Professional Documents
Culture Documents
Outlander
Outlander
GROUP 0
GENERAL
CONTENTS
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.
AC305592
AC305593
AC305594 AC305596
If any of the following parts are removed, they must In accordance with the instructions in this manual,
be replaced with new parts. apply the specified lubricants in the specified loca-
• Oil seals tions during assembly and installation.
• Gaskets (except rocker cover gasket)
• Packings BRAKE FLUID
M6001000900047
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
PARTS
M6001000600046
AC305285
AC305284
0-4 GENERAL
PRECAUTIONS BEFORE SERVICE
Approx.
40 cm
ACX00880AD ACX00881AE
Before replacing a component related to the electri- If high-pressure car-washing equipment or steam
cal system and before undertaking any repair proce- car-washing equipment is used to wash the vehicle,
dures involving the electrical system, be sure to first be sure to note the following information in order to
disconnect the negative (-) cable from the battery in avoid damage to plastic components, etc.
order to avoid damage caused by short-circuiting. • Spray nozzle distance: Approx. 40 cm or more
CAUTION • Spray pressure: 3,900 kPa or less
Before connecting or disconnecting the negative • Spray temperature: 82°C or less
(-) cable, be sure to turn off the ignition switch • Time of concentrated spray to one point: within
and the lighting switch. (If this is not done, there 30 sec.
is the possibility of semiconductor parts being
damaged.)
MULTI USE TESTER (M.U.T.-III) SUB
ASSEMBLY
APPLICATION OF ANTI-CORROSION M6001001900125
Refer to the "M.U.T.-III OPERATING INSTRUC-
AGENTS AND UNDERCOATS TIONS" for instructions on handling the M.U.T.-III.
M6001001100055
If oil or grease gets onto the oxygen sensor, it will AC302297
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
M6001001200052
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec- MB991910
tion can be carried out. If you see the words "Set the
vehicle to the pre-inspection condition" in this man- Diagnosis connector
ual, it means to set the vehicle to the following condi-
MB991824
tion.
• Engine coolant temperature: 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
• A/T: P range
MB991827 AC601854AB
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
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
PAINTWORK TERMS
1-5
PAINTWORK TERMS
M6010200100054
FIRST STEP
1. CONNECTION OF DARK CURRENT Press down the storage connector.
CONNECTOR
M6010300100181
CONNECTING PROCEDURE
Relay box Storage connector
AC602562AB
BODY
2. WRAP FILM To protect the exterior finish of vehicles prior to
M6010400100069 dealer delivery, a protective coating is used. The
coating is a thin white resin film. It is applied to all
painted exterior horizontal surfaces of the vehicle
and is held in place with a tacky adhesive backing.
AC305606
PRE-DELIVERY INSPECTION
BODY
1-7
Removal procedure
Peel off slowly from corners keeping parallel to the body. When
Wrap film removal the body temperature is high, lower it to 50ºC or less by
sprinkling water so that adhesive may not remain on the body.
Water washing
AC306352 AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are There should be no leftover adhesive, swelling or
checked. discoloration of the paint film, or other defects.
4 Treatment of parts where film is to be Treat the defects on the parts where film is to be
reapplied. reapplied. If a solvent is used to remove leftover
adhesive, wipe off the solvent thoroughly.
5 Reapplication 1. Basically, the parts where the film is to be applied
should be the same as the film that is to be applied.
2. Apply the film from the lower portion of the body,
working upward progressively. Apply pressure using
a plastic squeegee or similar tool.
3. As necessary, cut the film at the various parts such as
windshield washer nozzles, hood and trunk lid.
CAUTION
• Apply the film with the body at a temperature of 10 − 40°C. (Workability is good in this temperature
range.)
• If the outside surface of the film (the side with no adhesive) is brought into direct contact with the
paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not
get folded under or otherwise make contact with the paint film.
• Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort
should be made to prevent air bubbles from being trapped under the film by applying pressure
from the centre of the film outward toward the edges during application.
