5a4d20z30a 08 003eng

0-1
GROUP 0
GENERAL
CONTENTS
PRECAUTIONS BEFORE SERVICE. 0-2 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3

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

PROTECTING THE VEHICLE When checking a malfunction, find the cause of the
M6001000100029 problem. If it is determined that removal and/or dis-
assembly is necessary, perform the work by following
the procedures contained in this manual.
AC305590
If there is a likelihood of damaging interior or exterior

parts during service operations, protect them with AC305592
suitable covers (such as seat covers, fender covers, If punch marks or mating marks are made to avoid
etc.). error in assembly and facilitate the assembly work,
be sure to make them in locations which will have no
DOING SERVICE WORK IN GROUPS OF detrimental effect on performance and/or appear-
TWO OR MORE MECHANICS ance. If an area having many parts, similar parts,
M6001000200026
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.
AC305283
SPECIAL TOOLS
If the service work is to be done by two or more M6001000400031
mechanics working together, all the mechanics
involved should take safety into consideration while
they work.
REMOVAL AND DISASSEMBLY

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

do service of repair work, there is the danger that
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe-
AC305591 cial tool whenever doing any work for which the use
of one is specified.
GENERAL
0-3
PARTS TO BE REPLACED LUBRICANTS
M6001000500027 M6001000800028
AC305594 AC305596
If any of the following parts are removed, they must In accordance with the instructions in this manual,
be replaced with new parts. apply the specified lubricants in the specified loca-
• Oil seals tions during assembly and installation.
• Gaskets (except rocker cover gasket)
• Packings BRAKE FLUID
M6001000900025
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
PARTS
M6001000600024
AC305285
Be careful to avoid spilling any brake fluid, because if

it adheres to the vehicle body, the paint coat might be
discoloured.
SERVICING THE ELECTRICAL SYSTEM

AC305284 M6001001000025
When replacing parts, use MITSUBISHI genuine

parts.
TUBES AND OTHER RUBBER PARTS

M6001000700021
ACX00880AD
Before replacing a component related to the electri-

cal system and before undertaking any repair proce-
dures involving the electrical system, be sure to first
disconnect the negative (-) cable from the battery in
AC305595
order to avoid damage caused by short-circuiting.
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.
0-4 GENERAL
CAUTION MULTI USE TESTER (M.U.T.-III) SUB

Before connecting or disconnecting the negative ASSEMBLY
(-) cable, be sure to turn off the ignition switch M6001001800098
and the lighting switch. (If this is not done, there Refer to the "M.U.T.-III OPERATING INSTRUC-
is the possibility of semiconductor parts being TIONS" for instructions on handling the M.U.T.-III.
damaged.) AC302297
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. 16-pin
PRE-INSPECTION CONDITION MB991910

M6001001200029
"Pre-inspection condition" refers to the condition that MB991824
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 condi-
tion.
• Engine coolant temperature: 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF MB991827 AC310120AB
• M/T: Neutral Connect the M.U.T.-III to the diagnosis connector as

• A/T: P range shown in the illustration.
VEHICLE WASHING CAUTION
M6001001300037 Turn the ignition switch to the LOCK (OFF) posi-
tion before connecting or disconnecting the
M.U.T.-III.
Approx. IN ORDER TO PREVENT VEHICLES

40 cm FROM FIRE
M6001001500020
"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-
ACX00881AE
tions/repairs that may be carried out which involve
If high-pressure car-washing equipment or steam the electrical or fuel systems, MUST be carried out in
car-washing equipment is used to wash the vehicle, accordance with MMC's information/Instructions".
be sure to note the following information in order to
avoid damage to plastic components, etc.
• Spray nozzle distance: Approx. 40 cm or more
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
30 sec.
GENERAL
0-5
ENGINE OILS • Do not put oily rags in pockets, the use of overalls
M6001001600027 without pockets will avoid this.
Health Warning • Do not wear heavily soiled clothing and
Prolonged and repeated contact with mineral oil will oil-impregnated foot-wear. Overalls must be
result in the removal of natural fats from the skin, cleaned regularly and kept separately from per-
leading to dryness, irritation and dermatitis. In addi- sonal clothing.
tion, used engine oil contains potentially harmful con- • Where there is a risk of eye contact, eye protec-
taminants which may cause skin cancer. Adequate tion should be worn, for example, chemical gog-
means of skin protection and washing facilities must gles or face shields; in addition an eye wash
be provided. facility should be provided.
• Obtain First Aid treatment immediately for open
Recommended Precautions cuts and wounds.
The most effective precaution is to adapt working • Wash regularly with soap and water to ensure all
practices which prevent, as far as practicable, the oil is removed, especially before meals (skin
risk of skin contact with mineral oils, for example by cleansers and nail brushes will help). After clean-
using enclosed systems for handling used engine oil ing, the application of preparations containing
and by degreasing components, where practicable, lanolin to replace the natural skin oils is advised.
before handling them. • Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Other precautions: • Use barrier creams, applying them before each
• Avoid prolonged and repeated contact with oils, work period, to help the removal of oil from the
particularly used engine oils. skin after work.
• Wear protective clothing, including impervious • If skin disorders develop, obtain medical advice
gloves where practicable. without delay.
• Avoid contaminating clothes, particularly under-
pants, with oil.
NOTES
1-1
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-11

13. TYRE AND SPARE TYRE
PAINTWORK TERMS . . . . . . . . . . . . 1-6 PRESSURES . . . . . . . . . . . . . . . . . . . . . . . 1-11
14. SUSPENSION SYSTEM . . . . . . . . . . . . 1-12
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-7 15. STEERING LINKAGE AND
1. CONNECTION OF DARK CURRENT SPLIT PINS . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 1-7 16. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-12
BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 BEFORE ROAD TEST . . . . . . . . . . . . 1-13

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-7 17. SEAT ADJUSTERS AND
3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-9 SEAT BACK LATCHES . . . . . . . . . . . . . . . . 1-13
4. OPERATION OF DOOR LOCKING 18. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-13
SYSTEMS AND DOOR HINGES . . . . . . . . 1-9 19. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-13
5. OPERATION OF DOOR MIRRORS, 20. INSTRUMENT PANEL CONTROLS . . . 1-13
WINDOWS AND SUNROOF . . . . . . . . . . . 1-9 21. METERS, GAUGES, WARNING
LAMPS AND INDICATION LAMPS . . . . . . . 1-13
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-10 22. AIR CONDITIONER, HEATER AND
6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-10 DEFROSTER SYSTEM. . . . . . . . . . . . . . . . 1-13
7. BRAKE MASTER CYLINDER 23. WIPERS AND WASHERS. . . . . . . . . . . 1-14
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-10 24. OPERATION OF SERVICE BRAKES
8. CLUTCH MASTER CYLINDER AND PARKING BRAKES . . . . . . . . . . . . . . 1-14
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-10 25. CLUTCH OPERATION . . . . . . . . . . . . . 1-14
9. WASHER FLUID LEVEL. . . . . . . . . . . . . 1-10 26. OPERATION OF SEAT BELTS,
10. BATTERY CONDITION AND SHOULDER BELTS AND RETRACTORS . 1-15
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-11
11. POWER STEERING FLUID LEVEL . . . 1-11 Continued on next page
12. ELECTRICAL WIRING . . . . . . . . . . . . . 1-11
1-2
ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-15 37. MANUAL TRANSMISSION AND

27. ENGINE PERFORMANCE AND TRANSFER (4WD) OIL LEVEL . . . . . . . . . . 1-17
EXHAUST GAS. . . . . . . . . . . . . . . . . . . . . . 1-15 38. AUTOMATIC TRANSMISSION
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-18
28. TRANSMISSION IN ALL RANGES. . . . 1-15
29. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-16 39. ENGINE, TRANSMISSION,
STEERING GEAR BOX AND
30. STEERING CONTROL . . . . . . . . . . . . . 1-16 DIFFERENTIAL FOR LEAKS . . . . . . . . . . . 1-18
31. VIBRATION AND RATTLES . . . . . . . . . 1-16 40. FRONT AND REAR DIFFERENTIAL
32. ELECTRICAL EQUIPMENT . . . . . . . . . 1-16 OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . 1-18
41. HOSES, FLUID LINES AND
AFTER ROAD TEST . . . . . . . . . . . . . 1-17 CONNECTIONS LOCATED UNDER
33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-17 VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-17
35. RADIATOR COOLANT LEVEL . . . . . . . 1-17
FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-19
42. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-19
CONNECTIONS LOCATED UNDER 43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-19
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 44. EXTERIOR AND INTERIOR . . . . . . . . . 1-19
45. OWNER INSTRUCTIONS . . . . . . . . . . . 1-19
PRE-DELIVERY INSPECTION
NOTES CONCERNING ENTRIES
1-3
M6010100100057
This section describes the details and the inspection methods employed for the pre-delivery inspection of
vehicles.
The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY
INSPECTION.
Inspection methods are described following the TABLE OF PRE-DELIVERY INSPECTION.
NOTE: .
1. The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in kilo-
metres (miles), date of inspection, name of person conducting the inspection, and body colour must be
completed without fail.
2. The spaces for place of inspection, and name of owner should be completed as required.
1-4 PRE-DELIVERY INSPECTION
TABLE OF PRE-DELIVERY INSPECTION
Model
Chassis number
Engine number Before Road Test
Distance Travelled km 17. Seat adjusters and seat back latches
Owner 18. Choke system and inhibitor switch
Date of inspection
19. Idle control knob
Place of inspection
20. Instrument panel controls
Inspector
21. Meters, gauges, warning lamps and indication lamps
Body colour
22. Air conditioning, heater and defroster systems
Symbols to be used 23. Wipers and washers
24. Operation of service brakes and parking brakes
Needs Needs
Good A T 25. Clutch operation
adjustment retightening
26. Operation of seat belts, shoulder belts and retractors
Needs
Needs
Needs replenishment Road Test
C L X replenishment
cleaning of lubricant,
of repair 27. Engine performance and exhaust gas
water, etc.
28. Transmission in all ranges
INSPECTION PROCEDURE
29. Brakes
First Step
30. Steering control
1. Connection of the dark current connector
31. Vibration and rattles
Body
32. Electrical equipment
2. Wrap film
3. Exterior
After Road Test
4. Operation of door locking systems and door hinges
33. Idle speed
5. Operation of door mirrors, windows and sunroof
34. Ignition timing
Under Hood
35. Radiator coolant level
6. Engine oil level
36. Hoses, fluid lines and connections located under hood
7. Brake master cylinder fluid level
37. Manual transmission and transfer (4WD) oil level
8. Clutch master cylinder fluid level
38. Automatic transmission fluid level
9. Washer fluid level
39. Engine, transmission, steering gear box and
10. Battery condition and connections differential for leaks
11. Power steering fluid level 40. Front and rear differential oil levels
12. Electrical wiring 41. Hoses, fluid lines and connections located under vehicle
Under Vehicle Final Steps
13. Tyre and spare tyre pressures 42. Headlamp aiming
14. Suspension system 43. Equipment
15. Steering linkage and split pins 44. Exterior and interior
16. Under body 45. Owner instructions
AC401525
AC306353
PAINTWORK TERMS
1-5
PAINTWORK TERMS
M6010200100032
Term Definition Remarks

