Mitsubishi PAJERO IV Service Manual
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
0-2
HOW TO USE THIS MANUAL
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.
-
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
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
AD
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
AC
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
AB
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.
-
-
NOTES
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
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
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.
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
PRE-DELIVERY INSPECTION
PAINTWORK TERMS
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.
1-6
PRE-DELIVERY INSPECTION
FIRST STEP
FIRST STEP
1. CONNECTION OF DARK CURRENT CONNECTOR
M6010300100170
CONNECTING PROCEDURE
Storage connector
Relay box
AC608836
AB
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
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
AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are
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.
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
AB
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
AB
7. Verify that the rear doors can't be opened by the
inner door handle when the child protection knob
at the end of the door is shifted to the "LOCK"
position with the inside lock plunger raised.
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
AB
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.
PRE-DELIVERY INSPECTION
UNDER HOOD
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".
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
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.
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.
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.
AB
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
AC
1-14
27. ENGINE PERFORMANCE AND EXHAUST GAS
M6010800100023
PRE-DELIVERY INSPECTION
ROAD TEST
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
AB
2. Automatic transmission
(1) Make sure shift indicator lines up properly in
all ranges.
(2) Depress the accelerator completely to check
that the manual kickdown is operating
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.
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
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
AD
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
AB
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
AC
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.
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