located under vehicle

Final Steps

42. Headlamp aiming

43. Equipment

44. Exterior and interior

45. Owner instructions

AC306353AC401525

Page 11

PRE-DELIVERY INSPECTION

PAINTWORK TERMS

Term Definition Remark

Blister A raised bubble in the paint (from the base

or the undercoat) caused by abnormal moisture. The bubble may contain either water or air.

1-5

M6010200100140

Change in tone The colour tone of the painted surface is not

uniform.

Contact mark A mark on the painted surface as a result of

contact by hands or clothing at the time of paint application.

Crack A crack in the painted surface. Cracks may be either shallow or deep.

Dirt in paintwork Rough surface resulting from foreign

material in the paint or from dust deposited on wet paint during painting or storage.

Filed or earth traces

Orange peel The painted surface has the appearance of

Peeling The paint flakes off (partly or over a wide

Pin holes Tiny holes in the painted surface.

Runs A visible trickle of dried paint on the surface. Either undercoat or top-coat.

Scratches Scratches on the painted surface.

Deep scratches in sheet metal surface, resulting from improper use of buffer or sander, are not completely covered, and are visible through paint coating.

an orange peel.

area).

Including wrong colour, discoloration and decolouration.

The peeling may be minor, medium, or major.

Shrink The painted surface "shrinks", causing

wrinkles.

Smears Spots of soot or other material deposited on

the painted surface.

Spray mist The painted surface includes fine particles of

other paint.

Uneven lustre The lustre of the painted surface is not

uniform.

Uneven metallic dispersion

Visibly incomplete topcoating

The metallic dispersion of the painted surface is not uniform.

A part of the undercoating visible.

Including stains and water spots.

Page 12

1-6

PRE-DELIVERY INSPECTION

FIRST STEP

1. CONNECTION OF DARK CURRENT CONNECTOR

M6010300100170

CONNECTING PROCEDURE

Storage connector

Relay box

AC608836

2. WRAP FILM

M6010400100100

Press down the storage connector.

BODY

To protect the exterior finish of vehicles prior to dealer delivery, a protective coating is used. The coating is a thin white resin film. It is applied to all painted exterior horizontal surfaces of the vehicle and is held in place with a tacky adhesive backing.

AC305606

Page 13

REMOVAL PROCEDURE

Wrap film removal

Water washing

PRE-DELIVERY INSPECTION

BODY

Peel off slowly from corners keeping parallel to the body. When the body temperature is high, lower it to 50ºC or less by sprinkling water so that adhesive may not remain on the body.

1-7

Cleaning of border

Disposal of removed film: Burning is appropriate

Wipe-off by kerosene or white gasoline, etc. If it is considerably visible, use polishing compound.

AC306352

Wrapping work

No. Process Operation Content

1 Continuous peeling of film The film is peeled off.

2 Water rinse Sand and dust are removed from the vehicle body and it

is dried thoroughly.

3 Parts where the film is to be reapplied are

checked.

4 Treatment of parts where film is to be

reapplied.

There should be no leftover adhesive, swelling or discoloration of the paint film, or other defects.

Treat the defects on the parts where film is to be reapplied. If a solvent is used to remove leftover adhesive, wipe off the solvent thoroughly.

5 Reapplication

1. Basically, the parts where the film is to be applied should be the same as the film that is to be applied.

2. Apply the film from the lower portion of the body, working upward progressively. Apply pressure using a plastic squeegee or similar tool.

3. As necessary, cut the film at the various parts such as windshield washer nozzles, hood and trunk lid.

CAUTION

• Apply the film with the body at a temperature of 10 − 40° C. (Workability is good in this temperature range.)

• If the outside surface of the film (the side with no adhesive) is brought into direct contact with the paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not get folded under or otherwise make contact with the paint film.

• Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort should be made to prevent air bubbles from being trapped under the film by applying pressure from the centre of the film outward toward the edges during application.

• To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of the film securely.

Page 14

1-8

PRE-DELIVERY INSPECTION

BODY

3. EXTERIOR

M6010400200226

1. Visually inspect the entire exterior. (1) Paint condition (2) Corrosion, scratches (3) Bent edges, dented panels

2. Coated surfaces maintenance Touch up minor paint chips and flaws.

(Refer to paintwork terms)

4. OPERATION OF DOOR LOCKING

SYSTEMS AND DOOR HINGES

M6010400300137

Front

AC305608

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

NOTE: Adjust and lubricate the door latches, strikers and locks as required.

Child-protection knob

AC305610

7. Verify that the rear doors can't be opened by the inner door handle when the child protection knob at the end of the door is shifted to the "LOCK" position with the inside lock plunger raised.

NOTE: Set the lock to the "FREE" position on child protection of both rear doors. (For four door models)

5. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF

M6010400400112

1. Door mirrors

AC210253

1. Open each door to check the release mechanism and ease of operation.

2. Close the door to check the latch and striker.

3. Open the door, operate the lock lever and close the door to check the lock.

4. Partially close the door to check the open-door detent.

5. Unlock each door with the key to check lock operation.

Check that the mirror operate properly.

2. Door windows

Close all door windows to the fully closed position to check ease of operation.

3. Power windows

Check that the door windows operate when the respective switches are operated. Check that when the lock switches are depressed, the respective door windows can no more be opened or closed.

4. Slide window

Close the slide window to the fully closed position to check operation.

5. Sunroof

Close the sunroof to the fully closed position to check operation.

Page 15

PRE-DELIVERY INSPECTION

UNDER HOOD

1-9

6. ENGINE OIL LEVEL

M6010500100196

MAX

MIN

AC702169

Check that the oil level is between "MAX" and "MIN". If it is at or below MIN, add the necessary amount of the specified engine oil referring to GROUP 2, Peri

odic Inspection and Maintenance.

7. BRAKE MASTER CYLINDER FLUID

LEVEL

M6010500200148

9. WASHER FLUID LEVEL

M6010500400108

AC305614

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

1. Windshield washer reservoir

2. Rear window washer reservoir

10. BATTERY CONDITION AND CONNECTIONS

M6010500500042

AC702028

Check the fluid level. If it is below the "MIN" mark, replenish fresh brake fluid up to the "MAX" mark.

Specified Brake Fluid: DOT3 or DOT4

8. CLUTCH MASTER CYLINDER FLUID

LEVEL

Check the fluid level. If it is below the "MIN" mark, replenish fresh brake fluid up to the "MAX" mark.

Specified Brake Fluid: DOT3 or DOT4

M6010500300026

AC305613

AC305615

Inspect the battery connections. Verify that they are tightened.

NOTE: Do not wipe the lubricant from the battery posts and cable clamps.

11. POWER STEERING FLUID LEVEL

M6010500600072

AC305616

1. Check that the fluid level is between "MAX" and "MIN".

Page 16

1-10

PRE-DELIVERY INSPECTION

UNDER VEHICLE

2. If the fluid is added, start the engine and turn the steering wheel from stop to stop several times to expel air from the system.

Specified gear oil: Automatic transmission fluid DEXRON III or DEXRON II

12. ELECTRICAL WIRING

M6010500700024

AC305617

UNDER VEHICLE

1. Each electrical wiring harness and connector (1) Check each harness to be correctly routed

and securely clipped.

(2) Confirm that all connections are tight.

2. Ignition cable Be sure that all ignition cables are firmly attached to the spark plugs, distributor cap (or crank angle sensor) and ignition coil.

13. TYRE AND SPARE TYRE PRESSURES

M6010600100041

AC305618 AC305609

1. Tyre specification Check the correct tyre specification.

2. Tyre pressures Adjust each tyre pressure.

NOTE: Recommended pressure is shown on the tyre pressure label.

3. Valve stem extensions Verify that the valve stem extensions are installed where necessary.

4. Install the wheel covers, wheel rings and hub caps.

14. SUSPENSION SYSTEM

M6010600200082

Check to be sure that each installation bolt and nut is tightened. If split pins are used, make sure that they are properly installed.

1. Lower arm, Upper arm

2. Stabilizer bar

3. Strut assembly

Page 17

PRE-DELIVERY INSPECTION

BEFORE ROAD TEST

1-11

REMOVE FRONT SPRING RESTRAINTS

CAUTION

It is very important that these restraints must be removed during predelivery-inspection. Failure to do so could cause ride and handling com

plaints.

Spring restraints

AC305605

With the vehicle correctly positioned on the sub-frame contact points, and the suspension fully extended, remove the rubber restraints from the front springs.

15. STEERING LINKAGE AND SPLIT PINS

M6010600300023

1. Steering linkage retaining nuts and split pins Check visually and by feel that the steering linkage retaining nuts are correctly tightened and the split pins are correctly installed.

2. Tie rods and relay rod Check that the tie rods and relay rod of the steering linkage are not bent and that the tie rod end lock nuts are securely tightened.

3. Steering components (1) Check that each of the steering components is

tightened.

(2) Check the tie rod end, nuts and split pins for

proper installation.

(3) Check the condition of bellows-type dust

seals.

4. Split pins Check the front axle nuts and rear wheel spindle nuts for split pins.

16. UNDER BODY

M6010600400020

Check under body and under body coating for damage.

AC305604

BEFORE ROAD TEST

17. SEAT ADJUSTERS AND SEATBACK LATCHES

M6010700100082

AC305622

Check the operation of the various parts of the seats.

1. Mechanical adjusters of the seats

2. Operation of the latch for tilting the seatbacks forward and backward.

18. INHIBITOR SWITCH

M6010701100029

On models with an automatic transmission, be sure the engine starts in both "P" and "N" position, and does not start in other positions.

19. IDLE CONTROL KNOB

M6010700300020

Verify that the diesel engine revolution increases when the idle control knob is pulled out.

Page 18

1-12

PRE-DELIVERY INSPECTION

20. INSTRUMENT PANEL CONTROLS

M6010700400083

Check the operation of the following

1. Horn

2. Headlamps

3. Exterior and interior lamps

4. Instrument panel lamps

5. Instrument brightness control

BEFORE ROAD TEST

21. METERS, GAUGES, WARNING LAMPS AND INDICATION LAMPS

M6010700500024

AC305624

1. Check the meters and gauges are functioning properly.

2. Check each indicator lamp and warning lamp functions properly.

22. AIR CONDITIONER, HEATER AND

DEFROSTER SYSTEM

M6010700600021

Check the systems for proper operation.

AC305626

2. Heater and defroster (1) After the engine has warmed up, turn on the

heater. (2) Operate the blower motor switch in all ranges. (3) Move the control to "Defrost" position.

A: From front and side defroster B: From centre ventilators C: From side ventilators D: From under the instrument panel E: From under the front seat (some models only)

23. WIPERS AND WASHERS

M6010700700028

AC305625

1. Air conditioner (1) Operate the air conditioner system. (2) Operate the air conditioner light. (3) Operate the control lever in all ranges. (4) Operate the blower motor switch in all ranges.

AC305627

1. Front wiper and washer (1) Check operation of the front wipers in all

ranges. (2) Check the aim of the front washer stream. (3) Check the wiper blade-stop positions. (4) Verify that the interval between cycles of

wiping is shifted when timer knob is turned to

any position. (5) Verify that the front wipers function by

operating the washer switch.

2. Rear wiper and washer (1) Check the operation of the rear wiper. (2) Check the aim of the rear washer stream. (3) Check the wiper blade-stop positions.

Page 19

PRE-DELIVERY INSPECTION

BEFORE ROAD TEST

1-13

24. OPERATION OF SERVICE BRAKES AND PARKING BRAKES

M6010700800274

Depress the brake pedal with approximately 500 N force

AC305628

1. Service brakes (1) Check the clearance between the brake pedal

and the floor board when the brake pedal is depressed.

1. Check the clutch operation in all driving ranges.

2. Check the pedal to floorboard clearance when the clutch is just disengaged.

AC305631

3. Verify correct clutch pedal free play.

NOTE: For inspection and adjustment of the clutch pedal, refer to GROUP 2, Periodic Inspec

tion and Maintenance.

26. OPERATION OF SEAT BELTS,

SHOULDER BELTS AND RETRACTORS

M6010701000022

AC305629

(2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the service brake, refer to GROUP 2, Periodic Inspection and Maintenance.

2. Parking brake Check the parking brake drag and lever travel.

NOTE: For inspection and adjustment of the parking brake, refer to GROUP 2, Periodic Inspection and Maintenance.

25. CLUTCH OPERATION

M6010700900282

AC305632

1. Verify that the seat belt warning lamp operates properly.

2. Check all seat belts and harnesses to assure that they connect and hold properly.

3. Lean forward to check that the shoulder harnesses allow movement.

4. Check the condition of the belts and anchors.

5. Check for proper seat belt retraction.

AC305630

Page 20

1-14

27. ENGINE PERFORMANCE AND EXHAUST GAS

M6010800100023

PRE-DELIVERY INSPECTION

ROAD TEST

Button

AC305633

1. Engine performance Check the engine for proper performance and accelerator pedal for smooth operation.

2. Exhaust system (1) Check the exhaust system components for

gas leaks.

