0-1

GROUP 0

GENERAL
CONTENTS

HOW TO USE THIS MANUAL. . . . . . 0-2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

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

HOW TO USE THIS MANUAL

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

PRECAUTIONS BEFORE SERVICE

PROTECTING THE VEHICLE REMOVAL AND DISASSEMBLY
M6001000100029 M6001000300023

AC305590 AC305591

If there is a likelihood of damaging interior or exterior When checking a malfunction, find the cause of the
parts during service operations, protect them with problem. If it is determined that removal and/or dis-
suitable covers (such as seat covers, fender covers, assembly is necessary, perform the work by following
etc.). the procedures contained in this manual.

DOING SERVICE WORK IN GROUPS OF

TWO OR MORE MECHANICS
M6001000200026

AC305592

If punch marks or mating marks are made to avoid

AC305283
If the service work is to be done by two or more
mechanics working together, all the mechanics
involved should take safety into consideration while
they work.
error in assembly and facilitate the assembly work,
be sure to make them in locations which will have no
detrimental effect on performance and/or appear-
ance. If an area having many parts, similar parts,
and/or parts which are symmetrical right and left is
disassembled, be sure to arrange the parts so that
they do not become mixed during the assembly proc-
ess.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which
are to be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to
use only the exact size specified.
 GENERAL 0-3
PRECAUTIONS BEFORE SERVICE

SPECIAL TOOLS PARTS

M6001000400031 M6001000600024

AC305593 AC305284

If other tools are substituted for the special tools to When replacing parts, use MITSUBISHI MOTORS
do service of repair work, there is the danger that genuine parts.
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe- TUBES AND OTHER RUBBER PARTS
M6001000700021
cial tool whenever doing any work for which the use
of one is specified.

PARTS TO BE REPLACED
M6001000500027

AC305595

Be careful to avoid spilling any petrol, oil, etc.,

because if it adheres to any tubes or other rubber
parts, they might be adversely affected.
AC305594

If any of the following parts are removed, they must LUBRICANTS

M6001000800028
be replaced with new parts.
 Oil seals
 Gaskets (except rocker cover gasket)
 Packings
 O-rings
 Lock washers
 Split pins
 Self-locking nuts

AC305596

In accordance with the instructions in this manual,

apply the specified lubricants in the specified loca-
tions during assembly and installation.
0-4
PRECAUTIONS BEFORE SERVICE
BRAKE FLUID
M6001000900025
AC305285
Be careful to avoid spilling any brake fluid, because if
it adheres to the vehicle body, the paint coat might be
discoloured.
SERVICING THE ELECTRICAL SYSTEM
M6001001000081
CAUTION
Before connecting or disconnecting the negative
(-) cable, be sure to turn off the ignition switch
and the lighting switch. (If this is not done, there
is the possibility of semiconductor parts being
damaged.)
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
order to avoid damage caused by short-circuiting.
GENERAL
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
M6001001100022
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
M6001001200182
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
tion can be carried out. If you see the words "Set the
vehicle to the pre-inspection condition". In this man-
ual, it means to set the vehicle to the following condi-
tion.
 Engine coolant temperature: 80 to 90C
 Lamps, electric cooling fan and all accessories:
OFF
 M/T: Neutral
 A/T, CVT: P range
VEHICLE WASHING
M6001001300082
Approximately
40 cm or more
AC300832AC
If high-pressure car-washing equipment or steam
car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
 Spray nozzle distance: Approximately 40 cm or
more
 Spray pressure: 3,900 kPa or less
 Spray temperature: 82C or less
 Time of concentrated spray to one point: within
30 sec.
 GENERAL 0-5
PRECAUTIONS BEFORE SERVICE

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

M6001001600209
ASSEMBLY
M6001001900169 HEALTH WARNING
Refer to the "M.U.T.-III OPERATING INSTRUC- Prolonged and repeated contact with mineral oil will
TIONS" for instructions on handling the M.U.T.-III. result in the removal of natural fats from the skin,
CAUTION leading to dryness, irritation and dermatitis. In addi-
Turn the ignition switch to the LOCK (OFF) posi- tion, used engine oil contains potentially harmful con-
tion before connecting or disconnecting the taminants which may cause skin cancer. Adequate
M.U.T.-III. means of skin protection and washing facilities must
be provided.
Diagnosis connector
RECOMMENDED PRECAUTIONS
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
MB991910 risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
 Avoid prolonged and repeated contact with oils,
particularly used engine oils.
MB991824  Wear protective clothing, including impervious
gloves where practicable.
 Avoid contaminating clothes, particularly under-
pants, with oil.
 Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
 Do not wear heavily soiled clothing and
MB991827 AC505420AB oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from per-
Connect the M.U.T.-III to the diagnosis connector as
shown in the illustration. sonal clothing.
 Where there is a risk of eye contact, eye protec-
IN ORDER TO PREVENT VEHICLES tion should be worn, for example, chemical gog-
gles or face shields; in addition an eye wash
FROM FIRE facility should be provided.
M6001001500064
"Improper installation of electrical or fuel related parts  Obtain first aid treatment immediately for open
could cause a fire. In order to retain the high quality cuts and wounds.
and safety of the vehicle, it is important that any  Wash regularly with soap and water to ensure all
accessories that may be fitted or modifica- oil is removed, especially before meals (skin
tions/repairs that may be carried out which involve cleansers and nail brushes will help). After clean-
the electrical or fuel systems, must be carried out in ing, the application of preparations containing
accordance with MMC's information/Instructions". lanolin to replace the natural skin oils is advised.
 Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
 Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
 If skin disorders develop, obtain medical advice
without delay.
NOTES
 1-1

GROUP 1

PRE-DELIVERY
INSPECTION
CONTENTS

NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-16

14. TYRE AND SPARE TYRE 
PAINTWORK TERMS . . . . . . . . . . . . 1-5 PRESSURES . . . . . . . . . . . . . . . . . . . . . . . 1-16
15. SUSPENSION SYSTEM . . . . . . . . . . . . 1-16
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 16. STEERING LINKAGE 
1. CONNECTION OF DARK  AND SPLIT PINS. . . . . . . . . . . . . . . . . . . . . 1-16
CURRENT CONNECTOR . . . . . . . . . . . . . 1-6 17. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-17

BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 BEFORE ROAD TEST . . . . . . . . . . . . 1-17

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-8 18. SEAT ADJUSTERS AND 
3. WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 SEATBACK LATCHES . . . . . . . . . . . . . . . . 1-17
4. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-13 19. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-17
5. OPERATION OF DOOR LOCKING  20. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-17
SYSTEMS AND DOOR HINGES . . . . . . . . 1-13 21. INSTRUMENT PANEL CONTROLS . . . 1-17
6. OPERATION OF DOOR MIRRORS,  22. METERS, GAUGES, WARNING 
WINDOWS AND SUNROOF . . . . . . . . . . . 1-14 LAMPS AND INDICATION LAMPS . . . . . . . 1-17
23. AIR CONDITIONER, HEATER 
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-14 AND DEFROSTER SYSTEM . . . . . . . . . . . 1-17
7. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-14 24. WIPERS AND WASHERS. . . . . . . . . . . 1-18
8. BRAKE MASTER CYLINDER  25. OPERATION OF SERVICE BRAKES 
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-14 AND PARKING BRAKES . . . . . . . . . . . . . . 1-18
9. CLUTCH MASTER CYLINDER  26. CLUTCH OPERATION . . . . . . . . . . . . . 1-18
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-15 27. OPERATION OF SEAT BELTS, 
10. WASHER FLUID LEVEL. . . . . . . . . . . . 1-15 SHOULDER BELTS AND 
RETRACTORS . . . . . . . . . . . . . . . . . . . . . . 1-19
11. BATTERY CONDITION AND 
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-15
12. POWER STEERING FLUID LEVEL . . . 1-15
13. ELECTRICAL WIRING . . . . . . . . . . . . . 1-15

Continued on next page

1-2

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-19 38. MANUAL TRANSMISSION AND 

28. ENGINE PERFORMANCE  TRANSFER (4WD) OIL LEVEL . . . . . . . . . . 1-22
AND EXHAUST GAS . . . . . . . . . . . . . . . . . 1-19 39. AUTOMATIC TRANSMISSION 
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-22
29. TRANSMISSION IN ALL RANGES. . . . 1-19
30. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-20 40. ENGINE, TRANSMISSION, 
STEERING GEAR BOX AND 
31. STEERING CONTROL . . . . . . . . . . . . . 1-20 DIFFERENTIAL FOR LEAKS . . . . . . . . . . . 1-22
32. VIBRATION AND RATTLES . . . . . . . . . 1-20 41. FRONT AND REAR 
33. ELECTRICAL EQUIPMENT . . . . . . . . . 1-20 DIFFERENTIAL OIL LEVELS . . . . . . . . . . . 1-23
42. HOSES, FLUID LINES AND 
AFTER ROAD TEST . . . . . . . . . . . . . 1-21 CONNECTIONS LOCATED 
34. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-21 UNDER VEHICLE . . . . . . . . . . . . . . . . . . . . 1-23
35. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-21
36. RADIATOR COOLANT LEVEL . . . . . . . 1-21
FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-24
43. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-24
37. HOSES, FLUID LINES AND 
CONNECTIONS LOCATED  44. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-24
UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . 1-21 45. EXTERIOR AND INTERIOR . . . . . . . . . 1-24
46. OWNER INSTRUCTIONS . . . . . . . . . . . 1-24
 PRE-DELIVERY INSPECTION 1-3
NOTES CONCERNING ENTRIES

NOTES CONCERNING ENTRIES

M6010100100132
This section describes the details and the inspection methods employed for the pre-delivery inspection of
vehicles. 
The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY
INSPECTION. 
Inspection methods are described following the TABLE OF PRE-DELIVERY INSPECTION.
NOTE: The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in
kilometres (miles), date of inspection, name of person conducting the inspection, and body colour must be
completed without fail.
NOTE: The spaces for place of inspection, and name of owner should be completed as required.
1-4 PRE-DELIVERY INSPECTION
NOTES CONCERNING ENTRIES

TABLE OF PRE-DELIVERY INSPECTION

Model
Chassis number
Engine number 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
 PRE-DELIVERY INSPECTION 1-5
PAINTWORK TERMS

PAINTWORK TERMS
M6010200100098

Term Definition Remark

Blister A raised bubble in the paint (from the base
or the undercoat) caused by abnormal
moisture. The bubble may contain either
water or air.
Change in tone The colour tone of the painted surface is not Including wrong colour, discolouration
uniform. and decolouration.
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
1-6 PRE-DELIVERY INSPECTION
FIRST STEP

FIRST STEP
1. CONNECTION OF DARK CURRENT Press down the storage connector. After the connec-
CONNECTOR tor has been pressed down once, never pull up it.
M6010300100493 CAUTION
<EXCEPT EV, PHEV> Never disconnect the negative terminal of the
CONNECTING PROCEDURE auxiliary battery even if a vehicle is stored for
long term.
CAUTION
Turn the ignition switch to the LOCK (OFF) posi- CONFIRMATION OF PRODUCTION DATE
tion before connecting storage connector. OF MAIN BATTERY
Storage connector Confirm the production date of the main battery to
check whether the elapsed period after the main bat-
tery has been produced exceeds an estimated trans-
portation period. If it exceeds, compensate the BMU
by referring to the Workshop Manual.
For example:
If the estimated transportation period is three months
and the production date of the main battery is April:
Relay box  Before July 31: Compensation is not necessary
AC700018AB because the elapsed period does not exceed
Press down the storage connector. three months
 After August 1: Compensation is necessary
<EV> because the elapsed period exceeds three
months
CONNECTING PROCEDURE
CAUTION
Turn the electric motor switch to the LOCK (OFF)
position before connecting storage connector. Left rear tyre

<LHD> Storage connector

Bar-code Production Date

Junction block
ACA02852 AB

<RHD>
Serial number

AKA00558 AC

1. Location of production date

 The production date is labelled on the rear side of
Storage connector the main battery, and can be identified through
Junction block ACA02853 AB the rear left wheelhouse.
2. Estimated vehicle transportation period
 Europe: Three months
 PRE-DELIVERY INSPECTION
FIRST STEP
<PHEV>
CONNECTING PROCEDURE
CAUTION
Turn the electric motor switch to the LOCK (OFF)
position before connecting storage connector.
Storage connector
Relay box
AC700018AB
Press down the storage connector. After the connec-
tor has been pressed down once, never pull up it.
CAUTION
Never disconnect the negative terminal of the
auxiliary battery even if a vehicle is stored for
long term. If you turn the electric motor switch
"ON" while the storage connector is discon-
nected, the warning message as "EV SYSTEM
SERVICE REQUIRED" with a warning icon
appears on the centre display.
EV SYSTEM
SERVICE REQUIRED
ACD03919
It is the normal behaviour and nothing wrong
with the vehicle. However, if you connect the
storage connector under this condition, the diag-
nosis code will be set in the ECU. Consequently
you need to delete it before delivering the vehicle
to your customer. In order to avoid this unneces-
sary diagnosis code, please make sure that the
storage connector is connected only when the
electric motor switch is turned "OFF".
1-7
CONFIRMATION OF PRODUCTION DATE
OF MAIN BATTERY
Confirm the production date of the main battery to
check whether the elapsed period after the main bat-
tery has been produced exceeds an estimated trans-
portation period. If it exceeds, compensate the BMU
by referring to the Workshop Manual.
For example:
If the estimated transportation period is three months
and the production date of the main battery is April:
 Before July 31: Compensation is not necessary
because the elapsed period does not exceed
three months
 After August 1: Compensation is necessary
because the elapsed period exceeds three
months
Vehicles front
Drive battery
Bar code Production date
Serial number Parts number
ACD03690AD
1. Location of production date
 The production date is labelled on the rear side of
the main battery, and can be identified through
the rear left wheelhouse.
2. Estimated vehicle transportation period
 Europe: Three months
1-8 PRE-DELIVERY INSPECTION
BODY

BODY
2. WRAP FILM
M6010400100241

AC305606

Vehicles may be shipped from the assembly plant to

the distributors with a white plastic film or coating
(wrap film) applied for the purpose of protecting the
painted exterior from environmental elements where
the assembly plant and point of embarkation is
located.
Distributors are required to remove the wrap film
immediately after receiving vehicles, which is neces-
sary for PDI operations. Please refer to the following
chart for the procedures.