• To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of
the film securely.
1-8 PRE-DELIVERY INSPECTION
BODY
AC305607
(Refer to Paintwork terms) 7. Verify that the rear doors can't be opened by the
inner door handle when the child protection knob
4. OPERATION OF DOOR LOCKING at the end of the door is shifted to the "LOCK"
SYSTEMS AND DOOR HINGES position with the inside lock plunger raised.
M6010400300096
CAUTION
Set the lock to the "FREE" position on child pro-
tection of both rear doors. (For four door models)
Front
AC305608 AB
AC305607
1. Door mirrors
Check that the mirror operate properly.
AC210253AB 2. Door windows
Close all door windows to the fully closed position
1. Open each door to check the release mechanism to check ease of operation.
and ease of operation. 3. Power windows
2. Close the door to check the latch and striker. Check that the door windows operate when the
3. Open the door, operate the lock lever and close respective switches are operated. Check that
the door to check the lock. when the lock switches are depressed, the
respective door windows can no more be opened
or closed.
PRE-DELIVERY INSPECTION
UNDER HOOD
1-9
4. Slide window 5. Sunroof
Close the slide window to the fully closed position Close the sunroof to the fully closed position to
to check operation. check operation.
UNDER HOOD
6. ENGINE OIL LEVEL 8. CLUTCH MASTER CYLINDER FLUID
M6010500100044
LEVEL
M6010500300071
MAX
MIN
AC305611 AB
Check that the oil level is between "MAX" and "MIN". AC305613
If it is at or below MIN, add the necessary amount of Check the fluid level.
the specified engine oil referring to GROUP 2, Peri- If it is below the "MIN" mark, replenish fresh brake
odic Inspection and Maintenance P.2-3. fluid up to the "MAX" mark.
7. BRAKE MASTER CYLINDER FLUID Specified Brake Fluid: DOT3 or DOT4
LEVEL 9. WASHER FLUID LEVEL
M6010500200085 M6010500400045
AC305612 AC305614
Check the fluid level. Check the fluid level; if it is low, replenish the washer
If it is below the "MIN" mark, replenish fresh brake fluid at the up to MAX mark.
fluid up to the "MAX" mark. 1. Windshield washer reservoir
Specified Brake Fluid: DOT3 or DOT4 2. Rear window washer reservoir
1-10 PRE-DELIVERY INSPECTION
UNDER VEHICLE
10. BATTERY CONDITION AND 2. If the fluid is added, start the engine and turn the
CONNECTIONS steering wheel from stop to stop several times to
M6010500500097 expel air from the system.
Specified gear oil: Automatic transmission
fluid DEXRON III or DEXRON II
AC305615
11. POWER STEERING FLUID LEVEL 1. Each electrical wiring harness and connector
M6010500600146
(1) Check each harness to be correctly routed
and securely clipped.
(2) Confirm that all connections are tight.
2. Ignition cable
Be sure that all ignition cables are firmly attached
to the spark plugs, distributor cap (or crank angle
sensor) and ignition coil.
AC305616
UNDER VEHICLE
13. TYRE AND SPARE TYRE PRESSURES 1. Tyre specification
M6010600100096 Check the correct tyre specification.
2. Tyre pressures
Adjust each tyre pressure.
NOTE: Recommended pressure is shown on the
tyre pressure label.
3. Valve stem extensions
Verify that the valve stem extensions are installed
where necessary.
4. Install the wheel covers, wheel rings and hub
AC305618 caps.