Blister A raised bubble in the paint (from the base
or the undercoat) caused by abnormal
moisture. The bubble may contain either
water or air.
Change in tone The colour tone of the painted surface is not Including wrong colour, discoloration and
uniform. decoloration.
Contact mark A mark on the painted surface as a result of
contact by hands or clothing at the time of
paint application.
Crack A crack in the painted surface. Cracks may be either shallow or deep.
Dirt in paintwork Rough surface resulting from foreign
material in the paint or from dust deposited
on wet paint during painting or storage.
Filed or ground Deep scratches in sheet metal surface,
traces resulting from improper use of buffer or
sander, are not completely covered, and are
visible through paint coating.
Orange peel The painted surface has the appearance of
an orange peel.
Peeling The paint flakes off (partly or over a wide The peeling may be minor, medium, or
area). major.
Pin holes Tiny holes in the painted surface.
Runs A visible trickle of dried paint on the surface. Either undercoat or top-coat.
Scratches Scratches on the painted surface.
Shrink The painted surface "shrinks", causing
wrinkles.
Smears Spots of soot or other material deposited on Including stains and water spots.
the painted surface.
Spray mist The painted surface includes fine particles of
other paint.
Uneven lustre The lustre of the painted surface is not
uniform.
Uneven metallic The metallic dispersion of the painted
dispersion surface is not uniform.
Visibly incomplete A part of the undercoating visible.
topcoating
FIRST STEP
FIRST STEP
1. CONNECTION OF DARK CURRENT
CONNECTOR
M6010300100073
Connecting Procedure
Junction block
Storage connector
AC311576AB
Press down the storage connector.
BODY
2. WRAP FILM To protect the exterior finish of vehicles prior to
M6010400100025 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
BODY
1-7
Removal procedure
Peel off slowly from corners keeping parallel to the body. When
Wrap film removal the body temperature is high, lower it to 50ºC or less by
sprinkling water so that adhesive may not remain on the body.
Water washing
Wipe-off by kerosene or white gasoline, etc.

Cleaning of border
If it is considerably visible, use polishing compound.
Disposal of removed film: Burning is appropriate
AC306352 AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are There should be no leftover adhesive, swelling or
checked. discoloration of the paint film, or other defects.
4 Treatment of parts where film is to be Treat the defects on the parts where film is to be
reapplied. reapplied. If a solvent is used to remove leftover
adhesive, wipe off the solvent thoroughly.
5 Reapplication 1. Basically, the parts where the film is to be applied
should be the same as the film that is to be applied.
2. Apply the film from the lower portion of the body,
working upward progressively. Apply pressure using
a plastic squeegee or similar tool.
3. As necessary, cut the film at the various parts such as
windshield washer nozzles, hood and trunk lid.
CAUTION
1. Apply the film with the body at a temperature of 10 − 40°C. (Workability is good in this temperature
range.)
2. If the outside surface of the film (the side with no adhesive) is brought into direct contact with the
paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not
get folded under or otherwise make contact with the paint film.
3. Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort
should be made to prevent air bubbles from being trapped under the film by applying pressure
from the centre of the film outward toward the edges during application.
4. To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of
the film securely.
BODY
3. EXTERIOR 3. Open the door, operate the lock lever and close
M6010400200022 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.
6. Verify that all doors can be locked by the lock
buttons.
NOTE:
Adjust and lubricate the door latches, strikers and
AC305607 locks as required.
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.
NOTE:
For terms of paintwork, refer to P.1-6. Child-protection knob
AC305610 AB
4. OPERATION OF DOOR LOCKING 7. Verify that the rear doors can't be opened by the
SYSTEMS AND DOOR HINGES inner door handle when the child protection knob
M6010400300029
at the end of the door is shifted to the "LOCK"
position with the inside lock plunger raised.
CAUTION
Set the lock to the "FREE" position on child pro-
tection of both rear doors. (For four door models)
5. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF
M6010400400026
Front
AC305608 AB
AC305607
1. Door mirrors
AC210253AB
Check that the mirror operate properly.
1. Open each door to check the release mechanism 2. Door windows
and ease of operation. Close all door windows to the fully closed position
2. Close the door to check the latch and striker. to check ease of operation.
UNDER HOOD
1-9
3. Power windows 4. Slide window
Check that the door windows operate when the Close the slide window to the fully closed position
respective switches are operated. Check that to check operation.
when the lock switches are depressed, the 5. Sunroof
respective door windows can no more be opened
Close the sunroof to the fully closed position to
or closed.
check operation.
UNDER HOOD
6. ENGINE OIL LEVEL 8. CLUTCH MASTER CYLINDER FLUID
M6010500100022
LEVEL
M6010500300048
MAX
MIN
AC305611 AB
Check that the oil level is between "MAX" and "MIN". AC305613
If it is at or below MIN, add the necessary amount of Check the fluid level.
the specified engine oil referring to GROUP 2, Peri- If it is below the "MIN" mark, replenish fresh brake
odic Inspection and Maintenance P.2-3. fluid up to the "MAX" mark.
7. BRAKE MASTER CYLINDER FLUID Specified Brake Fluid: DOT4+
LEVEL 9. WASHER FLUID LEVEL
M6010500200041 M6010500400023
AC305612 AC305614
Check the fluid level. Check the fluid level; if it is low, replenish the washer
If it is below the "MIN" mark, replenish fresh brake fluid at the up to MAX mark.
fluid up to the "MAX" mark. 1. Windshield washer reservoir
Specified Brake Fluid: DOT4+ 2. Rear window washer reservoir
UNDER VEHICLE
10. BATTERY CONDITION AND 2. If the fluid is added, start the engine and turn the
CONNECTIONS steering wheel from stop to stop several times to
M6010500500020 expel air from the system.
Specified gear oil: Automatic transmission
fluid DEXRON II
12. ELECTRICAL WIRING

M6010500700024
AC305615
Inspect the battery connections. Verify that they are

tightened.
NOTE:
Do not wipe the lubricant from the battery posts and AC305617
cable clamps.
1. Each electrical wiring harness and connector
11. POWER STEERING FLUID LEVEL (1) Check each harness to be correctly routed
M6010500600027
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.
AC305616
1. Check that the fluid level is between "MAX" and

"MIN".
UNDER VEHICLE
13. TYRE AND SPARE TYRE PRESSURES 1. Tyre specification
M6010600100029 Check the correct tyre specification.
2. Tyre pressures
Adjust each tyre pressure.
NOTE:
Recommended pressure is shown on the tyre pres-
sure label.
3. Valve stem extensions
Verify that the valve stem extensions are installed
where necessary.
AC305618 4. Install the wheel covers, wheel rings and hub
caps.
UNDER VEHICLE
1-11
14. SUSPENSION SYSTEM 15. STEERING LINKAGE AND SPLIT PINS
M6010600200026 M6010600300023
AC305609 AC305604
Check to be sure that each installation bolt and nut is 1. Steering linkage retaining nuts and split pins
tightened. If split pins are used, make sure that they Check visually and by feel that the steering
are properly installed. linkage retaining nuts are correctly tightened and
1. Lower arm, Upper arm the split pins are correctly installed.
2. Stabilizer bar 2. Tie rods and relay rod
3. Strut assembly Check that the tie rods and relay rod of the
REMOVE FRONT SPRING RESTRAINTS steering linkage are not bent and that the tie rod
end lock nuts are securely tightened.
Spring 3. Steering components
restraints (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
AC305605 Check the front axle nuts and rear wheel spindle
With the vehicle correctly positioned on the nuts for split pins.
sub-frame contact points, and the suspension fully
extended, remove the rubber restraints from the front
16. UNDER BODY
M6010600400020
springs. Check under body and under body coating for dam-
CAUTION age.
It is very important that these restraints must be
removed during predelivery-inspection. Failure
to do so could cause ride and handling com-
plaints.
BEFORE ROAD TEST
BEFORE ROAD TEST

17. SEAT ADJUSTERS AND SEAT BACK 1. Check the meters and gauges are functioning
LATCHES properly.
M6010700100026 2. Check each indicator lamp and warning lamp
functions properly.
22. AIR CONDITIONER, HEATER AND

DEFROSTER SYSTEM
M6010700600021
Check the systems for proper operation.
AC305622
Check the operation of the various parts of the seats.

1. Mechanical adjusters of the seats
2. Operation of the latch for tilting the seatbacks
forward and backward.
18. INHIBITOR SWITCH AC305625
M6010701100029
On models with an automatic transmission, be sure 1. Air conditioner
the engine starts in both "P" and "N" position, and (1) Operate the air conditioner system.
does not start in other positions. (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
19. IDLE CONTROL KNOB (4) Operate the blower motor switch in all ranges.
M6010700300020
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.
20. INSTRUMENT PANEL CONTROLS

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

2. Heater and defroster
21. METERS, GAUGES, WARNING (1) After the engine has warmed up, turn on the
heater.
LAMPS AND INDICATION LAMPS
M6010700500024 (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)
AC305624
BEFORE ROAD TEST
1-13
23. WIPERS AND WASHERS
M6010700700028
AC305629
AC305627 (2) Verify correct brake pedal free play.

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

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

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

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

SHOULDER BELTS AND RETRACTORS
M6010701000022
AC305631
3. Verify correct clutch pedal free play.

