Pajero IV

0-1
GROUP 0
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 0-2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3
PRECAUTIONS BEFORE SERVICE. 0-2 SERVICING THE ELECTRICAL SYSTEM . 0-4
PROTECTING THE VEHICLE . . . . . . . . . . 0-2 APPLICATION OF ANTI-CORROSION AGENTS
DOING SERVICE WORK IN GROUPS OF TWO AND UNDERCOATS . . . . . . . . . . . . . . . . . . 0-4
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
PARTS TO BE REPLACED . . . . . . . . . . . . 0-3 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 IN ORDER TO PREVENT 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

error in assembly and facilitate the assembly work,
AC305283 be sure to make them in locations which will have no
detrimental effect on performance and/or appear-
If the service work is to be done by two or more ance. If an area having many parts, similar parts,
mechanics working together, all the mechanics and/or parts which are symmetrical right and left is
involved should take safety into consideration while disassembled, be sure to arrange the parts so that
they work. 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
SPECIAL TOOLS When replacing parts, use MITSUBISHI genuine
M6001000400031 parts.
TUBES AND OTHER RUBBER PARTS

M6001000700021
AC305593
If other tools are substituted for the special tools to

do service of repair work, there is the danger that AC305595
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe- Be careful to avoid spilling any petrol, oil, etc.,
cial tool whenever doing any work for which the use because if it adheres to any tubes or other rubber
of one is specified. parts, they might be adversely affected.
PARTS TO BE REPLACED LUBRICANTS

M6001000800028
M6001000500027
AC305594 AC305596
If any of the following parts are removed, they must In accordance with the instructions in this manual,
be replaced with new parts. apply the specified lubricants in the specified loca-
• Oil seals tions during assembly and installation.
• Gaskets (except rocker cover gasket)
• Packings BRAKE FLUID
M6001000900025
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
PARTS
M6001000600024
AC305285
Be careful to avoid spilling any brake fluid, because if

it adheres to the vehicle body, the paint coat might be
discoloured.
AC305284
0-4 GENERAL
SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING

M6001001000081 M6001001300123
CAUTION
Before connecting or disconnecting the negative
(-) cable, be sure to turn off the ignition switch Approximately
and the lighting switch. (If this is not done, there 40 cm or more
is the possibility of semiconductor parts being
damaged.)
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
ACX00880AD more
Before replacing a component related to the electri- • Spray pressure: 3,900 kPa or less
cal system and before undertaking any repair proce- • Spray temperature: 82° C or less
dures involving the electrical system, be sure to first • Time of concentrated spray to one point: within
disconnect the negative (-) cable from the battery in 30 sec.
order to avoid damage caused by short-circuiting.
MULTI USE TESTER (M.U.T.-III) SUB
APPLICATION OF ANTI-CORROSION ASSEMBLY
M6001001900169
AGENTS AND UNDERCOATS Refer to the "M.U.T.-III OPERATING INSTRUC-
M6001001100022
If oil or grease gets onto the oxygen sensor, it will TIONS" for instructions on handling the M.U.T.-III.
cause a drop in the performance of the sensor. CAUTION
Cover the oxygen sensor with a protective cover Turn the ignition switch to the LOCK (OFF) posi-
when applying anti-corrosion agents and undercoats. tion before connecting or disconnecting the
M.U.T.-III.
PRE-INSPECTION CONDITION
M6001001200041
"Pre-inspection condition" refers to the condition that Diagnosis connector
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- MB991910
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: P range
MB991824
MB991827 AC505420AB
GENERAL
0-5
Connect the M.U.T.-III to the diagnosis connector as Other precautions:
shown in the illustration. • Avoid prolonged and repeated contact with oils,
particularly used engine oils.
IN ORDER TO PREVENT VEHICLES • Wear protective clothing, including impervious
FROM FIRE gloves where practicable.
M6001001500064 • Avoid contaminating clothes, particularly under-
"Improper installation of electrical or fuel related parts pants, with oil.
could cause a fire. In order to retain the high quality • Do not put oily rags in pockets, the use of overalls
and safety of the vehicle, it is important that any without pockets will avoid this.
accessories that may be fitted or modifica- • Do not wear heavily soiled clothing and
tions/repairs that may be carried out which involve oil-impregnated foot-wear. Overalls must be
the electrical or fuel systems, must be carried out in cleaned regularly and kept separately from per-
accordance with MMC's information/Instructions". sonal clothing.
• Where there is a risk of eye contact, eye protec-
ENGINE OILS tion should be worn, for example, chemical gog-
M6001001600061
HEALTH WARNING gles or face shields; in addition an eye wash