(2) Verify that no black smoking is emitted from

the end of the exhaust pipe (diesel-powered vehicles).

28. TRANSMISSION IN ALL RANGES

M6010800200020

AC305635

2. Automatic transmission (1) Make sure shift indicator lines up properly in

all ranges.

(2) Depress the accelerator completely to check

that the manual kickdown is operating correctly.

(3) Stop the vehicle on a steep incline.

Put the automatic transmission in "P" position and slowly release the service brakes to see if "P" position lock holds. If it does not hold, the transmission requires further service.

29. BRAKES

M6010800300027

1. Service Brake Put the vehicle in gear and apply the brakes while the vehicle is in motion. Be sure brake operation is smooth and positive.

2. Parking Brake (1) Stop the vehicle on a steep incline.

With the service brakes firmly applied, place the transmission in "N" position, and set the parking brakes.

(2) Slowly release the service brakes to see if the

parking brakes will hold.

AC305634

1. Manual transmission Check the transmission in all forward ranges and in reverse.

30. STEERING CONTROL

M6010800400024

AC305636

1. Check for excessive play or looseness.

2. Check the steering wheel centre.

Page 21

PRE-DELIVERY INSPECTION

AFTER ROAD TEST

1-15

31. VIBRATION AND RATTLES

M6010800500021

1. Locate squeaks, rattles and unusual vibrations.

2. Verify that no noise occurs from the engine, transmission, axle and body.

32. ELECTRICAL EQUIPMENT

M6010800600028

AC305637

AFTER ROAD TEST

1. Radio

Tune the radio to a local broadcasting station and check the following:

(1) Operate the volume, tone, balance and fader

controls, etc.

(2) Pull out the pushbuttons, dial another station

and set each pushbuttons.

(3) Operate the AM/FM switch.

2. Tape player

Insert a cassette tape in the tape player and check as follows:

(1) Check the operation of the tape feeder and

rewind. (2) Check the ejection. (3) Check the operation of volume, tone, balance

and fader controls, etc.

33. IDLE SPEED

M6010900100172

Check the engine idle speed.

NOTE: For specific idle speed adjustment procedure, refer to GROUP 2, Periodic Inspection and Maintenance.

34. IGNITION TIMING

M6010900200179

AC305641

Check the ignition timing. Except MPI vehicles with crankshaft-mounted crankshaft angle sensor.

NOTE: For the inspection and adjustment of the ignition timing, refer to GROUP 2, Periodic Inspection and Maintenance.

35. RADIATOR COOLANT LEVEL

M6010900300154

CAUTION

Do not remove the radiator cap while the cooling system is under pressure. When removing the radiator cap, be careful of steam and boiling water. Add coolant only to the reserve tank if it is required.

1. Check that the coolant level in the reserve tank is at or above "LOW" mark at normal engine operating temperature. And check cooling system for leaks.

2. Check that the coolant concentration is 30% to 60%.

AC305642

Page 22

1-16

PRE-DELIVERY INSPECTION

AFTER ROAD TEST

36. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD

M6010900400203

CAUTION

Remember that the air conditioner system is under pressure.

AC305643

1. Check all brake, fuel, power steering and air conditioner lines and connections; verify proper routing, check connections for leaks, tighten loose connector as required.

2. Inspect routing and connections of all vacuum, and radiator and heater houses.

NOTE: Keep in mind that an oily residue around an air conditioner connector does not necessarily indicate a leak. Oil is used to lubricate fittings dur ing assembly. Be sure lines are not twisted or kinked.

37. MANUAL TRANSMISSION AND

TRANSFER (4WD) OIL LEVEL

M6010900500211

Transmission oil

38. AUTOMATIC TRANSMISSION FLUID LEVEL

M6010900600230

AC005861

1. Remove the dipstick and check the fluid level.

2. Fluid level is okay if it is in the specified range as illustration at normal engine operating temperature.

3. If the level is below the lower notch, replenish fluid until the level reaches the upper notch.

NOTE: For the specified automatic transmission fluid, refer to GROUP 2, Periodic Inspection and Maintenance.

39. ENGINE, TRANSMISSION, STEERING

GEAR BOX AND DIFFERENTIAL FOR

LEAKS

M6010900700055

Check the engine, transmission, steering gear box and differential for oil leaks.

40. FRONT AND REAR DIFFERENTIAL

OIL LEVELS

M6010900800234

1. Remove the filler plug.

2. Check the oil level. If the oil level is at or slightly below the filler hole, it is in satisfactory condition.

TYPE 1 TYPE 2

•

AC305644

1. Remove the filler plug.

2. Check the oil level. If the oil level is at or slightly below the filler hole, it is in satisfactory condition.

3. If the level is low, replenish the transmission and transfer case with fresh oil by using a lubricator.

NOTE: For the specified oil, refer to GROUP 2, Periodic Inspection and Maintenance.

Upper limit

Lower limit

8 mm

Gear oil

AC305646

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

gear oil level. Check that gear oil level is not 8 mm below the bottom of filler plug hole.

3. If the level is low, replenish the front and/or rear differential with fresh oil by using a lubricator.

Page 23

PRE-DELIVERY INSPECTION

FINAL STEPS

1-17

NOTE: For the specified oil, refer to GROUP 2, Periodic Inspection and Maintenance.

41. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE

M6010901000145

AC305647

FINAL STEPS

42. HEADLAMP AIMING

M6011000100116

Screen

Level surface

Check condition for headlamp aiming.

NOTE: For headlamp aiming procedures, refer to the Workshop Manual for that model.

43. EQUIPMENT

Headlamp

AC305648

M6011000200050

1. Check all hoses, fluid lines and connections for leaks.

2. Check all hoses and fluid lines for proper routing away from sharp edges and moving components.

Check the installation of the various equipment.

1. Floor mats

2. Spare tyre

3. Jack, jack handle and tool set

44. EXTERIOR AND INTERIOR

M6011000300187

Finally check and clean the exterior and interior.

1. Wash the vehicle to remove all traces of road grime and other dirt on the vehicle as a result of new vehicle preparations.

2. Clean exterior and interior glass surface.

3. Remove all protective covers.

4. Remove undercoat overspray, excess window sealer, and excess weatherstrip adhesive.

5. Verify that the secondary key can not unlock the glove box and tailgate/boot lid (if so equipped).

6. Remove shipping and inspection stickers.

AC305649

45. OWNER INSTRUCTIONS

M6011000400054

1. Verify that the owner's manual and service booklet is in the glove box.

2. Place the spare keys in envelope in the glove box before delivery.

Page 24

NOTES

Page 25

GROUP 2

PERIODIC

INSPECTION AND

MAINTENANCE

CONTENTS

2-1

PERIODIC INSPECTION AND

MAINTENANCE SCHEDULE . . . . . . 2-3

OPERATIONS INSIDE THE ENGINE

COMPARTMENT . . . . . . . . . . . . . . . . 2-7

A1. CHECK V-BELT FOR CRACKS, FRAYING,

WEAR, AND ADJUST ITS TENSION . . . . . 2-7

A2. CHECK VACUUM PUMP OIL HOSE FOR

DAMAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

A3. CHECK INTAKE AIR HOSE AND TURBOCHARGER OIL HOSE FOR DAMAGE 2-9

A4. REPLACE ENGINE TIMING BELT <EXCEPT VEHICLES WITH TIMING CHAIN> 2-9

A5. CHECK OPERATION OF CRANKCASE

EMISSION CONTROL SYSTEM . . . . . . . . 2-10

A6. REPLACE SPARK PLUGS. . . . . . . . . . 2-11

A7. CHECK VALVE CLEARANCE (EXCEPT

VEHICLES AUTO-LASH ADJUSTER) . . . . 2-11

A8. CHECK RADIATOR HOSES FOR DAMAGE

AND PROPER CONNECTION . . . . . . . . . . 2-15

A9. CHECK ENGINE COOLANT LEVEL IN

RESERVOIR. . . . . . . . . . . . . . . . . . . . . . . . 2-15

A10. CHANGE ENGINE COOLANT . . . . . . 2-15

A11. CHECK AIR CLEANER ELEMENT FOR

CLOGGING AND DAMAGE . . . . . . . . . . . . 2-17

A12. REPLACE AIR CLEANER ELEMENT 2-17

A13. CHECK FLUID LEVEL IN BRAKE

RESERVOIR. . . . . . . . . . . . . . . . . . . . . . . . 2-18

A14. CHECK FLUID LEVEL IN CLUTCH RESERVOIR (FOR HYDRAULIC TYPE

CLUTCH ONLY) . . . . . . . . . . . . . . . . . . . . . 2-18

A15. CHANGE BRAKE FLUID . . . . . . . . . . 2-18

A16. CHECK BATTERY ELECTROLYTE

LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

A17. CHECK INJECTION NOZZLE [IF DARK SMOKE IS EXHAUSTED OR ENGINE POWER

IS LOW] <4M40> . . . . . . . . . . . . . . . . . . . . . 2-20

A18. REPLACE FUEL FILTER . . . . . . . . . . 2-21

OPERATIONS UNDER THE VEHICLE 2-24

B1. CHECK SUSPENSION SYSTEM FOR

DAMAGE AND LOOSENESS . . . . . . . . . . . 2-24

B2. CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR

DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

B3. LUBRICATE PROPELLER SHAFT WITH

GREASE FITTING. . . . . . . . . . . . . . . . . . . . 2-25

B4. CHECK DRIVESHAFT BOOTS FOR

DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

B5. CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS

(Including seals and boots). . . . . . . . . . . . . 2-25

B6. CHECK GEAR OIL LEVEL IN MANUAL

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-26

B7. CHECK GEAR OIL LEVEL IN TRANSFER

CASE (4WD) . . . . . . . . . . . . . . . . . . . . . . . . 2-26

B8. CHANGE GEAR OIL IN MANUAL

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-26

B9. CHANGE GEAR OIL IN TRANSFER

CASE (4WD) . . . . . . . . . . . . . . . . . . . . . . . . 2-27

B10. CHECK GEAR OIL LEVEL IN FRONT

AND REAR DIFFERENTIAL . . . . . . . . . . . . 2-27

B11. CHANGE GEAR OIL IN FRONT AND

REAR DIFFERENTIAL . . . . . . . . . . . . . . . . 2-27

B12. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 2-28

Continued on next page

Page 26

2-2

OPERATIONS INSIDE THE VEHICLE 2-28

C1. CHECK BRAKE PEDAL AND CLUTCH

PEDAL FOR FREE PLAY . . . . . . . . . . . . . . 2-28

C2. CHECK PARKING BRAKE LEVER STROKE

AND PLAY . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

C3. REPLACE AIR PURIFIER FILTER. . . . 2-30

OPERATIONS OUTSIDE THE VEHICLE 2-31

D1. CHECK WHEEL ALIGNMENT . . . . . . . 2-31

D2. CHECK FRONT AND REAR WHEEL

BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-33

D3. CHECK BRAKE HOSES AND PIPES FOR

LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

D4. CHECK BRAKE PADS AND DISCS FOR

WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

D5. CHECK BRAKE SHOE LININGS AND

DISCS FOR WEAR. . . . . . . . . . . . . . . . . . . 2-35

D6. CHECK FUEL HOSES AND PIPES FOR

LEAKAGE OR DETERIORATION . . . . . . . 2-36

OPERATIONS AFTER ENGINE IS

WARMED UP . . . . . . . . . . . . . . . . . . . 2-37

E1. CHECK FLUID LEVEL IN AUTOMATIC

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-37

E2. CHANGE AUTOMATIC TRANSMISSION

FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

E3. CHANGE ENGINE OIL . . . . . . . . . . . . . 2-39

E4. REPLACE ENGINE OIL FILTER . . . . . 2-40

E5. CHECK ENGINE IDLING SPEED AND

CO CONCENTRATION . . . . . . . . . . . . . . . . 2-41

E6. CHECK EXHAUST GAS RECIRCULATION

(EGR) SYSTEM. . . . . . . . . . . . . . . . . . . . . . 2-44

OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-48

F1. CHECK BODY CONDITION FOR

DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

F2. CHECK THE COMMON RAIL ENGINE

(small injection quantity learning) . . . . . . . . 2-48

F3. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-48

Page 27

PERIODIC INSPECTION AND MAINTENANCE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

2-3

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

M6020100100702

For items which indicate both distance and time (in months), the inspection should be made at whichever (distance or time) comes first.