PRE-DELIVERY INSPECTION
UNDER VEHICLE
1-11
14. SUSPENSION SYSTEM 15. STEERING LINKAGE AND SPLIT PINS
M6010600200048 M6010600300045
AC305609 AC305604
Check to be sure that each installation bolt and nut is 1. Steering linkage retaining nuts and split pins
tightened. If split pins are used, make sure that they Check visually and by feel that the steering
are properly installed. linkage retaining nuts are correctly tightened and
1. Lower arm, Upper arm the split pins are correctly installed.
2. Stabilizer bar 2. Tie rods and relay rod
3. Strut assembly Check that the tie rods and relay rod of the
REMOVE FRONT SPRING RESTRAINTS steering linkage are not bent and that the tie rod
end lock nuts are securely tightened.
Spring 3. Steering components
restraints (1) Check that each of the steering components is
tightened.
(2) Check the tie rod end, nuts and split pins for
proper installation.
(3) Check the condition of bellows-type dust
seals.
4. Split pins
AC305605 Check the front axle nuts and rear wheel spindle
With the vehicle correctly positioned on the nuts for split pins.
sub-frame contact points, and the suspension fully
extended, remove the rubber restraints from the front
16. UNDER BODY
M6010600400042
springs. Check under body and under body coating for dam-
CAUTION age.
It is very important that these restraints must be
removed during predelivery-inspection. Failure
to do so could cause ride and handling com-
plaints.
1-12 PRE-DELIVERY INSPECTION
BEFORE ROAD TEST
AC305622
M6010701100041
On models with an automatic transmission, be sure 1. Air conditioner
the engine starts in both "P" and "N" position, and (1) Operate the air conditioner system.
does not start in other positions. (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
19. IDLE CONTROL KNOB (4) Operate the blower motor switch in all ranges.
M6010700300042
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.
AC305624
PRE-DELIVERY INSPECTION
BEFORE ROAD TEST
1-13
23. WIPERS AND WASHERS
M6010700700040
AC305629
AC305630
AC305628 AB
1. Service brakes
(1) Check the clearance between the brake pedal
and the floorboard when the brake pedal is
depressed.
AC305631
26. OPERATION OF SEAT BELTS, 1. Verify that the seat belt warning lamp operates
SHOULDER BELTS AND RETRACTORS properly.
M6010701000044 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.
AC305632
ROAD TEST
27. ENGINE PERFORMANCE AND 28. TRANSMISSION IN ALL RANGES
M6010800200042
EXHAUST GAS
M6010800100045
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 Button
gas leaks.
(2) Verify that no black smoking is emitted from
the end of the exhaust pipe (diesel-powered
vehicles).
AC305635 AB
2. Automatic transmission
(1) Make sure shift indicator lines up properly in
all ranges.
(2) Depress the accelerator completely to check
that the manual kickdown is operating
correctly.
PRE-DELIVERY INSPECTION
ROAD TEST
1-15
(3) Stop the vehicle on a steep incline. 31. VIBRATION AND RATTLES
Put the automatic transmission in "P" position M6010800500043
and slowly release the service brakes to see if 1. Locate squeaks, rattles and unusual vibrations.
"P" position lock holds. If it does not hold, the 2. Verify that no noise occurs from the engine,
transmission requires further service. transmission, axle and body.
AC305643
AC305642
Transmission oil
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
AC305644 AB
60%.
CAUTION 1. Remove the filler plug.
Do not remove the radiator cap while the cooling 2. Check the oil level. If the oil level is at or slightly
system is under pressure. below the filler hole, it is in satisfactory condition.
When removing the radiator cap, be careful of
3. If the level is low, replenish the transmission and
steam and boiling water. Add coolant only to the
transfer case with fresh oil by using a lubricator.
reserve tank if it is required.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance P.2-3.
PRE-DELIVERY INSPECTION
AFTER ROAD TEST
1-17
38. AUTOMATIC TRANSMISSION FLUID
•
TYPE 1 TYPE 2
LEVEL
M6010900600177
8 mm Gear oil
Upper
limit
Lower
limit
AC305646AC
OIL LEVELS 1. Check all hoses, fluid lines and connections for
M6010900800171 leaks.
1. Remove the filler plug.
2. Check all hoses and fluid lines for proper routing
2. Check the oil level. If the oil level is at or slightly away from sharp edges and moving components.
below the filler hole, it is in satisfactory condition.
