Mitsubishi PAJERO IV Service Manual
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Mitsubishi PAJERO IV Service Manual

Mitsubishi PAJERO IV Service Manual

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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 . . . . . . . . . . . .
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBES AND OTHER RUBBER PARTS . . .
GROUP 0
GENERAL
CONTENTS
0-2
0-2
0-2
0-2
0-2
0-3
0-3
0-3
0-3
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . .
0-1
0-3
0-3
0-4
0-4
0-4
0-4
0-4
0-5
0-5

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February 13, 2025

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Summary of Contents for Mitsubishi PAJERO IV

  • Page 1 GROUP 0 GENERAL CONTENTS HOW TO USE THIS MANUAL..LUBRICANTS ..... . . BRAKE FLUID ..... . . PRECAUTIONS BEFORE SERVICE.

  • Page 2: How To Use This Manual

    GENERAL HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL M6000000100026 This manual contains Pre-delivery inspection and Group 0 and 1 have the contents for all vehicle mod- Periodic inspection and maintenance. els, and Group 2 has contents for the relevant vehi- cle models.

  • Page 3: Special Tools

    GENERAL PRECAUTIONS BEFORE SERVICE SPECIAL TOOLS When replacing parts, use MITSUBISHI genuine parts. M6001000400031 TUBES AND OTHER RUBBER PARTS M6001000700021 AC305593 If other tools are substituted for the special tools to do service of repair work, there is the danger that...

  • Page 4: Vehicle Washing

    GENERAL PRECAUTIONS BEFORE SERVICE SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING M6001001000081 M6001001300123 CAUTION Before connecting or disconnecting the negative (-) cable, be sure to turn off the ignition switch Approximately and the lighting switch. (If this is not done, there 40 cm or more is the possibility of semiconductor parts being damaged.)

  • Page 5: Engine Oils

    GENERAL PRECAUTIONS BEFORE SERVICE Connect the M.U.T.-III to the diagnosis connector as Other precautions: shown in the illustration. • Avoid prolonged and repeated contact with oils, particularly used engine oils. IN ORDER TO PREVENT VEHICLES • Wear protective clothing, including impervious FROM FIRE gloves where practicable.
  • Page 6 NOTES...

  • Page 7: Table Of Contents

    GROUP 1 PRE-DELIVERY INSPECTION CONTENTS NOTES CONCERNING ENTRIES . . . 15. STEERING LINKAGE AND SPLIT PINS 1-11 16. UNDER BODY....1-11 PAINTWORK TERMS .
  • Page 8 AFTER ROAD TEST ... . . 1-15 39. ENGINE, TRANSMISSION, STEERING GEAR BOX AND DIFFERENTIAL FOR LEAKS 1-16 33. IDLE SPEED ..... 1-15 40.

  • Page 9: Notes Concerning Entries

    PRE-DELIVERY INSPECTION NOTES CONCERNING ENTRIES 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.
  • Page 10 PRE-DELIVERY INSPECTION NOTES CONCERNING ENTRIES TABLE OF PRE-DELIVERY INSPECTION Model Chassis number Engine number Before Road Test Distance Travelled Seat adjusters and seat back latches Owner Choke system and inhibitor switch Date of inspection Idle control knob Place of inspection Instrument panel controls Inspector Meters, gauges, warning lamps and indication lamps...

  • Page 11: Paintwork Terms

    PRE-DELIVERY INSPECTION PAINTWORK TERMS PAINTWORK TERMS M6010200100140 Term Definition Remark Blister A raised bubble in the paint (from the base or the undercoat) caused by abnormal moisture. The bubble may contain either water or air. Change in tone The colour tone of the painted surface is not Including wrong colour, discoloration and uniform.

  • Page 12: First Step

    PRE-DELIVERY INSPECTION FIRST STEP FIRST STEP 1. CONNECTION OF DARK CURRENT Press down the storage connector. CONNECTOR M6010300100170 CONNECTING PROCEDURE Storage connector Relay box AC608836 AB BODY 2. WRAP FILM To protect the exterior finish of vehicles prior to dealer delivery, a protective coating is used. The M6010400100100 coating is a thin white resin film.

  • Page 13: Removal Procedure

    PRE-DELIVERY INSPECTION BODY REMOVAL PROCEDURE Peel off slowly from corners keeping parallel to the body. When the body temperature is high, lower it to 50ºC or less by Wrap film removal sprinkling water so that adhesive may not remain on the body. Water washing Wipe-off by kerosene or white gasoline, etc.