Maintenance item Maintenance

operation

OPERATIONS INSIDE THE ENGINE COMPARTMENT

A1 Check V-belt for cracks, fraying, wear, and

adjust its tension

A2 Check vacuum pump oil hose for damage

(diesel-powered vehicles)

A3 Check intake air hose and turbocharger oil

hose for damage (vehicles with turbocharger)

A4 Replace engine timing belt (except vehicles

with timing chain)

A5 Check operation of crankcase emission

control system

A6 Replace spark plugs 3 earth

electrodes semi-surfa ce discharge type

Iridium-tipp ed type

A7 Check valve

clearance (except vehicles with auto-lash adjuster)

A8 Check radiator hoses for damage and proper

connection

A9 Check engine coolant level in reservoir Inspection First 1,000 km, thereafter every

A10 Change engine coolant Change Every 40,000 km or every 2 years

Except vehicles with 6G75 engine

Vehicles with 6G75 (intake side) engine

Leaded petrol-pow ered vehicles

Unleaded petrol-pow ered vehicles

Inspection First 1,000 km, thereafter every

Inspection Every 20,000 km or every 12 months

Inspection Every 40,000 km or every 2years (over

Replace Every 100,000 km

Inspection Every 40,000 km or every 2 years

Replace Every 40,000 km

Replace Every 100,000 km

Inspection First 1000 km, thereafter every 20,000

Inspection Every 40,000 km or every 2 years (If

Inspection Every 40,000 km or every 2 years

Maintenance interval

20,000 km or every 12 months

100,000 km, every 20,000 km for turbocharger oil hose)

km or every 12 months

valve noise increases, check valve clearance additionally to the scheduled service.)

20,000 km or every 12 months

A11 Check air cleaner element for clogging and

damage

Inspection Norma

l usage

Severe usage

Every 20,000 km or every 12 months

Every 10,000 km or every 6 months

Page 28

2-4

PERIODIC INSPECTION AND MAINTENANCE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

Maintenance item Maintenance

operation

A12 Replace air cleaner element Replace Norma

A13 Check fluid level in brake reservoir Inspection First 1,000 km, thereafter every

A14 Check fluid level in clutch reservoir (for

hydraulic type clutch only)

A15 Change brake fluid Change Every 40,000 km or every 2 years

A16 Check battery electrolyte level Inspection First 1,000 km, thereafter every

A17 Check injection nozzle [If dark smoke is

exhausted or engine power is low]

A18 Replace fuel filter Petrol-powered

vehicles

Diesel-powered vehicles

OPERATIONS UNDER THE VEHICLE

B1 Check suspension system for damage and

looseness

B2 Check suspension arm ball joints for play, and

dust covers for damage

B3 Lubricate propeller shaft with grease fitting Lubrication Every 20,000 km or every 12 months

B4 Check driveshaft boots for damage Inspection Norma

Inspection First 1,000 km

Inspection Every 50,000 km or every 2.5 years

Replace Every 60,000 km or every 3 years

Replace Every 20,000 km or every 12 months

Inspection First 1,000 km, thereafter every

Inspection Every 20,000 km or every 12 months

Maintenance interval

Every 40,000 km or every 2

l usage

Severe usage

10,000 km or every 6 months

20,000 km or every 12 months

l usage

years

More frequently

Every 20,000 km or every 12 months

Severe usage

B5 Check steering linkage for damage and loose

connections (including seals and boots)

B6 Check gear oil level in manual transmission Inspection Every 20,000 km or every 12 months

B7 Check gear oil level in transfer case (4WD) Inspection Every 20,000 km or every 12 months

B8 Change gear oil in manual transmission Change Norma

B9 Change gear oil in transfer case (4WD) Change Norma

B10 Check gear oil level in front and rear

differential

Inspection Every 20,000 km or every 12 months

l usage

Severe usage

l usage

Severe usage

Inspection Every 20,000 km or every 12 months

First 1,000 km, thereafter every 10,000 km or every 6 months

Every 100,000 km or every 5 years

Every 40,000 km or every 2 years

Every 100,000 km or every 5 years

Every 40,000 km or every 2 years

Page 29

PERIODIC INSPECTION AND MAINTENANCE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

2-5

Maintenance item Maintenance

operation

B11 Change gear oil in front and rear differential Change Norma

B12 Check exhaust pipe connections for gas

leakage, and check pipe installation

OPERATIONS INSIDE THE VEHICLE

C1 Check brake pedal and clutch pedal for free

play

C2 Check parking brake lever stroke and play Inspection First 1,000 km, thereafter every

C3 Replace air purifier filter Replace Every 15,000 km or every 12 months

OPERATIONS OUTSIDE THE VEHICLE

D1 Check wheel alignment Inspection Every 20,000 km or every 12 months

D2 Check front and rear wheel bearings for play Inspection Every 60,000 km or every 3 years

D3 Check brake hoses and pipes for leakage Inspection Every 20,000 km or every 12 months

D4 Check brake pads and discs for wear Inspection Norma

Inspection Every 20,000 km or every 12 months

Inspection Every 10,000 km or every 6 months

Maintenance interval

Every 80,000 km or every 4

l usage

Severe usage

20,000 km or every 12 months

l usage

years

Every 40,000 km or every 2 years

Every 20,000 km or every 12 months

Severe usage

D5 Check brake shoe linings and discs for wear Inspection Norma

l usage

Severe usage

D6 Check fuel hoses and pipes for leakage or

deterioration

OPERATIONS AFTER ENGINE IS WARMED UP

E1 Check fluid level in automatic transmission Inspection Every 20,000 km or every 12 months

E2 Change automatic transmission fluid Change Severe

E3 Change engine oil

<6G7>

Change engine oil <4M40>

Change engine oil <4M41>

ACEA classification "For service A1/B1, A3/B3, A3/B4 or A5/B5" API classification "For service SG" or higher

ACEA classification "For service A1/B1, A3/B3, A3/B4 or A5/B5" API classification "For service CD" or higher

Inspection Every 40,000 km or every 2 years

usage

Change Norma

l usage

Severe usage

Change Norma

l usage

Severe usage

Change Norma

l usage

Severe usage

Every 5,000 km or every 6 months

Every 40,000 km or every 2 years

Every 10,000 km or every 6 months

Every 40,000 km or every 2 years

Every 15,000 km or every 12 months

Every 5,000 km

Every 5,000 km or every 6 months

Every 3,000 km

Every 15,000 km or every 12 months

Every 7,500 km

Page 30

2-6

PERIODIC INSPECTION AND MAINTENANCE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

Maintenance item Maintenance

operation

E4 Replace engine oil filter <6G7> Replace Norma

Replace engine oil filter <4M40> Replace Norma

Replace engine oil filter <4M41> Replace Norma

E5 Check engine idling speed and CO

concentration (petrol-powered vehicles)

Check engine idling speed (diesel-powered vehicles)

E6 Check exhaust gas recirculation (EGR)

system

Inspection First 1,000 km, thereafter every

Inspection Every 20,000 km or every 12 months

Maintenance interval

l usage

Severe usage

l usage

Severe usage

l usage

Severe usage

20,000 km or every 12 months

Every 15,000 km or every 12 months

Every 5,000 km

Every 10,000 km or every 12 months

Every 6,000 km

Every 15,000 km or every 12 months

Every 7,500 km

OTHERS

F1 Check body condition for damage Inspection Every year

F2 Check the common rail engine (small injection

quantity learning)

F3 Road test Inspection First 1,000 km, thereafter every

NOTE: "Severe usage" specifications apply to only vehicles used under severe operating conditions. Severe operating conditions include the following cases:

1. Driving in a dusty area or in an area in which the vehicle is likely to be exposed to salty air or brine.

2. Driving on rough roads, on submerged roads, or hilly areas.

3. Driving in cold zones.

4. Engine idling for a long time or short-distance travel during cold weather.

5. Frequent, sudden application of brakes.

6. Towing of a trailer.

7. Use as a taxi or as a rent-a-car.

8. More than 50% of operation time in heavy city traffic in hot temperatures of 32°C or higher.

9. More than 50% of operation time at speeds of 120 km/h or higher in hot temperatures of 30°C or higher.

Inspection Every 20,000 km or every 12 months

20,000 km or every 12 months

10. Operation under excessive load.

Page 31

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-7

A1. CHECK V-BELT FOR CRACKS, FRAYING, WEAR, AND ADJUST ITS TENSION

M6020200100561

V-BELT CONDITION

Check the whole rounds of the V-belt for cracks, fraying and wear.

V-BELT TENSION ALTERNATOR DRIVE BELT TENSION

CHECK <6G7>

CAUTION

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

Alternator drive belt auto-tensioner

<4M41>

Item When

checked

Vibration frequency Hz

Tension N 245 − 441 294 − 392 392 − 588

Deflection mm (Reference)

150 − 201 164 − 190 190 − 232

9.1 − 12.7 9.8 − 11.7 7.2 − 9.8

When adjusted

When replaced

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

Belt tension meter set (MB992080)

MB992081

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.

NOTE: The alternator drive belt tension check is not necessary as alternator drive belt auto-ten sioner is adopted.

Indicator mark

AC511210

ALTERNATOR DRIVE BELT TENSION CHECK AND ADJUSTMENT <4M4>

Check the drive belt tension in the following procedure.

STANDARD VALUE:

<4M40>

Item When

checked

Vibration frequency Hz

Tension N 294 − 490 343 − 441 490 − 686

Deflection mm (Reference)

103 − 132 111 − 125 132 − 156

8.0 − 11.0 9.0 − 11.0 8.0 − 9.0

When adjusted

When replaced

MB992082

AC507219

1. Connect the Special tool microphone assembly (MB992082) to the Special tool belt tension meter

(MB992081) of the Special tool belt tension meter set (MB992080).

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

3. Press number key 1. Check to ensure that "No. 01" appears on the upper left of the display and that the following numeric values are displayed for individual items (M, W, and S):

M 000.9 g/m

W 010.0 mm/R

S 0100 mm

If numeric values have not been entered (new tool), set them according to the belt specifications as shown below. Once you set them, you do not have to set them again. The settings remain undeleted even after battery replacement.

Page 32

2-8

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

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.

<Setting procedure> (1) Press down the "MASS" button till the belt

mass select display appears.

(2) Press the "UP" or "DOWN" button to select "01

1.5GT 0.9" and press the "MEASURE" button to decide it.

Check to ensure that "M 000.9 g/m" is displayed.

(3) Press the "WIDTH" button to change to the

belt width input display.

(4) Press number keys 0, 1, 0, and 0 sequentially,

and press the "SELECT" button to apply them. Check to ensure that "W 010.0 mm/R" appears on the display.

(5) Press the "SPAN" button to change to the

span length input display.

(6) Press number keys 0, 1, 0, and 0 sequentially,

and press the "SELECT" button to apply them. Check to ensure that "S 0100 mm" appears on the display.

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

CAUTION

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

• 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 is 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.

MB992080 (Microphone)

15˚

10 – 15 mm

Alternator pulley

15˚

Gentry tap with your finger

Water pump pulley

AC600283

5. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10

− 15 mm away from the rear surface of the belt and 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.

8. After the completion of the measurement, press and hold the "POWER" button to turn off the power supply.

Page 33

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-9

Water pump

Tension gauge

Alternator pulley

pulley

AC600285

Use a belt tension gauge to check that the belt tension is within the standard value.

Approximately 100N

Deflection

Water pump pulley

Crankshaft pulley

4. Tighten the nut for alternator pivot bolt.

Tightening torque: 47 ± 9 N⋅ m

5. Tighten the alternator fixing nut.

Tightening torque: 24 ± 4 N⋅ m

6. Tighten the adjusting bolt.

Tightening torque: 5.0 ± 1.0 N⋅ m

A2. CHECK VACUUM PUMP OIL HOSE FOR DAMAGE

M6020200400108

Hose

AC502483

1. Inspect the surface of hose for evidence of heat and mechanical damage.

Alternator pulley

AK500540AB

Apply approximately 100 N of force to the middle of the drive belt between the pulleys (at the place indi

cated by the arrow) and check that the amount of deflection is within the standard value. When the belt tension is adjusted by measuring the deflection, adjust it with a tool for vibration frequency measurement or tension measurement afterward.

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

Adjusting bolt

Alternator fixing nut

Alternator pivot bolt

AC702321

1. Loosen the nut of the alternator pivot bolt.

2. Loosen the alternator fixing nut.

3. Use the adjusting bolt to adjust the belt tension

and belt deflection to the standard values.

A3. CHECK INTAKE AIR HOSE AND TURBOCHARGER OIL HOSE FOR DAMAGE

M6020200500235

Turbocharger

AC305652

1. Inspect the intake air hoses for cracks or damage.

2. Inspect the turbocharger oil hoses for cracks or damage.

A4. REPLACE ENGINE TIMING BELT <EXCEPT VEHICLES WITH TIMING CHAIN>

M6020200600306

For information concerning the replacement procedures, refer to the Workshop Manual.

Page 34

2-10

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

A5. CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM

M6020200700347

BREATHER HOSE

Breather hose

AC610025

1. Inspect the breather hose for cracks or damage.

2. Clean the inside of the breather hose if necessary.

3. Inspect the ventilation filter for clogging.

VENTILATION HOSE

1. Check entire circumference and length of hoses using a mirror as required.

2. Check all clamps for tightness and the connections for leakage.

3. Hoses should be replaced immediately if there is any evidence of deterioration or damage.

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK

Ventilation hose

1. Remove the ventilation hose from the PCV (Positive crankcase ventilation) valve.

2. Remove the PCV valve from the rocker cover.

3. Reinstall the PCV valve at the ventilation hose.

4. Start the engine and run at idle.

<6G72>

PCV valve

AC305653

<6G75>

PCV valve

AC609736

5. Place finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt.

NOTE: At this moment, the plunger in the PCV valve moves back and forth.