NOTE: AC305632
For inspection and adjustment of the free play of

the clutch pedal, refer to GROUP 2, Periodic
1. Verify that the seat belt warning lamp operates
Inspection and Maintenance P.2-3.
properly.
2. Check all seat belts and harnesses to assure that
they connect and hold properly.
3. Lean forward to check that the shoulder
harnesses allow movement.
4. Check the condition of the belts and anchors.
5. Check for proper seat belt retraction.
ROAD TEST
27. ENGINE PERFORMANCE AND (2) Verify that no black smoking is emitted from
EXHAUST GAS the end of the exhaust pipe (diesel-powered
M6010800100023 vehicles).
28. TRANSMISSION IN ALL RANGES

M6010800200020
AC305633
1. Engine performance
AC305634
Check the engine for proper performance and
accelerator pedal for smooth operation.
1. Manual transmission
2. Exhaust system
Check the transmission in all forward ranges and
(1) Check the exhaust system components for in reverse.
gas leaks.
ROAD TEST
1-15
30. STEERING CONTROL
M6010800400024
Button
AC305635 AB
AC305636
2. Automatic transmission
(1) Make sure shift indicator lines up properly in 1. Check for excessive play or looseness.
all ranges. 2. Check the steering wheel centre.
(2) Depress the accelerator completely to check
that the manual kickdown is operating 31. VIBRATION AND RATTLES
M6010800500021
correctly. 1. Locate squeaks, rattles and unusual vibrations.
(3) Stop the vehicle on a steep incline. 2. Verify that no noise occurs from the engine,
Put the automatic transmission in "P" position transmission, axle and body.
and slowly release the service brakes to see if
"P" position lock holds. If it does not hold, the 32. ELECTRICAL EQUIPMENT
transmission requires further service. M6010800600028
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 AC305637
the transmission in "N" position, and set the
parking brakes. 1. Radio
(2) Slowly release the service brakes to see if the Tune the radio to a local broadcasting station and
parking brakes will hold. 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.
AFTER ROAD TEST
AFTER ROAD TEST

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

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

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

TRANSFER (4WD) OIL LEVEL
M6010900500103
Filler plug hole

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

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

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

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

AC305647
OIL LEVELS
M6010900800041 1. Check all hoses, fluid lines and connections for
1. Remove the filler plug. leaks.
2. Check the oil level. If the oil level is at or slightly 2. Check all hoses and fluid lines for proper routing
below the filler hole, it is in satisfactory condition. away from sharp edges and moving components.
FINAL STEPS
FINAL STEPS
42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR
M6011000100042 M6011000300046
Screen
Headlamp
Level surface
AC305648 AB AC305650
Check condition for headlamp aiming. Finally check and clean the exterior and interior.
NOTE: 1. Wash the vehicle to remove all traces of road
For headlamp aiming procedures, refer to the Work- grime and other dirt on the vehicle as a result of
shop Manual for that model. new vehicle preparations.
2. Clean exterior and interior glass surface.
43. EQUIPMENT 3. Remove all protective covers.
M6011000200049
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.
45. OWNER INSTRUCTIONS

M6011000400043
1. Verify that the owner's manual and service
booklet is in the glove box.
AC305649
2. Place the spare keys in envelope in the glove box
Check the installation of the various equipment. before delivery.
1. Floor mats
2. Spare tyre
3. Jack, jack handle and tool set
2-1
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
PERIODIC INSPECTION AND A12. CHANGE BRAKE FLUID . . . . . . . . . . 2-18

MAINTENANCE SCHEDULE . . . . . . 2-3 A13. CHECK BATTERY ELECTROLYTE
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
OPERATIONS INSIDE THE ENGINE A14. REPLACE FUEL FILTER . . . . . . . . . . 2-19
COMPARTMENT . . . . . . . . . . . . . . . . 2-6
A1. CHECK V-BELT FOR CRACKS, OPERATIONS UNDER THE
FRAYING, WEAR, AND ADJUST VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 2-21
ITS TENSION . . . . . . . . . . . . . . . . . . . . . . . 2-6 B1. CHECK SUSPENSION SYSTEM
A2. CHECK INTAKE AIR HOSE FOR FOR DAMAGE AND LOOSENESS. . . . . . . 2-21
DAMAGE (VEHICLES WITH B2. CHECK SUSPENSION ARM
TURBOCHARGER) . . . . . . . . . . . . . . . . . . 2-11 BALL JOINTS FOR PLAY, AND
A3. REPLACE ENGINE TIMING BELT DUST COVERS FOR DAMAGE . . . . . . . . . 2-22
<EXCEPT VEHICLES WITH TIMING CHAIN> 2-12 B3. CHECK DRIVE SHAFT BOOTS
A4. CHECK OPERATION OF CRANKCASE FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-22
EMISSION CONTROL SYSTEM . . . . . . . . 2-12 B4. CHECK STEERING LINKAGE FOR
A5. REPLACE SPARK PLUGS. . . . . . . . . . 2-13 DAMAGE AND LOOSE CONNECTIONS
A6. CHECK RADIATOR HOSES FOR (INCLUDING SEALS AND BOOTS) . . . . . . 2-22
DAMAGE AND PROPER CONNECTION. . 2-13 B5. CHECK GEAR OIL LEVEL IN
A7. CHECK ENGINE COOLANT LEVEL MANUAL TRANSMISSION
IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . 2-14 (include Automated manual transmission) . 2-23
A8. CHANGE ENGINE COOLANT . . . . . . . 2-14 B6. CHANGE GEAR OIL IN MANUAL
TRANSMISSION (include Automated
A9. CHECK AIR CLEANER ELEMENT
manual transmission) . . . . . . . . . . . . . . . . . 2-23
FOR CLOGGING AND DAMAGE . . . . . . . . 2-17
B7. CHECK EXHAUST PIPE CONNECTIONS
A10. REPLACE AIR CLEANER ELEMENT 2-17
FOR GAS LEAKAGE, AND CHECK PIPE
A11. CHECK FLUID LEVEL IN BRAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 2-23
RESERVOIR AND CLUTCH RESERVOIR
(for hydraulic-type clutch only) . . . . . . . . . . 2-18
Continued on next page
2-2
OPERATIONS INSIDE THE VEHICLE 2-24 OPERATIONS AFTER ENGINE IS

C1. CHECK BRAKE PEDAL AND WARMED UP . . . . . . . . . . . . . . . . . . . 2-29
CLUTCH PEDAL FOR FREE PLAY . . . . . . 2-24 E1. CHANGE ENGINE OIL . . . . . . . . . . . . . 2-29
C2. CHECK PARKING BRAKE LEVER E2. REPLACE ENGINE OIL FILTER . . . . . 2-31
STROKE AND PLAY. . . . . . . . . . . . . . . . . . 2-24 E3. CHECK ENGINE IDLING SPEED. . . . . 2-31
C3. REPLACE AIR PURIFIER FILTER. . . . 2-25
E4. CHECK CO CONCENTRATION . . . . . . 2-32
E5. CHECK VALVE CLEARANCE
OPERATIONS OUTSIDE THE (EXCEPT VEHICLES WITH AUTO-LASH
VEHICLE . . . . . . . . . . . . . . . . . . . . . . 2-25 ADJUSTER) . . . . . . . . . . . . . . . . . . . . . . . . 2-33
D1. CHECK UNEVEN TYRE WEAR. . . . . . 2-25
D2. CHECK FRONT AND REAR WHEEL OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-38
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-26 F1. CHECK BODY CONDITION FOR
D3. CHECK BRAKE HOSES AND DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
PIPES FOR LEAKAGE . . . . . . . . . . . . . . . . 2-27 F2. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-38
D4. CHECK BRAKE PADS AND DISCS
FOR WEAR. . . . . . . . . . . . . . . . . . . . . . . . . 2-28
D5. CHECK BRAKE SHOE LININGS
AND DRUMS FOR WEAR . . . . . . . . . . . . . 2-28
D6. CHECK FUEL HOSES AND PIPES
FOR LEAKAGE OR DETERIORATION . . . 2-29
PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
2-3
M6020100100542
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
•: Applicable for COLT, COLT CZ3/CZT
Maintenance item Maintenance Maintenance interval Application
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
A1 Check V-belt for cracks, fraying, wear, and Inspection Every 20,000 km or every •
adjust its tension 12 months
A2 Check intake air hose for damage (vehicles Inspection Every 40,000 km or every •
with turbocharger) 2 years
A3 Replace engine timing belt (except vehicles Replace Every 100,000 km •
with timing chain)
A4 Check operation of crankcase emission control Inspection Every 40,000 km or every •
system (petrol-powered vehicles) 2 years
A5 Replace spark plugs Standard type Replace Every 40,000 km •
Iridium tipped type Replace Every 100,000 km •
A6 Check radiator hoses for damage and proper Inspection Every 40,000 km or every •
connection 2 years
A7 Check engine coolant Petrol-powered Inspection Every 40,000 km or every •
level in reservoir vehicles 2 years
Diesel-powered Inspection Every 20,000 km or every •
vehicles 12 months
A8 Change engine coolant Petrol-powered Change Every 60,000 km or every •
vehicles 4 years
Diesel-powered Change Every 60,000 km or every •
vehicles 3 years
A9 Check air cleaner element for clogging and Inspection Normal Every 20,000 •
damage usage km
Severe Every 10,000 •
usage km
A10 Replace air cleaner element Replace Normal Every 40,000 •
usage km or every 3
years
Severe More frequently •
usage
A11 Check fluid level in brake reservoir and clutch Inspection Every 20,000 km or every •
reservoir (for hydraulic type clutch) 12 months
A12 Change brake fluid Change Every 40,000 km or every •
2 years
A13 Check battery electrolyte level Inspection Every 20,000 km or every •
12 months
2-4 PERIODIC INSPECTION AND MAINTENANCE

operation
A14 Replace fuel filter Petrol-powered Replace Every 160,000 km or •
vehicles every 10 years
Diesel-powered Replace Every 60,000 km or every •
vehicles 4 years
OPERATIONS UNDER THE VEHICLE
B1 Check suspension system for damage and Inspection Every 40,000 km or every •
looseness 2 years
B2 Check suspension arm ball joints for play, and Inspection Every 40,000 km or every •
dust covers for damage 2 years
B3 Check drive shaft boots for damage Inspection Normal Every 40,000 •
usage km or every 2
years
usage km
B4 Check steering linkage for damage and loose Inspection Every 20,000 km or every •
connections (including seals and boots) 12 months
B5 Check gear oil level in manual transmission Inspection Every 20,000 km or every •
(include Automated manual transmission) 12 months
B6 Change gear oil in Petrol-powered Change Normal Every 200,000 •
manual transmission vehicles usage km or every 10
(include Automated years
manual transmission) Severe Every 100,000 •
usage km or every 5
years
Diesel-powered Change Normal Every 250,000 •
vehicles usage km or every 10
years
usage km or every 5
years
B7 Check exhaust pipe connections for gas Inspection Every 40,000 km or every •
leakage, and check pipe installation 2 years
OPERATIONS INSIDE THE VEHICLE
C1 Check brake pedal and clutch pedal for free Inspection Every 20,000 km or every •
play 12 months
C2 Check parking brake lever stroke and play Inspection Every 20,000 km or every •
12 months
C3 Replace air purifier filter Replace Every 20,000 km or every •
12 months
OPERATIONS OUTSIDE THE VEHICLE
D1 Check uneven tyre wear 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
2-5
operation
D3 Check brake hoses and pipes for leakage Inspection Every 40,000 km or every •
2 years
D4 Check brake pads and discs for wear Inspection Normal Every 20,000 •
usage km or every 12
months
usage km or every 6
months
D5 Check brake shoe linings and drums for wear Inspection Normal Every 40,000 •
usage km or every 2
years
usage km or every 12
months
D6 Check fuel hoses and pipes for leakage or Inspection Every 40,000 km or every •
deterioration 2 years
OPERATIONS AFTER ENGINE IS WARMED UP
E1 Change engine oil MB229.1 or higher Change Normal Every 20,000 •
(petrol-powered vehicles usage km or every 12
without a turbocharger) months
usage km
Change engine oil ACEA classification: Change Normal Every 10,000 •
(petrol-powered vehicles "For service A1/B1, usage km or every 6
with a turbocharger) A3/B3, A3/B4 or months
A5/B5" Severe Every 5,000 km •
API classification: usage
"For service SG" or
higher
Change engine oil MB229.1 or higher Change Every 20,000 km or every •
(diesel-powered 12 months
vehicles)
E2 Replace engine oil filter MB229.1 or higher Replace Normal Every 20,000 •
(petrol-powered vehicles usage km or every 12
without a turbocharger) months
usage km
Replace engine oil filter ACEA classification: Replace Normal Every 10,000 •
(petrol-powered vehicles "For service A1/B1, usage km or every 6
with a turbocharger) A3/B3, A3/B4 or months
A5/B5" Severe Every 5,000 km •
API classification: usage
"For service SG" or
higher
Replace engine oil filter MB229.1 or higher Replace Every 20,000 km or every •
(diesel-powered 12 months
vehicles)