  • Page 14: Exterior

    PRE-DELIVERY INSPECTION BODY 3. EXTERIOR 6. Verify that all doors can be locked by the lock buttons. M6010400200226 1. Visually inspect the entire exterior. NOTE: Adjust and lubricate the door latches, strikers (1) Paint condition and locks as required. (2) Corrosion, scratches (3) Bent edges, dented panels 2.

  • Page 15: Under Hood

    PRE-DELIVERY INSPECTION UNDER HOOD UNDER HOOD 6. ENGINE OIL LEVEL 9. WASHER FLUID LEVEL M6010500100196 M6010500400108 AC702169 AC305614 Check that the oil level is between "MAX" and "MIN". Check the fluid level; if it is low, replenish the washer If it is at or below MIN, add the necessary amount of fluid.

  • Page 16: Electrical Wiring

    1-10 PRE-DELIVERY INSPECTION UNDER VEHICLE 2. If the fluid is added, start the engine and turn the 1. Each electrical wiring harness and connector steering wheel from stop to stop several times to (1) Check each harness to be correctly routed expel air from the system.

  • Page 17: Steering Linkage And Split Pins

    1-11 PRE-DELIVERY INSPECTION BEFORE ROAD TEST REMOVE FRONT SPRING RESTRAINTS 1. Steering linkage retaining nuts and split pins Check visually and by feel that the steering CAUTION linkage retaining nuts are correctly tightened and It is very important that these restraints must be the split pins are correctly installed.

  • Page 18: Instrument Panel Controls

    1-12 PRE-DELIVERY INSPECTION BEFORE ROAD TEST 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 21. METERS, GAUGES, WARNING AC305626 LAMPS AND INDICATION LAMPS 2.

  • Page 19: Operation Of Service Brakes And Parking Brakes

    1-13 PRE-DELIVERY INSPECTION BEFORE ROAD TEST 24. OPERATION OF SERVICE BRAKES 1. Check the clutch operation in all driving ranges. AND PARKING BRAKES 2. Check the pedal to floorboard clearance when the clutch is just disengaged. M6010700800274 Depress the brake pedal with approximately 500 N force AC305628...

  • Page 20: Road Test

    1-14 PRE-DELIVERY INSPECTION ROAD TEST ROAD TEST 27. ENGINE PERFORMANCE AND EXHAUST GAS M6010800100023 Button AC305635 2. Automatic transmission (1) Make sure shift indicator lines up properly in AC305633 all ranges. 1. Engine performance (2) Depress the accelerator completely to check that the manual kickdown is operating Check the engine for proper performance and correctly.

  • Page 21: Vibration And Rattles

    1-15 PRE-DELIVERY INSPECTION AFTER ROAD TEST 31. VIBRATION AND RATTLES 1. Radio M6010800500021 Tune the radio to a local broadcasting station and 1. Locate squeaks, rattles and unusual vibrations. check the following: 2. Verify that no noise occurs from the engine, (1) Operate the volume, tone, balance and fader transmission, axle and body.

  • Page 22: Automatic Transmission Fluid

    1-16 PRE-DELIVERY INSPECTION AFTER ROAD TEST 36. HOSES, FLUID LINES AND 38. AUTOMATIC TRANSMISSION FLUID CONNECTIONS LOCATED UNDER HOOD LEVEL M6010900400203 M6010900600230 CAUTION Remember that the air conditioner system is under pressure. AC005861AD 1. Remove the dipstick and check the fluid level. 2.

  • Page 23: Headlamp Aiming

    1-17 PRE-DELIVERY INSPECTION FINAL STEPS NOTE: For the specified oil, refer to GROUP 2, 1. Check all hoses, fluid lines and connections for Periodic Inspection and Maintenance. leaks. 2. Check all hoses and fluid lines for proper routing 41. HOSES, FLUID LINES AND away from sharp edges and moving components.
  • Page 24 NOTES...

  • Page 25: Continued On Next Page

    GROUP 2 PERIODIC INSPECTION AND MAINTENANCE CONTENTS PERIODIC INSPECTION AND A17. CHECK INJECTION NOZZLE [IF DARK MAINTENANCE SCHEDULE ..SMOKE IS EXHAUSTED OR ENGINE POWER IS LOW] <4M40> ..... 2-20 OPERATIONS INSIDE THE ENGINE A18.
  • Page 26 OPERATIONS INSIDE THE VEHICLE 2-28 OPERATIONS AFTER ENGINE IS WARMED UP ....2-37 C1. CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY ....2-28 E1.