REMOVAL PROCEDURE

Flow Chart of Wrap Film Removal

Wrap film removal Peel off from the corners of the wrap film. High temperature or
low temperature may cause wrap film to become brittle. For
easier removal, the recommended Wrap Film temperature is
below 40˚C. (i.e.: If the surface of the vehicle is hot, lower it to
40˚C or less by sprinkling water so the peeling off will be
easier.)

Rinse off debris such as sand and dust thoroughly. Then dry
Water washing the surface thoroughly.

If adhesive residue is left on the painted surface, wipe it off

with kerosene or white gasoline. If the residue is still visible,
Cleaning of border use a polishing compound for a fine finish. If you use such
solvents or compound, make sure to wipe it off.

Dispose removed film according to local

regulations. ACB04862 AB
 PRE-DELIVERY INSPECTION
BODY
The procedures to re-apply the wrap film
ACB04328
If there is an environment that the vehicles in stock
may be exposed to elements such as acid rain, dust
particles, it may be recommendable to re-apply the
wrap film for the purpose of protecting the painted
exterior from the environment. Please refer to the fol-
lowing chart for the procedures to re-apply the wrap
film.
Steps. Process
1 Remove old wrap film
2 Prepare the surface to adhere the wrap
film
3 Re-apply the wrap film
1-9
Tips
Follow the "flow chart of removing the wrap film"
Make sure there is no debris such as sand or dust. Dry
the surface thoroughly. The temperature of the area to
apply the wrap film should be below 40C for workability.
The area to re-apply the wrap film is the same area
where the original wrap film was applied.
1. Begin adhering the wrap film from the low part of the
vehicle and move upward. Maintain some tension on
the wrap film so it will not get wrinkled or trap air
bubbles. Although air bubbles it self will not damage
the paint, you can avoid trapping air by adhering the
wrap film from the centre to the out side of the
vehicle. Use a tool such as a squeezer to adhere the
wrap film firmly to the vehicle.
2. For moving panels such as the hood and trunk lid, or
portion where parts such as windshield washer
nozzles are pointing out, cut the wrap film
accordingly, so it will adhere to the paint surface
firmly.
3. If the top side of the film (the side without the
adhesive) is left to contact the painted surface, it may
damage the paint surface. (for example, become
lusterless). The edges of the wrap film and
overlapping portions should be firmly adhered to
prevent entry of rain under the wrap film.
4. To prevent colour difference to be recognised
between the areas wrapped and unwrapped due to
exposure to sunlight etc. during storage, we
recommend the boundary of wrapped and
unwrapped areas be on a vertical location.
1-10 PRE-DELIVERY INSPECTION
BODY

Steps. Process Tips

CAUTION
 Be careful not to damage the paint surface while cutting the wrap film.
 Once the wrap film is adhered to the vehicle, it should remain on the vehicle for no more than 6
months. If it is necessary, a new wrap film should be adhered to the vehicle following the steps
above, based on your inventory management schedule.

Guidelines to give you an estimate of the How to acquire the wrap film
labour costs It will be a direct transaction between O-WELL. Fill
Approximate labour time to adhere wrap film the necessary information, contact information;*1
and ordering quantity;*2 in the specified portion of
area to apply wrap film (m2) labour time (min) the document attached below and send to O-WELL
3.5 - 5.5 10 - 15 Corporation. The necessary information is stated in
the document attached below. O-WELL will give you
5.5 - 7.0 15 - 20
a quotation in return.
PRE-DELIVERY INSPECTION 1-11
BODY
1-12 PRE-DELIVERY INSPECTION
BODY
 PRE-DELIVERY INSPECTION 1-13
BODY

3. WHEEL 5. OPERATION OF DOOR LOCKING

M6010400500012
SYSTEMS AND DOOR HINGES
M6010400300137

ACD02910 Front
AC305608 AB
Vehicles may be shipped from the assembly plant to
the distributors with a plastic film or cover (non-adhe-
sive type) applied in order to avoid rust of the brake
disc. Distributors should remove the plastic film or
cover just before delivering the vehicle to your cus-
tomer. However, the plastic film should be removed
in five months after the vehicle is delivered to the dis-
tributor. The plastic cover can be kept for more than
five months.
CAUTION
Be careful not to damage the paint surface when AC210253AB
removing the plastic film or cover.
1. Open each door to check the release mechanism
4. EXTERIOR and ease of operation.
M6010400200301
2. Close the door to check the latch and striker.
1. Visually inspect the entire exterior.
(1) Paint condition 3. Open the door, operate the lock lever and close
the door to check the lock.
(2) Corrosion, scratches
4. Partially close the door to check the open-door
(3) Bent edges, dented panels
detent.
2. Coated surfaces maintenance 
5. Unlock each door with the key to check lock
Touch up minor paint chips and flaws.
operation.
(Refer to paintwork terms)
6. Verify that all doors can be locked by the lock
buttons.
NOTE: Adjust and lubricate the door latches, strikers
and locks as required.
1-14 PRE-DELIVERY INSPECTION
UNDER HOOD

6. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF
M6010400400190
1. Door mirrors
Check that the mirror operate properly.
2. Door windows
Close all door windows to the fully closed position
to check ease of operation.
Child-protection knob
AC305610 AB
3. Power windows
7. Verify that the rear doors can't be opened by the Check that the door windows operate when the
inner door handle when the child protection knob respective switches are operated. Check that
at the end of the door is shifted to the "LOCK" when the lock switches are depressed, the
position with the inside lock plunger raised. respective door windows can no more be opened
or closed.
NOTE: Set the lock to the "FREE" position on child
protection of both rear doors. (For four door models) 4. Slide window
Close the slide window to the fully closed position
to check operation.
5. Sunroof
Close the sunroof to the fully closed position to
check operation.

UNDER HOOD
7. ENGINE OIL LEVEL 8. BRAKE MASTER CYLINDER FLUID
M6010500100293
LEVEL
M6010500200223

MAX

MIN

AC702169

Check that the oil level is between "MAX" and "MIN". AC702028

If it is at or below "MIN", add the necessary amount Check the fluid level.
of the specified engine oil referring to GROUP 2, If it is below the "MIN" mark, replenish fresh brake
Periodic Inspection and Maintenance. fluid up to the "MAX" mark.
Specified Brake Fluid: DOT3 or DOT4
 PRE-DELIVERY INSPECTION 1-15
UNDER HOOD

9. CLUTCH MASTER CYLINDER FLUID 12. POWER STEERING FLUID LEVEL

M6010500600072
LEVEL
M6010500300026

AC305616

AC305613
1. Check that the fluid level is between "MAX" and
Check the fluid level. "MIN".
If it is below the "MIN" mark, replenish fresh brake 2. If the fluid is added, start the engine and turn the
fluid up to the "MAX" mark. steering wheel from stop to stop several times to
Specified Brake Fluid: DOT3 or DOT4 expel air from the system.
Specified gear oil: Automatic transmission
10. WASHER FLUID LEVEL fluid DEXRON III or DEXRON II
M6010500400186

13. ELECTRICAL WIRING

M6010500700024

AC305614

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

fluid. AC305617
1. Windshield washer reservoir
1. Each electrical wiring harness and connector
2. Rear window washer reservoir
(1) Check each harness to be correctly routed
11. BATTERY CONDITION AND and securely clipped.
(2) Confirm that all connections are tight.
CONNECTIONS
M6010500500042 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.

AC305615

Inspect the battery connections. Verify that they are

tightened.
NOTE: Do not wipe the lubricant from the battery
posts and cable clamps.
1-16 PRE-DELIVERY INSPECTION
UNDER VEHICLE

UNDER VEHICLE
14. TYRE AND SPARE TYRE PRESSURES REMOVE FRONT SPRING RESTRAINTS
M6010600100041
CAUTION
It is very important that these restraints must be
removed during pre-delivery inspection. Failure
to do so could cause ride and handling com-
plaints.

Spring
restraints

AC305618

1. Tyre specification 
Check the correct tyre specification.
2. Tyre pressures 
Adjust each tyre pressure. AC305605

NOTE: Recommended pressure is shown on the With the vehicle correctly positioned on the
tyre pressure label. sub-frame contact points, and the suspension fully
3. Valve stem extensions  extended, remove the rubber restraints from the front
Verify that the valve stem extensions are installed springs.
where necessary.
4. Install the wheel covers, wheel rings and hub 16. STEERING LINKAGE AND SPLIT PINS
M6010600300023
caps.
5. On vehicles with TPMS, the 'Tyre Pressure
Monitoring System (TPMS)' needs to be activated
during the pre-delivery inspection of the vehicle 
(if applicable). During PDI each Tyre Pressure
Monitoring sensor in four tyres (with a tyre repair
kit) or five tyres (including a spare wheel) needs to
be activated with the trigger tool to enable the tyre
pressure monitoring function.
AC305604
15. SUSPENSION SYSTEM
M6010600200178
1. Steering linkage retaining nuts and split pins
Check visually and by feel that the steering
linkage retaining nuts are correctly tightened and
the split pins are correctly installed.
2. Tie rods and relay rod 
Check that the tie rods and relay rod of the
steering linkage are not bent and that the tie rod
end lock nuts are securely tightened.
3. Steering components
(1) Check that each of the steering components is
AC305609
tightened.
Check to be sure that each installation bolt and nut is (2) Check the tie rod end, nuts and split pins for
tightened. If split pins are used, make sure that they proper installation.
are properly installed.
(3) Check the condition of bellows-type dust
1. Lower arm, Upper arm seals.
2. Stabilizer bar
3. Strut assembly
 PRE-DELIVERY INSPECTION 1-17
BEFORE ROAD TEST

4. Split pins  17. UNDER BODY

Check the front axle nuts and rear wheel spindle M6010600400020

nuts for split pins. Check under body and under body coating for dam-
age.

BEFORE ROAD TEST

18. SEAT ADJUSTERS AND SEATBACK 22. METERS, GAUGES, WARNING
LATCHES LAMPS AND INDICATION LAMPS
M6010700100082 M6010700500024

AC305622 AC305624

Check the operation of the various parts of the seats. 1. Check the meters and gauges are functioning
1. Mechanical adjusters of the seats properly.
2. Operation of the latch for tilting the seatbacks 2. Check each indicator lamp and warning lamp
forward and backward. functions properly.
19. INHIBITOR SWITCH 23. AIR CONDITIONER, HEATER AND
M6010701100029
On models with an automatic transmission, be sure DEFROSTER SYSTEM
M6010700600128
the engine starts in both "P" and "N" position, and
Check the systems for proper operation.
does not start in other positions.

20. IDLE CONTROL KNOB

M6010700300020
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.