6. If vacuum is not felt, clean the PCV valve or replace it.

7. Apply a small amount of new engine oil to the O-ring on the PCV valve, and tighten to the specified torque. <6G75>

Tightening torque: 2.5 ± 0.4 N⋅ m

PCV valve

AC610047

Page 35

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-11

PCV VALVE CHECK

<6G72>

<6G75>

PCV valve

AC305654

AC609737

5. Move the rocker arms on the No. 1 and No. 4 cylinders up and down by hand to determine which cylinder has its piston at the top dead centre on the compression stroke. If rocker arms have a valve lash, the piston in the cylinder corresponding to these rocker arms is at the top dead centre on the compression stroke.

Right bank

No. 1 No. 3 No. 5

No. 2 No. 4 No. 6

Exhaust side

Intaake side

1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves.

2. If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve.

A6. REPLACE SPARK PLUGS

M6020200800281

After removing old spark plugs, install new ones and tighten them at the specified torque.

A7. CHECK VALVE CLEARANCE (EXCEPT VEHICLES AUTO-LASH ADJUSTER)

M6020202400137

VALVE CLEARANCE (Intake side) CHECK AND ADJUSTMENT <6G75>

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

1. Turn the ignition switch to the "LOCK" (OFF) position.

2. Remove all ignition coils.

3. Remove the rocker cover.

4. Turn the crankshaft clockwise until the notch on the pulley is lined up with the "T" mark on the timing indicator.

Left bank

Exhaust side

AK404086

6. Valve clearance inspection and adjustment can be performed on rocker arms indicated by white arrow mark when the No. 1 cylinder piston is at the top dead centre on the compression stroke, and on rocker arms indicated by black arrow mark when the No. 4 cylinder piston is at the top dead centre on the compression stroke.

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 while turning the adjusting screw.

Standard value (cold engine): Intake valve: 0.10 mm

NOTE: Valve clearance check and adjustment is unnecessary for exhaust side due to auto lash adjuster installed.

8. Turn the crankshaft through 360 degree angle to line up the notch on the crankshaft pulley with the "T" mark on the timing indicator.

9. Repeat steps 7 and 8 on other valves for clearance adjustment.

10.Install the rocker cover.

11.Install the ignition coils.

Page 36

2-12

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

VALVE CLEARANCE CHECK AND ADJUSTMENT <4M40>

NOTE: Perform the valve clearance check and adjustment at the engine cold state.

1. Remove the rocker cover.

2. Remove the glow plug plate and all of the glow plugs from the cylinder head.

CAUTION

Never turn the crankshaft anticlockwise (the opposite direction) as the tensioner, which adjust the timing chain tension at the timing gear, may be damaged. If so, remove and reinstall the ten sioner.

"0"

Intake No. 1

Intake No. 2

Exhaust No. 1

Intake No. 3

Exhaust No. 2

Intake No. 4

Exhaust No. 3

Exhaust No. 4

AK603846AB

4. Check the valve clearances at the places by arrows in the illustration by the following procedure.

White arrow: When No. 1 cylinder is at compression top dead centre position Black arrow: When No. 4 cylinder is at compression top dead centre position

Crankshaft pulley

AK601576AB

3. Align the notch of the crankshaft pulley with the "0" timing mark to set the No. 1 or No. 4 cylinder to the compression top dead centre position.

Dent

AK601577AB

NOTE: If the dent on the camshaft is pointing directly upwards, the No. 1 cylinder will be at the compres

sion top dead centre position. If the crankshaft is then turned once, the No. 4 cylinder will then be at the compression top dead centre position.

Valve clearance

AK603982

(1) Use a thickness gauge to measure the valve

clearance. If deviated from standard value, make a note for the valve clearance.

Standard valve (Cold engine): Intake side 0.15 − 0.25 mm Exhaust side 0.25 − 0.35 mm

NOTE: There should be certain amount of resistance against the thickness gauge when taking the measurements. If the thickness gauge is moving too smoothly, a correct meas urement cannot be obtained.

(2) Use the measured values as a reference for

selecting adjustment shims which will bring the incorrect valve clearance to the standard value.

A: thickness of newly installed shim B: thickness of removed shim C: measured valve clearance Equation Intake valve: A = B + (C − 0.2) mm Exhaust valve: A = B + (C − 0.3) mm

NOTE: The thicknesses of the adjustment shims are between 2,250

−

3,150 mm (37types

which increase in thickness by 0.025 mm)

Page 37

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-13

Identification size mark

AK603848

NOTE: Size identification mark: "2775" = 2.775 mm thickness

(3) Remove the camshaft and install the shim

which was selected in step (2).

(4) Re-measure the valve clearances and check

that they are all at the standard value.

5. Turn the crankshaft once to align the notch of the

crankshaft pulley with the timing mark "0".

6. Check and adjust the other valve clearances

according to the step 4.

2. Use the special tool fuel injection pipe wrench (MB992188) to remove the fuel injection pipe.

3. Remove the rocker cover.

CAUTION

The crankshaft should always be turned in a clockwise direction.

Timing marks

Camshaft sprocket

Timing marks

VALVE CLEARANCE CHECK AND ADJUSTMENT <4M41>

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

1. Remove the EGR pipe.

CAUTION

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

MB992188

AC609910

Crankshaft pulley

AC610704

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

Exhaust valve side

Intake valve side

AK500544AB

5. 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 camshaft and the roller while turning the adjusting screw.

Standard value (cold engine): Intake valve: 0.10 mm Exhaust valve: 0.15 mm

MB992188

AK600672

Page 38

2-14

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

CAUTION

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

MB992188

MB992046

Thickness gauge

AK500542

6. 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: 9.8 ± 1 N⋅ m

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

Exhaust valve side

Intake valve side

AK500544AC

8. Measure the valve clearances at the places indicated by arrows in the illustration. If the clearance is not within the standard value, repeat steps 5 and 6 above.

9. Install the rocker cover.

AC609910

MB992188

AK600672

10.Use the special tool fuel injection pipe wrench (MB992188) to tighten the fuel injection pipe to the specified torque.

Tightening torque: 35 ± 5 N⋅ m

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 injection 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.

11.Install the EGR pipe.

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

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

14.Select SPECIAL FUNCTION from the function menu.

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

Page 39

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-15

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

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

A8. CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION

M6020200900545

<6G7>

AC608822

<4M4>

A10. CHANGE ENGINE COOLANT

M6020201100683

1. Stop the engine after it is fully warmed up.

2. Add detergent to the engine coolant in order to flush the cooling system, and start the engine.

AC305655

3. Loosen the drain plug, remove the radiator can and drain the coolant.

4. Feed fresh water into the cooling system through the filler port of the radiator in order to wash the cooling system, and then tighten the drain plug.

5. Drain the coolant from the radiator condenser tank.

6. Install the radiator condenser tank.

AC608825

1. Check entire circumference and length of hoses, using a mirror as required.

2. Check that hoses installed in grommets pass through the centre of the grommets.

3. Check all clamps for tightness and connections for leakage.

A9. CHECK ENGINE COOLANT LEVEL IN RESERVOIR

M6020201000545

CAUTION

Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause the corrosion of the aluminium com

ponents.

AC305656

7. Depending upon conditions of operation, determine the amount of long life coolant, antifreeze or antirust to be added to the coolant.

Recommended antifreeze: DIA QUEEN SUPER LONG LIFE COOLANT or equivalent

Condenser tank

AC608829

Check that the coolant level is between the "FULL" and "LOW" lines when the engine is at the normal operating temperature.

8. Fill the cooling system with soft water through the filler port, and add long life coolant, if necessary.

9. Fill the radiator condenser tank with coolant.

10.Install the radiator cap and the radiator condenser tank cap.

Page 40

2-16

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

CAUTION

When removing the radiator cap, be careful to blow out steam and boiling water.

11.Recheck the engine coolant level after a road test.

REMOVAL OF ENGINE COOLANT FROM THE CYLINDER BLOCK DRAIN PLUG

1. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.

<6G7-Left bank>

AC609816

<6G7-Right bank>

AC609817

2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block <6G7>.

<4M40>

29 N·m

Water drain plug

<4M41>

31 ± 2 N·m

Water drain plug

Engine oil filter

AC610385

Engine oil cooler assembly

AC503525

3. Remove the water drain plug of engine oil cooler to drain the coolant inside the water jacket. <4M4>.

4. Remove the radiator condenser tank and drain the coolant.

5. Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area.

Cylinder block drain plug

AC200625

6. Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque <6G7>.

Specified sealant: 3M Nut Locking Part

No.4171 or equivalent

Tightening torque: 39 ± 5 N⋅ m

7. Replace the gasket and tighten the water drain plug to the specified torque <4M4>.

Tightening torque:

<4M40> 29 N⋅ m <4M41> 31 ± 2 N⋅ m

Page 41

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-17

8. Securely tighten the drain plug of the radiator.

9. Reinstall the radiator condenser tank.

CAUTION

Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminium components.

MB991871

AC602117

10.By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Use special tool LLC changer (MB991871) to refill the coolant. A convenient mixture is a 50% water and 50% antifreeze solution (freezing point: − 31° C).

Recommended antifreeze: DIA QUEEN SUPER

LONG LIFE COOLANT or equivalent

Quantity (including 0.65 L in the radiator con-

denser tank):

<Short wheelbase, Long wheelbase (vehi-

cles without rear heater)> 9.0 L

<Long wheelbase (vehicles with rear

heater)> 10.5 L

NOTE: For how to use special tool (MB991871), refer to its manufacturer’s instructions.

11.Reinstall the radiator cap.

12.Start the engine and let it warm up until the thermostat opens.

13.After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.

14.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap.

CAUTION

Do not overfill the radiator condenser tank.

A11. CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE

M6020201200475

AC608830

1. Check air cleaner element for clogging and damage.

2. Clean deposited dust from the element in the following manner.

(1) Lightly tap the element against the top of a

bench.

(2) Blow compressed air from inside the element.

3. Wipe off dust on the air cleaner interior.

4. Install the air cleaner body.

A12. REPLACE AIR CLEANER ELEMENT

M6020201300524

The air cleaner element will become dirty and loaded with dust during use, and the filtering effect will be substantially reduced. Replace it with a new one.

AC608831

1. Unclasp the air cleaner cover clip.

2. Remove the air cleaner element and install a new one.

3. Be sure to close the air cleaner cover completely when clamping it.

15.Add coolant to the radiator condenser tank between the "FULL" and "LOW" mark if necessary.

Page 42

2-18

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

A13. CHECK FLUID LEVEL IN BRAKE RESERVOIR

M6020202200230

AC608832

AC609839

A15. CHANGE BRAKE FLUID

M6020201600581

AC305659

1. Remove the cap of the bleeder screw, connect a vinyl tube, and place its other end in a receptacle.

CAUTION

If the reservoir tank completely runs out of fluid during operation, air will find way into the brake line. Pay attention, therefore, to the fluid level and replenish as necessary.

2. Loosen the bleeder screw and depress the brake pedal; supply new brake fluid when the level of the fluid within the reservoir tank decreases.

Specified brake fluid: DOT3 or DOT4

1. Check that the fluid level is between the "MAX" and "MIN" mark.

2. If it is below the "MIN" marks, replenish with fresh brake fluid up to the "MAX" mark.

A14. CHECK FLUID LEVEL IN CLUTCH RESERVOIR (FOR HYDRAULIC TYPE CLUTCH ONLY)

M6020201500205

AC609400

1. Check that the fluid level is between the "MAX" and "MIN" mark.

2. If it is below the "MIN" marks, replenish with fresh brake fluid up to the "MAX" mark.

CAUTION

Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. If brake fluid is exposed to the air, it will absorb moisture; as water is absorbed from the atmos

phere, the boiling point of the brake fluid will decrease and the braking performance will be seriously impaired. For this reason use a hermet ically sealed 1 L or 0.5 L brake fluid container. Firmly close the cap of the brake fluid container after use.

3. When fresh fluid has come to flow out from the

vinyl tube, tighten the bleeder screw.

NOTE: This change from existing to fresh fluid can be judged by change in colour of fluid that flows out.

3 (4)

4 (3)

( ): RH drive vehicles

AC608770

4. Repeat above steps for other bleeder screws.

Page 43

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-19

MASTER CYLINDER BLEEDING <VEHICLES WITHOUT ABS>

The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier (When brake fluid is not contained in the mas ter cylinder).

1. Fill the reservoir with brake fluid.

2. Keep the brake pedal depressed.

AC608769

3. Have another person cover the master cylinder outlet with a finger.

4. With the outlet still closed, release the brake pedal.

5. Repeat steps 2 − 4 three or four times to fill the inside of the master cylinder with brake fluid.

HBB SYSTEM AIR BLEEDING <VEHICLES WITH ABS>

1. Air bleeding from front brake system Turn the ignition switch to the LOCK (OFF) position. Bleed air from the front brake calipers (right and left) by pumping the brake pedal.