operation
E3 Check engine idling speed Inspection Every 20,000 km or every •
12 months
E4 Check CO concentration (petrol-powered Inspection Every 20,000 km or every •
vehicles) 12 months
E5 Check valve clearance (except vehicles with Inspection Every 100,000 km •
auto-lash adjuster)
OTHERS
F1 Check body condition for damage Inspection Every year •
F2 Road test Inspection Every 20,000 km or every •
12 months
NOTE: "Severe usage" specifications apply to only vehicles used under severe operating conditions.
Severe operating conditions include the followings:
.
1. Driving in a dusty area.
2. Driving on rough roads, on submerged roads, or hilly areas.
3. Driving cold zones.
4. Engine idling for a long time or short-distance travel during cold weather.
5. Frequent, sudden application of brakes.
6. Towing of a trailer.
7. Use as a taxi or as a rent-a-car.
8. When more than 50% of driving is in heavy city traffic and the ambient temperature is 32°C or more.
9. When more than 50% of driving is at 120 km/h or more and the ambient temperature is 30°C or more.

A1. CHECK V-BELT FOR CRACKS, Standard value:
FRAYING, WEAR, AND ADJUST ITS Item When When When
checked adjusted replaced
TENSION
M6020200100475 Vibration 142 − 174 151 − 167 196 − 218
V-BELT CONDITION frequency
Check the whole rounds of the V-belt for cracks, fray- Hz
ing and wear. Tension N 392 − 588 441 − 539 784 − 980
Deflection 10.9 − 16.5 11.9 − 14.6 6.3 − 7.6
V-BELT TENSION mm
ALTERNATOR AND A/C DRIVE BELT (Reference)
TENSION CHECK <134, 135>
Check the drive belt tension in the following proce-
dure.
2-7
<When the vibration frequency is (3) Press the "WIDTH" button to change to the
measured {Special tool (MB992080) is belt width input display.
used}: Recommendation> (4) Press number keys 0, 1, 0, and 0 sequentially,
and press the "SELECT" button to apply them.
NOTE: The vibration frequency measuring method is Check to ensure that "W 010.0 mm/R"
recommended for check and adjustment of the drive appears on the display.
belt tension. (5) Press the "SPAN" button to change to the
Belt tension meter set (MB992080) span length input display.
(6) Press number keys 0, 1, 0, and 0 sequentially,
MB992081 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).
MB992082 CAUTION
AC507219AB
• The temperature of the surface of the belt
should be as close as possible to normal tem-
1. Connect the Special tool microphone assembly perature.
(MB992082) to the Special tool belt tension meter • Do not let any contaminants such as water or
(MB992081) of the Special tool belt tension meter oil get onto the microphone.
set (MB992080). • If strong gusts of wind blow against the
2. Press the "POWER" button to turn on the power microphone or if there is loud sources of
supply. noise nearby, the values measured by the
3. Press number key 1. Check to ensure that "No. microphone may not correspond to actual
01" appears on the upper left of the display and values.
that the following numeric values are displayed for • If the microphone is touching the belt while
individual items (M, W, and S): the measurement is being made, the values
M 000.9 g/m measured by the microphone may not corre-
spond to actual values.
W 010.0 mm/R • Do not take the measurement while the vehi-
S 0100 mm cle's engine is running.
If numeric values have not been entered (new Alternator
15˚
tool), set them according to the belt specifications 15˚ pulley
as shown below. Once you set them, you do not
have to set them again. The settings remain MB992080
(Microphone)
undeleted even after battery replacement.
10 – 15 mm
NOTE: This operation is to temporarily set the Water pump
preset data such as the belt specifications, pulley
because if the measurement is taken without input Crankshaft
pulley
of the belt specifications, conversion to tension
value (N) cannot be made, resulting in judgement A/C compressor pulley AC700322 AB
of error.
5. Hold the microphone to the middle of the drive
<Setting procedure> belt between the pulleys (at the place indicated by
(1) Press down the "MASS" button till the belt the arrow), about 10 − 15 mm away from the rear
mass select display appears. surface of the belt and so that it is perpendicular
(2) Press the "UP" or "DOWN" button to select "01 to the belt (within an angle of ± 15 °).
1.5GT 0.9" and press the "MEASURE" button 6. Press the "MEASURE" button.
to decide it.
Check to ensure that "M 000.9 g/m" is
displayed.
7. Gently tap the middle of the belt between the CAUTION

pulleys (the place indicated by the arrow) with 1. The temperature of the surface of the belt
your finger as shown in the illustration, and check should be as close as possible to normal tem-
that the vibration frequency of the belt is within the perature.
standard value. 2. Do not let any contaminants such as water or
NOTE: To take the measurement repeatedly, fillip oil get onto the microphone.
the belt again. 3. If strong gusts of wind blow against the
8. After the completion of the measurement, press microphone or if there is loud sources of
and hold the "POWER" button to turn off the noise nearby, the values measured by the
power supply. microphone may not correspond to actual
values.
<When using the vehicle communication 4. If the microphone is touching the belt while
interface (V.C.I.)> the measurement is being made, the values
1. Connect the special tool belt tension meter set measured by the microphone may not corre-
(MB991668) to the special tool V.C.I (MB991824). spond to actual values.
2. Connect the special tool V.C.I (MB991824) to the 5. Do not take the measurement while the vehi-
diagnosis connector. cle's engine is running.
3. Turn the ignition switch to the "ON" position and <When using the tension gauge>
select "Belt Tension Measurement" from the menu
screen. Alternator
pulley
4. Hold the microphone to the middle of the drive Tension
belt between the pulleys (at the place indicated by gauge
the arrow), about 10 − 20 mm away from the rear Water pump
surface of the belt and so that it is perpendicular pulley
to the belt (within an angle of ± 15 °). A/C compressor
pulley
15˚ Alternator
15˚ pulley Crankshaft
MB991668 pulley
(Microphone) AK305688AB
Use a belt tension gauge to check that the belt ten-

10 – 20 mm sion is within the standard value.
Water pump
Crankshaft
pulley
<Belt deflection check>
pulley
Alternator
A/C compressor pulley AK305687 AB Approximately pulley
100 N (22 lb)
5. Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
Water pump
your finger as shown in the illustration, and check pulley
Deflection
that the vibration frequency of the belt is within the
A/C compressor
standard value. pulley
Crankshaft
pulley AK305689 AB
Apply approx. 100 N of force to the middle of the

drive belt between the pulleys (at the place indicated
by the arrow) and check that the amount of deflection
is within the standard value.
2-9
ALTERNATOR AND A/C DRIVE BELT <When the vibration frequency is
TENSION ADJUSTMENT <134, 135> measured {Special tool (MB992080) is
used}: Recommendation>
Adjusting bolt
NOTE: The vibration frequency measuring method is
recommended for check and adjustment of the drive
Alternator fixing nut belt tension.
Belt tension meter set (MB992080)
MB992081
Nut for alternator
pivot bolt
AC310987AB
1. Loosen the nut of the nut for alternator pivot bolt.