21. INSTRUMENT PANEL CONTROLS

M6010700400083
Check the operation of the following
1. Horn
AC305625
2. Headlamps
3. Exterior and interior lamps 1. Air conditioner
4. Instrument panel lamps (1) Operate the air conditioner system.
5. Instrument brightness control (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
(4) Operate the blower motor switch in all ranges.
1-18 PRE-DELIVERY INSPECTION
BEFORE ROAD TEST

25. OPERATION OF SERVICE BRAKES

AND PARKING BRAKES
M6010700800382

Depress the brake pedal

with approximately 500
N force

AC305626

2. Heater and defroster

(1) After the engine has warmed up, turn on the AC305628 AB
heater.
(2) Operate the blower motor switch in all ranges. 1. Service brakes
(3) Move the control to "Defrost" position. (1) Check the clearance between the brake pedal
A: From front and side defroster and the floorboard when the brake pedal is
depressed.
B: From centre ventilators
C: From side ventilators
D: From under the instrument panel
E: From under the front seat (some models
only)

24. WIPERS AND WASHERS

M6010700700028

AC305629

(2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the
service brake, refer to GROUP 2, Periodic
Inspection and Maintenance.
2. Parking brake 
AC305627
Check the parking brake drag and lever travel.
NOTE: For inspection and adjustment of the park-
1. Front wiper and washer ing brake, refer to GROUP 2, Periodic Inspection
(1) Check operation of the front wipers in all and Maintenance.
ranges.
(2) Check the aim of the front washer stream. 26. CLUTCH OPERATION
M6010700900282
(3) Check the wiper blade-stop positions.
(4) Verify that the interval between cycles of
wiping is shifted when timer knob is turned to
any position.
(5) Verify that the front wipers function by
operating the washer switch.
2. Rear wiper and washer
(1) Check the operation of the rear wiper.
(2) Check the aim of the rear washer stream.
AC305630AC
(3) Check the wiper blade-stop positions.
1. Check the clutch operation in all driving ranges.
 PRE-DELIVERY INSPECTION 1-19
ROAD TEST

2. Check the pedal to floorboard clearance when the 27. OPERATION OF SEAT BELTS,
clutch is just disengaged. SHOULDER BELTS AND RETRACTORS
M6010701000022

AC305631
3. Verify correct clutch pedal free play.
NOTE: For inspection and adjustment of the
clutch pedal, refer to GROUP 2, Periodic Inspec-
tion and Maintenance.
AC305632
1. Verify that the seat belt warning lamp operates
properly.
2. Check all seat belts and harnesses to assure that
they connect and hold properly.
3. Lean forward to check that the shoulder
harnesses allow movement.
4. Check the condition of the belts and anchors.
5. Check for proper seat belt retraction.

ROAD TEST
28. ENGINE PERFORMANCE AND 29. TRANSMISSION IN ALL RANGES
M6010800200020
EXHAUST GAS
M6010800100023

AC305634

AC305633
1. Manual transmission 
1. Engine performance  Check the transmission in all forward ranges and
Check the engine for proper performance and in reverse.
accelerator pedal for smooth operation.
2. Exhaust system
(1) Check the exhaust system components for
gas leaks.
(2) Verify that no black smoking is emitted from
the end of the exhaust pipe (diesel-powered
vehicles).
1-20 PRE-DELIVERY INSPECTION
ROAD TEST

31. 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 32. 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 33. ELECTRICAL EQUIPMENT
transmission requires further service. M6010800600028

30. 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.
 PRE-DELIVERY INSPECTION 1-21
AFTER ROAD TEST

AFTER ROAD TEST

34. IDLE SPEED 37. HOSES, FLUID LINES AND
M6010900100172
Check the engine idle speed. CONNECTIONS LOCATED UNDER HOOD
M6010900400203
NOTE: For specific idle speed adjustment proce- CAUTION
dure, refer to GROUP 2, Periodic Inspection and Remember that the air conditioner system is
Maintenance. under pressure.
35. IGNITION TIMING
M6010900200179

AC305643

AC305641
Check the ignition timing. Except MPI vehicles with
crankshaft-mounted crankshaft angle sensor.
NOTE: For the inspection and adjustment of the igni-
tion timing, refer to GROUP 2, Periodic Inspection
and Maintenance.
36. RADIATOR COOLANT LEVEL
M6010900300154
CAUTION
Do not remove the radiator cap while the cooling
system is under pressure. 
When removing the radiator cap, be careful of
steam and boiling water. Add coolant only to the
reserve tank if it is required.
1. Check all brake, fuel, power steering and air
conditioner lines and connections; verify proper
routing, check connections for leaks, tighten loose
connector as required.
2. Inspect routing and connections of all vacuum,
and radiator and heater houses.
NOTE: Keep in mind that an oily residue around
an air conditioner connector does not necessarily
indicate a leak. Oil is used to lubricate fittings dur-
ing assembly. Be sure lines are not twisted or
kinked.

AC305642

1. Check that the coolant level in the reserve tank is

at or above "LOW" mark at normal engine
operating temperature. And check cooling system
for leaks.
2. Check that the coolant concentration is 30% to
60%.
1-22 PRE-DELIVERY INSPECTION
AFTER ROAD TEST

38. MANUAL TRANSMISSION AND 39. AUTOMATIC TRANSMISSION FLUID

TRANSFER (4WD) OIL LEVEL LEVEL
M6010900500330 M6010900600230

CAUTION
Gaskets (or packing) for the oil filler plug and the
drain plug are non-reusable parts. Always
replace them with new one, or oil leaks may be
caused.

Filler plug hole

Gasket
AC005861AD

1. Remove the dipstick and check the fluid level.

Filler plug
Transmission oil
AC700330AL
1. Remove the filler plug.
2. Check the oil level. If the oil level is at or slightly
below the filler hole, it is in satisfactory condition.
NOTE: For oil level, refer to GROUP 2, Periodic
Inspection and Maintenance.
3. If the level is low, replenish the transmission and
transfer case with fresh oil by using a lubricator.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance.
4. Renew a gasket, because it is a non-reusable
part.
5. Install the filler plug with a new gasket, and tighten
it to the specified torque.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance.
2. Fluid level is okay if it is in the specified range as
illustration at normal engine operating
temperature.
3. If the level is below the lower notch, replenish fluid
until the level reaches the upper notch.
NOTE: For the specified automatic transmission
fluid, refer to GROUP 2, Periodic Inspection and
Maintenance.
40. ENGINE, TRANSMISSION, STEERING
GEAR BOX AND DIFFERENTIAL FOR
LEAKS
M6010900700055
Check the engine, transmission, steering gear box
and differential for oil leaks.
 PRE-DELIVERY INSPECTION 1-23
AFTER ROAD TEST

41. FRONT AND REAR DIFFERENTIAL 42. HOSES, FLUID LINES AND
OIL LEVELS CONNECTIONS LOCATED UNDER
M6010900800427
VEHICLE
CAUTION M6010901000145
Gaskets (or packing) for the oil filler plug and the
drain plug are non-reusable parts. Always
replace them with new one, or oil leaks may be
caused.
1. Remove the filler plug.
2. Check the oil level. If the oil level is at or slightly
below the filler hole, it is in satisfactory condition.


TYPE 1 TYPE 2

AC305647

1. Check all hoses, fluid lines and connections for

Gear oil
Upper leaks.
limit
2. Check all hoses and fluid lines for proper routing
away from sharp edges and moving components.
Lower
limit
AC305646 AD

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

gear oil level.
NOTE: For oil level, refer to GROUP 2, Periodic
Inspection and Maintenance.
3. If the level is low, replenish the front and/or rear
differential with fresh oil by using a lubricator.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance.
4. Renew a gasket, because it is a non-reusable
part.
5. Install the filler plug with a new gasket, and tighten
it to the specified torque.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance.
1-24 PRE-DELIVERY INSPECTION
FINAL STEPS

FINAL STEPS
43. HEADLAMP AIMING 45. EXTERIOR AND INTERIOR
M6011000100116 M6011000300262
Finally check and clean the exterior and interior.
1. Wash the vehicle to remove all traces of road
Screen grime and other dirt on the vehicle as a result of
Headlamp
new vehicle preparations.
2. Clean exterior and interior glass surface.
3. Remove all protective covers.
Level surface 4. Remove undercoat overspray, excess window
sealer, and excess weatherstrip adhesive.
AC305648 AB
5. Verify that the secondary key can not unlock the
glove box and tailgate/boot lid (if so equipped).
Check condition for headlamp aiming. 6. Remove shipping and inspection stickers.
NOTE: For headlamp aiming procedures, refer to the
Workshop Manual for that model. 46. OWNER INSTRUCTIONS
M6011000400054

44. EQUIPMENT 1. Verify that the owner's manual and service

M6011000200209 booklet is in the glove box.
2. Place the spare keys in envelope in the glove box
before delivery.

AC305649

Check the installation of the various equipment.

1. Trunk room floor mats
2. Spare tyre
3. Jack, jack handle and tool set
 2-1

GROUP 2

PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS

PERIODIC INSPECTION AND  OPERATIONS UNDER 

MAINTENANCE SCHEDULE . . . . . . 2-3 THE VEHICLE. . . . . . . . . . . . . . . . . . . 2-19
CHECK SUSPENSION SYSTEM 
OPERATIONS INSIDE THE  FOR DAMAGE AND LOOSENESS. . . . . . . 2-19
ENGINE COMPARTMENT. . . . . . . . . 2-6 CHECK SUSPENSION ARM 
CHECK DRIVE BELT FOR  BALL JOINTS FOR PLAY, AND 
CRACKS, FRAYING, WEAR,  DUST COVERS FOR DAMAGE . . . . . . . . . 2-20
AND ADJUST ITS TENSION . . . . . . . . . . . 2-6 LUBRICATE PROPELLER SHAFT 
CHECK INTAKE AIR HOSE AND  WITH GREASE FITTING . . . . . . . . . . . . . . 2-20
TURBOCHARGER OIL HOSE  CHECK DRIVESHAFT BOOTS 
FOR DAMAGE (VEHICLES  FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-20
WITH TURBOCHARGER) . . . . . . . . . . . . . 2-10 CHECK STEERING LINKAGE 
CHECK VALVE CLEARANCE  FOR DAMAGE AND 
(EXCEPT VEHICLES WITH  LOOSE CONNECTIONS 
AUTO-LASH ADJUSTER) . . . . . . . . . . . . . 2-10 (INCLUDING SEALS AND BOOTS) . . . . . . 2-20
CHECK RADIATOR HOSES  CHECK MANUAL TRANSMISSION 
FOR DAMAGE AND  FOR OIL LEAKAGE 
PROPER CONNECTION . . . . . . . . . . . . . . 2-13 (IN CASE OF LEAKAGE, 
CHECK ENGINE COOLANT  CHECK THE OIL LEVEL) . . . . . . . . . . . . . . 2-21
LEVEL IN RESERVOIR . . . . . . . . . . . . . . . 2-13 CHECK TRANSFER FOR 
CHANGE ENGINE COOLANT . . . . . . . . . . 2-13 OIL LEAKAGE 
(IN CASE OF LEAKAGE, 
CHECK AIR CLEANER ELEMENT 
CHECK THE OIL LEVEL) . . . . . . . . . . . . . . 2-21
FOR CLOGGING AND DAMAGE . . . . . . . . 2-14
CHANGE GEAR OIL IN 
REPLACE AIR CLEANER ELEMENT . . . . 2-14
MANUAL TRANSMISSION . . . . . . . . . . . . . 2-22
CHECK FLUID LEVEL IN 
CHANGE GEAR OIL IN TRANSFER . . . . . 2-22
BRAKE RESERVOIR AND 
CLUTCH RESERVOIR . . . . . . . . . . . . . . . . 2-15 CHECK FRONT AND REAR 
DIFFERENTIAL FOR OIL LEAKAGE 
CHANGE BRAKE FLUID . . . . . . . . . . . . . . 2-15
(IN CASE OF LEAKAGE, 
CHECK BATTERY CONDITION. . . . . . . . . 2-16 CHECK THE OIL LEVEL) . . . . . . . . . . . . . . 2-23
REPLACE FUEL FILTER . . . . . . . . . . . . . . 2-17

Continued on next page

2-2

CHANGE GEAR OIL IN FRONT  CHECK BRAKE SHOE LININGS 

AND REAR DIFFERENTIAL . . . . . . . . . . . . 2-24 AND DRUMS FOR WEAR . . . . . . . . . . . . . 2-34
CHECK EXHAUST PIPE  CHECK FUEL HOSES AND 
CONNECTIONS FOR GAS LEAKAGE,  PIPES FOR LEAKAGE 
AND CHECK PIPE INSTALLATION . . . . . . 2-26 OR DETERIORATION. . . . . . . . . . . . . . . . . 2-35

OPERATIONS INSIDE  OPERATIONS AFTER ENGINE 

THE VEHICLE . . . . . . . . . . . . . . . . . . 2-26 IS WARMED UP . . . . . . . . . . . . . . . . . 2-36
CHECK BRAKE PEDAL  CHECK FLUID LEVEL IN 
AND CLUTCH PEDAL  AUTOMATIC TRANSMISSION . . . . . . . . . . 2-36
FOR FREE PLAY . . . . . . . . . . . . . . . . . . . . 2-26 CHANGE AUTOMATIC 
CHECK PARKING BRAKE  TRANSMISSION FLUID . . . . . . . . . . . . . . . 2-38
LEVER STROKE AND PLAY . . . . . . . . . . . 2-28 CHANGE ENGINE OIL . . . . . . . . . . . . . . . . 2-39
REPLACE AIR PURIFIER FILTER . . . . . . . 2-28 REPLACE ENGINE OIL FILTER . . . . . . . . . 2-39