1-18 PRE-DELIVERY INSPECTION
FINAL STEPS
FINAL STEPS
42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR
M6011000100161 M6011000300110
Screen
Headlamp
Level surface
AC305648 AB AC305650
Check condition for headlamp aiming. Finally check and clean the exterior and interior.
NOTE: For headlamp aiming procedures, refer to the 1. Wash the vehicle to remove all traces of road
Workshop Manual for that model. grime and other dirt on the vehicle as a result of
new vehicle preparations.
43. EQUIPMENT 2. Clean exterior and interior glass surface.
M6011000200113
3. Remove all protective covers.
4. Remove undercoat overspray, excess window
sealer, and excess weatherstrip adhesive.
5. Verify that the secondary key can not unlock the
glove box and tailgate/boot lid (if so equipped).
6. Remove shipping and inspection stickers.
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
OPERATIONS INSIDE THE VEHICLE 2-14 D5. CHECK BRAKE SHOE LININGS
C1. CHECK BRAKE PEDAL AND AND DISCS FOR WEAR. . . . . . . . . . . . . . . 2-20
CLUTCH PEDAL FOR FREE PLAY . . . . . . 2-14 D6. CHECK FUEL HOSES AND PIPES
FOR LEAKAGE OR DETERIORATION . . . 2-21
C2. CHECK PARKING BRAKE LEVER
STROKE AND PLAY. . . . . . . . . . . . . . . . . . 2-15
C3. REPLACE AIR PURIFIER FILTER. . . . 2-16 OPERATIONS AFTER ENGINE IS
WARMED UP . . . . . . . . . . . . . . . . . . . 2-22
OPERATIONS OUTSIDE E1. CHANGE ENGINE OIL . . . . . . . . . . . . . 2-22
THE VEHICLE . . . . . . . . . . . . . . . . . . 2-17 E2. REPLACE ENGINE OIL FILTER . . . . . 2-22
D1. CHECK UNEVEN TYRE WEAR. . . . . . 2-17 E3. CHECK ENGINE IDLING SPEED. . . . . 2-22
D2. CHECK FRONT AND REAR WHEEL E4. CHECK EXHAUST GAS
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-18 RECIRCULATION (EGR) SYSTEM . . . . . . 2-23
D3. CHECK BRAKE HOSES AND PIPES
FOR LEAKAGE. . . . . . . . . . . . . . . . . . . . . . 2-19 OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-23
D4. CHECK BRAKE PADS AND DISCS F1. CHECK BODY CONDITION FOR
FOR WEAR. . . . . . . . . . . . . . . . . . . . . . . . . 2-20 DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
F2. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-23
PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
2-3
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
M6020100100445
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
•: Applicable for OUTLANDER
Maintenance item Maintenance Maintenance interval Application
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
A1 Check V-belt for cracks, fraying, wear, and Inspection Every 15,000 km or every 12 •
adjust its tension months
A2 Check intake air hose for damage (vehicles Inspection Every 30,000 km or every 2 •
with turbocharger) years
A3 Replace engine timing belt Replace Every 120,000 km •
A4 Check radiator hoses for damage and Inspection Every 30,000 km or every 2 •
proper connection years
A5 Check engine coolant level in reservoir Inspection Every 30,000 km or every 2 •
years
A6 Change engine coolant Change Every 60,000 km or every 4 •
years
A7 Check air cleaner element for clogging and Inspection Normal Every 15,000 km •
damage usage or every 12 months
Severe Every 7,500 km or •
usage every 6 months
A8 Replace air cleaner element Replace Normal Every 45,000 km •
usage or every 3 years
Severe More frequently •
usage
A9 Check fluid level in brake reservoir and Inspection Every 15,000 km or every 12 •
clutch reservoir (for hydraulic type clutch) months
A10 Change brake fluid Change Every 30,000 km or every 2 •
years
A11 Check battery electrolyte level Inspection Every 15,000 km or every 12 •
months
A12 Replace fuel filter Replace Every 30,000 km or every 2 •
years
OPERATIONS UNDER THE VEHICLE
B1 Check suspension system for damage and Inspection Every 30,000 km or every 2 •
looseness years
B2 Check suspension arm ball joints for play, Inspection Every 30,000 km or every 2 •
and dust covers for damage years
B3 Check driveshaft boots for damage Inspection Normal Every 30,000 km •
usage or every 2 years
Severe Every 7,500 km •
usage
2-4 PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
Indicator mark
A AC602559AB
Turbocharger AC602560AB
AC508128AB
AC504232 AB
10.When the coolant in the radiator condenser tank 3. Wipe off dust on the air cleaner interior.