2. Loosen the alternator fixing nut.
MB992082
3. Use the adjusting bolt to adjust the belt tension AC507219AB
and belt deflection to the standard values.
Standard value: 1. Connect the Special tool microphone assembly
Items When When (MB992082) to the Special tool belt tension meter
adjusted replaced (MB992081) of the Special tool belt tension meter
set (MB992080).
Vibration frequency 151 − 167 196 − 218
Hz 2. Press the "POWER" button to turn on the power
supply.
Tension N 441 − 539 784 − 980
3. Press number key 1. Check to ensure that "No.
Deflection mm 11.9 − 14.6 6.3 − 7.6 01" appears on the upper left of the display and
(Reference) that the following numeric values are displayed for
4. Tighten the nut of the nut for alternator pivot bolt. individual items (M, W, and S):
Tightening torque: 39.5 ± 4 N⋅m M 000.9 g/m
5. Tighten the alternator fixing nut. W 010.0 mm/R
Tightening torque: 20 ± 2 N⋅m S 0100 mm
6. Tighten the adjusting bolt. If numeric values have not been entered (new
Tightening torque: 5.0 ± 1.0 N⋅m tool), set them according to the belt specifications
as shown below. Once you set them, you do not
ALTERNATOR DRIVE BELT TENSION have to set them again. The settings remain
CHECK <4G1> undeleted even after battery replacement.
Check the drive belt tension in the following proce- NOTE: This operation is to temporarily set the
dure. preset data such as the belt specifications,
Standard value: because if the measurement is taken without input
of the belt specifications, conversion to tension
Item When When When
value (N) cannot be made, resulting in judgement
checked adjusted replaced
of error.
Vibration 218 − 266 231 − 255 308 − 344
frequency <Setting procedure>
Hz (1) Press down the "MASS" button till the belt
mass select display appears.
Tension N 392 − 588 441 − 539 785 − 981
(2) Press the "UP" or "DOWN" button to select "01
Deflection 6.3 − 8.0 6.6 − 7.5 4.1 − 5.0 1.5GT 0.9" and press the "MEASURE" button
mm to decide it.
(Reference) Check to ensure that "M 000.9 g/m" is
displayed.
(3) Press the "WIDTH" button to change to the 6. Press the "MEASURE" button.
belt width input display. 7. Gently tap the middle of the belt between the
(4) Press number keys 0, 1, 0, and 0 sequentially, pulleys (the place indicated by the arrow) with
and press the "SELECT" button to apply them. your finger as shown in the illustration, and check
Check to ensure that "W 010.0 mm/R" that the vibration frequency of the belt is within the
appears on the display. standard value.
(5) Press the "SPAN" button to change to the NOTE: To take the measurement repeatedly, fillip
span length input display. the belt again.
(6) Press number keys 0, 1, 0, and 0 sequentially, 8. After the completion of the measurement, press
and press the "SELECT" button to apply them. and hold the "POWER" button to turn off the
Check to ensure that "S 0100 mm" appears on power supply.
the display.
4. Press "Hz" button twice to change the display to <When using the vehicle communication
the frequency display (Hz). interface (V.C.I.)>
CAUTION 1. Connect the special tool belt tension meter set
• The temperature of the surface of the belt (MB991668) to the special tool V.C.I. (MB991824)
should be as close as possible to normal tem- 2. Connect the special tool V.C.I. (MB991824) to the
perature. diagnosis connector.
• Do not let any contaminants such as water or 3. Turn the ignition switch to the "ON" position and
oil get onto the microphone. select "Belt Tension Measurement" from the menu
• If strong gusts of wind blow against the screen.
microphone or if there is loud sources of 4. Hold the microphone to the middle of the drive
noise nearby, the values measured by the belt between the pulleys (at the place indicated by
microphone may not correspond to actual the arrow), about 10 − 20 mm away from the rear
values. surface of the belt and so that it is perpendicular
• If the microphone is touching the belt while to the belt (within an angle of ± 15 °).
the measurement is being made, the values
measured by the microphone may not corre- Water pump 10 – 20 mm
pulley
spond to actual values. 15˚
• Do not take the measurement while the vehi- 15˚
cle's engine is running.
MB991668
Water pump 10 – 15 mm (Microphone)
pulley
Crankshaft
15˚ Alternator pulley
pulley
15˚
MB992080 AK402044AC
(Microphone)
Crankshaft 5. Gently tap the middle of the belt between the
Alternator pulley pulleys (the place indicated by the arrow) with
pulley
your finger as shown in the illustration, and check
AK600562AB that the vibration frequency of the belt is within the
standard value.
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 °).
2-11
CAUTION ALTERNATOR DRIVE BELT TENSION
1. The temperature of the surface of the belt ADJUSTMENT <4G1>
should be as close as possible to normal tem-
perature. Alternator fixing nut
2. Do not let any contaminants such as water or
oil get onto the microphone.
3. If strong gusts of wind blow against the
microphone or if there is loud sources of Adjusting bolt
noise nearby, the values measured by the
microphone may not correspond to actual
values.
Nut for alternator
4. If the microphone is touching the belt while pivot bolt AKX01155AE
the measurement is being made, the values
measured by the microphone may not corre- 1. Loosen the nut of the nut for alternator pivot bolt.
spond to actual values. 2. Loosen the alternator fixing nut.
5. Do not take the measurement while the vehi- 3. Use the adjusting bolt to adjust the belt tension
cle's engine is running. and belt deflection to the standard values.
<When using the tension gauge> Standard value:
Items When When
Water pump adjusted replaced
pulley
Vibration frequency 231 − 255 308 − 344
Hz
Tension Tension N 441 − 539 785 − 981
Gauge
Deflection mm 6.6 − 7.5 4.1 − 5.0
(Reference)
Alternator
pulley Crankshaft 4. Tighten the nut of the nut for alternator pivot bolt.
pulley
AK402045AC Tightening torque: 44 ± 10 N⋅m
Use a belt tension gauge to check that the belt ten- 5. Tighten the alternator fixing nut.
sion is within the standard value. Tightening torque: 23 ± 2 N⋅m
6. Tighten the adjusting bolt.
<Belt deflection check>
Tightening torque: 5.0 ± 1.0 N⋅m
Water pump Deflection
pulley
A2. CHECK INTAKE AIR HOSE FOR
Approximately DAMAGE (VEHICLES WITH
100 N
TURBOCHARGER)
M6020200500075
Alternator
pulley Crankshaft Air intake hose
pulley
AK402046AC
Apply approx. 100 N of force to the middle of the Turbocharger

drive belt between the pulleys (at the place indicated
by the arrow) and check that the amount of deflection
is within the standard value.
AC400556AB
Inspect the intake air hoses for cracks or damage.

A3. REPLACE ENGINE TIMING BELT POSITIVE CRANKCASE VENTILATION

<EXCEPT VEHICLES WITH TIMING SYSTEM CHECK
CHAIN> <134, 135>
M6020200600061
For information concerning the replacement proce-
dures, refer to the Workshop Manual.
A4. CHECK OPERATION OF

CRANKCASE EMISSION CONTROL
SYSTEM PCV valve
M6020200700110
BREATHER HOSE
AC310830AC
<134, 135>
<4G1>
Ventilation hose
PCV valve
Breather hose
AC311577AC
AC404368AB
<4G1>
1. Remove the ventilation hose from the PCV
Ventilation hose (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.
<134, 135>
Breather hose
AC404365AB
1. Inspect the breather hose for cracks or damage.

2. Clean the inside of the breather hose if necessary.
VENTILATION HOSE PCV valve

1. Check all clamps for tightness and the
connections for leakage. AK300021AF
2. Hoses should be replaced immediately if there is <4G1>

any evidence of deterioration or damage.
PCV valve
AK402735 AB
5. Place finger at the opening of the PCV valve and

check that vacuum of the intake manifold is felt.
2-13
NOTE: A6. CHECK RADIATOR HOSES FOR
At this moment, the plunger in the PCV valve DAMAGE AND PROPER CONNECTION
moves back and forth. M6020200900103
6. If vacuum is not felt, clean the PCV valve or

< 134, 135 >
replace it.
PCV VALVE CHECK

<134, 135>
PCV valve
Radiator hose
AC310828AC
<4G1>
AK300022 AF
<4G1>
PCV valve
Radiator hose
AC404366AB
< 639 >
AK402736AB
1. Insert a thin rod into the PCV valve from the side Radiator
shown in the illustration (rocker cover installation condenser
side), and move the rod back and forth to check tank
that the plunger moves.
Radiator hose
2. If the plunger does not move, there is clogging in AC400555AC
the PCV valve. In this case, clean or replace the
PCV valve. 1. Check entire circumference and length of hoses,
using a mirror as required.
A5. REPLACE SPARK PLUGS 2. Check that hoses installed in grommets pass
M6020200800076
After removing old spark plugs, install new ones and through the centre of the grommets.
tighten them at the specified torque. 3. Check all clamps for tightness and connections
for leakage.
A7. CHECK ENGINE COOLANT LEVEL IN

RESERVOIR
M6020201000095
< 134, 135 >
AC305655
Reserve tank
3. Loosen the drain plug, remove the radiator can
AC310829AC
and drain the coolant.
4. Feed fresh water into the cooling system through
<4G1> 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 reserve tank.
6. Install the reserve tank.
Reserve tank
AC404367AB
< 639 >
AC305656
7. Depending upon conditions of operation,

determine the amount of long life coolant,
Radiator antifreeze or antirust to be added to the coolant.
condenser tank
Recommended antifreeze: High-quality eth-
AC400553AD
ylene glycol based coolant
Check that the coolant level is between the "FULL"
CAUTION
and "LOW" lines when the engine is at the normal
Do not use alcohol or methanol anti-freeze or any
operating temperature.
engine coolants mixed with alcohol or methanol
A8. CHANGE ENGINE COOLANT anti-freeze. The use of an improper anti-freeze
M6020201100531 can cause the corrosion of the aluminium com-
1. Stop the engine after it is fully warmed up. ponents.
2. Add detergent to the engine coolant in order to 8. Fill the cooling system with soft water through the
flush the cooling system, and start the engine. filler port, and add long life coolant, if necessary.
9. Fill the reserve tank with coolant.
10.Install the radiator cap and the reserve tank cap.
11.Recheck the engine coolant level after a road test.
2-15
CAUTION
When removing the radiator cap, be careful to MB991871
blow out steam and boiling water.
REMOVAL OF ENGINE COOLANT FROM
THE CYLINDER BLOCK DRAIN PLUG
<134, 135>
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug Air hose
and removing the radiator cap. AC311478 AB
8. By referring to the section on coolant, select an

appropriate concentration for safe operating
temperature within the range of 45 to 60%. Use
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50% water and
50% antifreeze solution (freezing point: −31°C).
Recommended antifreeze: High-quality ethyl-
ene glycol based coolant
AC313745 Quantity:
<134> 4.2 L
2. Drain the water in the water jacket by unplugging <135> 4.6 L
the drain plug of the cylinder block. NOTE: For how to use special tool MB991871,
3. Remove the radiator condenser tank and drain refer to its manufacturer’s instructions.
the coolant. CAUTION
4. Drain the coolant then clean the path of the Do not use alcohol or methanol anti-freeze or any
coolant by injecting water into the radiator from engine coolants mixed with alcohol or methanol
the radiator cap area. anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium compo-
nents.
Cylinder block
drain plug 9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the
thermostat opens.
11.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
Gasket 12.Remove the radiator cap after the engine has
AC313746AC become cold, and pour in coolant up to the brim.
Reinstall the cap.
5. Install a new cylinder block drain plug gasket and 13.Add coolant to the radiator condenser tank
then tighten the cylinder block drain plug to the between the "F" and "L" mark if necessary.
specified torque.
CAUTION
Tightening torque: 27 ± 3 N⋅m Do not overfill the radiator condenser tank.
6. Securely tighten the drain plug of the radiator.
7. Reinstall the radiator condenser tank. REMOVAL OF ENGINE COOLANT FROM
THE CYLINDER BLOCK DRAIN PLUG
<4G1>
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.

Water pump appropriate concentration for safe operating
Cylinder block inlet pipe temperature within the range of 45 to 60%. Use
drain plug 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: High-quality ethyl-
Quantity: 6.0 L
AC402236AB NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.
2. Drain the water in the water jacket by unplugging
the drain plug of the cylinder block. CAUTION
3. Remove the radiator condenser tank and drain Do not use alcohol or methanol anti-freeze or any
the coolant. engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
4. Drain the coolant then clean the path of the
can cause corrosion of the aluminium compo-
coolant by injecting water into the radiator from
nents.
the radiator cap area.
9. Reinstall the radiator cap.
Cylinder block 10.Start the engine and let it warm up until the
drain plug
thermostat opens.
11.After repeatedly revving the engine up to 3,000
12.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
13.Remove the radiator condenser tank cap, and
AC104528AB refill the coolant up to the line "F" on the cap level
gauge.
5. Apply the designated sealant to the screw area of
the cylinder block drain plug, and then tighten to CAUTION
the standard torque. Do not overfill the radiator condenser tank.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent
ENGINE COOLANT REPLACEMENT
Tightening torque: 40 ± 5 N⋅m <639>
6. Securely tighten the drain plug of the radiator. 1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
7. Reinstall the radiator condenser tank.
and removing the radiator condenser tank cap.
Engine oil cooler water hose
MB991871
Air hose
Oil filter
AC402237AB
AC400551AB
2. Disconnect the engine oil cooler water hose to

drain water from the water line.
2-17
3. Drain the coolant then clean the path of the A9. CHECK AIR CLEANER ELEMENT
coolant by injecting water into the radiator from FOR CLOGGING AND DAMAGE
the radiator cap area. M6020201200077
4. Securely tighten the drain plug of the radiator.