OPERATIONS OUTSIDE  OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-40

THE VEHICLE . . . . . . . . . . . . . . . . . . 2-29 CHECK BODY CONDITION 
CHECK WHEEL ALIGNMENT . . . . . . . . . . 2-29 FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-40
CHECK FRONT WHEEL  CHECK THE COMMON RAIL ENGINE 
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-31 (SMALL INJECTION QUANTITY 
CHECK BRAKE HOSES AND  LEARNING) . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
PIPES FOR LEAKAGE . . . . . . . . . . . . . . . . 2-31 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 2-41
CHECK BRAKE PADS AND 
DISCS FOR WEAR. . . . . . . . . . . . . . . . . . . 2-32
 PERIODIC INSPECTION AND MAINTENANCE 2-3
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

M6020100102902
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
Maintenance item Maintenance Maintenance interval
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
Check drive belt for cracks, fraying, wear, and Inspection Every 40,000 km or every 2 years
adjust its tension (P.2-6)
Check intake air hose for damage  Inspection Every 40,000 km or every 2 years
(vehicles with turbocharger) (P.2-10)
Check valve clearance*1 Inspection Every 60,000km
(except vehicles with auto-lash adjuster) (P.2-10)
Check radiator hoses for damage and proper Inspection Every 20,000 km or every 12 months
connection (P.2-13)
Check engine coolant level in reservoir (P.2-13) Inspection Every 20,000 km or every 12 months
Change engine coolant (P.2-13) Change First 200,000 km or 10 years, thereafter
every 120,000 km or 6 years
Check air cleaner element for clogging and Inspection Normal Every 20,000 km or every 12
damage (P.2-14) usage months
Severe Every 10,000 km or every 6
usage months
Replace air cleaner element (P.2-14) Replace Normal Every 60,000 km or every 3
usage years
Severe More frequently
usage
Check fluid level in brake reservoir and clutch Inspection Every 20,000 km or every 12 months
reservoir (P.2-15)
Change brake fluid (P.2-15) Change Every 40,000 km or every 2 years
Check battery condition (P.2-16) Inspection Every 20,000 km or every 12 months
Replace fuel filter (P.2-17) Replace Every 40,000 km or every 2 years
OPERATIONS UNDER THE VEHICLE
Check suspension system for damage and Inspection Every 20,000 km or every 12 months
looseness (P.2-19)
Check suspension arm ball joints for play, and Inspection Every 20,000 km or every 12 months
dust covers for damage (P.2-20)
Check steering linkage for damage and loose Inspection Every 20,000 km or every 12 months
connections (including seals and boots) (P.2-20)
Lubricate propeller shaft with grease fitting Lubrication Every 20,000 km or every 12 months
(P.2-20)
Check driveshaft boots for damage (P.2-20) Inspection Normal Every 20,000 km or every 12
usage months
Severe Every 10,000 km
usage
2-4 PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

Check manual transmission for oil leakage Inspection Every 20,000 km or every 12 months
(In case of leakage, check the oil level) (P.2-21)
Check transfer for oil leakage Inspection Every 20,000 km or every 12 months
(In case of leakage, check the oil level) (P.2-21)
Change gear oil in manual transmission (P.2-22) Change Normal Every 100,000 km
usage
Severe Every 40,000 km
usage
Change gear oil in transfer (P.2-22) Change Normal Every 100,000 km
usage
Severe Every 40,000 km
usage
Check front and rear differential for oil leakage Inspection Every 20,000 km or every 12 months
(In case of leakage, check the oil level) (P.2-23)
Change gear oil in front and rear differential Change Normal Every 80,000 km
(P.2-24) usage
Severe Every 40,000 km
usage
Check exhaust pipe connections for gas leakage, Inspection Every 40,000 km or every 2 years
and check pipe installation (P.2-26)
OPERATIONS INSIDE THE VEHICLE
Check brake pedal and clutch pedal for free play Inspection Every 20,000 km or every 12 months
(P.2-26)
Check parking brake lever stroke and play Inspection Every 20,000 km or every 12 months
(P.2-28)
Replace air purifier filter. (P.2-28) Replace Every 15,000 km or every 12 months
OPERATIONS OUTSIDE THE VEHICLE
Check wheel alignment (P.2-29) Inspection Every 20,000 km or every 12 months
Check front and rear wheel bearings for play Inspection Every 60,000 km or every 3 years
(P.2-31)
Check brake hoses and pipes for leakage Inspection Every 20,000 km or every 12 months
(P.2-31)
Check brake pads and discs for wear (P.2-32) Inspection Normal Every 20,000 km or every 12
usage months
Severe Every 10,000 km or every 6
usage months
Check brake shoe linings and drums for wear Inspection Normal Every 40,000 km or every 2
(P.2-34) usage years
Severe Every 20,000 km or every 12
usage months
Check fuel hoses and pipes for leakage or Inspection Every 40,000 km or every 2 years
deterioration (P.2-35)
 PERIODIC INSPECTION AND MAINTENANCE 2-5
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

OPERATIONS AFTER ENGINE IS WARMED UP

Check automatic transmission for fluid leakage Inspection Every 20,000 km or every 12 months
(In case of leakage, check the oil level) (P.2-36)
Change automatic transmission fluid (P.2-38) Change Severe Every 100,000 km
usage
Change engine oil (P.2-39) Change Normal Every 20,000 km or every 12
usage months
Severe Every 10,000 km
usage
Replace engine oil filter (P.2-39) Replace Normal Every 20,000 km or every 12
usage months
Severe Every 10,000 km
usage
OTHERS
Check body condition for damage (P.2-40) Inspection Every year
Check the common rail engine Inspection Every 20,000 km or every 12 months
(small injection quantity learning) (P.2-40)
Road test (P.2-41) Inspection Every 20,000 km or every 12 months

NOTE: *1: If found any noise from the valve any time, please check valve clearance.
"Severe usage" specifications apply to only vehicles used under severe operating conditions.
Severe operating conditions include the following cases:
.
1. Driving in a dusty area or in an area in which the vehicle is likely to be exposed to salty air or brine.
2. Driving on rough roads, on submerged roads, or hilly areas.
3. Driving cold zones.
4. Engine idling for a long time or short-distance travel during cold weather.
5. Frequent, sudden application of brakes.
6. Towing of a trailer.
7. Use as a taxi or as a rent-a-car.
8. More than 50% of operation time in heavy city traffic in hot temperatures of 32C or higher.
9. More than 50% of operation time at speeds of 120 km/h or higher in hot temperatures of 30C or higher.
2-6 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT

OPERATIONS INSIDE THE ENGINE COMPARTMENT

CHECK DRIVE BELT FOR CRACKS, POWER STEERING OIL PUMP AND A/C
FRAYING, WEAR, AND ADJUST ITS COMPRESSOR DRIVE BELT TENSION
TENSION CHECK AND ADJUSTMENT <4N1>
M6020202901102
DRIVE BELT TENSION CHECK 
.

DRIVE BELT CONDITION

Check the whole rounds of the V-belt for cracks, fray-
<Vehicles without A/C>
ing and wear. CAUTION
 When checking the drive belt tension, make
ALTERNATOR DRIVE BELT TENSION sure that the engine is cold.
CHECK <4N1>  Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
CAUTION
Check the drive belt tension in the following proce-
Check the drive belt tension after turning the dure.
crankshaft clockwise one turn or more.
Standard value:
Item When When When
checked adjusted replaced
Vibration A 167  214 193  214 227  245
frequency B 125  160 144  160 169  183
B Hz
Indicator mark Tension N A, 294  490 392  490 542  640
B
Deflection A 8.4  11.6 8.4  9.9 6.8  7.8
ACE02203AB
mm B 11.0  14.7 11.0  12.7 9.0  10.2
(Reference)
Drive belt .

auto-tensioner A <When the vibration frequency is

measured: Recommendation>
Belt tension meter set (MB992080)

Indicator mark MB992081

View B ACE02204AB

1. Make sure that the indicator mark is within the

area marked with A in the illustration.
2. If the mark is out of the area, replace the drive MB992082
belt. AC507219AB

NOTE: The drive belt tension adjustment is not
necessary as the drive belt auto-tensioner is
adopted.
1. Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
(MB992081) of special tool belt tension meter set
(MB992080).
2. Press the "POWER" button to turn on the power
supply.
3. Check how the belt tension meter is set.
 PERIODIC INSPECTION AND MAINTENANCE 2-7
OPERATIONS INSIDE THE ENGINE COMPARTMENT

4. Press "Hz" button twice to change the display to
the frequency display (Hz).
CAUTION
 Do not let any contaminants such as water or
oil get onto the microphone.
 If strong gusts of wind blow against the
microphone or if there is loud sources of
noise nearby, the values measured by the
microphone may not correspond to actual
values.
 If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not corre-
6. Press the "MEASURE" button.
7. Gently tap the middle of the drive belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration.
8. Check that the vibration frequency of the drive
belt is within the standard value.
NOTE: To take the measurement repeatedly, fillip
the drive belt again.
9. After the completion of the measurement, press
and hold the "POWER" button to turn off the
power supply.
.

<When tension is measured>

spond to actual values.
 Do not take the measurement while the vehi-
Power steering
cle's engine is running.
oil pump pulley

Power steering
oil pump pulley

10 – 15 mm

Gently tap
A
with your finger
15˚
B Belt tension
15˚ gauge

B Idler pulley
MB992080

Idler pulley
ACE03250AB

Use a belt tension gauge in the middle of the drive

ACE03249AB
5. Hold special tool MB992080 to the middle of the
drive belt between the pulleys (at the place
indicated by arrow) where it does not contact the
belt between the pulleys shown in the figure to check
that the drive belt tension is within the standard
value.
.

drive belt (approximately 10  15 mm away from

the rear surface of the belt) so that it is
perpendicular to the drive belt (within an angle of
 15).
2-8 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT

<When deflection is measured> <When the vibration frequency is

measured: Recommendation>
Power steering
oil pump pulley Belt tension meter set (MB992080)
Deflection
MB992081

MB992082
A AC507219AB
Approximately
100 N 1. Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
(MB992081) of special tool belt tension meter set
(MB992080).
B Idler pulley
2. Press the "POWER" button to turn on the power
supply.
3. Check how the belt tension meter is set.
ACE03251AB
4. Press "Hz" button twice to change the display to
Apply approximately 100 N of force to the middle of the frequency display (Hz).
the drive belt between the pulleys (at the place indi-
CAUTION
cated by the arrow) and check that the amount of
 Do not let any contaminants such as water or
deflection is within the standard value.
oil get onto the microphone.
.
 If strong gusts of wind blow against the
DRIVE BELT TENSION CHECK  microphone or if there is loud sources of
<Vehicles with A/C> noise nearby, the values measured by the
CAUTION microphone may not correspond to actual
 When checking the drive belt tension, make values.
sure that the engine is cold.  If the microphone is touching the belt while
 Check the drive belt tension after turning the the measurement is being made, the values
crankshaft clockwise one turn or more. measured by the microphone may not corre-
Check the drive belt tension in the following proce- spond to actual values.
dure.  Do not take the measurement while the vehi-
cle's engine is running.
Standard value:
Item When When When
checked adjusted replaced
Vibration 141  181 163  181 191  207
frequency
Hz
Tension N 294  490 392  490 542  640
Deflection 9.9  13.5 9.9  11.5 8.0  9.2
mm
(Reference)
.
 PERIODIC INSPECTION AND MAINTENANCE 2-9
OPERATIONS INSIDE THE ENGINE COMPARTMENT

<When tension is measured>

Power steering
oil pump pulley Power steering
oil pump pulley
10 – 15 mm

Gently tap
with your finger
15˚

15˚

MB992080
Belt tension
gauge

A/C compressor
pulley A/C compressor
ACE02207AB
pulley
ACE02208AB
5. Hold special tool MB992080 to the middle of the
drive belt between the pulleys (at the place Use a belt tension gauge in the middle of the drive
indicated by arrow) where it does not contact the belt between the pulleys shown in the figure to check
drive belt (approximately 10  15 mm away from that the drive belt tension is within the standard
the rear surface of the belt) so that it is value.
perpendicular to the drive belt (within an angle of
 15).
.