  • Page 27: Periodic Inspection And Maintenance Schedule

    PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE 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 Maintenance interval operation OPERATIONS INSIDE THE ENGINE COMPARTMENT...
  • Page 28 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation A12 Replace air cleaner element Replace Norma Every 40,000 km or every 2 l usage years Severe More frequently usage A13 Check fluid level in brake reservoir Inspection First 1,000 km, thereafter every 10,000 km or every 6 months...
  • Page 29 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation B11 Change gear oil in front and rear differential Change Norma Every 80,000 km or every 4 l usage years Severe Every 40,000 km or every 2 usage years B12 Check exhaust pipe connections for gas...
  • Page 30 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation Replace engine oil filter <6G7> Replace Norma Every 15,000 km or every 12 l usage months Severe Every 5,000 km usage Replace engine oil filter <4M40> Replace Norma Every 10,000 km or every 12...

  • Page 31: Operations Inside The Engine Compartment

    PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT OPERATIONS INSIDE THE ENGINE COMPARTMENT A1. CHECK V-BELT FOR CRACKS, <4M41> Item When When When FRAYING, WEAR, AND ADJUST ITS checked adjusted replaced TENSION Vibration 150 − 201 164 − 190 190 −...
  • Page 32 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT NOTE: This operation is to temporarily set the CAUTION preset data such as the belt specifications, • The temperature of the surface of the belt because if the measurement is taken without input should be as close as possible to normal tem- of the belt specifications, conversion to tension perature.

  • Page 33: A2. Check Vacuum Pump Oil Hose For Damage

    PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT <WHEN USING THE TENSION GAUGE> 4. Tighten the nut for alternator pivot bolt. Tightening torque: 47 ± 9 N⋅ m Water pump 5. Tighten the alternator fixing nut. pulley Tension Tightening torque: 24 ± 4 N⋅ m gauge 6.

  • Page 34: A5. Check Operation Of Crankcase Emission Control System

    2-10 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A5. CHECK OPERATION OF 1. Remove the ventilation hose from the PCV (Positive crankcase ventilation) valve. CRANKCASE EMISSION CONTROL 2. Remove the PCV valve from the rocker cover. SYSTEM 3. Reinstall the PCV valve at the ventilation hose. M6020200700347 BREATHER HOSE 4.

  • Page 35: A6. Replace Spark Plugs

    2-11 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT PCV VALVE CHECK 5. Move the rocker arms on the No. 1 and No. 4 cylinders up and down by hand to determine <6G72> which cylinder has its piston at the top dead centre on the compression stroke.
  • Page 36 2-12 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT VALVE CLEARANCE CHECK AND ADJUSTMENT <4M40> Intake Intake Intake Intake No. 1 No. 2 No. 3 No. 4 NOTE: Perform the valve clearance check and adjustment at the engine cold state. 1.
  • Page 37 2-13 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT 2. Use the special tool fuel injection pipe wrench Identification (MB992188) to remove the fuel injection pipe. size mark 3. Remove the rocker cover. CAUTION The crankshaft should always be turned in a clockwise direction.
  • 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 MB992188 bend. AC609910 AB Thickness MB992046 gauge...

  • Page 39: A8. Check Radiator Hoses For Damage And Proper Connection

    2-15 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A10. CHANGE ENGINE COOLANT NOTE: During the test, the engine speed and the fuel pressure is 2, 000 r/min and 180MPa for 20 seconds M6020201100683 1. Stop the engine after it is fully warmed up. respectively.
  • Page 40 2-16 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION <4M40> 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.

  • Page 41: A11. Check Air Cleaner Element For Clogging And Damage

    2-17 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A11. CHECK AIR CLEANER ELEMENT 8. Securely tighten the drain plug of the radiator. FOR CLOGGING AND DAMAGE 9. Reinstall the radiator condenser tank. M6020201200475 CAUTION Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze.

  • Page 42: A13. Check Fluid Level In Brake Reservoir

    2-18 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A13. CHECK FLUID LEVEL IN BRAKE A15. CHANGE BRAKE FLUID RESERVOIR M6020201600581 M6020202200230 <Vehicles with ABS> AC305659 1. Remove the cap of the bleeder screw, connect a AC608832 AC vinyl tube, and place its other end in a receptacle. <Vehicles without ABS>...