2. Air bleeding from rear brake system

CAUTION

• If too much brake fluid is drained at a time, the accumulator pressure may be dropped abnormally. So limit drain amount at a time to 100 cm3 or less, and check that the pump motor stops per one air-bleeding.

• If the brake fluid level in the reservoir has been dropped, air may enter the pump motor accidentally. To avoid this, always maintain the brake fluid between the MIN and MAX marks.

While the ignition switch is turned ON and the brake pedal is depressed, bleed air from the right and left rear brake calipers.

A16. CHECK BATTERY ELECTROLYTE LEVEL

M6020201700577

CAUTION

• If the battery fluid is below the LOWER

LEVEL, the battery could explode in using.

• If the battery fluid is over the UPPER LEVEL, leakage could result.

Thermometer

Hydrometer

Battery fluid

AC504567

1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.

2. Use a hydrometer and thermometer to check the specific gravity of the battery fluid.

Standard value: 1.220 − 1.290 (electrolyte temperature 20

° C)

3. The specific gravity of the battery fluid varies with the temperature, so use the following formula to calculate the specific gravity for 20

° C. Use the calculated value to determine whether or not the specific gravity is satisfactory.

D20 = (t - 20) × 0.0007 + Dt D20: Specific gravity converted to a value for

electrolyte temperature of 20

° C.

t: Electrolyte temperature at the time of meas-

urement

Dt: Actual specific gravity

Page 44

2-20

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

A17. CHECK INJECTION NOZZLE [IF DARK SMOKE IS EXHAUSTED OR ENGINE POWER IS LOW] <4M40>

M6020201800080

FUEL INJECTION INITIAL PRESSURE CHECK

AK500622 AB

1. Install the injection nozzle to a nozzle tester.

2. Move the lever of the nozzle tester 2 − 3 times to inject fuel and to bleed the air.

3. Gently press down the lever of the nozzle tester, and take a reading of the indication value on the pressure gauge at the point where the needle slowly rises and then suddenly drops.

Standard value (Fuel injection initial pressure): 14,710 − 15,690 kPa

4. If the fuel injection initial pressure is outside the standard value, disassembly the nozzle holder to clean it, and the change the thickness of the shim to adjust the fuel injection initial pressure.

NOTE: When the shim thickness is increased by

0.1 mm, the fuel injection initial pressure increases by approximately 1,177

−

2,157 kPa.

1. Move the lever of the nozzle tester rapidly (4 − 6 times per second) to eject the fuel continuously. Check to be sure that the injection spray comes out evenly in a cone shape (injection spray comes out evenly in a cone shape (injection spray angle

° ). The injection spray patterns shown in the

is 0 illustration.

a. Injection angle is tool large b. Bias

c. Intermittent fuel injection

AK500624

2. Check to be sure that no fuel drips after injection is completed.

3. If there are any drips, disassemble the nozzle, clean it and reinspect, or replace the nozzle.

NOZZLE FUEL-TIGHT CHECK

INJECTION SPRAY CONDITION CHECK

ABC

AK500623 AB

AK500625 AB

1. Gently raise the lever of the nozzle tester until the pressure inside the nozzle (value displayed on pressure gauge) becomes 12,750

− 13,730 kPa, and after holding this pressure for approximately 10 seconds, check to be sure that there are no fuel leaks from the nozzle.

2. If there are any leaks, disassemble the injection nozzle, clean it and re-inspect, or replace the nozzle.

Page 45

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-21

A18. REPLACE FUEL FILTER

M6020201900582

<6G7> SHORT WHEELBASE

1. Remove the front scuff plate (R.H.) and outer seat belt (front) anchor bolt (R.H.), and then turn the floor carpet.

Floor carpet

Service hole cover

2. Remove the service hole cover.

Fuel tank suction hose

Fuel tank pump module assembly connector

AC609842

7. Install the retainer plate to the fuel tank and tighten the mounting nuts.

8. Connect the fuel tank pump module assembly connector, fuel tank suction hose, fuel high-pressure tube.

Fuel tank pump module assembly

Fuel high-pressure tube

Quick connector

3 mm

AC703276

CAUTION

After connecting the fuel high-pressure tube, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.

9. Install the service hole cover.

10.Spread the floor carpet, ant then install the front scuff plate (R.H.) and outer seat belt (front) anchor bolt (R.H.).

Fuel high-pressure tube

AC703247

3. Disconnect the fuel tank pump module assembly connector, fuel suction hose, fuel high-pressure tube.

4. Remove the mounting nuts and retainer plate, and remove the fuel tank pump module assembly from the service hole.

FUEL PUMP MODULE

Fuel tank

Fuel tank filter assembly

Packing

pump assembly

AC703246

5. Replace the fuel tank filter assembly and packing with a new one.

6. Install the fuel tank pump module assembly to the fuel tank through the service hole.

LONG WHEELBASE

1. Tumble the second seat (R.H.).

Service hole cover (upper side)

Second seat (R.H.)

2. Remove the service hole cover (upper side).

3. Remove the service hole cover (lower side).

AC609845

Service hole cover (lower side)

AC609846

Page 46

2-22

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

Fuel high-pressure tube

Fuel tank pump module assembly connector

Fuel tank suction hose

AC703272

4. Disconnect the fuel tank pump module assembly connector, fuel tank suction hose, fuel high-pressure tube.

5. Remove the mounting nuts and retainer plate, and remove the fuel pump module assembly from the service hole.

FUEL PUMP MODULE

Fuel tank

Fuel tank filter assembly

pump assembly

CAUTION

After connecting the fuel high-pressure tube, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.

10.Install the service hole cover (lower side).

11.Install the service hole cover (upper side).

12.Restore the second seat (R.H.).

<4M4>

1. Remove the fuel tank cap to release the pressure inside the fuel tank.

<4M40>

<4M41>

Fuel filter assembly

AC610457

Packing

AC703246

6. Replace the fuel tank filter assembly and packing with a new one.

7. Install the fuel tank pump module assembly to the fuel tank through the service hole.

8. Install the retainer plate to the fuel tank and tighten the mounting nuts.

9. Connect the fuel tank pump module assembly connector, fuel tank suction hose, fuel high-pressure tube.

Fuel tank pump module assembly

Fuel high-pressure tube

Quick connector

3 mm

AC703276

Fuel filter assembly

AC608826

2. Disconnect the connector and the fuel hose, and then remove the fuel filter assembly from the bracket.

3. Remove the water level sensor.

AC609422

4. Use an oil filter wrench to remove the fuel filter cartridge from the fuel filter pump body.

Page 47

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

2-23

5. Install a new filter, and bleed the air from fuel line. <4M40>

Hand pump

Air plug

Fuel filter assembly

AC610095

(1) Loosen the Air plug. (2) Cover the circumference of the air plug

with cloth and use a hand pump repeatedly until no bubbles come out of the air plug hole.

(3) Replace the air plug and O-ring with a new one. Tighten the air plug to the specified torque.

Tightening torque: 6.0 ± 1.0 N⋅ m

(4) Repeat until the hand pump operation becomes stiff.

<4M41>

<4M40>

Hand pump

Fuel filter assembly

Water level sensor

AC610094

1. Loosen the water level sensor.

2. After water is evacuated by using a hand pump, tighten the water level sensor to the specified torque.

Tightening torque: 2.5 ± 0.5 N⋅ m

<4M41>

Hand pump

Battery

Fuel feed hose

AC608827

(1) Connect the all fuel feed hose to the fuel filter, and pump the hand pump until the hand pump becomes stiff.

REMOVAL OF WATER FROM THE FUEL FILTER

Water is in the fuel filter cartridge when fuel filter indicator lamp illuminates. Evacuate water by the following procedures.

Battery

Drain plug

AC608828

1. Loosen the drain plug.

2. After water is evacuated by using an hand pump, tighten the drain plug.

WATER LEVEL SENSOR CHECK

AC609849

Float

1. Connect the circuit tester to the water level sensor.

2. There should be continuity when the float is raised, while there is no continuity when it is lowered.

3. Replace the water level sensor if it is faulty.

Page 48

2-24

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS UNDER THE VEHICLE

B1. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS

M6020300100342

FRONT SUSPENSION

Deterioration and sagging

Noise and oil leakage

REAR SUSPENSION

Bends and damage

Cracks, bends and dents

Noise and oil leakage

Deterioration and sagging

Bends and damage

Cracks, bends and dents

AC608833

Page 49

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS UNDER THE VEHICLE

2-25

B2. CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR DAMAGE

M6020300200349

BALL JOINTS FOR PLAY

AC502481

1. With the vehicle unladen, check the top end of tyre for the amount of movement.

2. Remove the stabilizer link from the lower arm.

3. Jack up the lower arm and move the bottom of tyre to check the amount of movement.

DUST COVER FOR DAMAGE

B3. LUBRICATE PROPELLER SHAFT WITH GREASE FITTING

M6020300300023

Front propeller shaft

AC608835

Fill the multi-purpose grease fitting of the propeller shaft joints.

B4. CHECK DRIVESHAFT BOOTS FOR DAMAGE

M6020300400343

AC608834

1. Press the lower arm ball joint cover with your finger to check that there are no cracks or damage in the lower arm ball joint cover.

2. If the lower arm ball joint cover is cracked or damaged, replace the lower arm ball joint assembly.

NOTE: If the lower arm ball joint cover is cracked or damaged, it is possible that there may also be damage to the ball joint.

3. Press the upper arm ball joint cover with your finger to check that there are no cracks or damage in the upper arm ball joint cover.

4. If the upper arm ball joint cover is cracked or damaged, replace the upper arm ball joint assembly.

NOTE: If the upper arm ball joint cover is cracked or damaged, it is possible that there may also be damage to the ball joint.

AC305661

Check the driveshaft boots for damage.

B5. CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS (Including seals and boots)

M6020300500351

AC305662

1. Move the steering wheel bit by bit to the left or right, and check to be sure that there is no play or looseness in the linkage coupling, that the installation is not loose, and that the rod or arm is not bent or damaged.

Page 50

2-26

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS UNDER THE VEHICLE

B7. CHECK GEAR OIL LEVEL IN TRANSFER CASE (4WD)

M6020300700236

Filler plug hole

AC608838

2. Check to be sure that the seal and boot of the ball joint are correctly installed (in the correct position), and that they are not damaged.

3. Check tie-rod end lock nut for looseness. If lock nut is loose, adjust toe-in and then tighten lock nut to the specified torque.

Tightening torque: 93 ± 15 N⋅ m

B6. CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION

M6020300600206

Filler plug hole

Transmission oil

Filler plug

AC604825

Transfer oil

Filler plug

AC604825

1. Remove the filler plug.

2. Check that oil level is up to the lower edge of the filler plug hole.

3. Check that the oil is not noticeably dirty.

4. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

B8. CHANGE GEAR OIL IN MANUAL TRANSMISSION

M6020300800244

Filler plug

1. Remove the filler plug.

2. Check that oil level is up to the lower edge of the filler plug hole.

3. Check that the oil is not noticeably dirty.

4. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

Drain plug

AC604827

1. Remove the oil filler plug.

2. Remove the drain plug and drain the oil.

3. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

4. Fill with specified oil till the level comes to the lower portion of oil filler plug hole.

Specified transmission oil:

Gear oil API classification GL-4 SAE 75W−

85W

Quantity: 3.2 L

5. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

Page 51

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS UNDER THE VEHICLE

B9. CHANGE GEAR OIL IN TRANSFER CASE (4WD)

M6020300900252

2-27

Gear oil

Filler plug

Drain plug

AC604828

1. Remove the filler plug.

2. Remove the drain plug and drain the oil.

3. Tighten the drain plug to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

4. Fill with specified oil till the level comes to the lower portion of oil filler plug hole.

Specified transfer oil:

Gear oil API classification GL-4 SAE 75W− 85W

Quantity: 2.8 L

5. Tighten the oil filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

B10. CHECK GEAR OIL LEVEL IN FRONT AND REAR DIFFERENTIAL

M6020301000315

FRONT DIFFERENTIAL

1. Remove the under cover and filler plug.

Upper limit

Lower limit

5 mm

AC102739

2. Check that gear oil level is not 5 mm below the bottom of filler plug hole.

3. Tighten the filler plug to the specified torque.

Tightening torque : 50 ± 10 N⋅ m

B11. CHANGE GEAR OIL IN FRONT AND REAR DIFFERENTIAL

M6020301100356

<Front>

Filler plug

Drain plug

<Rear>

Filler plug

Drain plug

AC608839

FRONT DIFFERENTIAL

1. Remove the under cover and filler plug.

2. Remove the drain plug and drain oil.

3. Tighten the drain plug to the specified torque

Tightening torque : 65 ± 5 N⋅ m

Gear oil

Upper limit

Lower limit

8 mm

AC102739AB

2. Check that gear oil level is not 8 mm below the bottom of filler plug hole

3. Tighten the filler plug to the specified torque.

Tightening torque : 50 ± 10 N⋅ m

REAR DIFFERENTIAL

1. Remove the filler plug.

4. Add the oil until the level comes to the lower portion of the filler plug hole.

Specified lubricant: Gear oil API classification GL-5 or higher Above 10° C: SAE 90 Below 10° C: SAE 80W Quantity: 1.15 L

5. Tighten the filler plug to the specified torque.

Tightening torque : 50 ± 10 N⋅ m

REAR DIFFERENTIAL

1. Remove the filler plug.

2. Remove the drain plug and drain oil.

3. Tighten the drain plug to the specified torque.

Tightening torque : 65 ± 5 N⋅ m

Page 52

2-28

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE VEHICLE

4. Add the oil until the level comes to the lower portion of the filler plug hole.

Specified lubricant : Gear oil API classification GL-5 or higher Above 10° C: SAE 90 Below 10° C: SAE 80W Quantity: 1.6 L

5. Tighten the filler plug to the specified torque.

Tightening torque : 50 ± 10 N⋅ m

OPERATIONS INSIDE THE VEHICLE

C1. CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY

M6020400100509

BRAKE PEDAL FREE PLAY <VEHICLES WITH ABS>

1. Turn the ignition switch ON, and fully accumulate the brake fluid in the HBB accumulator.

NOTE: If the brake fluid is not fully accumulated in the accumulator, the pump motor will start to run. When the accumulator is fully accumulated, the pump motor stops. When the brake fluid is accu mulated in the accumulator, the pump motor does not run.