is gone, refill the coolant again to the "FULL" line 4. Install the air cleaner body.
of the radiator condenser tank as slowly as
possible. A8. REPLACE AIR CLEANER ELEMENT
M6020201300320
11.Repeat steps 9 and 10 until the coolant in the
The air cleaner element will become dirty and loaded
radiator condenser tank stops reducing.
with dust during use, and the filtering effect will be
12.If the coolant in the radiator condenser tank substantially reduced. Replace it with a new one.
stopped reducing, let the engine run at 2,000
r/min (heater temperature adjustment: MAX
COOL, air volume adjustment: OFF) until the
cooling fan starts running.
13.When the cooling fan starts running, let the
engine idle until the cooling fan stops running.
14.When the cooling fan has started running, let the
engine run at 2,000 r/min (heater temperature
adjustment: MAX HOT, air volume adjustment:
MAX) for 3 minutes and check that the coolant in AC602561AB
the radiator condenser tank is not reducing. If the
coolant reduces, refill the coolant to the "FULL" 1. Unclasp the air cleaner cover clip.
line of the radiator condenser tank. 2. Remove the air cleaner element and install a new
15.Stop the engine and wait until the coolant cools one.
down. Check that the coolant in the radiator 3. Be sure to close the air cleaner cover completely
condenser tank is not reduced excessively. when clamping it.
NOTE: If the reduction is approximately 10 mm,
the change can be attributed to hot and cold sta- A9. CHECK FLUID LEVEL IN BRAKE
tuses of the coolant. Thus, it is judged good. RESERVOIR AND CLUTCH RESERVOIR
(For hydraulic type clutch)
A7. CHECK AIR CLEANER ELEMENT M6020202300066
MAX
MIN
AC507763
AC507627
1. Check that the fluid level is between the "MAX"
and "MIN" mark.
1. Check air cleaner element for clogging and 2. If it is below the "MIN" marks, replenish with fresh
damage. brake fluid up to the "MAX" mark.
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.
PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT
2-9
A10. CHANGE BRAKE FLUID <L.H. drive vehicles>
M6020201600376
4 1
Front of
vehicle
2 3
AC607427AB
A11. CHECK BATTERY ELECTROLYTE 3. The specific gravity of the battery fluid varies with
LEVEL the temperature, so use the following formula to
M6020201700395 calculate the specific gravity for 20°C. Use the
Thermometer Hydrometer calculated value to determine whether or not the
specific gravity is satisfactory.
D20 = (t - 20) × 0.0007 + Dt
D20: Specific gravity of the battery fluid calcu-
lated for 20°C.
t: Actually measured temperature
Battery fluid
Dt: Actually measured specific gravity
CAUTION
Fuel filter
• If the battery fluid is below the LOWER
LEVEL, the battery could explode in using.
• If the battery fluid is over the UPPER LEVEL,
leakage could result.
1. Inspect whether or not the battery fluid is between
the UPPER LEVEL and LOWER LEVEL marks.
2. Use a hydrometer and thermometer to check the
specific gravity of the battery fluid. AC607841AB
Standard value: 1.220 − 1.290 [20°C] • Unclasp the fuel filter bracket clamp.
PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS UNDER THE VEHICLE
2-11
OPERATIONS UNDER THE VEHICLE
B1. CHECK SUSPENSION SYSTEM FOR
DAMAGE AND LOOSENESS
M6020300100289
FRONT SUSPENSION
Deterioration
and sagging
Bends and
damage
Noise and
oil leakage
Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Bends and
damage
Deterioration
and sagging
Bends and
damage
Cracks, bends
and dents
AC606684 AB
2-12 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS UNDER THE VEHICLE
B2. CHECK SUSPENSION ARM BALL B4. CHECK STEERING LINKAGE FOR
JOINTS FOR PLAY, AND DUST COVERS DAMAGE AND LOOSE CONNECTIONS
FOR DAMAGE (INCLUDING SEALS AND BOOTS)
M6020300200297 M6020300500306
Dust cover
AC305662
Lower arm 1. Move the steering wheel bit by bit to the left or
AC507631AB right, and check to be sure that there is no play or
looseness in the linkage coupling, that the
1. Raise the vehicle. installation is not loose, and that the rod or arm is
2. Move the lower arm up and down with your hands not bent or damaged.
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly.
Driveshaft <LH>
Filler plug
Drain plug
AC210553 AB AC406030AE
5. Fill with specified oil till the level comes to the 2. Fit the drain plug and tighten it to the specified
lower portion of oil filler plug hole. torque.
Specified transfer oil: Gear oil API classifica- Tightening torque: 32 ± 2 N⋅m
tion GL- 5 SAE 90
Quantity: 0.54 L
Filler plug
6. Tighten the oil filler plug to the specified torque.
Tightening torque: 32 ± 2 N⋅m
AC508618AB
Gear oil 3. Remove the filler plug and add the specified gear
oil up to the bottom end of the filler plug hole.
Upper Specified gear oil: Gear oil API classification
limit GL- 5, SAE 80W
Lower Quantity: 0.5 L
limit 8 mm
4. Fit the filler plug and tighten it to the specified
AC102739 AD torque.
1. Remove the filler plug. Tightening torque: 32 ± 2 N⋅m
2. Check that the gear oil level is not 8mm below the
B11. CHECK EXHAUST PIPE
bottom of filler plug hole.
CONNECTIONS FOR GAS LEAKAGE,
3. Tighten the filler plug to the specified torque.
AND CHECK PIPE INSTALLATION
Tightening torque: 32 ± 2 N⋅m M6020301200289
1. Confirm that the exhaust pipe does not interfere
B10. CHANGE GEAR OIL IN FRONT AND with any body components.
REAR DIFFERENTIAL 2. Check the exhaust pipe for damage by stones,
M6020301100301
1. Remove the drain plug to discharge the gear oil. etc.
3. Start the engine and check for gas leaks from the
exhaust pipe connections.
AC311474 AC
AC505506AD
thickness of the disc brake pad, and correct or 4. Check that the clutch pedal height (B) and the
replace as necessary. clearance (C) between the clutch pedal and the
4. Recover the floor carpet under the brake pedal. toe board when the clutch is disengaged are
within the standard value.
Clutch pedal free play Standard value (B): 151 ± 3 mm
NOTE: This clutch pedal assembly is unadjustable Standard value (C): 77 mm or more
because of its structure. 5. When the clutch pedal height and the clearance
between the clutch pedal and toe board when the
clutch is disengaged are not within the standard
value, the air may be intruded into the hydraulic
system, or either the clutch master cylinder or the
clutch release cylinder may be faulty. In this case,
perform air bleeding, or check the clutch master
cylinder or the clutch release cylinder, and replace
it if necessary.
A
AC601326AB C2. CHECK PARKING BRAKE LEVER
STROKE AND PLAY
1. Measure the clutch pedal looseness (A). M6020400200335
Standard value (A): 1.5 mm or less Pull the parking brake lever with a force of approx.