  • Page 43: A16. Check Battery Electrolyte Level

    2-19 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT MASTER CYLINDER BLEEDING <VEHI- A16. CHECK BATTERY ELECTROLYTE CLES WITHOUT ABS> LEVEL M6020201700577 The master cylinder used has no check valve, so if CAUTION bleeding is carried out by the following procedure, •...

  • Page 44: A17. Check Injection Nozzle [If Dark Smoke Is Exhausted Or Engine Power Is Low] <4M40

    2-20 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A17. CHECK INJECTION NOZZLE [IF 1. Move the lever of the nozzle tester rapidly (4 − 6 times per second) to eject the fuel continuously. DARK SMOKE IS EXHAUSTED OR Check to be sure that the injection spray comes ENGINE POWER IS LOW] <4M40>...

  • Page 45: A18. Replace Fuel Filter

    2-21 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A18. REPLACE FUEL FILTER 7. Install the retainer plate to the fuel tank and tighten the mounting nuts. M6020201900582 <6G7> 8. Connect the fuel tank pump module assembly SHORT WHEELBASE connector, fuel tank suction hose, fuel high-pressure tube.
  • Page 46 2-22 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION Fuel high-pressure After connecting the fuel high-pressure tube, 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).
  • Page 47 2-23 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT <4M40> 5. Install a new filter, and bleed the air from fuel line. <4M40> Hand pump Hand pump Air plug Fuel filter assembly Water level sensor Fuel filter assembly AC610094AB AC610095AB 1.

  • Page 48: Operations Under The Vehicle

    2-24 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE OPERATIONS UNDER THE VEHICLE B1. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS M6020300100342 FRONT SUSPENSION Deterioration and sagging Noise and oil leakage Bends and damage Cracks, bends and dents REAR SUSPENSION Noise and oil leakage Deterioration...

  • Page 49: B2. Check Suspension Arm Ball Joints For Play, And Dust Covers For Damage

    2-25 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE B2. CHECK SUSPENSION ARM BALL B3. LUBRICATE PROPELLER SHAFT JOINTS FOR PLAY, AND DUST COVERS WITH GREASE FITTING M6020300300023 FOR DAMAGE M6020300200349 BALL JOINTS FOR PLAY Front propeller shaft AC608835 AB Fill the multi-purpose grease fitting of the propeller shaft joints.

  • Page 50: B6. Check Gear Oil Level In Manual Transmission

    2-26 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE B7. CHECK GEAR OIL LEVEL IN TRANSFER CASE (4WD) M6020300700236 Filler plug hole AC608838 AB 2. Check to be sure that the seal and boot of the ball Filler plug Transfer oil joint are correctly installed (in the correct AC604825AC position), and that they are not damaged.

  • Page 51: B9. Change Gear Oil In Transfer Case (4Wd)

    2-27 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE B9. CHANGE GEAR OIL IN TRANSFER CASE (4WD) M6020300900252 Gear oil Filler plug Upper limit Lower 5 mm limit Drain plug AC102739 AG 2. Check that gear oil level is not 5 mm below the bottom of filler plug hole.

  • Page 52: B12. Check Exhaust Pipe Connections For Gas Leakage, And Check Pipe Installation

    2-28 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE B12. CHECK EXHAUST PIPE 4. Add the oil until the level comes to the lower portion of the filler plug hole. CONNECTIONS FOR GAS LEAKAGE, Specified lubricant : AND CHECK PIPE INSTALLATION Gear oil API classification GL-5 or higher M6020301200331 1.
  • Page 53 2-29 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE CLEARANCE BETWEEN BRAKE PEDAL CAUTION AND FLOORBOARD Do not push in the master cylinder pushrod at this time, otherwise the clutch will not operate 1. Turn up the carpet etc. under the brake pedal. properly.

  • Page 54: C2. Check Parking Brake Lever Stroke And Play

    2-30 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE 7. If the measured free play and distance do not (3) Remove the adjustment hole plug of the rear agree with the standard value ranges, it is brake backing plate <Short wheelbase, Long probably the result of either air in the hydraulic wheelbase-2800, 3000>...

  • Page 55: Operations Outside The Vehicle

    2-31 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE OPERATIONS OUTSIDE THE VEHICLE D1. CHECK WHEEL ALIGNMENT Inner Short wheelbase 36° 49' ± 1° 30' M6020500100487 wheels FRONT WHEEL ALIGNMENT Long wheelbase 36° 01' ± 1° 30' Measure wheel alignment with alignment equipment Outer Short wheelbase 32°...