<When deflection is measured>

6. Press the "MEASURE" button.
7. Gently tap the middle of the drive belt between the Power steering
pulleys (the place indicated by the arrow) with oil pump pulley
Deflection
your finger as shown in the illustration.
8. Check that the vibration frequency of the drive
belt is within the standard value.
NOTE: To take the measurement repeatedly, fillip
the drive belt again.
9. After the completion of the measurement, press
and hold the "POWER" button to turn off the
power supply.
.
Approximately
100 N

A/C compressor
pulley
ACE02209AB

Apply approximately 100 N of force to the middle of

the drive belt between the pulleys (at the place indi-
cated by the arrow) and check that the amount of
deflection is within the standard value.
2-10 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT

DRIVE BELT TENSION ADJUSTMENT CHECK INTAKE AIR HOSE AND

If not within the standard value, adjust the belt ten- TURBOCHARGER OIL HOSE FOR
sion by the following procedure. DAMAGE
1. Remove the air hose B.
(VEHICLES WITH TURBOCHARGER)
M6020200500677

Turbocharger

Nut Bolt

ACE02210AB

AC305652 AB
2. Loosen the idler pulley nut.
3. Loosen the adjusting bolt. 1. Inspect the intake air hoses for cracks or dam-
age.
4. Temporarily tighten the idler pulley nut.
2. Inspect the turbocharger oil hoses for cracks or
Tightening torque: 7.5  2.5 Nm damage.
5. Use the adjusting bolt to adjust the belt tension to
the standard values. CHECK VALVE CLEARANCE
6. Tighten the idler pulley nut. (EXCEPT VEHICLES WITH AUTO-LASH
Tightening torque: 50  2 Nm ADJUSTER)
M6020202401464
7. Tighten the adjusting bolt. VALVE CLEARANCE CHECK AND
Tightening torque: 5.5  1.5 Nm ADJUSTMENT <Except MIVEC>
CAUTION NOTE: The valve clearance check and adjustment
When checking the belt tension, turn the crank- should be done when the engine is cold.
shaft clockwise one turn or more. 1. Remove the rocker cover.
8. Check the belt tension, and readjust if necessary. CAUTION
9. When the belt tension is adjusted by measuring The crankshaft should always be turned in a
the deflection, adjust it with a tool for vibration clockwise direction.
frequency measurement or tension measurement
afterward. Camshaft sprocket
10.Install the air hose B.

Timing marks
AK802487AB

2. Align the camshaft sprocket timing marks and set

the No. 1 cylinder at compression stroke top dead
centre.
 PERIODIC INSPECTION AND MAINTENANCE 2-11
OPERATIONS INSIDE THE ENGINE COMPARTMENT

Engine front (3) While holding the adjusting screw with a

screwdriver to prevent it from turning, tighten
the lock nut to the specified torque using
special tool valve adjusting socket
(MB991477).
Tightening torque: 9.0  1.0 Nm
<Exhaust side>
(4) By using the thickness gauge, measure the
clearance between the cam and roller.
ACD02455AD
Standard value (cold engine): 0.16  0.03 mm
3. For the portions with the arrows shown below, (5) By using the thickness gauge, measure the
measure and adjust the valve clearances by using clearance between the cam and roller.
the following procedures.
CAUTION
<Inlet side>
Pay special attention that the tightening torque is
not beyond this valve. If the tightening torque is
MB992852 beyond the valve, the valve stem would possibly
bend.
Driver

MB992046 Thickness gauge

Cam
Nut

AKB00108AB

(1) By using special tool valve adjusting feeler

gauge (MB992852), check that the clearance Adjusting
is within the standard value between the valve screw
Roller AK802845AD
stem and adjusting screw.
(6) While holding the adjusting screw with a
Standard value (cold engine): 0.14  0.03 mm
screwdriver to prevent it from turning, tighten
(2) If the valve clearance is not as specified, the lock nut to the specified torque using
loosen the adjusting screw lock nut and adjust special tool valve adjusting socket
the clearance using special tool (MB992852) (MB992046), valve adjusting socket.
between the valve stem and the adjusting Tightening torque: 9.8  1.0 Nm
screw while turning the adjusting screw.
4. Turn the crankshaft 360 clockwise to bring No. 4
CAUTION cylinder to the top dead centre position.
Pay special attention that the tightening torque is
not beyond this valve. If the tightening torque is Engine front
beyond the valve, the valve stem would possibly
bend.
MB992852
MB991477
Driver
Cam
Nut

ACD02455AE
Adjusting
screw 5. For the portions with the arrows shown below,
measure and adjust the valve clearances by using
Roller
AKB00109AB the same procedures as ones in the Step 3.
6. Install the rocker cover.
2-12 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT

VALVE CLEARANCE CHECK AND <Inlet side>

ADJUSTMENT <MIVEC>
NOTE: The valve clearance check and adjustment
should be done when the engine is cold. MB991477
1. Remove the rocker cover.
CAUTION
The crankshaft should always be turned in a
clockwise direction.
Thickness gauge
AK802488AB
Camshaft sprocket
<Exhaust side>

MB992046

Timing marks
AK802487AB

2. Align the camshaft sprocket timing marks and set Thickness gauge AK802489AB

the No. 1 cylinder at top dead centre.

5. While holding the adjusting screw with a
Engine front screwdriver to prevent it from turning, tighten the
lock nut to the specified torque using the special
tool, valve adjusting socket.
Special tool (valve adjusting socket):
Inlet side: MB991477
Exhaust side: MB992046
Tightening torque:
Inlet side: 9.0  1.0 Nm
ACE02391AB Exhaust side: 9.8  1.0 Nm
6. Turn the crankshaft 360 clockwise to bring No. 4
3. By using the thickness gauge, respectively cylinder to the top dead centre position.
measure the clearance between the cam at the
portion marked with the arrow and the roller, as Engine front
shown in the illustration.
Standard value (cold engine):
Inlet valve: 0.08  0.03 mm
Exhaust valve: 0.16  0.03 mm
4. If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance
using a thickness gauge between the cam and the
roller while turning the adjusting screw. ACE02391AC

CAUTION
Pay special attention that the tightening torque is
not beyond this valve. If the tightening torque is
beyond the valve, the valve stem would possibly
bend.
7. Respectively measure the clearance at the
portion marked with the arrow, according to step
3.
8. If the clearance is not within the standard value,
repeat steps 4 and 5 above.
9. Install the rocker cover.
 PERIODIC INSPECTION AND MAINTENANCE 2-13
OPERATIONS INSIDE THE ENGINE COMPARTMENT

CHECK RADIATOR HOSES FOR CHANGE ENGINE COOLANT

M6020201102429
DAMAGE AND PROPER CONNECTION 1. Remove the under skid plate and engine room
M6020200901366
under cover front.
WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the radiator cap and
turn the radiator cap anti-clockwise a little to
let the pressure escape through the vinyl
tube. After relieving the steam pressure,
remove the radiator cap by slowly turning it
ACE01987 AB
anti-clockwise.
1. Check entire circumference and length of hoses, 2. Remove the radiator drain plug to drain the
using a mirror as required. engine coolant.
2. Check that hoses installed in grommets pass 3. Securely tighten the drain plug of the radiator.
through the centre of the grommets. 4. Disconnect water hose I from the engine oil
3. Check all clamps for tightness and connections cooler.
for leakage. 5. Air-blow the system to drain the engine coolant
through the radiator cap.
CHECK ENGINE COOLANT LEVEL IN 6. Connect water hose I from the engine oil cooler.
RESERVOIR 7. Remove the thermostat.
M6020201001311
8. Air-blow the system to drain the engine coolant
through the radiator cap.
9. Install the thermostat.
10.Disconnect the radiator condenser tank hose the
radiator.
11.Suspend the radiator condenser tank hose
downwards to drain the tank.
12.Connect the radiator condenser tank hose.
CAUTION
 Do not use alcohol or methanol anti-freeze or
ACE01989

Check that the coolant level is between the "FULL" any engine coolants mixed with alcohol or
and "LOW" lines when the engine is at the normal methanol anti-freeze. The use of an improper
operating temperature. anti-freeze can cause corrosion of the alumin-
ium components.
 Use the MITSUBISHI MOTORS GENUINE
SUPER LONG LIFE COOLANT PREMIUM with-
out adding water because the concentration
is preadjusted to 50%.
2-14 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT

CHECK AIR CLEANER ELEMENT FOR

CLOGGING AND DAMAGE
M6020201201058
MB991871

AC503144AB

13.Use special tool LLC changer (MB991871) to refill

the engine coolant up to the top of the radiator
port.
Recommended antifreeze: MITSUBISHI
MOTORS GENUINE SUPER LONG LIFE
COOLANT PREMIUM or equivalent*
NOTE: *similar high quality ethylene glycol
based non-silicate, non-amine, non-nitrate
and non-borate coolant with long life hybrid
organic acid technology
Quantity (Includes volume inside condense
tank): 7.7 L
NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.
14.Reinstall the radiator cap.
15.Start the engine and let it warm up until the
thermostat opens.
16.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
17.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
Do not overfill the condenser tank.
18.Add engine coolant to the condenser tank
between the "F" and "L" mark if necessary.
19.Install the under skid plate and engine room
under cover front.
AC502427
1. Check air cleaner element for clogging and
damage.
2. Clean deposited dust from the element in the
following manner.
(1) Lightly tap the element against the top of a
bench.
(2) Blow compressed air from inside the element.
3. Wipe off dust on the air cleaner interior.
4. Install the air cleaner body.
REPLACE AIR CLEANER ELEMENT
M6020201301215
The air cleaner element will become dirty and loaded
with dust during use, and the filtering effect will be
substantially reduced. Replace it with a new one.
ACE01988
1. Unclasp the air cleaner cover clip.
2. Remove the air cleaner element and install a new
one.
3. Be sure to close the air cleaner cover completely
when clamping it.
 PERIODIC INSPECTION AND MAINTENANCE 2-15
OPERATIONS INSIDE THE ENGINE COMPARTMENT

CHECK FLUID LEVEL IN BRAKE CAUTION

RESERVOIR AND CLUTCH RESERVOIR If the reservoir tank completely runs out of fluid
M6020203000541 during operation, air will find way into the brake
<BRAKE> line. Pay attention, therefore, to the fluid level
and replenish as necessary.
2. Loosen the bleeder screw and depress the brake
pedal; supply new brake fluid when the level of
the fluid within the reservoir tank decreases.
Specified brake fluid: DOT3 or DOT4
CAUTION
Use the specified brake fluid. Avoid using a mix-
ACE01990 AB ture of the specified brake fluid and other fluid. If
brake fluid is exposed to the air, it will absorb
<CLUTCH> moisture; as water is absorbed from the atmos-
phere, the boiling point of the brake fluid will
decrease and the braking performance will be
seriously impaired. For this reason use a hermet-
ically sealed 1 L or 0.5 L brake fluid container.
Firmly close the cap of the brake fluid container
after use.
3. When fresh fluid has come to flow out from the
vinyl tube, tighten the bleeder screw.
ACE01991 AB
NOTE: This change from existing to fresh fluid
1. Check that the fluid level is between the "MAX" can be judged by change in colour of fluid that
and "MIN" mark. flows out.
2. If it is below the "MIN" marks, replenish with fresh
brake fluid up to the "MAX" mark. 4 2
Specified brake fluid: DOT 3 or DOT 4

CHANGE BRAKE FLUID

M6020201601410

CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix
the specified brake fluid with other fluid as it will 3 1
influence the braking performance significantly. ACE04293AB

4. Repeat above steps for other bleeder screws.

AC305659

1. Remove the cap of the bleeder screw, connect a

vinyl tube, and place its other end in a receptacle.
2-16 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT
CHECK BATTERY CONDITION
M6020203100582
FLUID LEVEL AND SPECIFIC GRAVITY
CHECK
CAUTION
 If the battery is used with the electrolyte level
below the LOWER LEVEL indicator, there is
the danger that explosions may occur, so add
water to the battery until the electrolyte level
is between the LOWER LEVEL and UPPER
LEVEL indications.
 If too much water is added to make the level
rise above the UPPER LEVEL indication, the
electrolyte may leak out, so adjust so that the
electrolyte level is between the LOWER
LEVEL and UPPER LEVEL indications.
OK
Thermometer
Specific
gravity meter
AC102027AB
1. Check that the battery electrolyte level is between
the UPPER LEVEL and LOWER LEVEL
indications.
2. Use a specific gravity meter and a thermometer to
measure the specific gravity.
Standard value: 1.220  1.290 (electrolyte
temperature 20C) <Vehicles without Auto
Stop & Go (AS&G) System>
Standard value: 1.250  1.290 (electrolyte
temperature 20C) <Vehicles with Auto Stop
& Go (AS&G) System>
The specific gravity of the battery electrolyte
changes according to the temperature, so the spe-
cific gravity when the electrolyte is at a temperature
of 20C can be calculated using the following for-
mula. Use the converted value to judge whether the
electrolyte is okay or not.
D20 = (t  20)  0.0007 + Dt
D20: Specific gravity converted to a value for
electrolyte temperature of 20C
t: Electrolyte temperature at the time of
measurement
Dt: Actual specific gravity
 PERIODIC INSPECTION AND MAINTENANCE 2-17
OPERATIONS INSIDE THE ENGINE COMPARTMENT

REPLACE FUEL FILTER

M6020201901723

<4N1>
Post-installation Operation
 Evacuation of Air from Fuel Line.

N 2

ACE03797AD

Fuel filter removal steps

<<A>> >>A<< 1. Fuel filter cap
2. Fuel filter
2-18 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

. .

<<A>> FUEL FILTER CAP REMOVAL >>A<< FUEL FILTER CAP INSTALLATION
1. Loosen the drain plug to drain the fuel. Then,
tighten the drain plug.