B12. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE INSTALLATION

M6020301200331

1. Confirm that the exhaust pipe does not interfere with any body components.

2. Check the exhaust pipe for damage by stones, etc.

3. Start the engine and check for gas leaks from the exhaust pipe connections.

• Brake pedal height

• Installation position of the stop lamp switch, etc.

BRAKE PEDAL FREE PLAY <VEHICLES WITHOUT ABS>

AC606585

2. Operate the pedal by hand, and check that the pedal stroke (free play) meets the standard value at the point where resistance is felt.

Standard value (B): 3 mm or less

3. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary:

• Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod

1. Turn the ignition switch to the "LOCK" (OFF) position, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range.

Standard value (B): 3 − 8 mm

2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary:

• Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod

• Brake pedal height

• Installation position of the stop lamp switch, etc.

Page 53

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE VEHICLE

2-29

CLEARANCE BETWEEN BRAKE PEDAL AND FLOORBOARD

1. Turn up the carpet etc. under the brake pedal.

AC606587

2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floorboard.

Standard value (C): <Short wheelbase, Long wheelbase-2800, 3000> 85 mm or more <Long wheelbase-3200, 3800> 80 mm or more

3. If the clearance is outside the standard value, check for air trapped in the brake line and thickness of the disc brake pad.

4. Return the carpet, etc.

CAUTION

Do not push in the master cylinder pushrod at this time, otherwise the clutch will not operate properly.

Clutch switch

Pushrod

Locking nut

12 ± 3 N·m

Setting nut

AC704095

4. If the clutch pedal height is not within the standard value, loosen the setting nut and the locking nut (vehicles with auto-cruise control) to adjust the clutch pedal height to the standard value and move the pushrod and the clutch switch (vehicles with auto-cruise control).

5. If the clutch pedal clevis pin play is not within the standard value, loosen the setting nut and move the pushrod to adjust.

Clutch pedal free play

CLUTCH PEDAL CHECK AND ADJUSTMENT

1. Turn back the carpet etc. under the clutch pedal.

Clutch pedal height

2. Measure the clutch pedal height. If the height is outside the standard value, go to step 4.

Standard value (A): <LHD> 202.7 − 205.7 mm <RHD> 195.7 − 198.7 mm

3. Measure the clutch pedal clevis pin play. If the play is outside the standard value, go to Step 5.

Standard value (B): 1 − 3 mm

Clutch pedal clevis pin play

AC604551

Distance between the clutch pedal and the floorboard when the clutch is disengaged

AC604553

6. After the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the floorboard when the clutch is disengaged are within the standard value ranges.

Standard value (C): 4 − 13 mm Standard value (D): <LHD> 125 mm or more <RHD> 120 mm or more

Page 54

2-30

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS INSIDE THE VEHICLE

7. If the measured free play and distance do not agree with the standard value ranges, it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch.

8. Reinstall the carpet, etc.

C2. CHECK PARKING BRAKE LEVER STROKE AND PLAY

M6020400200540

1. Pull the parking brake lever with a force of approx. 200 N and count the number of notches.

Standard value: 6 − 7 notches

2. If the parking brake lever stroke is not the standard value, adjust as described below.

Cable rod

Adjusting nut

AC608399

(1) Remove the cup holder, and then loosen the

adjusting nut to move it to the cable rod end so that the cable will be free.

(2) Remove the rear wheels.

(3) Remove the adjustment hole plug of the rear

brake backing plate <Short wheelbase, Long wheelbase-2800, 3000> or the rear brake disc <Long wheelbase-3200, 3800>, and then use a flat-tip screwdriver to turn the adjuster in the direction of the arrow (the direction which expands the shoe) so that the disc will not rotate.

(4) Return the adjuster six notches <Short

wheelbase, Long wheelbase-2800, 3000> or eight notches <Long wheelbase-3200, 3800> in the direction opposite to the direction of the arrow.

CAUTION

If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag.

(5) Turn the adjusting nut to adjust the parking

brake lever stroke to the standard value. After adjusting, check that there is no space between the adjusting nut and the parking brake lever.

(6) Release the parking brake and turn the rear

wheels to check that the rear brakes are not dragging.

C3. REPLACE AIR PURIFIER FILTER

M6020400300280

Adjuster assembly

Brake disc

Backing plate

AC604648

Adjuster assembly

AC604649

AC608840

1. Remove the glove box.

2. Loosen the two screw as shown to replace the air purifier filter.

3. Install the glove box.

Page 55

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS OUTSIDE THE VEHICLE

2-31

D1. CHECK WHEEL ALIGNMENT

M6020500100487

FRONT WHEEL ALIGNMENT

Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, wheels, and tires should be serviced to nor mal condition before measuring wheel alignment.

TOE-IN

Standard value: At the centre of tyre tread: 0 − 5 mm Toe angle (per wheel): 0 ° 00’ − 0 ° 12’

Clip

Lock nut

AC603507

Inner wheels

Outer wheels (reference)

Short wheelbase 36° 49' ± 1° 30'

Long wheelbase 36° 01' ± 1° 30'

Short wheelbase 32° 06'

Long wheelbase 32° 18'

CAMBER, CASTER AND KINGPIN INCLINATION

Standard value:

Item Standard value

Camber 0° 00' ± 0° 30'*

Caster Short

wheelbase

Long wheelbase

Kingpin inclination 11° 30'

NOTE: *: Difference between right and left wheels must be less than 30'

3° 39' ± 1° 00'*

3° 31' ± 1° 00'*

1. Adjust the toe-in by undoing the clip and lock nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions).

NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle.

2. Install the clip and tighten the lock nut to the specified torque.

Tightening torque: 93 ± 15 N⋅ m

3. Confirm that the toe-in is at the standard value.

AC306798

4. Use a turning radius gauge to check that the steering angle is at the standard value.

Standard value:

Compensator

AC603508

NOTE: For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge by using a compen sator.

CAMBER AND CASTER REFERENCE TABLE

Vehicles centre

Outside of vehicles

AC603509

Page 56

2-32

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS OUTSIDE THE VEHICLE

1. Adjust the camber and caster until they meets the standard value by turning the lower arm camber adjusting bolt.

Front side adjust bolt scale

Direction A

Rear side adjust bolt scale

Direction B

0˚ 53'

0˚ 40'

0˚ 26'

1˚ 06'

0˚ 13'

0˚ 00'

–0˚ 13'

–0˚ 26'

–0˚ 40'

–0˚ 53'

–1˚ 06'

Direction B

2. How to read this table (example). If the camber difference 0

° 36' and the caster difference is

− 0° 13' by comparing the measurement value with

the standard value, rotate the front adjusting cam by 1.5 graduations and the rear adjusting cam by

2.5 graduations to the "B" direction.

–1

–2

–3

–4

–5

–0˚ 36'

–1

–2

–0˚ 29'

–3

–0˚ 22'

–4

–0˚ 15'

–5

–0˚ 07'

0˚ 36'

0˚ 29'

0˚ 22'

0˚ 15'

0˚ 07'

0˚ 00'

Direction A

: Caster angle : Camber angle

AC702880

NOTE: Solid lines show caster, broken lines show camber.

REAR WHEEL ALIGNMENT

1. The rear suspension, wheel and tires must be serviced to normal condition before measuring the wheel alignment.

2. Measure the wheel alignment with the vehicle parked on a level surface.

CAMBER

Standard value: 0° 00' ± 30' (difference between right and left wheels must be less than 30')

Compensator

ACX00712AD

NOTE: For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge by using a compen sator.

If camber is not within the standard value, adjust by following procedures.

Page 57

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS OUTSIDE THE VEHICLE

2. Remove the brake disc from the front hub.

Adjusting bolt

2-33

Lower arm

AC603223AB

1. Adjust by turning the adjusting bolt of the lower arm.

Left wheel: Turning clockwise (+) camber Right wheel: Turning clockwise (-) camber

2. After adjusting the camber, the toe-in should be adjusted.

TOE-IN

Standard value: At the centre of tyre tread: 3 ± 3 mm Toe angle (per wheel): 0° 06' ± 0° 06'

If toe-in is not within the standard value, adjust as follows.

1. Be sure to adjust the camber before making toe adjustment.

Toe control arm

AC602402

3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction.

Limit : 0 mm

4. If the play exceeds the limit value, disassemble hub knuckle to check each component. If the front hub bearing is faulty, replace the front hub assembly.

<Rear>

1. Remove the rear brake assembly and remove the brake disc while holding it with wires to prevent it from falling.

Adjusting bolt

AC603222AB

2. Adjust by turning the adjusting bolt (toe control arm mounting bolt which faces the inside of the body).

Left wheel: Turning clockwise (+) toe-in Right wheel: Turning clockwise (-) toe-in

D2. CHECK FRONT AND REAR WHEEL BEARINGS FOR PLAY

M6020500900041

<Front>

1. Remove the caliper assembly and suspend it with a wire.

ACX01084AC

2. Fit the dial gauge as shown in the diagram and move the hub in the axial direction to measure the play.

Limit : 0 mm

3. If the play exceeds the limit, replace the rear hub assembly.

Page 58

2-34

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS OUTSIDE THE VEHICLE

D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300351

Hydraulic brake booster (HBB)

Rear disc brake

Front disc brake

1. Check entire circumference and length of hoses and pipes.

2. Check all clamps for tightness and connections for leakage.

D4. CHECK BRAKE PADS AND DISCS FOR WEAR

M6020500400507

AC102396

1. Check the brake pad thickness through the caliper body check port.

Standard value:

Item Brake pad

AC608397

Limit

thickness

Front Short wheelbase,

10.0 mm 2.0 mm Long wheelbase-2800, 3000

Long

11.5 mm 2.0 mm wheelbase-3200, 3800

Rear Short wheelbase,

10.0 mm 2.0 mm Long wheelbase-2800, 3000

Long

10.0 mm 2.0 mm wheelbase-3200, 3800

2. When the thickness is less than the limit, always replace the pads at an axle set.

ACX00668

Page 59

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS OUTSIDE THE VEHICLE

3. Using a micrometer, measure disc thickness at eight positions, approximately 45

° apart and 10

mm in from the outer edge of the disc.

Standard value:

Item Brake disc

Limit

thickness

2-35

Front Short wheelbase,

26.0 mm 24.4 mm Long wheelbase-2800, 3000

Long

28.0 mm 26.0 mm wheelbase-3200, 3800

Rear Short wheelbase,

22.0 mm 20.4 mm Long wheelbase-2800, 3000

Long

18.0 mm 16.0 mm wheelbase-3200, 3800

4. If the disc thickness is less than the limits, replace it with a new one.

BRAKE DISC RUN-OUT CHECK

1. Remove the brake assembly, and then hold it with wire.

ACX00708

2. Measure the thickness of the brake lining at several places.

Standard value:

<Short wheelbase, Long wheelbase-2800,

3000> 3.0 mm

<Long wheelbase-3200, 3800> 4.0 mm

Limit: 1.0 mm

3. If the thickness of the brake lining has worn down to the limit value or more, replace the shoe and lining assemblies on both sides of the vehicle.

BRAKE DISC INSIDE DIAMETER CHECK

1. Remove the brake disc.

ACX00669

2. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.