  • Page 56: Rear Wheel Alignment

    2-32 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE 1. Adjust the camber and caster until they meets the 2. How to read this table (example). If the camber standard value by turning the lower arm camber difference 0° 36' and the caster difference is adjusting bolt.

  • Page 57: D2. Check Front And Rear Wheel Bearings For Play

    2-33 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE 2. Remove the brake disc from the front hub. Adjusting bolt Lower arm AC603223AB 1. Adjust by turning the adjusting bolt of the lower arm. AC602402AB Left wheel: Turning clockwise (+) camber Right wheel: Turning clockwise (-) camber 3.

  • Page 58: D3. Check Brake Hoses And Pipes For Leakage

    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 AC608397AB 1. Check entire circumference and length of hoses Item Brake pad Limit and pipes.

  • Page 59: D5. Check Brake Shoe Linings And Discs For Wear

    2-35 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 Front Short wheelbase, 26.0 mm 24.4 mm...

  • Page 60: D6. Check Fuel Hoses And Pipes For Leakage Or Deterioration

    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 tank assembly Fuel injector <Diesel-powered vehicles> Fuel injector assembly Fuel tank assembly AC609411 1. Check entire circumference and length of hoses 2.

  • Page 61: Warmed Up

    2-37 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP OPERATIONS AFTER ENGINE IS WARMED UP E1. CHECK FLUID LEVEL IN AUTOMATIC 5. Check that the A/T fluid level is between the HOT marks on the oil level gauge. If the A/T fluid level TRANSMISSION is too low, add more A/T fluid until the level M6020600100439...
  • Page 62 2-38 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP 8. Connect the hose which was disconnected in step CAUTION 1, and then securely re-insert the oil level gauge. The engine should be stopped within one minute of it being started. If the A/T fluid has all been dis- 9.

  • Page 63: E3. Change Engine Oil

    2-39 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP AUTOMATIC TRANSMISSION FLUID 3. Remove the engine oil pan drain plug to drain engine oil. COOLER LINE FLUSHING Engine oil pan side Engine oil pan drain plug gasket AC603625 AC607505AB 4.

  • Page 64: E4. Replace Engine Oil Filter

    2-40 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP Engine oil pan side MB991610 Engine oil pan drain plug gasket AC609881 AB AC609879 AB 5. Use the special tool oil filter wrench (MB991610) 4. Install a new engine oil pan drain plug gasket so to remove the oil filter.

  • Page 65: E5. Check Engine Idling Speed And Co Concentration

    2-41 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP E5. CHECK ENGINE IDLING SPEED AND CO CONCENTRATION M6020600500545 IDLE SPEED AND MIXTURE CHECK AND MH061590 ADJUSTMENT <6G72> <VEHICLES WITHOUT CATALYTIC CON- VERTER> 1. Before inspection, set the vehicle to the pre-inspection condition.
  • 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 ° Diagnosis NOTE: Wait till approximately 1 minute passes after connector the engine started, and check the ignition timing when the engine stabilized.
  • Page 67 2-43 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 −...

  • Page 68: E6. Check Exhaust Gas Recirculation (Egr) System

    2-44 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP IDLE SPEED CHECK <4M40> NOTE: Check that the injection timing is normal. Diagnosis 1. Before inspection, set the vehicle to the connector pre-inspection condition. CAUTION When the speedometer is connected to the injec- tion pipe, the pipe mounting clamps should all be MB991910 removed.
  • Page 69 2-45 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.
  • Page 70 2-46 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP 2. Measure the resistance between terminal No. 2 4. Connect terminals No. 1 and No. 3 to the negative and either terminal No. 1 or terminal No. 3 of the (−...

  • Page 71: System Check

    2-47 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP EGR VALVE (DC MOTOR) CHECK <4M41> 3. A tester is to be connected between the terminal No.1 and No. 2. System Check 4. Connect the terminal (+) of the power supply with Exhaust gas recircilation valve the terminal No.

  • Page 72: Others

    2-48 PERIODIC INSPECTION AND MAINTENANCE OTHERS OTHERS F1. CHECK BODY CONDITION FOR • Power steering: Static state DAMAGE 3. Select SPECIAL FUNCTION from the function menu. M6020700100254 1. Check underbody coating for damage. 4. Select SMALL INJECTION QUANTITY 2. Check body painting for damage. LEARNING from the SPECIAL FUNCTION menu to execute learning.

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