Air hose
MB995109
MB995110 AC311579
AC609666AB 1. Check air cleaner element for clogging and

damage.
appropriate concentration for safe operating 2. Clean deposited dust from the element in the
temperature within the range of 45 to 60%. A following manner.
convenient mixture is a 50% water and 50% (1) Lightly tap the element against the top of a
antifreeze solution (freezing point: −31°C). bench.
• LLC changer (MB995109) (2) Blow compressed air from inside the element.
• LLC changer adapter (MB995110) 3. Wipe off dust on the air cleaner interior.
Recommended antifreeze: High-quality ethyl- 4. Install the air cleaner body.
Quantity: 6.6 L A10. REPLACE AIR CLEANER ELEMENT
M6020201300096
CAUTION The air cleaner element will become dirty and loaded
Do not use alcohol or methanol anti-freeze or any with dust during use, and the filtering effect will be
engine coolants mixed with alcohol or methanol substantially reduced. Replace it with a new one.
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium compo- Air cleaner element
nents.
6. Reinstall the radiator condenser tank cap.
7. Start the engine and let it warm up until the
thermostat opens.
8. After repeatedly revving the engine up to 3,000
9. Remove the radiator condenser tank cap after the
AC311578AB
engine has become cold, and pour in coolant up
to "FULL" mark. Reinstall the cap. 1. Unclasp the air cleaner cover clip.
CAUTION 2. Remove the air cleaner element and install a new
Do not overfill the radiator condenser tank. one.
3. Be sure to close the air cleaner cover completely
when clamping it.
A11. CHECK FLUID LEVEL IN BRAKE CAUTION

RESERVOIR AND CLUTCH RESERVOIR Use the specified brake fluid. Avoid using a mix-
(for hydraulic-type clutch only) ture of the specified brake fluid and other fluid. If
M6020201400071 brake fluid is exposed to the air, it will absorb
moisture; as water is absorbed from the atmos-
Reservoir tank phere, the boiling point of the brake fluid will
decrease and the braking performance will be
seriously impaired. For this reason use a hermet-
ically sealed 1 lit. or 0.5 lit. brake fluid container.
Firmly close the cap of the brake fluid container
after use.
3. When fresh fluid has come to flow out from the
vinyl tube, tighten the bleeder screw.
AC312910AD NOTE:
This change from existing to fresh fluid can be
1. Check that the fluid level is between the "MAX"
judged by change in color of fluid that flows out.
and "MIN" mark.
2. If it is below the "MIN" marks, replenish with fresh
brake fluid up to the "MAX" mark.
A12. CHANGE BRAKE FLUID

M6020201600097
( ):R.H. drive vehicle AC305660 AB
4. Repeat above steps for other bleeder screws.

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

outlet with a finger.
2-19
4. With the outlet still closed, release the brake Fuel vapour Fuel main tube
pedal. control line tube
5. Repeat steps (2) - (4) three or four times to fill the <135, 134, 4G1>
inside of the master cylinder with brake fluid.
A13. CHECK BATTERY ELECTROLYTE

LEVEL
M6020201700298
Fuel return tube
Thermometer Hydrometer <4G1, 639>
AC400608AC
2. Disconnect the fuel main tube, fuel return tube

<4G1> and fuel vapour control line tube <134,
135, 4G1>.
Battery fluid
Fuel tank pump and
gauge mounting cap
MB991991
AC504567AB
1. Inspect whether or not the battery fluid is between

the UPPER LEVEL and LOWER LEVEL marks.
CAUTION
1. If the battery fluid is below the LOWER
LEVEL, the battery could explode in using.
2. If the battery fluid is over the UPPER LEVEL, AC313226AB
leakage could result.
2. Use a hydrometer and thermometer to check the 3. Install the fuel tank cap wrench (special tool
specific gravity of the battery fluid. MB991991) as shown in the figure, and remove
Standard value: 1.220 − 1.290 [20°C] the fuel tank pump and gauge mounting cap.
4. Remove the fuel tank pump and gauge assembly
3. The specific gravity of the battery fluid varies with
from the service hole.
the temperature, so use the following formula to
calculate the specific gravity for 20°C. Use the CAUTION
calculated value to determine whether or not the When withdrawing the fuel tank pump and gauge
specific gravity is satisfactory. assembly via the service hole, be careful not to
D20 = (t - 20) × 0.0007 + Dt damage the gauge and the float.
D20: Specific gravity of the battery fluid cal-
culated for 20°C.
Dt: Actually measured specific gravity Fuel tank pump and
t: Actually measured temperature gauge assembly
A14. REPLACE FUEL FILTER

M6020201900139
<134, 135, 4G1 engine>

1. Reduce fuel line pressure.
AC313782AB
5. Replace the fuel tank pump and gauge assembly

and the fuel tank pump gasket with new ones
respectively.
6. Install the fuel tank pump and gauge assembly to
the fuel tank through the service hole.
CAUTION Fuel return tube <4G1, 639>,

When installing the fuel tank pump and gauge fuel vapour control line tube <134, 135, 4G1>
assembly from the service hole to the fuel tank, or fuel main tube
Corresponding side
be careful not to damage the gauge of fuel tank
pump and gauge assembly and the float.
Fuel tank pump and

gauge mounting cap 3 mm
MB991991
Quick connector
AC313166AC
CAUTION
After connecting the fuel return tube <4G1> fuel
vapour control line tube <134, 135, 4G1>or fuel
main tube, slightly pull it to ensure that it is
installed securely. Also confirm that there is a
AC313226AB play approximately 3 mm.
Fuel tank pump
7. Install the fuel tank cap wrench (special tool Fuel main tube
and gauge assembly
MB991991) as shown in the figure. connector
8. Align the mating marks in the following procedure.
6˚
Mating marks Fuel vapour

Fuel return tube
control line tube
<4G1, 639>
<135, 134, 4G1> AC400420AC
9. Connect the fuel tank pump and gauge assembly

connector, fuel main tube, fuel return tube <4G1>
AC313190AB and fuel vapour control line tube <134, 135,
(1) Tighten the fuel tank pump and gauge 4G1>.
mounting cap to align the mating marks. 10.Install the service hole cover.
(2) Use a torque wrench to ensure that the fuel 11.Return the centre carpet to the original state.
tank pump and gauge mounting cap is 12.Install the rear seat assembly.
tightened to 60 N⋅m or more.
(3) Remove the fuel tank cap wrench (special tool <639 engine>
MB991991), and check that the mark on the
fuel tank pump and gauge mounting cap is Fuel filter assembly
within the area shown.
AC400557AC
Unclasp the fuel filter bracket clamp.

2-21
B1. CHECK SUSPENSION SYSTEM FOR
DAMAGE AND LOOSENESS
M6020300100063
FRONT SUSPENSION
Deterioration
and sagging
Noise and
oil leakage
Bends and
damage
Cracks, bends
and dents Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Deterioration
and sagging
Cracks, bends
and dents
AC313282AB
B2. CHECK SUSPENSION ARM BALL B4. CHECK STEERING LINKAGE FOR
JOINTS FOR PLAY, AND DUST COVERS DAMAGE AND LOOSE CONNECTIONS
FOR DAMAGE (INCLUDING SEALS AND BOOTS)
M6020300200059 M6020300500050
LOWER ARM BALL JOINT END PLAY

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

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

1. Press the dust cover with your finger to check that
there are no cracksor damage in the dust cover.
2. If the dust cover is cracked or damaged, replace AC311580AB
the lower arm assembly.
2. Check to be sure that the seal and boot of the ball
NOTE: If the dust cover is cracked or damaged, it joint are correctly installed (in the correct
is possible that there may also be damage to the position), and that they are not damaged.
ball joint.
3. Check tie-rod end jam nut for looseness. If jam
B3. CHECK DRIVE SHAFT BOOTS FOR nut is loose, adjust toe-in and then tighten jam nut
to the specified torque.
DAMAGE
M6020300400031 Tightening torque: 43 ± 7 N⋅m
AC305661
Check the drive shaft boots for damage.

2-23
B5. CHECK GEAR OIL LEVEL IN MANUAL <Right side view>
TRANSMISSION (include Automated
manual transmission)
M6020300600035
Filler plug hole

Drain plug
AC311888AB
0 - 5 mm
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.
Filler plug
Tightening torque: 43 ± 3 N⋅m
Transmission oil
AC311891AB
4. Fill the specified transmission oil until the level
1. Remove the filler plug. comes to the lower portion of filler plung hole.
2. Check that the oil level is with in 0 - 5 mm from the Transmission oil:
lower edge of the filler plug hole. Castrol BOT 328 Produced by Burmach Oil
Technology GmbH (or exact equivalents):
3. Check that the transmission oil is not noticeably
SAE 75W - 90 API GL-4 full synthetic oil
dirty, and that it has a suitable viscosity.
Quantity: 1.75L
4. Tighten the filler plug to the specified torque.
Tightening torque: 43 ± 3 N⋅m 5. Tighten the filler plug to the specified torque.
B6. CHANGE GEAR OIL IN MANUAL
TRANSMISSION (include Automated B7. CHECK EXHAUST PIPE
manual transmission) CONNECTIONS FOR GAS LEAKAGE,
M6020300800051 AND CHECK PIPE INSTALLATION
M6020301200074
<Left side view>
1. Confirm that the exhaust pipe does not interfere
with any body components.
2. Check the exhaust pipe for damage by stones,
etc.
Filler plug 3. Start the engine and check for gas leaks from the
exhaust pipe connections.
AC311889AB
1. Remove the filler plug.


C1. CHECK BRAKE PEDAL AND CLUTCH 2. If the clutch pedal lateral play and the distance
PEDAL FOR FREE PLAY between the clutch pedal and the toeboard when
M6020400100071 the clutch is disengaged do not agree with the
BRAKE PEDAL FREE PLAY standard values, it is probably the result of either
The brake pedal assembly cannot be adjusted struc- air in the hydraulic system or a faulty master
turally and so the brake pedal clevis pin play nor the cylinder, release cylinder or clutch. Bleed the air,
brake pedal free play is not set. and inspect the master cylinder, release cylinder
or clutch.
Brake pedal lateral play
C2. CHECK PARKING BRAKE LEVER
STROKE AND PLAY
M6020400200089
1. Pull the parking brake lever with a force of
approximately 196 N and count the number of
notches.
Standard value: 5 − 7 notches
B
AC311382 AC CAUTION
The 196 N force of the parking brake lever must
1. Measure the brake pedal lateral play. be strictly observed.
Standard value (B): 1.5 mm or less
2. If the parking brake lever stroke is not the
2. If the brake pedal lateral play and the distance standard value, adjust as described below.
between the brake pedal and the toeboard when (1) Remove the rear cup holder.
the brake is disengaged do not agree with the
standard values, it is probably the result of either
air in the hydraulic system or a faulty master
cylinder, release cylinder or brake. Bleed the air,
and inspect the master cylinder, release cylinder
or brake.
CLUTCH PEDAL FREE PLAY