facility should be provided.
Prolonged and repeated contact with mineral oil will
• Obtain first aid treatment immediately for open
result in the removal of natural fats from the skin,
cuts and wounds.
leading to dryness, irritation and dermatitis. In addi-
• Wash regularly with soap and water to ensure all
tion, used engine oil contains potentially harmful con-
oil is removed, especially before meals (skin
taminants which may cause skin cancer. Adequate
cleansers and nail brushes will help). After clean-
means of skin protection and washing facilities must
ing, the application of preparations containing
be provided.
lanolin to replace the natural skin oils is advised.
• Do not use petrol, kerosine, diesel fuel, gas oil,
RECOMMENDED PRECAUTIONS thinners or solvents for cleaning skin.
The most effective precaution is to adapt working • Use barrier creams, applying them before each
practices which prevent, as far as practicable, the work period, to help the removal of oil from the
risk of skin contact with mineral oils, for example by skin after work.
using enclosed systems for handling used engine oil • If skin disorders develop, obtain medical advice
and by degreasing components, where practicable, without delay.
before handling them.
NOTES
1-1
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
NOTES CONCERNING ENTRIES . . . 1-3 15. STEERING LINKAGE AND SPLIT PINS 1-11
16. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-11
PAINTWORK TERMS . . . . . . . . . . . . 1-5
BEFORE ROAD TEST . . . . . . . . . . . . 1-11
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 17. SEAT ADJUSTERS AND SEATBACK
1. CONNECTION OF DARK CURRENT LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 1-6 18. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-11
19. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-11
BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 20. INSTRUMENT PANEL CONTROLS . . . 1-12
2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-6 21. METERS, GAUGES, WARNING LAMPS
3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-7 AND INDICATION LAMPS . . . . . . . . . . . . . 1-12
4. OPERATION OF DOOR LOCKING SYSTEMS 22. AIR CONDITIONER, HEATER AND
AND DOOR HINGES . . . . . . . . . . . . . . . . . 1-8 DEFROSTER SYSTEM. . . . . . . . . . . . . . . . 1-12
5. OPERATION OF DOOR MIRRORS, 23. WIPERS AND WASHERS. . . . . . . . . . . 1-12
WINDOWS AND SUNROOF . . . . . . . . . . . 1-8 24. OPERATION OF SERVICE BRAKES AND
PARKING BRAKES . . . . . . . . . . . . . . . . . . . 1-13
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-9 25. CLUTCH OPERATION . . . . . . . . . . . . . 1-13
6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-9 26. OPERATION OF SEAT BELTS, SHOULDER
7. BRAKE MASTER CYLINDER FLUID LEVEL 1-9 BELTS AND RETRACTORS . . . . . . . . . . . . 1-13
8. CLUTCH MASTER CYLINDER FLUID LEVEL 1-9

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-14
9. WASHER FLUID LEVEL. . . . . . . . . . . . . 1-9
27. ENGINE PERFORMANCE AND EXHAUST
10. BATTERY CONDITION AND
GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-9
28. TRANSMISSION IN ALL RANGES . . . . 1-14
11. POWER STEERING FLUID LEVEL . . . 1-9
29. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-14
12. ELECTRICAL WIRING . . . . . . . . . . . . . 1-10
30. STEERING CONTROL . . . . . . . . . . . . . 1-14
UNDER VEHICLE . . . . . . . . . . . . . . . 1-10 31. VIBRATION AND RATTLES . . . . . . . . . 1-15
32. ELECTRICAL EQUIPMENT . . . . . . . . . 1-15
13. TYRE AND SPARE TYRE PRESSURES 1-10
14. SUSPENSION SYSTEM. . . . . . . . . . . . 1-10
Continued on next page
1-2
AFTER ROAD TEST . . . . . . . . . . . . . 1-15 39. ENGINE, TRANSMISSION, STEERING