Fastener ACE01406
nut
1. Install the fuel filter cap by aligning the marks on
ACB01912 AB
the fuel filter cap and the fuel filter case.
2. Insert a flat-tipped screwdriver into the groove of
the fastener nut. Mark
3. Loosen the fastener nut using the flat-tipped
screwdriver until it can be loosened by hand. OPEN

ACE01407AB

2. Securely tighten the fastener nut until the mark is

in the position shown in the figure (until it clicks in
place).
 PERIODIC INSPECTION AND MAINTENANCE 2-19
OPERATIONS UNDER THE VEHICLE

OPERATIONS UNDER THE VEHICLE

CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS
M6020300100795

FRONT SUSPENSION

Deterioration
and sagging
Noise and
oil leakage

Cracks, bends
and dents

Bends and
damage

Cracks, bends
and dents

REAR SUSPENSION

Noise and
oil leakage
Deterioration,
wear and cracks

Bends and damage

Cracks, bends
and dents

Deformation
and cracks
AC508512AB
2-20 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS UNDER THE VEHICLE

CHECK SUSPENSION ARM BALL JOINTS LUBRICATE PROPELLER SHAFT WITH

FOR PLAY, AND DUST COVERS FOR GREASE FITTING
M6020301300093
DAMAGE
M6020300200651
.

BALL JOINTS FOR PLAY

AC503034AB

Fill the multi-purpose grease fitting of the propeller

shaft joints.
AC502481

1. With the vehicle unladen, check the top end of CHECK DRIVESHAFT BOOTS FOR
tyre for the amount of movement. DAMAGE
2. Remove the stabilizer link from the lower arm. M6020300400622

3. Jack up the lower arm and move the bottom of

tyre to check the amount of movement.
.

DUST COVERS FOR DAMAGE

AC305661

Check the driveshaft boots for damage.

CHECK STEERING LINKAGE FOR

AC508161AB
DAMAGE AND LOOSE CONNECTIONS
(INCLUDING SEALS AND BOOTS)
1. Press the lower arm ball joint cover with your M6020300500704
finger to check that there are no cracks or
damage in the lower arm ball joint cover.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm ball joint
assembly.
NOTE: If the lower arm ball joint cover is cracked
or damaged, it is possible that there may also be
damage to the ball joint.
3. Press the upper arm ball joint cover with your
finger to check that there are no cracks or AC305662
damage in the upper arm ball joint cover.
4. If the upper arm ball joint cover is cracked or 1. Move the steering wheel bit by bit to the left or
damaged, replace the upper arm ball joint right, and check to be sure that there is no play or
assembly. looseness in the linkage coupling, that the
NOTE: If the upper arm ball joint cover is cracked installation is not loose, and that the rod or arm is
or damaged, it is possible that there may also be not bent or damaged.
damage to the ball joint.
 PERIODIC INSPECTION AND MAINTENANCE 2-21
OPERATIONS UNDER THE VEHICLE

1. Remove the filler plug and gasket.

2. Check that the oil level is up to the lower edge of
the filler plug hole.
3. Check that the oil is not noticeably dirty.
4. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37  11 Nm

AC508162AB
CHECK TRANSFER FOR OIL LEAKAGE
(IN CASE OF LEAKAGE, CHECK THE OIL
2. Check to be sure that the seal and boot of the ball
joint are correctly installed (in the correct LEVEL)
M6020302400598
position), and that they are not damaged. .

3. Check tie-rod end lock nut for looseness. If lock CHECK OIL LEAKAGE
nut is loose, adjust toe-in and then tighten lock nut Check the transfer case for oil leakage visually or by
to the specified torque. touching it with hand.
Tightening torque: 93  15 Nm NOTE: If an oil leakage is not detected, the oil level
check is necessary.
CHECK MANUAL TRANSMISSION FOR
OIL LEAKAGE TRANSFER OIL LEVEL CHECK
(IN CASE OF LEAKAGE, CHECK THE OIL <V6M5A>
LEVEL)
M6020302300643
.

CHECK OIL LEAKAGE

Check the transmission case for oil leakage visually
or by touching it with hand.
NOTE: If an oil leakage is not detected, the oil level
check is necessary. Filler plug
Drain plug ACE01619AB
TRANSMISSION OIL LEVEL CHECK
<R6M5A, V6M5A>
Filler plug hole

Gasket

Filler plug

Filler plug

Transfer oil
Drain plug ACE01621AB AC700330AM

1. Remove the filler plug and gasket.

Filler plug hole 2. Check that the oil level is up to the lower edge of
the filler plug hole.
Gasket
3. Check that the oil is not noticeably dirty.
4. Install the filler plug and new gasket, then tighten
them to the specified torque.
Filler plug Tightening torque: 37  11 Nm
Transmission oil
AC700330AL
2-22 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS UNDER THE VEHICLE

CHANGE GEAR OIL IN MANUAL CHANGE GEAR OIL IN TRANSFER

M6020302600785
TRANSMISSION
M6020300801311 <V6M5A>
<R6M5A, V6M5A>

Filler plug

Filler plug
Drain plug ACE01619AB
Drain plug ACE01621AB

Filler plug hole

Filler plug hole Gasket
Gasket

Filler plug
Transmission oil
AC700330AL
1. Remove the filler plug and gasket.
2. Remove the drain plug and gasket, and then drain
the oil.
3. Install the drain plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37  11 Nm
4. Fill with gear oil MITSUBISHI MOTORS
GENUINE NEW MULTI GEAR OIL ECO API
classification GL-4, SAE 75W-80 until the level
comes to the lower portion of filler plug hole.
Quantity: 2.2 L
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37  11 Nm
Filler plug
Transfer oil
AC700330AM
1. Remove the filler plug and gasket.
2. Remove the drain plug and gasket, and then drain
the oil.
3. Install the drain plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37  11 Nm
4. Fill with gear oil MITSUBISHI MOTORS
GENUINE NEW MULTI GEAR OIL ECO API
classification GL-4, SAE 75W-80 until the level
comes to the lower portion of filler plug hole.
Quantity: 1.15 L (Easy select 4WD)
Quantity: 1.34 L (Super select 4WD)
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37  11 Nm
 PERIODIC INSPECTION AND MAINTENANCE 2-23
OPERATIONS UNDER THE VEHICLE

CHECK FRONT AND REAR REAR DIFFERENTIAL

DIFFERENTIAL FOR OIL LEAKAGE .

Vehicle is lifted (not standing on wheels)

(IN CASE OF LEAKAGE, CHECK THE OIL
LEVEL)
M6020301000661

CHECK OIL LEAKAGE

.

Check the area around the differential for oil leakage

visually or by touching it with hand.
NOTE: If an oil leakage is detected, the oil level
Filler plug
check is necessary. and gasket

CHECK OIL LEVEL ACE02541AC

FRONT DIFFERENTIAL 1. Remove the filler plug and gasket.

Inspection tool
Filler plug
Oil level
A

Bottom edge
of the filler
plug hole
Drain plug ACE02535AB
ACE04286AB

1. Remove the under cover, filler plug and gasket. 2. Insert an inspection tool as shown so that it
touches the bottom of the filler plug. The
Filler plug hole inspection tool: 10 mm-diameter L shaped bar
(e.g. 10 mm-diameter angled hexagon wrench).
Gear oil Gasket
3. Remove the inspection tool, and then check that
dimension A (between the bottom edge and the
Upper oil level) conforms to the table below.
limit
Lower Oil filler plug Item Dimension A
limit
8 mm Size and number of the M10  12 Within 38 mm
AC700330 BS nuts securing the
differential carrier
2. Check that the oil level is in between the upper
assembly
limit (bottom of the filler plug hole) and the lower
limit as shown. 4. Install the filler plug and new gasket, then tighten
3. If the oil level is not in between the upper limit and them to the specified torque.
the lower limit, refill the specified oil to the bottom Tightening torque: 50  10 Nm
of the oil filler plug hole.
.

Specified gear oil:

Mitsubishi Motors Genuine Super Hypoid
Gear Oil ECOLOGY API GL-5 SAE 80
4. Install the filler plug and new gasket, and tighten
to the specified torque.
Tightening torque: 50  10 Nm
5. Install the under cover.
2-24 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS UNDER THE VEHICLE

Vehicle is standing on wheels CHANGE GEAR OIL IN FRONT AND

REAR DIFFERENTIAL
M6020301100947

Front differential

Filler plug
Filler plug
and gasket

ACE02541AC

1. Remove the filler plug and gasket.

Drain plug ACE02535AB

Inspection tool 1. Remove the under cover, filler plug and gasket.
Oil level
2. Remove the drain plug and gasket, to drain the
A oil.
3. Install the drain plug and new gasket, and tighten
to the specified torque.
Bottom edge
of the filler Tightening torque: 65  5 Nm
plug hole
ACD01282AD
Filler plug hole
2. Insert an inspection tool as shown so that it
Gasket
touches the bottom of the filler plug. The
inspection tool: 10 mm-diameter L shaped bar
(e.g. 10 mm-diameter angled hexagon wrench).
3. Remove the inspection tool, and then check that
dimension A (between the bottom edge and the Filler plug
oil level) conforms to the table below. Gear oil
AC700330BR
Item Dimension A
4. Add the oil until the level comes to the lower
Size and number of the M10  12 Within 30 mm
portion of the filler plug hole.
nuts securing the
differential carrier Specified gear oil:
assembly Mitsubishi Motors Genuine Super Hypoid Gear
Oil ECOLOGY API GL-5 SAE 80
4. Install the filler plug and new gasket, then tighten Amount to use: 1.2 L
them to the specified torque.
5. Install the filler plug and new gasket, and tighten
Tightening torque: 50  10 Nm to the specified torque.
Tightening torque: 50  10 Nm
6. Install the under cover.
 PERIODIC INSPECTION AND MAINTENANCE 2-25
OPERATIONS UNDER THE VEHICLE

Rear differential Vehicle is standing on wheels

.

Vehicle is lifted (not standing on wheels)

Drain plug
and gasket
Drain plug
and gasket Filler plug
and gasket
Filler plug
and gasket ACE02541AB

ACE02541AB 1. Remove the filler plug and gasket.

2. Remove the drain plug and gasket, and drain the
1. Remove the filler plug and gasket.
oil.
2. Remove the drain plug and gasket, and drain the
3. Tighten the drain plug and new gasket, to the
oil.
specified torque.
3. Tighten the drain plug and new gasket, to the
Tightening torque: 60  10 Nm
specified torque.
Tightening torque: 60  10 Nm

Inspection tool

Inspection tool Oil level A

Oil level
A

Bottom edge
of the filler
plug hole
Bottom edge
ACD01282AD
of the filler
plug hole
ACE04286AB 4. Fill the Mitsubishi Motors Genuine Super Hypoid
Gear Oil ECOLOGY API GL-5 SAE 80 until the
4. Fill the Mitsubishi Motors Genuine Super Hypoid level satisfies the specification.
Gear Oil ECOLOGY API GL-5 SAE 80 until the
level satisfies the specification. Item Dimension A
Size and number of the M10  12 Within 30 mm
Item Dimension A
nuts securing the
Size and number of the M10  12 Within 38 mm differential carrier
nuts securing the assembly
differential carrier
assembly Specified gear oil:
Mitsubishi Motors Genuine Super Hypoid Gear
Specified gear oil: Oil ECOLOGY API GL-5 SAE 80
Mitsubishi Motors Genuine Super Hypoid Gear Amount to use:
Oil ECOLOGY API GL-5 SAE 80 Size and number of the nuts securing the differ-
Amount to use: ential carrier assembly (M1012): 2.3 L
Size and number of the nuts securing the differ-
ential carrier assembly (M1012): 2.3 L 5. Install the filler plug and new gasket, then tighten
them to the specified torque.
5. Install the filler plug and new gasket, then tighten
Tightening torque: 50  10 Nm
them to the specified torque.
Tightening torque: 50  10 Nm
.
2-26 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE VEHICLE

CHECK EXHAUST PIPE CONNECTIONS 2. Check the exhaust pipe for damage by stones,
FOR GAS LEAKAGE, AND CHECK PIPE etc.
INSTALLATION 3. Start the engine and check for gas leaks from the
M6020301200966 exhaust pipe connections.
1. Confirm that the exhaust pipe does not interfere
with any body components.