Limit: 0.06 mm or less

D5. CHECK BRAKE SHOE LININGS AND DISCS FOR WEAR

M6020500500311

BRAKE LINING THICKNESS CHECK

1. Remove the brake disc.

ACX00709

2. Measure the inside diameter of the brake disc in two places or more.

Standard value:

<Short wheelbase, Long wheelbase-2800,

3000> 199.0 mm

<Long wheelbase-3200, 3800> 210.0 mm

Limit:

<Short wheelbase, Long wheelbase-2800,

3000> 200.0 mm

<Long wheelbase-3200, 3800> 211.0 mm

3. If the inside of the brake disc has worn down to the limit value or more, of if it is excessively worn on one side, replace the brake disc.

Page 60

2-36

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS OUTSIDE THE VEHICLE

D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION

M6020500600352

<Petrol-powered vehicles>

Fuel injector

<Diesel-powered vehicles>

Fuel injector assembly

Fuel tank assembly

1. Check entire circumference and length of hoses and pipes.

AC609411

2. Check all clamps for tightness and connections for leakage.

Page 61

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

2-37

E1. CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION

M6020600100439

1. Drive the vehicle until the A/T fluid temperature reaches the normal temperature (70

NOTE: Use M.U.T.-III. measure the A/T fluid temperature.

Fluid level (mm)

-10

-20

-30

-40 40 60 80

NOTE: Check the fluid level referring to the characteristics chart shown if it takes some time to reach the normal operation temperature of A/T

−

fluid (70

80°C).

2. Park the vehicle on a level surface.

3. Move the selector lever to all positions to fully charge the torque converter and the fluid lines with A/T fluid, and then move the selector lever to the P position.

4. After wiping away any dirt from around the oil level gauge, pull out the oil level gauge and check the level of A/T fluid.

NOTE: If the A/T fluid has a burnt smell, or if it has become very contaminated or dirty, it means that the A/T fluid has become contaminated by minute particles form bushings (metal) or worn parts. In such a case, the transmission needs to be over hauled and the A/T fluid cooler line needs to be flushed out.

− 80° C)

Oil level gauge

AC100600

HOT

5. Check that the A/T fluid level is between the HOT marks on the oil level gauge. If the A/T fluid level is too low, add more A/T fluid until the level reaches between the HOT marks.

A/T fluid: DIA QUEEN ATF SP III

NOTE: If the A/T fluid level is too low, the oil pump draws air into the system along with the A/T fluid, and air bubbles will thus from in the fluid circuit. This will cause a drop in fluid pressure and cause the shift points to change and the clutches and brakes to slip. If the A/T fluid level is too high, the gear will churn the A/T fluid and cause bubbles to develop, which can then cause the same prob

lems as when the A/T fluid is too low. In either case, the air bubbles can cause overheating and oxidation of the A/T fluid, and also prevent the valves, clutches and brakes from operating nor

mally. In addition, if bubbles develop in the A/T fluid, the A/T fluid can overflow from the transmis sion vent holes and be mistaken for leaks.

6. Securely re-insert the oil level gauge.

E2. CHANGE AUTOMATIC TRANSMISSION FLUID

M6020600200511

SPECIFICATIONS

Automatic transmission fluid

DIA QUEEN ATF SP III 9.7 L V4A5A,

Quantity Remarks

V5A5A

CHANGE PROCEDURE

If you have an A/T fluid changer, use the A/T fluid changer to flush the A/T fluid. If you do not have an A/T fluid changer, follow the procedure given below.

AC000846

ACX01184

1. Remove the hose shown in the illustration which allows the A/T fluid to flow from the A/T fluid cooler to the transmission.

Page 62

2-38

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

CAUTION

The engine should be stopped within one minute of it being started. If the A/T fluid has all been dis charged before this, stop the engine at that point.

2. Start the engine and discharge the A/T fluid.

Driving conditions: N range, idling

Discharge amount: Approx. 3.5 L

ACX01185

3. Remove the drain plug at the bottom of the transmission case to drain out the remaining A/T fluid.

Discharge amount: Approx. 2.0 L

4. Install the drain plug with a gasket in between, and tighten it to the specified torque.

Tightening torque: 32 ± 2 N⋅ m

CAUTION

Stop pouring in the A/T fluid once 5.5 L has been poured in.

5. Pour the new A/T fluid in through the oil filler tube.

Amount to add: Approx. 5.5 L

6. Repeat the operation in step 2.

7. Pour in new A/T fluid through the oil filler tube.

Amount to add: Approx. 3.5 L

NOTE: Carry out steps 2 and 7 so that at least 8.0 L has been discharged from the cooler hose. After this, discharge a small quantity of A/T fluid and check for contamination. If the A/T fluid is contam inated, repeat steps 6 and 7.

8. Connect the hose which was disconnected in step 1, and then securely re-insert the oil level gauge.

9. Start the engine, and let it run at idle for 1 − 2

minutes.

10.Move the selector lever to all positions once, and then return it to the P position.

AC000846

11.Check that the A/T fluid level on the oil level gauge is at the COLD mark. if it is not up to this mark, add more A/T fluid.

12.Drive the vehicle until the A/T fluid temperature reaches the normal temperature (70

− 80° C), and

then re check the A/T fluid level.

NOTE: The COLD mark is for reference only; the HOT marks should be used as the standard for judgment.

NOTE: Use M.U.T.-III. measure the A/T fluid temperature.

Fluid level (mm)

NOTE: Check the fluid level referring to the char-

-10

-20

-30

-40 40 60 80

Oil level gauge

AC100600

HOT

acteristics chart shown if it takes some time until reaching the normal operation temperature of A/T fluid (70

−

80°C.)

13.When A/T fluid is under the specified level, top up A/T fluid. When A/T fluid is over the specified level, drain the excessive A/T fluid from the drain plug to adjust A/T fluid level to the specified level.

14.Securely insert the oil level gauge into the oil filler tube.

ACX01184

Page 63

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

2-39

AUTOMATIC TRANSMISSION FLUID COOLER LINE FLUSHING

AC607505

1. Remove the hose shown in the illustration which allows the A/T fluid to flow from the A/T fluid cooler to the transmission.

CAUTION

The engine should be stopped within one minute of it being started. If the A/T fluid has all been dis charged before this, stop the engine at that point.

2. Start the engine and discharge the A/T fluid.

3. Remove the engine oil pan drain plug to drain engine oil.

Engine oil pan side

Engine oil pan drain plug gasket

AC603625

4. Install a new engine oil pan drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the engine oil pan drain plug to the specified torque.

Tightening torque: 39 ± 5 N⋅ m

Driving conditions: N range, idling

Discharge amount: Approx. 3.5 L

CAUTION

Stop pouring in the A/T fluid once 3.5 L has been poured in.

3. Pour in new A/T fluid through the oil filler tube.

Amount to add: Approx. 3.5 L

4. Repeat the operation in step 2 and 3.

NOTE: Carry out steps 2 and 3 so that at least 8.0 L has been discharged from the cooler hose. After this, discharge a small quantity of A/T fluid and check for contamination. If the A/T fluid is contam inated, repeat steps 2 and 3.

5. Carry out the procedure in "CHANGE PROCEDURE" from step 2 onwards.

E3. CHANGE ENGINE OIL

M6020600300637

<6G7>

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80

CAUTION

Use care as engine oil could be hot.

2. Remove the engine oil filler cap.

° C to 90° C.

AC609878

5. Refill with specified quantity of engine oil.

Specified Engine Oil

• ACEA classification: "For service A1/B1, A3/B3, A3/B4 or A5/B5"

• API classification: "For service SG" or

Total quantity (Includes volume inside oil fil-

higher

ter): 4.9 L

6. Install the engine oil filler cap.

7. Check engine oil level.

<4M4>

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80

° C.

CAUTION

Use care as engine oil could be hot.

2. Remove the engine oil filler cap.

3. Remove the drain plug to drain engine oil.

° C to 90

Page 64

2-40

Engine oil pan side

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

Engine oil pan drain plug gasket

AC609879

MB991610

AC609881

4. Install a new engine oil pan drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the engine oil pan drain plug to the specified torque.

Tightening torque: 39 ± 5 N⋅ m

AC609880

5. Refill with specified quantity of engine oil.

Specified Engine Oil

• ACEA classification: "For service A1/B1, A3/B3, A3/B4 or A5/B5"

• API classification: "For service CD" or higher

Total quantity (Includes volume inside oil filter

and oil cooler): 9.8 L

6. Install the engine oil filler cap.

7. Check engine oil level.

E4. REPLACE ENGINE OIL FILTER

M6020600400526

<6G7>

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80

° C.

CAUTION

Use care as engine oil could be hot.

2. Remove the oil filler cap.

3. Remove the engine oil pan drain plug to drain engine oil.

4. Remove the under cover.

° C to 90

5. Use the special tool oil filter wrench (MB991610) to remove the oil filter.

6. Clean the filter bracket side mounting surface.

O-ring

AC609882

7. Apply a small amount of engine oil to the O-ring of the new oil filter.

Oil filter number: MD352626

8. Once the O-ring of the oil filter is touching the flange, use the special tool oil filter wrench (MB991610) to tighten to the specified torque.

Tightening torque: Approximately 3/4 turn

± 2 N⋅ m)

(14

9. Install the engine oil pan drain plug and refill the engine oil.

10.Race the engine 2−3 times, and check to be sure that no engine oil leaks from installation section of the oil filter.

11.Install the under cover.

<4M4>

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80

° C.

CAUTION

Use care as engine oil could be hot.

2. Remove the oil filler cap.

3. Remove the engine oil pan drain plug to drain engine oil.

4. Remove the under cover.

° C to 90

Page 65

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

MH061590

AC609883

5. Use the special tool oil filter wrench (MH061590) to remove the engine oil filter.

6. Clean the filter bracket side mounting surface.

2-41

E5. CHECK ENGINE IDLING SPEED AND CO CONCENTRATION

M6020600500545

IDLE SPEED AND MIXTURE CHECK AND ADJUSTMENT <6G72>

1. Before inspection, set the vehicle to the pre-inspection condition.

Diagnosis connector

MB991910

O-ring

AC609884

7. Apply a small amount of engine oil to the O-ring of the new engine oil filter.

Oil filter number: <4M40> ME013307 <4M41> 1230A046

8. Once the O-ring of the oil filter is touching the flange, use the special tool (MH061590) to tighten to the specified torque.

Tightening torque: <4M40> Approximately 5/8 turn (20 ± 2 N⋅ m) <4M41> Approximately 3/4 turn (20 ± 2 N⋅ m)

9. Install the engine oil pan drain plug and refill the engine oil.

10.Race the engine 2− 3 times, and check to be sure that no engine oil leaks from installation section of the oil filter.

11.Install the under cover.

MB991824

MB991827

AC608423

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

No. 1 Ignition coil

AK602718

3. Set a timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

4. Start the engine and let it run at idle.

5. Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC

NOTE: The ignition timing may fluctuate within

± 7°

. This is normal.

Page 66

2-42

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

NOTE: In higher altitude, the ignition timing is more advanced than the standard value by approximately 5

NOTE: Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.

6. Check the idle speed.

Standard value: 700 ± 100 r/min

NOTE: The idle speed is controlled automatically by the idle speed control system.

NOTE: When using the M.U.T.-III, select item No. 02 and take a reading of the idle speed.

7. If the idle speed is outside the standard value, inspect the MPI system (Refer to WORKSHOP MANUAL GROUP 13

− Troubleshooting).

8. Set the CO tester.

9. Check the CO contents at idle.

Standard value: 1.0 ± 0.5%

MB991824

MB991827

Diagnosis connector

MB991910

AC608423

MD998299

Mixture adjusting screw

Air flow sensor

AK603844 AB

10.If there is deviation from the standard value, set the idle mixture to the specified value by adjusting the mixture adjusting screw (variable resister).

Use the special tool MAS screwdriver (MD998299) to turn the mixture adjusting screw.

11.Remove the timing light.

12.Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-III.

1. Before inspection, set the vehicle to the pre-inspection condition.

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

No. 1 Ignition coil

AK602718

3. Set a timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

4. Start the engine and let it run at idle.

5. Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC

NOTE: The ignition timing may fluctuate within ± 7°. This is normal.

NOTE: In higher altitude, the ignition timing is more advanced than the standard value by approximately 5

NOTE: Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.

6. Check the idle speed.

Standard value: 700 ± 100 r/min

NOTE: The idle speed is controlled automatically by the idle speed control system.

Page 67

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

NOTE: When using the, M.U.T.-III select item No. 02 and take a reading of the idle speed.

7. If the idle speed is outside the standard value, inspect the MPI system (Refer to WORKSHOP MANUAL GROUP 13

− Troubleshooting).

8. Run the engine at 2,500 r/min for 2 minutes.

9. Set the CO, HC tester.

10.Check the CO contents and the HC contents at idle.

Standard value

CO contents: 0.5% or less HC contents: 100 ppm or less

11.If there is a deviation from the standard value, inspect the MPI system (Refer to WORKSHOP MANUAL GROUP 13

− Troubleshooting).

12.Remove the timing light.