33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-15 GEAR BOX AND DIFFERENTIAL FOR LEAKS 1-16
34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-15 40. FRONT AND REAR DIFFERENTIAL OIL
LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
35. RADIATOR COOLANT LEVEL . . . . . . . 1-15
41. HOSES, FLUID LINES AND CONNECTIONS
36. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE . . . . . . . . . . . 1-17
LOCATED UNDER HOOD . . . . . . . . . . . . . 1-16
37. MANUAL TRANSMISSION AND TRANSFER
FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-17
(4WD) OIL LEVEL. . . . . . . . . . . . . . . . . . . . 1-16
42. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-17
38. AUTOMATIC TRANSMISSION FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-17
44. EXTERIOR AND INTERIOR . . . . . . . . . 1-17
45. OWNER INSTRUCTIONS . . . . . . . . . . . 1-17
PRE-DELIVERY INSPECTION
NOTES CONCERNING ENTRIES
1-3
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
TABLE OF PRE-DELIVERY INSPECTION
Model
Chassis number
Engine number Before Road Test
Distance Travelled km 17. Seat adjusters and seat back latches
Owner 18. Choke system and inhibitor switch
Date of inspection
19. Idle control knob
Place of inspection
20. Instrument panel controls
Inspector
21. Meters, gauges, warning lamps and indication lamps
Body colour
22. Air conditioning, heater and defroster systems
Symbols to be used 23. Wipers and washers
24. Operation of service brakes and parking brakes
Needs Needs
Good A T 25. Clutch operation
adjustment retightening
26. Operation of seat belts, shoulder belts and retractors
Needs
Needs
Needs replenishment Road Test
C L X replenishment
cleaning of lubricant,
of repair 27. Engine performance and exhaust gas
water, etc.
28. Transmission in all ranges
INSPECTION PROCEDURE
29. Brakes
First Step
30. Steering control
1. Connection of the dark current connector
31. Vibration and rattles
Body
32. Electrical equipment
2. Wrap film
3. Exterior
After Road Test
4. Operation of door locking systems and door hinges
33. Idle speed
5. Operation of door mirrors, windows and sunroof
34. Ignition timing
Under Hood
35. Radiator coolant level
6. Engine oil level
36. Hoses, fluid lines and connections located under hood
7. Brake master cylinder fluid level
37. Manual transmission and transfer (4WD) oil level
8. Clutch master cylinder fluid level
38. Automatic transmission fluid level
9. Washer fluid level
39. Engine, transmission, steering gear box and
10. Battery condition and connections differential for leaks
11. Power steering fluid level 40. Front and rear differential oil levels
12. Electrical wiring 41. Hoses, fluid lines and connections located under vehicle
Under Vehicle Final Steps
13. Tyre and spare tyre pressures 42. Headlamp aiming
14. Suspension system 43. Equipment
15. Steering linkage and split pins 44. Exterior and interior
16. Under body 45. Owner instructions
AC401525
AC306353
PAINTWORK TERMS
1-5
PAINTWORK TERMS
M6010200100140
Term Definition Remark

Blister A raised bubble in the paint (from the base
or the undercoat) caused by abnormal
moisture. The bubble may contain either
water or air.
Change in tone The colour tone of the painted surface is not Including wrong colour, discoloration and
uniform. 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 earth Deep scratches in sheet metal surface,
traces resulting from improper use of buffer or
sander, are not completely covered, and are
visible through paint coating.
Orange peel The painted surface has the appearance of
an orange peel.
Peeling The paint flakes off (partly or over a wide The peeling may be minor, medium, or
area). major.
Pin holes Tiny holes in the painted surface.
Runs A visible trickle of dried paint on the surface. Either undercoat or top-coat.
Scratches Scratches on the painted surface.
Shrink The painted surface "shrinks", causing
wrinkles.
Smears Spots of soot or other material deposited on Including stains and water spots.
the painted surface.
Spray mist The painted surface includes fine particles of
other paint.
Uneven lustre The lustre of the painted surface is not
uniform.
Uneven metallic The metallic dispersion of the painted
dispersion surface is not uniform.
Visibly incomplete A part of the undercoating visible.
topcoating
FIRST STEP
FIRST STEP
1. CONNECTION OF DARK CURRENT Press down the storage connector.
CONNECTOR
M6010300100170
CONNECTING PROCEDURE
Storage connector
Relay box
AC608836 AB
BODY
2. WRAP FILM To protect the exterior finish of vehicles prior to
M6010400100100 dealer delivery, a protective coating is used. The
coating is a thin white resin film. It is applied to all
painted exterior horizontal surfaces of the vehicle
and is held in place with a tacky adhesive backing.
AC305606
BODY
1-7
REMOVAL PROCEDURE
Peel off slowly from corners keeping parallel to the body. When
Wrap film removal the body temperature is high, lower it to 50ºC or less by
sprinkling water so that adhesive may not remain on the body.
Water washing
Wipe-off by kerosene or white gasoline, etc.