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

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

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

D1. CHECK UNEVEN TYRE WEAR 1. Adjust the toe-in by undoing the clip and jam nut,
M6020500100272 and turning the left and right tie rod turnbuckles by
Check the entire periphery of the tyres for uneven the same amount (in opposite directions).
wear. If any tyre shows uneven wear, check the
toe-in and toe-out, and adjust if necessary. NOTE:
The toe will move out as the left turnbuckle is
TOE-IN turned toward the front of the vehicle and the right
Standard value: turnbuckle is turned toward the rear of the vehicle.
At the centre of tyre tread: 0 ± 2 mm 2. Install the clip and tighten the jam nut to the
Toe angle (per wheel): 0°00’ ± 06’ specified torque.
Clip
Jam nut
3. Confirm that the toe-in is at the standard value.
AC312518AB
AC306798
4. Use a turning radius gauge to check that the NOTE: .

steering angle is at the standard value. 1. *: difference between right and left wheels must
Standard value: be less than 30'
2. Camber and caster are preset at the factory and
Item Specifications cannot be adjusted.
Inner wheels 36°40' ± 1°30' 3. For vehicles with aluminium wheels, attach the
Outer wheels 32°50' camber/caster/kingpin gauge to the driveshaft by
(for reference) using special tool wheel alignment gauge attach-
ment (MB991004). Tighten the special tool to the
TOE-OUT ANGLE ON TURNS same torque 236 ± 19 N⋅m as the driveshaft nut.
To check the steering linkage, especially after the CAUTION
vehicle has been involved in an accident or if an acci- To prevent the wheel bearing from damage, never
dent is presumed, it is advisable to check the toe-out subject the wheel bearings to the vehicle load
angle on turns in addition to the wheel alignment. when the drive shaft nuts are loosened.
Conduct this test on the left turn as well as on the
right turn. REAR TOE-IN
Standard value: The rear suspension, wheels, and tyres should be
serviced to the normal condition prior to wheel align-
Item Specifications ment measurement.
Toe-out angle on turns (inner 21°21' Standard value:
wheel when outer wheel at 20°) At the centre of tyre tread:
<Standard suspension> 3 ± 3.5 mm
CAMBER, CASTER AND KINGPIN <High−ground suspension> 2.5 ± 3.5 mm
INCLINATION
REAR CAMBER
MB991004
Compensator
AC001079 AB
AC102503AD
Standard value:
Standard value: −1°00’ ± 0° 45’ (Left/right
Item Specifications deviation within 30’
Standard High-ground NOTE: .
suspension suspension 1. For vehicles with aluminium wheel, we recom-
Camber −0°30' ± 0° −0°15' ± 0° mend that a compensator be used to measure
30'* 30'* the camber.
2. Camber is preset at the factory and cannot be
Caster 2°40' ± 0° 30'* 2°30' ± 0° 30'* adjusted.
Kingpin inclination 13°20' ± 0° 13°00' ± 0° 30'
30' D2. CHECK FRONT AND REAR WHEEL
BEARINGS FOR PLAY
M6020500900063
<Front>
1. Remove the disc brake caliper and suspend it
with a wire.
2. Remove the brake disc from the front hub.
2-27
Vehicles with
rear drum brake
AC209503AC AC208743 AC
3. Attach a dial gauge as shown in the illustration, Vehicles with

and then measure the axial play while moving the disc brake
hub in the axial direction.
Limit: 0.05 mm
4. If axial play exceeds the limit, replace the front
hub assembly.
<Rear>
1. For vehicles with drum brake, remove the brake AC311430 AB
drum.
2. For vehicles with disc brake, remove the caliper 3. Check the bearing's axial play. Place a dial gauge
assembly, and suspend the caliper assembly with against the hub surface; then move the hub in the
a wire and remove the brake disc. axial direction and check whether or not there is
axial play.
Limit: 0.05 mm
4. If the play exceeds the limit, replace the rear hub
assembly.
D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300113
Brake booster
Hydraulic unit
Rear disc brake
AC403774AB
Front disc brake
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
D4. CHECK BRAKE PADS AND DISCS BRAKE DISC RUN-OUT CHECK
FOR WEAR 1. Remove the brake assembly, and then hold it with
M6020500400411 wire.
2. Temporarily install the disc with the hub nut.
AC102396AF
1. Check the brake pad thickness through the caliper ACX00669AF
body check port.

3. Place a dial gauge approximately 5 mm from the
Standard value: outer circumference of the brake disc, and
<Front> 11.2 mm (except 4G1), 10.5 mm (4G1) measure the run-out of the disc.
<Rear> 10.0 mm
Limit:
Limit: 1.5 mm <Front> 0.06 mm
2. When the thickness is less than the limit, always <Rear> 0.10 mm
replace the pads at an axle set.
D5. CHECK BRAKE SHOE LININGS AND
DRUMS FOR WEAR
M6020500500173
BRAKE LINING THICKNESS CHECK

1. Remove the brake drum.
ACX00668AF
A
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: ACX00708AE
<Front> 24.0 mm (except 4G1), 25.8 mm (4G1)
<Rear> 10.0 mm 2. Measure the thickness of the brake lining at
Limit: several places.
<Front> 21.5 mm (except 4G1), 23.5 mm (4G1) Standard value (A):
<Rear> 8.0 mm <Leading> 4.6 mm
<Trailing> 3.3 mm
4. If the disc thickness is less than the limits, replace
Limit (A): 0.5 mm
it with a new one.
3. If the thickness of the brake lining is below the
limit, replace the shoe and lining assemblies on
both sides of the vehicle. Never replace only one
side.
2-29
BRAKE DRUM INSIDE DIAMETER CHECK 2. Measure the inside diameter of the brake drum in
1. Remove the brake drum. two places or more.
Standard value: 203.0 mm
Limit: 204.4 mm
3. If the inside diameter exceeds the limit, or if it is
excessively worn or one side, replace the brake
A drum.
AC000893AD
D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION

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

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

E1. CHANGE ENGINE OIL CAUTION
M6020600300347
Use care as oil could be hot.
<134, 135, 639 engine>
4. Install a new engine oil pan drain plug gasket and
1. Start the engine and allow it to warm up until the then tighten the engine oil pan drain plug to the
temperature of the coolant reaches 80°C to 90°C. specified torque.
2. Stop the engine and remove the engine oil filler Tightening torque:
cap. <134, 135> 39 ± 5 N⋅m
3. Remove the engine oil pan drain plug to drain <639> 30 ± 2 N⋅m
engine oil.
<134, 135> CAUTION

Engine oil
pan drain
Engine oil pan plug gasket
drain plug
AC404572 AB
Engine oil
pan side
<639>
AC402262AD
4. Install a new drain plug gasket so that it faces in

the direction shown in the illustration, and then
tighten the drain plug to the specified torque.
AC404573AB
5. Refill with specified quantity of engine oil.

Specified Engine Oil: MB229.1 or higher
Total quantity (Includes volume inside oil fil-
ter):
<134> 3.2L
<135> 4.2L AC405038
<639> 5.5 L
5. Refill with specified quantity of engine oil.
6. Install the engine oil filler cap.
7. Start the engine and run it for a few minutes. Specified Engine Oil
• ACEA classification: "For service
8. Stop the engine and check the oil level. A1/B1, A3/B3, A3/B4 or A5/B5"
• API classification: "For service SG" or
<4G1 engine> higher
1. Start the engine and allow it to warm up until the Total quantity (Includes volume inside oil filter
temperature of the coolant reaches 80°C to 90°C. and oil cooler): 3.7 L
2. Remove the engine oil filler cap. 6. Install the engine oil filler cap.
3. Remove the drain plug to drain oil. 7. Start the engine and run it for a few minutes.
8. Stop the engine and check the oil level.
2-31
E2. REPLACE ENGINE OIL FILTER 7. Where the oil filter O-ring touches the oil pan
M6020600400087 flange, tighten the oil filter to the specified torque
<134, 135, 4G1 engine> using the commercially-available tool.
1. Start the engine and allow it to warm up until the Engine Number Tightening torque
temperature of the coolant reaches 80°C to 90°C.
134, 135 MR984204 Approximately 3/4 turn
2. Remove the engine oil filler cap.
(11 ± 1 N⋅m)
3. Remove the drain plug to drain oil.
4G1 MD136466, Approximately 3/4 turn
CAUTION MD322508 (17 ± 3 N⋅m)
MD356000 Approximately 3/4 turn
<134, 135> (14 ± 2 N⋅m)
Commercially-
available tool 8. Install the drain plug and refill the engine oil.
9. Race the engine 2-3 times, and check to be sure
that no engine oil leaks from installation section of
the oil filter.
A/C compressor
E3. CHECK ENGINE IDLING SPEED
M6020600500471
<134, 135, 4G1 engine>

AC312138AC
1. Before inspection, set the vehicle to the
<4G1> pre-inspection condition.
Commercially- 2. Turn the ignition switch to "LOCK" (OFF) position.
available tool
AC206895
MB991910
ACX00395AG
Diagnosis
connector
4. Use the commercially-available tool to remove the
engine oil filter.
5. Clean the filter bracket side mounting surface.
MB991824
MB991827 AC311450AB
O-ring
AC103250AD 3. Connect the M.U.T.-III to the diagnosis connector.
6. Apply a small amount of engine oil to the O-ring of

the new oil filter.
<134>
<639 engine>
AC206895
No.1 Ignition coil
MB991910
Diagnosis
AC613107AB connector
<135>
MB991824
No.1 Ignition coil

AC613108AB
MB991827 AC311450AB
4. Set a timing light to the power supply line
1. Before inspection, set the vehicle to the
(terminal No.1) of the ignition coil No.1.
pre-inspection condition.
NOTE: The power supply line is looped and also
2. Turn the ignition switch to "LOCK" (OFF) position.
longer than the other ones.
3. Connect the M.U.T.-III to the diagnosis connector.
5. Start the engine and let it run at idle.
6. Check that ignition timing is at the standard value.
5. Check the idle speed.
Standard value: approximately 10° BTDC
Standard value: 900 ± 30 r/min
7. Check the idle speed.
NOTE: The idle speed is controlled automatically
Standard value: by the idle speed control system.
<134> 830 ± 100 r/min
6. If the idle speed is outside the standard value,
<135> 750 ± 100 r/min
inspect the diesel fuel system (Refer to
<4G1> 750 ± 100 r/min
WORKSHOP MANUAL GROUP 13
NOTE: .
−Troubleshooting)
1. The idle speed is controlled automatically by
7. Turn the ignition switch to the "LOCK" (OFF)
the idle speed control system.
position and then remove the M.U.T.-III.
2. When using the M.U.T.-III, select item No.003
<134, 135>, No.3 <4G1> and take a reading of E4. CHECK CO CONCENTRATION
the idle speed. M6020601000208
8. If the idle speed is outside the standard value, 1. Before inspection, set the vehicle to the
inspect the MPI system (Refer to WORKSHOP pre-inspection condition.
MANUAL GROUP 13 − Troubleshooting). 2. Turn the ignition switch to "LOCK" (OFF) position.
9. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-III.
2-33
AC206895 7. Run the engine at 2,500 r/min for 2 minutes.
8. Set the CO, HC tester.
MB991910 9. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
Diagnosis
connector 10.If there is a deviation from the standard value,
check the following items:
• Diagnosis output
MB991824 • Fuel pressure
• Injector
• Ignition coil, spark plug
• Evaporative emission control system
• Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
MB991827 AC311450AB normal on all items.
11.Turn the ignition switch to the "LOCK" (OFF)
3. Connect the M.U.T.-III to the diagnosis connector. position and then remove the M.U.T.-III.
<134>
E5. CHECK VALVE CLEARANCE
No.1 Ignition coil
(EXCEPT VEHICLES WITH AUTO-LASH
ADJUSTER)
M6020600900275
VALVE CLEARANCE CHECK AND