OPERATIONS INSIDE THE VEHICLE

CHECK BRAKE PEDAL AND CLUTCH CLUTCH PEDAL CHECK AND ADJUST-
PEDAL FOR FREE PLAY MENT
M6020400101256
1. Turn back the carpet etc. under the clutch pedal.
BRAKE PEDAL FREE PLAY
AC709695
Clutch pedal free play

Clutch pedal

Stopper

B
A
ACE02958 AB
ACE01167AB

2. Measure the clutch pedal clevis pin play (A). If the

1. Turn the ignition switch to the "LOCK" (OFF) play is outside the standard value, go to Step 3.
position, depress the brake pedal two or three
Standard value (A): 1  3 mm
times. After eliminating the vacuum in the brake
booster, press the pedal down by hand, and 3. Remove the clutch switch.
confirm that the amount of movement before
resistance is met (free play) is within the standard CAUTION
value range. Do not push in the master cylinder pushrod at
Standard value (B): 3  8 mm this time, otherwise the clutch will not operate
2. If the brake pedal play is not within the standard properly.
value, check the following, and adjust or replace if
necessary:
 Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the
Pushrod
brake booster operating rod Clutch pedal
 Brake pedal height
 Installation position of the stop lamp switch, etc.
Setting nut
13 ± 2 N·m
AC712193 AC

4. If the clutch pedal height is not within the standard

value, loosen the setting nut to adjust the clutch
pedal height to the standard value and move the
pushrod.
 PERIODIC INSPECTION AND MAINTENANCE 2-27
OPERATIONS INSIDE THE VEHICLE

AC610163 AC709695
Clutch pedal free play
Dash panel

Clutch pedal

B
Stopper Stopper

Released
Depressed A
ACE02960AB ACE02958 AB

AC611454 AC611454
Dash panel Dash panel

Stopper Stopper

C C
ACE02959AB ACE02959AB

5. Check that the height (B) as well as the clearance
(C) between the clutch pedal and stopper when
the clutch is disengaged are within the standard
value.
Standard value (B):
117  122 mm <LHD>
133.5  139 mm <RHD>
Standard value (C):
30 mm or more <LHD>
35 mm or more <RHD>
6. If the clutch pedal play and height as well as the
clearance between the clutch pedal and stopper
when the clutch is disengaged are not within the
standard value, the air intrusion into the hydraulic
system may have occurred, or either the clutch
master cylinder or the clutch release cylinder may
have an abnormality. In this case, perform air
bleeding, or check the clutch master cylinder or
the clutch release cylinder, and replace if
necessary.
7. Install the clutch switch.
8. If the clutch pedal clevis pin play is not within the
standard value, loosen the setting nut and move
the pushrod to adjust.
9. After the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal
pad) and the distance between the clutch pedal
(the face of the pedal pad) and the floorboard
when the clutch is disengaged are within the
standard value ranges.
Standard value (A): 4  13 mm
Standard value (C):
30 mm or more <LHD>
35 mm or more <RHD>
10.If the measured free play and distance do not
agree with the standard value ranges, it is
probably the result of either air in the hydraulic
system or a faulty master cylinder or clutch. Bleed
the air, or disassemble and inspect the master
cylinder or clutch.
11.Reinstall the carpet, etc.
2-28 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE VEHICLE

CHECK PARKING BRAKE LEVER (5) Turn the ignition switch to "OFF" position, and
STROKE AND PLAY stop the engine.
M6020400201253
CAUTION
Pull If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
Spring balance (6) Turn the adjuster to adjust the parking brake
lever stroke to the standard value. After
adjusting, check that there is no space
between the adjuster and the parking brake
lever. Check that the adjuster is secured with
Approximately
the adjuster holder.
40 mm ACX00701AF
(7) After adjusting the parking brake lever stroke,
1. Attach the spring scale to the centre of the parking jack up the rear end of the vehicle, and then
brake lever grip. Then, check that the stroke is release the parking brake and turn the rear
within the standard value when the parking brake wheels to check that the rear brakes are not
lever is pulled to the vertical direction of the lever dragging.
with a force of approximately 200 N.
REPLACE AIR PURIFIER FILTER
Standard value: 8  9 notches M6020400300558

2. If the parking brake lever stroke is not the 1. Remove the glove box.
standard value, adjust as described below.
(1) Remove the rear floor console assembly.

Cable rod
Adjuster

Heater side cover

ACE01676 AB

2. Remove the heater side cover.

ACE02344AC
3. Replace the clean air filter.
(2) Loosen the adjuster to move it to the cable rod NOTE: The arrow on the clean air filter should
end so that the cable will be free. face downwards.
NOTE: On vehicle with front bench seat,
loosen the adjuster from underfloor. <Front view>

(3) Turn the ignition switch to "ON" position, and

start the engine.
(4) Repeatedly depress the brake pedal until the AIR
pedal stroke no longer changes with the FLOW

engine running.
NOTE: If the pedal stroke stops changing, the
Install with the arrow
automatic-adjustment mechanism is function- facing down.
ing normally, and the clearance between the ACE01951AB
shoe and drum is correct.
4. Install the glove box.
 PERIODIC INSPECTION AND MAINTENANCE 2-29
OPERATIONS OUTSIDE THE VEHICLE

OPERATIONS OUTSIDE THE VEHICLE

CHECK WHEEL ALIGNMENT
M6020500101576

FRONT WHEEL ALIGNMENT CHECK AND

ADJUSTMENT
CAUTION
When the suspension is adjusted, the calibration
of steering wheel sensor must be performed.

Measure wheel alignment with alignment equipment

AC000756AB
on a level surface. The front suspension, steering
system, wheels, and tyres should be serviced to nor-
4. Use a turning radius gauge to check that the
mal condition before measuring wheel alignment.
.
steering angle is at the standard value.
Standard value:
TOE-IN  Inner wheel: 3650’  200’*
Standard value:  Outer wheel: 3240’ (reference value)
At the centre of tyre tread: 0  5 mm NOTE: *: Difference between right and left wheels
Toe-angle (per wheel): 000'  012' must be 200’ or less.

CAMBER, CASTER AND KINGPIN

Clip
INCLINATION

Lock nut

Compensator

AC502611AB

1. Adjust the toe-in by undoing the clip and lock nut,

and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions). ACX00712AC

NOTE: The toe will move out as the left turnbuckle

Standard value:
is turned toward the front of the vehicle and the
right turnbuckle is turned toward the rear of the Camber 000'  030'*
vehicle.
Caster 347'  100'*
2. Install the clip and tighten the lock nut to the
specified torque. Kingpin inclination 1246'
Tightening torque: 93  15 Nm NOTE: *: Difference between right and left wheels
must be 030' or less.
3. Confirm that the toe-in is at the standard value.
2-30 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE

CAMBER AND CASTER REFERENCE

TABLE
.

HOW TO READ THIS TABLE (EXAMPLE)

B A

Lower arm
mounting bolt
AC407369AD

If the camber difference 035' and the caster differ-

ence is 017' by comparing the measurement value
with the standard value, rotate the front adjusting
cam by 1.5 graduations to the "B" direction and the
rear adjusting cam by 2.5 graduations to the "A"
direction.

Front side
adjust bolt scale
Direction A
6'
'

2'

7'
˚2

˚4

˚3

˚1
–1

–1

–0

–0

0˚

7'
+4 ˚1
+0
2'
˚3

+3
+0
6'
˚4

+2
+0
'
˚2

+1
+1

Rear side
adjust bolt scale
Direction A Direction B
+4 +3 +2 +1 0 –1 –2 –3 –4
–0
˚3
5'

–1
–0
˚2
6'

–2
–0
˚1
8'

–3
–0
˚1
0'

–4
–0
+0

+0

+0

+0

: Caster angle
˚3

˚2

˚1

˚1

: Camber angle
5'

6'

8'

0'

Direction B AC407327 AC

NOTE: Solid lines show caster, broken lines show

camber.
 PERIODIC INSPECTION AND MAINTENANCE 2-31
OPERATIONS OUTSIDE THE VEHICLE

CHECK FRONT WHEEL BEARINGS FOR 3. If axial play exceeds the limit, disassemble the
PLAY front hub assembly and check the parts.
M6020500200473 4. After checking, install the brake disc and the
<FRONT WHEEL> caliper assembly.
1. Remove the caliper assembly and brake disc, and
retain the caliper assembly with a wire and the like <REAR WHEEL>
to prevent from falling. .

AXLE SHAFT AXIAL PLAY CHECK

AC004839 AB

AC602402AB 1. Measure the axle shaft axial play by using a dial

indicator.
2. Attach a dial gauge as shown in the illustration,
and then measure the axial play while moving the Standard value: 0  0.3 mm
hub in the axial direction. 2. If not within specifications, replace the axle shaft
Limit: 0 mm assembly.

CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300704

Brake booster

Rear drum brake

Front disc brake

AC601742AB

1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
2-32 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE

CHECK BRAKE PADS AND DISCS FOR BRAKE DISC CHECK

WEAR .

BRAKE DISC THICKNESS CHECK

M6020500401232

BRAKE PAD CHECK 1. Remove contaminants or corrosion from the brake

disc surface.
CAUTION
If there is a significant difference in thickness
between the brake pads at right and left, check Approx. 10 mm
the sliding area and the run-out of the brake disc.
AC503003

ACX00668AH

2. Use a micrometer to measure the brake disc

thickness at minimum eight points which are 10
ACE04294 AB mm inward from its circumference.
1. Visually check the thickness of brake pad from the Standard value: 28.0 mm
inspection hole of the caliper body. Limit: 26.4 mm
<Standard brake pads> 3. If the brake disc thickness is worn beyond the limit
Standard value: 9.5 mm value at more than one point, replace the brake
Limit: 1.5 mm disc and check its run-out.
<Low steel brake pads> .

Standard value: 10.0 mm

Limit: 1.5 mm BRAKE DISC THICKNESS UNEVENNESS
2. If the brake pad thickness is less than the limit
CHECK AND CORRECTION
value, replace the brake pad. 1. Remove contaminants or corrosion from the brake
disc surface.

Approx. 10 mm

ACX00668AH

2. Use a micrometer to measure the brake disc

thickness at minimum eight points which are 10
mm inward from its circumference. Then record
the measurements.
3. If the brake disc thickness unevenness (the
difference between the maximum and minimum
values measured above) is 0.015 mm or less, it is
within the standard value.
 PERIODIC INSPECTION AND MAINTENANCE 2-33
OPERATIONS OUTSIDE THE VEHICLE

4. If the brake disc thickness unevenness exceeds
the standard value, grind it according to the
procedure below while it is mounted on the
vehicle.
NOTE: If it is suspected that the brake disc thick-
ness will become less than the limit value after the
grinding, replace the brake disc and check its
run-out.
(1) Check for wheel bearing looseness in the axial
direction.
CAUTION

BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Check for wheel bearing looseness in the axial
direction.
2. If the axial play is within the limit value, secure the
brake disc by tightening the nut (M121.5) evenly
to the specified torque (100 Nm).If the axial play
still exceeds the limit value, replace the wheel
bearing. Then secure the brake disc by tightening
the nut (M121.5) evenly to the specified torque
(100 Nm).

Approx. 5 mm

M12 Flat washer

ACX00669AG

3. Place a dial gauge ca. 5 mm inward from the

circumference of the brake disc to measure its
run-out.
M12 Flat washer Limit: 0.06 mm
4. If the brake disc run-out exceeds the limit value,
rephase the brake disc to the hub so that the
minimum brake disc run-out is obtained.

AC006226 AE

 Insert M12 plain washer and then install the

adapter as shown before grinding. Failure to
use the M12 plain washer will cause the brake
disc to be deformed and ground incorrectly.
 To grind the brake disc, ensure that all the
nuts (M12 X 1.5) are tightened evenly and in a
diagonal sequence to the specified torque
(100 Nm). Failure to use all the nuts
(M121.5), excessive or uneven tightening
torque will cause the brake disc to deform or
judder.
(2) Correct the brake disc uneven thickness by
grinding it while in place on the vehicle.
.
2-34 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE

CAUTION CHECK BRAKE SHOE LININGS AND



DRUMS FOR WEAR

M6020500501002

M12 Flat washer

BRAKE LINING THICKNESS CHECK
CAUTION
 Whenever the shoe and lining assembly is
replaced, replace both RH and LH assemblies
as a set to prevent the car from pulling to one
side when braking.
 If there is a significant difference in the thick-
ness of the shoe and lining assemblies on the
left and right sides, check the sliding condi-
tion of the piston.
1. Remove the brake drum.
M12 Flat washer

AC006226 AE

 Insert M12 plain washer and then install the

adapter as shown before grinding. Failure to ACX00708AB
use the M12 plain washer will cause the brake
disc to be deformed and ground incorrectly. 2. Measure the thickness of the brake lining at the
 To grind the brake disc, ensure that all the area with the worst wear.
nuts (M12 X 1.5) are tightened evenly and in a Standard value:
diagonal sequence to the specified torque 5.0 mm
(100 Nm). Failure to use all the nuts Limit:
(M121.5), excessive or uneven tightening 1.0 mm
torque will cause the brake disc to deform or
judder. 3. Replace the shoe and lining assembly if the brake
lining thickness is less than the limit or if it is not
5. If the brake disc run-out exceeds the limit value worn evenly. For installation procedures for the
after rephasing, grind the disc while in place on shoe and lining assembly.
the vehicle so that the brake disc run-out is within
the limit value.
NOTE: If it is suspected that the brake disc thick-
ness will be below the limit value, replace the
brake disc.Then rephase the brake disc so that
the minimum brake disc run-out is obtained, or
grind the disc while in place on the vehicle so that
its run-out is below the limit value.
 PERIODIC INSPECTION AND MAINTENANCE 2-35
OPERATIONS OUTSIDE THE VEHICLE

BRAKE DRUM INSIDE DIAMETER CHECK BRAKE LINING AND BRAKE DRUM CON-
1. Remove the brake drum. TACT CHECK
1. Remove the brake drum.
2. Remove the shoe and lining assembly.