13.Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-III.

IDLE SPEED AND MIXTURE CHECK AND ADJUSTMENT <6G75>

1. Before inspection, set the vehicle to the pre-inspection condition.

Diagnosis connector

MB991910

MB991824

2-43

No.1 Ignition coil

AK602719

3. Set a timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

4. Start the engine and let it run at idle.

5. Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC

NOTE: The ignition timing may fluctuate within ± 7°. This is normal.

NOTE: In higher altitude, the ignition timing is more advanced than the standard value by approximately 5

NOTE: Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.

6. Check the idle speed.

Standard value: 700 ± 100 r/min

NOTE: The idle speed is controlled automatically by the idle speed control system.

NOTE: When using the M.U.T.-III, select item No. 02 and take a reading of the idle speed.

7. If the idle speed is outside the standard value, inspect the MPI system (Refer to WORKSHOP MANUAL GROUP 13

− Troubleshooting).

8. Run the engine at 2,500 r/min for 2 minutes.

9. Set the CO, HC tester.

10.Check the CO contents and the HC contents at idle.

Standard value CO contents: 0.5% or less HC contents: 100 ppm or less

MB991827

AC608423

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

11.If there is a deviation from the standard value, inspect the MPI system (Refer to WORKSHOP MANUAL GROUP 13

− Troubleshooting).

12.Remove the timing light.

13.Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-III.

Page 68

2-44

PERIODIC INSPECTION AND MAINTENANCE

IDLE SPEED CHECK <4M40>

OPERATIONS AFTER ENGINE IS WARMED UP

NOTE: Check that the injection timing is normal.

1. Before inspection, set the vehicle to the pre-inspection condition.

CAUTION

When the speedometer is connected to the injection pipe, the pipe mounting clamps should all be removed.

Speedometer

Injection nozzle

AK603857AB

2. Connect the speedometer to the injection nozzle ore the injection pipe.

3. Start the engine and run it at idle.

4. Check the idle speed.

Standard value: 750 ± 100 r/min

Acceleratorlever

Locking nut

Idle speed adjusting screw

AK603858

5. If not within the standard value, loosen idle adjusting screw lock nut and adjust the idle speed by rotating adjusting screw. And tighten locking nut.

IDLE SPEED CHECK <4M41>

1. Before inspection, set the vehicle to the pre-inspection condition.

Diagnosis connector

MB991910

MB991824

MB991827

AC608423

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

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

4. Check the idle speed.

Standard value: 700 ± 30 r/min

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

− Troubleshooting).

6. Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-III.

E6. CHECK EXHAUST GAS RECIRCULATION (EGR) SYSTEM

M6020600800375

EGR VALVE CHECK <6G72>

1. Remove the exhaust gas recirculation valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly.

AKX00348

Page 69

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

2. Connect a hand vacuum pump to the exhaust gas recirculation valve.

3. Apply 67 kPa of vacuum, and check that the vacuum is maintained.

4. Apply a vacuum and check the passage of air by blowing through one side of the exhaust gas recirculation passage.

Vacuum Passage of air

2-45

5.6 kPa or less Air is not blown out

29 kPa or more Air is blown out

5. Replace the gasket, and tighten to the specified torque.

Tightening torque: 23 ± 6 N⋅ m

EGR CONTROL SOLENOID VALVE CHECK <6G72>

NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.

1. Disconnect the vacuum hose from the solenoid valve.

2. Disconnect the harness connector.

Battery

AK100015

3. Connect a hand vacuum pump to nipple (A) of the solenoid valve.

4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the exhaust gas recirculation control solenoid valve and without applying voltage.

Battery voltage

Nipple condition

Normal condition

Applied Open Vacuum leaks

B nipple

Vacuum maintained

closed

Not applied Open Vacuum leaks

AK100016

5. Measure the resistance between the terminals of the solenoid valve.

Standard value: 29 − 35 Ω (at 20° C)

EGR VALVE (STEPPER MOTOR) CHECK <6G75>

Checking the Operation Sound

Exhaust gas recirculation valve (stepper motor)

AK602173AB

1. Check that the operation sound of the stepper motor can be heard from the exhaust gas recirculation valve when the ignition switch is turned ON (without starting the engine).

2. If the operation sound cannot be heard, inspect the drive circuit of the stepper motor.

NOTE: If the circuit is normal, either the stepper motor or the engine-ECU <M/T> or engine-A/T-ECU <A/T> may have failed.

Checking the Coil Resistance

1. Remove the exhaust gas recirculation valve.

123 456

C nipple closed

Vacuum maintained

123 456

AK200805

Page 70

2-46

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

2. Measure the resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the exhaust gas recirculation valve.

Standard value: 20 − 24 Ω (at 20° C)

3. Measure the resistance between terminal No. 5 and either terminal No. 6 or terminal No. 4 of the connector at the exhaust gas recirculation valve.

Standard value: 20 − 24 Ω (at 20° C)

4. Using a new gasket, install the exhaust gas recirculation valve by tightening its mounting bolts to the specified torque.

Tightening Torque: 23 ± 6 N⋅ m

Operation Check

123 456

Exhaust gas recirculation valve

AK502151

1. Remove the exhaust gas recirculation valve.

2. Attach a test wiring harness (special tool MB991658) to the connector at the exhaust gas recirculation valve.

CAUTION

Connecting battery voltage to the exhaust gas recirculation valve for a long term could damage the coil.

4. Connect terminals No. 1 and No. 3 to the negative

−) terminal of the battery, in order to test whether

( the stepper motor vibrates (with a slight shudder), indicating that the stepper motor is operating.

CAUTION

Connecting battery voltage to the exhaust gas recirculation valve for a long term could damage the coil.

MB991658

Battery

AK304039

5. Connect the positive (+) terminal of the battery to terminal No. 5.

6. Connect terminals No. 4 and No. 6 to the negative

−) terminal of the battery, in order to test whether

( the stepper motor vibrates (with a slight shudder), indicating that the stepper motor is operating.

7. If a vibration can be felt during the test, the stepper motor is normal.

8. Using a new gasket, install the exhaust gas recirculation valve by tightening its mounting bolts to the specified torque.

Tightening torque: 23 ± 6 N⋅ m

Cleaning the EGR Valve

CAUTION

Do not use a solvent or detergent, which could enter the motor and cause it to malfunction.

MB991658

Battery

AK302886

3. Connect the positive (+) terminal of the battery to terminal No. 2.

1. Remove the exhaust gas recirculation valve and check that the exhaust gas recirculation valve is not stuck or clogged with carbon deposits. Use a wire brush to clean the valve if necessary.

2. Using a new gasket, install the exhaust gas recirculation valve by tightening its mounting bolts to the specified torque.

Tightening torque: 23 ± 6 N⋅ m

Page 71

PERIODIC INSPECTION AND MAINTENANCE

OPERATIONS AFTER ENGINE IS WARMED UP

2-47

EGR VALVE (DC MOTOR) CHECK <4M41> System Check

Exhaust gas recircilation valve (Exhaust gas recircilation sensor built)

AK602177AB

1. Connect the M.U.T.-III to the diagnosis connector to check for date list item No. 16.

2. Start the engine, and warm up the engine.

3. Raise the engine speed gradually, and make sure that the valve open degree changes from 0 % to 100 %.

Operation Check

3. A tester is to be connected between the terminal No.1 and No. 2.

4. Connect the terminal (+) of the power supply with the terminal No. 6 of the exhaust gas recirculation valve connector, and connect the terminal (

−) of the power supply with the terminal No. 4. Confirm the exhaust gas recirculation valve is opened.

NOTE: At this time, the power supply voltage is to be 5 V. When the valve is not opened, increase the voltage 1 V by 1 V. For each voltage, current is to be applied within 5 seconds. Once the valve is opened, the voltage is not to be increased any more.

Valve open

AK500442

123 456

Exhaust gas recirculation valve

AK500440

1. Remove the exhaust gas recirculation valve.

5 V

123 456

5 V

AK603110

2. Connect the terminal (+) of the sensor power supply (5 V) with the terminal No. 3 of the exhaust gas recirculation valve connector, and connect the terminal (

−) of the sensor power supply (5 V) with

the terminal No. 2.

5. Confirm the voltage is changed between the terminal No. 1 and No. 2 together with the exhaust gas recirculation valve opening movement.

6. By the voltage changed, the DC is recognized as being normal.

7. Use a new gasket and tighten the installation bolt to the tightening torque.

Tightening torque: 48 ± 6 N⋅ m

Cleaning the EGR Valve

CAUTION

Do not use a solvent or detergent, which could enter the motor and cause it to malfunction.

1. Remove the exhaust gas recirculation valve and check that the exhaust gas recirculation valve is not stuck or clogged with carbon deposits. Use a wire brush to clean the valve if necessary.

2. Using a new gasket, install the exhaust gas recirculation valve by tightening its mounting bolts to the specified torque.

Tightening torque: 48 ± 6 N⋅ m

Page 72

2-48

PERIODIC INSPECTION AND MAINTENANCE

OTHERS

F1. CHECK BODY CONDITION FOR DAMAGE

M6020700100254

1. Check underbody coating for damage.

2. Check body painting for damage.

F2. CHECK THE COMMON RAIL ENGINE (small injection quantity learning)

M6020700400017

LEARNING PROCEDURE

Diagnosis connector

MB991910

MB991824

• Power steering: Static state

3. Select SPECIAL FUNCTION from the function menu.

4. Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNCTION menu to execute learning.

CAUTION

• If the vehicle conditions go out of the learning conditions during idling, learning is inter

rupted.

• To reexecute learning, the ignition switch must once be turned off.

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

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

F3. ROAD TEST

M6020700200325

MB991827

AC608423

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

• 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>

AC609417

Drive the vehicle and check for conditions.

1. Check free play of steering wheel.

2. Check efficiency of service brakes and parking brakes system.

3. Check driveability of engine.

4. Check condition of instruments, gauges indicators, exterior lamps, heater and ventilators.

5. Check abnormal noise of each part.

6. Check the tyres for wear and for the correct air

pressure.

Mitsubishi PAJERO IV Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL

HOW TO USE THIS MANUAL

PRECAUTIONS BEFORE SERVICE

PROTECTING THE VEHICLE

DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS

REMOVAL AND DISASSEMBLY

SPECIAL TOOLS

PARTS TO BE REPLACED

TUBES AND OTHER RUBBER PARTS

LUBRICANTS

PARTS

BRAKE FLUID

SERVICING THE ELECTRICAL SYSTEM

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

PRE-INSPECTION CONDITION

VEHICLE WASHING

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

IN ORDER TO PREVENT VEHICLES FROM FIRE

ENGINE OILS

HEALTH WARNING

RECOMMENDED PRECAUTIONS

NOTES CONCERNING ENTRIES

PAINTWORK TERMS

FIRST STEP

1. CONNECTION OF DARK CURRENT CONNECTOR

CONNECTING PROCEDURE

2. WRAP FILM

BODY

REMOVAL PROCEDURE

3. EXTERIOR

UNDER HOOD

6. ENGINE OIL LEVEL

9. WASHER FLUID LEVEL

10. BATTERY CONDITION AND CONNECTIONS

11. POWER STEERING FLUID LEVEL

UNDER VEHICLE

12. ELECTRICAL WIRING

13. TYRE AND SPARE TYRE PRESSURES

14. SUSPENSION SYSTEM

BEFORE ROAD TEST

REMOVE FRONT SPRING RESTRAINTS

15. STEERING LINKAGE AND SPLIT PINS

16. UNDER BODY

17. SEAT ADJUSTERS AND SEATBACK LATCHES

18. INHIBITOR SWITCH

19. IDLE CONTROL KNOB

20. INSTRUMENT PANEL CONTROLS

21. METERS, GAUGES, WARNING LAMPS AND INDICATION LAMPS

23. WIPERS AND WASHERS

24. OPERATION OF SERVICE BRAKES AND PARKING BRAKES

25. CLUTCH OPERATION

27. ENGINE PERFORMANCE AND EXHAUST GAS

ROAD TEST

28. TRANSMISSION IN ALL RANGES

29. BRAKES

30. STEERING CONTROL

AFTER ROAD TEST

31. VIBRATION AND RATTLES

32. ELECTRICAL EQUIPMENT

33. IDLE SPEED

34. IGNITION TIMING

35. RADIATOR COOLANT LEVEL

36. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD

38. AUTOMATIC TRANSMISSION FLUID LEVEL

FINAL STEPS

41. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE

42. HEADLAMP AIMING

43. EQUIPMENT

44. EXTERIOR AND INTERIOR

45. OWNER INSTRUCTIONS

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

OPERATIONS INSIDE THE ENGINE COMPARTMENT

A1. CHECK V-BELT FOR CRACKS, FRAYING, WEAR, AND ADJUST ITS TENSION

V-BELT CONDITION

A2. CHECK VACUUM PUMP OIL HOSE FOR DAMAGE

A3. CHECK INTAKE AIR HOSE AND TURBOCHARGER OIL HOSE FOR DAMAGE