ADJUSTMENT <134>
NOTE: Perform the valve clearance check and
AC613107AB
adjustment at the engine cold state.
1. Remove all ignition coils.
<135> 2. Remove the cylinder head cover.
Timing mark
No.1 Ignition coil

AC613108AB
4. Set a timing light to the power supply line AK604590AB

(terminal No.1) of the ignition coil No.1.
NOTE: The power supply line is looped and also 3. Turn the crankshaft clockwise, and align the
longer than the other ones. timing mark on the exhaust camshaft sprocket
against the upper face of the cylinder head as
shown in Figure. Therefore No.1 cylinder goes to
6. Check that ignition timing is at the standard value. the compression top dead centre.
Standard value: approximately 10° BTDC
CAUTION
Paint mark
Turn the crankshaft always clockwise.
12 teeth
Paint mark (120 degrees)
6.5 teeth
(65 degrees)
Paint mark
Timing mark
AK604593AB
7. Apply the paint mark to the 12th tooth (120

AK604591AB degrees) anti-clockwise from the paint mark.
4. Apply the paint mark to the 6.5th tooth (65
degrees) anti-clockwise from the timing mark on
the exhaust camshaft sprocket.
Timing mark
120˚ Paint mark
Paint mark
65˚ AK604594AB
Paint mark
8. Turn the crankshaft clockwise 240 degrees, and
Timing mark align the paint mark against the upper face of the
AK604592AB cylinder head as shown in Figure.
5. Turn the crankshaft clockwise 130 degrees, and Exhaust valve side
No.2
align the paint mark against the upper face of the
cylinder head as shown in Figure.
Exhaust valve side
No.3
No. 3
Intake valve side AK305588 AF
9. Using a thickness gauge, measure the valve

No. 1
clearance with the arrow shown in Figure. If
Intake valve side AK305588AD
deviated from the standard value, make note for
6. Using a thickness gauge, measure the valve the valve clearance.
clearance with the arrow shown in Figure. If Standard value:
deviated from the standard value, make note for Intake valve 0.22 ± 0.04 mm
the valve clearance. Exhaust valve 0.30 ± 0.04 mm
Standard value:
Intake valve 0.22 ± 0.04 mm
Exhaust valve 0.30 ± 0.04 mm
2-35
Paint mark Wall

thickness
5.5 teeth Paint mark

(55 degrees)
Timing mark
AK604595AB AK304938 AB
10.Apply the paint mark to the 5.5th tooth (55 14.Using a micrometer, measure the thickness of the
degrees) clockwise from the timing mark on the removed valve tappet.
exhaust camshaft sprocket.
Top view Under view
Paint mark Timing mark Identification mark
120˚ Paint mark

Identification mark
Paint mark AK604588AB
AK604596AB
15.Calculate the thickness of the newly installed
11.Turn the crankshaft clockwise 240 degrees, and valve tappet through the following equation.
align the paint mark against the upper face of the A: thickness of newly installed valve tappet
cylinder head as shown in Figure.
B: thickness of removed valve tappet
Exhaust valve side
No.1 C: measured valve clearance
Equation
Intake valve: A = B + (C − 0.22 mm)
Exhaust valve: A = B + (C − 0.30 mm)
NOTE: The valve tappet ranges 2.70 − 3.30 mm
and has 31 types per 0.02 mm. The thickness
below a decimal point is stamped on the reverse
No. 2 side of the valve tappet.
Intake valve side AK305588 AE Example: In case of 2.90 mm, "90" is stamped.
16.Install the valve tappet selected through the
12.Check the valve clearance with the arrow shown
procedure 15, and put the camshaft in position.
in Figure. If deviated from the standard value,
For the camshaft installation, refer to
make note for the valve clearance.
WORKSHOP MANUAL.
13.If the valve clearance is deviated from the
17.Remove any liquid gasket remaining on the
standard value, remove the camshaft and the
cylinder head cover, the timing chain case and the
valve tappet. For the camshaft removal, refer to
cylinder head.
WORKSHOP MANUAL.
CAUTION
Turn the crankshaft always clockwise.
Exhaust valve side
No. 1 No. 3
AK304933AB
18.Apply a 4 mm bead of liquid gasket as illustrated. No. 1 No. 2

Intake valve side AK305589AB
Specified sealant:
LOCTITE 5971 or exact equivalent 4. Using a thickness gauge, measure the valve
CAUTION clearance with the arrow shown in Figure. If
The timing chain should be installed within 3 deviated from the standard value, make note for
minutes of applying liquid gasket. the valve clearance.
19.Install the cylinder head cover by tightening the Standard value:
fittings to 9.0 ± 1.0 N⋅m. Intake valve 0.22 ± 0.04 mm
Exhaust valve 0.30 ± 0.04 mm
20.Install the ignition coils.
VALVE CLEARANCE CHECK AND Timing mark

ADJUSTMENT <135>
NOTE: Perform the valve clearance check and
adjustment at the engine cold state.
1. Remove all ignition coils.
2. Remove the cylinder head cover. 180˚
Timing mark AK604598AB
5. Turn the crankshaft clockwise 360 degrees, and

put the timing mark on the exhaust camshaft
sprocket in position shown in Figure. Therefore,
No.4 cylinder goes to the compression top dead
centre.
Exhaust valve side
No. 2 No. 4
AK604597AB
3. Turn the crankshaft clockwise, and align the

timing mark on the exhaust camshaft sprocket
against the upper face of the cylinder head as
shown in Figure. Therefore, No.1 cylinder goes to
the compression top dead centre.
No. 3 No. 4
Intake valve side AK305589 AC
6. Check the valve clearance with the arrow shown

in Figure. In the same procedure as 4.
7. If the valve clearance is deviated from the
standard value, remove the camshaft and the
valve tappet. For the camshaft removal, refer to
WORKSHOP MANUAL.
2-37
NOTE: The valve tappet ranges 2.70 − 3.30 mm
Wall
and has 31 types per 0.02 mm. The thickness
thickness
below a decimal point is stamped on the reverse
side of the valve tappet.
Example: In case of 2.90 mm, "90" is stamped.
10.Install the valve tappet selected through the
procedure 9, and put the camshaft in position. For
the camshaft installation, refer to WORKSHOP
MANUAL.
AK304938 AB 11.Remove any liquid gasket remaining on the
cylinder head cover, the timing chain case and the
8. Using a micrometer, measure the thickness of the cylinder head.
removed valve tappet.
Top view Under view

Identification mark
Identification mark AK304933AB

AK604588AB
12.Apply a 4 mm bead of liquid gasket as illustrated.
9. Calculate the thickness of the newly installed Specified sealant:
valve tappet through the following equation. LOCTITE 5971 or exact equivalent
A: thickness of newly installed valve tappet
CAUTION
B: thickness of removed valve tappet The timing chain should be installed within 3
C: measured valve clearance minutes of applying liquid gasket.
Equation 13.Install the cylinder head cover by tightening the
Intake valve: A = B + (C − 0.22 mm) fittings to 9.0 ± 1.0 N⋅m.
Exhaust valve: A = B + (C − 0.30 mm) 14.Install the ignition coils.
OTHERS
OTHERS
F1. CHECK BODY CONDITION FOR Drive the vehicle and check for conditions.
DAMAGE 1. Check free play of steering wheel.
M6020700100027 2. Check efficiency of service brakes and parking
1. Check underbody coating for damage. brakes system.
2. Check body painting for damage. 3. Check driveability of engine.
F2. ROAD TEST 4. Check condition of instruments, gauges
M6020700200091 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.
AC404799

5a4d20z30a 08 003eng

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

5a4d20z30a 08 003eng

Transféré par

Droits d'auteur :

Formats disponibles

0-1

PRECAUTIONS BEFORE SERVICE. 0-2 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3

PRECAUTIONS BEFORE SERVICE

If there is a likelihood of damaging interior or exterior

REMOVAL AND DISASSEMBLY

If other tools are substituted for the special tools to

Be careful to avoid spilling any brake fluid, because if

SERVICING THE ELECTRICAL SYSTEM

When replacing parts, use MITSUBISHI genuine

TUBES AND OTHER RUBBER PARTS

Before replacing a component related to the electri-

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

PRE-INSPECTION CONDITION MB991910

• M/T: Neutral Connect the M.U.T.-III to the diagnosis connector as

Approx. IN ORDER TO PREVENT VEHICLES

NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-11

BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 BEFORE ROAD TEST . . . . . . . . . . . . 1-13

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-15 37. MANUAL TRANSMISSION AND

TABLE OF PRE-DELIVERY INSPECTION

Term Definition Remarks

Press down the storage connector.

Wipe-off by kerosene or white gasoline, etc.

Disposal of removed film: Burning is appropriate

1. Visually inspect the entire exterior.

5. OPERATION OF DOOR MIRRORS,

12. ELECTRICAL WIRING

Inspect the battery connections. Verify that they are

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

BEFORE ROAD TEST

22. AIR CONDITIONER, HEATER AND

Check the operation of the various parts of the seats.

18. INHIBITOR SWITCH AC305625

20. INSTRUMENT PANEL CONTROLS

5. Instrument brightness control

AC305627 (2) Verify correct brake pedal free play.

2. Rear wiper and washer

24. OPERATION OF SERVICE BRAKES

1. Check the clutch operation in all driving ranges.

26. OPERATION OF SEAT BELTS,

3. Verify correct clutch pedal free play.

For inspection and adjustment of the free play of

28. TRANSMISSION IN ALL RANGES

AFTER ROAD TEST

34. IGNITION TIMING

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

37. MANUAL TRANSMISSION AND

Filler plug hole

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

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

39. ENGINE, TRANSMISSION, STEERING

40. FRONT AND REAR DIFFERENTIAL

45. OWNER INSTRUCTIONS

PERIODIC INSPECTION AND A12. CHANGE BRAKE FLUID . . . . . . . . . . 2-18

OPERATIONS INSIDE THE VEHICLE 2-24 OPERATIONS AFTER ENGINE IS

Maintenance item Maintenance Maintenance interval Application

Maintenance item Maintenance Maintenance interval Application

OPERATIONS INSIDE THE ENGINE COMPARTMENT

7. Gently tap the middle of the belt between the CAUTION

Use a belt tension gauge to check that the belt ten-

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

1. Loosen the nut of the nut for alternator pivot bolt.

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

Inspect the intake air hoses for cracks or damage.