AC000893

2. Measure the inside diameter of the brake drum at

AC000856
two or more locations.
Standard value: 3. Chalk the inner surface of the brake drum and rub
295 mm with the shoe and lining assembly.
Limit: 4. Replace the shoe and lining assembly or brake
297 mm drums if there are any irregular contact areas.
3. Replace the brake drums, shoe and lining NOTE: Clean off chalk after check.
assembly when wear exceeds the limit value or is
badly imbalanced.

CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION

M6020500600750

Fuel filter assembly

Fuel injector assembly

Fuel tank assembly

Supply pump assembly
AC501365AD

1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
2-36 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS AFTER ENGINE IS WARMED UP

OPERATIONS AFTER ENGINE IS WARMED UP

CHECK FLUID LEVEL IN AUTOMATIC <2WD>
TRANSMISSION
M6020600100752

FLUID LEAK CHECK

After cleaning the lower side of transmission, check
visually or by touching that there is no oozing or leak-
ing of fluid from the transmission.
Filler plug

FLUID LEVEL CHECK

ACE02024 AB
CAUTION
During the fluid level check, the fluid temperature <4WD>
must be between 40 and 45C. If the temperature
is outside this range, set the fluid temperature to
the suitable temperature, and then check the
fluid level.
.

<WHEN THE M.U.T.-III IS USED>

1. Connect the M.U.T.-III.
2. Pull the parking brake lever, and start the engine.
3. Depress the brake pedal, move the selector lever
from the P to D range, and then move it to every
position by holding 2 seconds or more at each
range. Repeat this cycle twice, and then return
the lever to the P range.
4. Using the M.U.T.-III, check that the fluid
temperature is between 40 to 45C.
NOTE: When the ambient temperature is low
(10C or lower), move the selector lever to the P
range, warm up the engine for 15 minutes with the
engine speed of 2,000 to 2,500 r/min. Then, the
fluid temperature becomes approximately 40C.
In such case, after the fluid temperature
increased, leave the engine idling for 5 minutes,
and then check the fluid level.
Filler plug
ACE02025 AB
Overflow plug
Drain plug
ACE02026 AB
5. Remove the filler plug and the overflow plug, and
drain the fluid from the overflow plug hole.
6. <When the fluid is drained>
Wait until the fluid becomes oil drops, and then
tighten the overflow plug with a new gasket and
the filler plug with a new O-ring to the specified
torque.
<When the fluid is not drained>
Pour in the fluid through the filler plug hole until
the fluid is drained from the overflow plug hole.
Wait until the fluid becomes oil drops, and then
tighten the overflow plug with a new gasket and
the filler plug with a new O-ring to the specified
torque.
Tightening torque:
20  2 Nm (overflow plug)
39  15 Nm (filler plug)

.
 PERIODIC INSPECTION AND MAINTENANCE 2-37
OPERATIONS AFTER ENGINE IS WARMED UP

<WHEN THE M.U.T.-III IS NOT USED>  When the ambient temperature is low (10C or
lower), move the selector lever to the P range,
warm up the engine for 15 minutes with the
engine speed of 2,000 to 2,500 r/min. Then,
the fluid temperature becomes approximately
40C. In such case, after the fluid temperature
increased, leave the engine idling for 5 min-
utes, and then check the fluid level.
Diagnosis connector <2WD>

ACE02027AB

1. Earth the diagnosis connector terminal No. 1.

2. Pull the parking brake lever, and start the engine.
3. Depress the brake pedal, move the selector lever Filler plug
from the P to D range, and then move it to every
position by holding 2 seconds or more at each
ACE02024 AB
range. Repeat this cycle twice, and then return
the lever to the P range.
<4WD>
A/T fluid temperature
warning lamp

Filler plug
ACE02025 AB
ACE01954AC

4. Move the selector lever (N  D  N) within 1.5 Overflow plug

seconds, and continue the operation until the A/T
fluid temperature warning lamp illuminates. After
the A/T fluid temperature warning lamp
illuminated, return the selector lever to the P
range. The warning lamp goes out within a few
seconds.
NOTE: . Drain plug
 The status of A/T fluid temperature warning ACE02026 AB

lamp shows if the fluid temperature is suitable

5. Remove the filler plug and the overflow plug, and
for the fluid level check.
drain the fluid from the overflow plug hole.
 Warning lamp is off: The fluid temperature
is 40C or less, thus checking is impossi-
ble.
 Warning lamp is on: The fluid temperature
is between 40 to 45C, thus checking is
possible.
 Warning lamp is blinking: The fluid temper-
ature is 45C or higher, thus checking is
impossible.
2-38 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS AFTER ENGINE IS WARMED UP

6. <When the fluid is drained> <2WD>

Wait until the fluid becomes oil drops, and then
tighten the overflow plug with a new gasket and
the filler plug with a new O-ring to the specified
torque.
<When the fluid is not drained>
Filler plug
Fill the fluid from the filler plug until the fluid is
drained from the overflow plug hole, and wait until
the fluid becomes oil drops. Then, tighten the ACE02024 AB
overflow plug with a new gasket and the filler plug
with a new O-ring to the specified torque. <4WD>
Tightening torque:
20  2 Nm (overflow plug)
39  15 Nm (filler plug)

CHANGE AUTOMATIC TRANSMISSION

FLUID
M6020600201008
.
Filler plug
SPECIFICATIONS ACE02025 AB

Automatic transmission fluid Quantity

MITSUBISHI MOTORS GENUINE 10.9 L Overflow plug
ATF-PA

A/T FLUID CHANGE

If there is an ATF changer, use it. If there is no ATF
changer, replace the fluid as described below.
NOTE: Drain plug
Oil return hose ACE02026 AB

1. Remove the filler plug and the drain plug, and

drain the fluid from the drain plug hole.
Discharge volume: Approx. 3.0 L
2. Install the drain plug with a new gasket in
between, and tighten it to the specified torque.
Oil return tube Tightening torque: 20  2 Nm
ACE03177AB 3. Remove the overflow plug.
If you use an ATF changer, disconnect the oil return 4. Pour in the fluid through the filler plug hole until
hose from the oil return tube. Then connect the ATF the fluid is drained from the overflow plug hole.
changer between them. Wait until the fluid becomes oil drops, and then
tighten the overflow plug with a new gasket and
CAUTION
the filler plug with a new O-ring to the specified
When draining the fluid from the drain plug hole,
torque.
use a plate to prevent the fluid from dripping on
the centre member assembly. Tightening torque:
20  2 Nm (overflow plug)
39  15 Nm (filler plug)
5. Check the fluid level.
6. During the fluid level check, check the drained
fluid for contamination. If the fluid is contaminated,
perform steps 1 to 5 again.
 PERIODIC INSPECTION AND MAINTENANCE 2-39
OPERATIONS AFTER ENGINE IS WARMED UP

CHANGE ENGINE OIL 10.Warm up engine for 10 minutes and wait for
M6020600302332 further 10 minutes.
1. Start the engine and allow it to warm up until the
11.Check that the oil level is between maximum
temperature of the coolant reaches 80 C to 90
marking and minimum marking.
C.
12.If no, add the oil until the oil level gauge indicates
2. Remove the oil filler cap. between maximum marking and minimum
3. Remove the under skid plate and engine room marking.
under cover front.
WARNING REPLACE ENGINE OIL FILTER
M6020600401518
Use care as oil could be hot.
<4N1>
4. Remove the oil drain plug to drain oil. 1. Remove the oil drain plug to drain engine oil.

MB991396 or
commercially-
available tool

ACE01737AB
AC904112 AB

5. Install a new oil drain plug gasket, and then
tighten the drain plug to the specified torque.
Tightening torque: 39  5 Nm
6. Install the under skid plate and engine room under
cover front.
7. Refill with specified quantity of oil.
2. Use special tool oil filter wrench (MB991396) or
commercially-available tool to remove the oil filter.
3. Clean the oil filter installing surface on the cylinder
block side.
(Engine oil)

Specified Engine Oil Gasket

 ACEA classification: "For service C1, C2,
C3 or C4"
 JASO classification: "For service DL-1"
Total quantity (Includes volume inside oil fil-
ter and oil cooler): 8.4L
NOTE:
AC904113 AC

4. Apply a small amount of engine oil to the new oil

ACA00381AB
Select engine oil of the proper SAE viscosity
number according to the atmospheric tempera-
ture.
8. Install the oil filler cap.
9. Check oil level indicate below maximum marking.
filter gasket.
5. For the specified tightening torque, refer to the
caution label attached on the oil filter.
6. Tighten the oil filter until the gasket contacts with
the installation surface.
7. In the same manner as removal, use special tool
oil filter wrench (MB991396) or
commercially-available tool to tighten the oil filter
to the specified torque.
8. Install the oil drain plug and refill the engine oil.
9. Rev the engine a few times, and check to be sure
that no engine oil leaks from the installation
section of the oil filter.
2-40 PERIODIC INSPECTION AND MAINTENANCE
OTHERS

OTHERS
CHECK BODY CONDITION FOR DAMAGE LEARNING PROCEDURE
M6020700100470
1. Check underbody coating for damage. CAUTION
To prevent damage to M.U.T.-III, always turn the
2. Check body painting for damage.
ignition switch to the "LOCK" (OFF) position
CHECK THE COMMON RAIL ENGINE <except vehicles with KOS> (or put the power
supply mode is OFF <vehicles with KOS>) before
(SMALL INJECTION QUANTITY connecting or disconnecting M.U.T.-III.
LEARNING)
M6020700400352 <LHD>

CAUTION Diagnosis connector

1. If small injection quantity learning has not
been executed, the engine warning lamp
blinks.
2. When the requirements for learning are satis-
fied by operation after replacement of the
engine-ECU, learning is automatically exe-
MB992745, MB991910
cuted even if no instruction is given from the
M.U.T.-III. Accordingly, the malfunction indica- MB992744, MB991824
tor lamp goes off. However, the learning thus
executed is tentative and limited. Be sure to
complete leaning using the M.U.T.-III.

PURPOSE
To keep emission and noise level at adequate levels,
the engine-ECU must learn injector fuel injection in
idle mode.
During learning, the engine-ECU calculates actual MB992747, MB992748, MB991827 ACE00805 AC
injection from each cylinder based on changes in
engine speeds and corrects pilot injection control. It <RHD>
then keeps records of this amount of correction as a
learned value. Diagnosis connector
For this reason, after the engine-ECU or injector is
replaced, learning must be executed using the
M.U.T.-III.
NOTE: Engine friction changes or injector deteriora-
tion over time may cause fluctuation in pilot injection.
After use over time, it may prevent injection of an
MB992745, MB991910
accurate amount of fuel according to the indication
by the engine-ECU. This is why learning must be
MB992744, MB991824
executed again periodically.
For this reason, the engine-ECU periodically leans
injection according to the cumulative mileage.
Note that making the M.U.T.-III learn again resets the
cumulative mileage.
NOTE: The engine sound may change or idling
engine speeds may increase during injection learn-
ing. These are not abnormalities.
MB992747, MB992748, MB991827 ACE00807AC
 PERIODIC INSPECTION AND MAINTENANCE
OTHERS
1. After the ignition switch is in the "LOCK" (OFF)
position <except vehicles with KOS> (or put the
power supply mode is OFF <vehicles with KOS>),
connect the M.U.T.-III to the diagnosis connector.
2. Put the vehicle in the following idling stable
conditions:
 Engine coolant temperature: 76.5  100C
 Fuel temperature: 30  100C
 Intake air temperature: 30 to 100C
 Barometric pressure: 78.7 kPa or more
 A/T fluid temperature: 25C or more <vehicles
with A/T>
 Lamps, radiator fan and all accessories: OFF
 Transmission: Neutral
 Power steering: Static state
3. Select "MPI/GDI/DIESEL" from System select
Screen of the M.U.T.-III.
4. Select "Special Function" from MPI/GDI/DIESEL
Screen.
5. Select "Learning" from Special Function Screen.
6. Select Item No. 1 "Small Injection qt. Learning"
from the Learning Screen to execute learning.
2-41
CAUTION
If the vehicle conditions go out of the learning
conditions during idling, learning is interrupted.
To reexecute learning, the ignition switch must
once be turned off.
7. Continue idling for about 3 minutes before
learning is completed.
8. Confirm that the engine warning lamp is off. If it
still blinks, reexecute learning.
ROAD TEST
M6020700200831
Drive the vehicle and check for conditions.
1. Check free play of steering wheel.
2. Check efficiency of service brakes and parking
brakes system.
3. Check driveability of engine/motor.
4. Check condition of instruments, gauges
indicators, exterior lamps, heater and ventilators.
5. Check abnormal noise of each part.
6. Check the tyres for wear and for the correct air
pressure.
NOTES