200 N and count the number of notches.
2. When the clutch pedal looseness is not within the
standard value, the clutch pedal assembly or the Standard value: 3 − 5 notches
clutch master cylinder may be faulty. In this case, 1. If the parking brake lever stroke is not the
check the clutch pedal assembly or the clutch standard value, adjust as described below.
master cylinder, and replace it if necessary. (1) Remove the floor console assembly.
3. Turn up the floor carpet under the clutch pedal.
2-16 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE VEHICLE
AC505182AB AC505182AB
AC506352AD
AC306798
AC305666
MB991004
Using a toe-in gauge, measure toe-in.
Toe-in = B − A
Standard value: 1 ± 2 mm
Standard value:
Item Specifications
Camber 0°20' ± 0°30'*
Caster 2°35' ± 0°30'*
Lock nut
AC506665AB
Kingpin inclination 12°45' ± 1°30'
1. Adjust the toe-in by undoing the clip and lock nut, NOTE: The*: difference between right and left
and turning the left and right tie rod turnbuckles by wheels must be less than 30'
the same amount (in opposite directions). NOTE: The camber and the caster are pre-adjusted
NOTE: The toe moves to the outside by turning at factory and not adjustable.
the tie-rod: left to the forward direction, and right
to the reverse direction.
2-18 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE
TOE-IN
NOTE: For vehicles with aluminium wheels, attach
Standard value: 3 ± 2 mm the camber/caster/kingpin gauge to the driveshaft by
If toe-in is not within the standard value, adjust by fol- using special tool wheel alignment gauge attachment
lowing procedures. (MB991004). Tighten the special tool to the same
torque 160 ± 16 N⋅m as the driveshaft nut.
Toe adjusting bolt
D2. CHECK FRONT AND REAR WHEEL
BEARINGS FOR PLAY
M6020500200235
<Front>
1. Remove the caliper assembly, and retain it with a
wire and the like to prevent from falling.
AC506806AB
AC511300AC
Brake booster
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
2-20 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE
D4. CHECK BRAKE PADS AND DISCS BRAKE DISC RUN-OUT CHECK
FOR WEAR 1. Remove the brake assembly, and then hold it with
M6020500400347 wire.
2. Temporarily install the disc with the hub nut.
AC102396AF
ACX00668AF
ACX00709AD
Unit injector
AC605478AC
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
2-22 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS AFTER ENGINE IS WARMED UP
MB991824
AC607301AB
Tightening torque: 30 N⋅m 2. Turn the ignition switch to "LOOK" (OFF) position,
5. Install the lid of the lower under cover panel R.H. and connect the diagnosis connector to the
M.U.T.-III.
6. Refill with specified quantity of engine oil.
3. Start the engine, and let it run at idle.
Specified Engine Oil: VW 50501/50601 or
higher 4. Check the idle speed. Select item No. 2 and take
a reading of the idle speed.
Total quantity (Includes volume inside engine
oil filter): 5.5 L Standard value: 830 ± 50 r/min
7. Install the engine oil filler cap. 5. If the idle speed is not within the standard value,
8. Check engine oil level. inspect the diesel system (Refer to WORKSHOP
MANUAL GROUP 13 - Troubleshooting).
E2. REPLACE ENGINE OIL FILTER 6. Turn the ignition switch to the "LOCK" (OFF)
M6020600400281 position and then remove the M.U.T.-III.
Emission control
solenoid assembly
AC606690AB
OTHERS
F1. CHECK BODY CONDITION FOR Drive the vehicle and check for conditions.
DAMAGE 1. Check free play of steering wheel.
M6020700100210 2. Check efficiency of service brakes and parking
1. Check underbody coating for damage. brakes system.
2. Check body painting for damage. 3. Check driveability of engine.
F2. ROAD TEST 4. Check condition of instruments, gauges
M6020700200273 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.
AC508542
NOTES