Cleaning of border
If it is considerably visible, use polishing compound.
Disposal of removed film: Burning is appropriate
AC306352 AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are There should be no leftover adhesive, swelling or
checked. discoloration of the paint film, or other defects.
4 Treatment of parts where film is to be Treat the defects on the parts where film is to be
reapplied. reapplied. If a solvent is used to remove leftover
adhesive, wipe off the solvent thoroughly.
5 Reapplication 1. Basically, the parts where the film is to be applied
should be the same as the film that is to be applied.
2. Apply the film from the lower portion of the body,
working upward progressively. Apply pressure using
a plastic squeegee or similar tool.
3. As necessary, cut the film at the various parts such as
windshield washer nozzles, hood and trunk lid.
CAUTION
• 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.
BODY
3. EXTERIOR 6. Verify that all doors can be locked by the lock

M6010400200226 buttons.
1. Visually inspect the entire exterior.
NOTE: Adjust and lubricate the door latches, strikers
(1) Paint condition
and locks as required.
(2) Corrosion, scratches
(3) Bent edges, dented panels
2. Coated surfaces maintenance
Touch up minor paint chips and flaws.
(Refer to paintwork terms)
4. OPERATION OF DOOR LOCKING

SYSTEMS AND DOOR HINGES
M6010400300137
Child-protection knob
AC305610 AB
7. Verify that the rear doors can't be opened by the

inner door handle when the child protection knob
at the end of the door is shifted to the "LOCK"
position with the inside lock plunger raised.
NOTE: Set the lock to the "FREE" position on child
protection of both rear doors. (For four door models)
Front
AC305608 AB 5. OPERATION OF DOOR MIRRORS,
WINDOWS AND SUNROOF
M6010400400112
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.
3. Power windows
Check that the door windows operate when the
AC210253AB respective switches are operated. Check that
when the lock switches are depressed, the
1. Open each door to check the release mechanism respective door windows can no more be opened
and ease of operation. or closed.
2. Close the door to check the latch and striker. 4. Slide window
3. Open the door, operate the lock lever and close Close the slide window to the fully closed position
the door to check the lock. to check operation.
4. Partially close the door to check the open-door 5. Sunroof
detent.
Close the sunroof to the fully closed position to
5. Unlock each door with the key to check lock check operation.
operation.
UNDER HOOD
1-9
UNDER HOOD
6. ENGINE OIL LEVEL 9. WASHER FLUID LEVEL
M6010500100196 M6010500400108
MAX
MIN
AC702169 AC305614
Check that the oil level is between "MAX" and "MIN". Check the fluid level; if it is low, replenish the washer
If it is at or below MIN, add the necessary amount of fluid.
the specified engine oil referring to GROUP 2, Peri- 1. Windshield washer reservoir
odic Inspection and Maintenance.
2. Rear window washer reservoir
7. BRAKE MASTER CYLINDER FLUID 10. BATTERY CONDITION AND
LEVEL
M6010500200148 CONNECTIONS
M6010500500042
AC702028
Check the fluid level. AC305615
If it is below the "MIN" mark, replenish fresh brake Inspect the battery connections. Verify that they are
fluid up to the "MAX" mark. tightened.
Specified Brake Fluid: DOT3 or DOT4 NOTE: Do not wipe the lubricant from the battery
posts and cable clamps.
8. CLUTCH MASTER CYLINDER FLUID
LEVEL 11. POWER STEERING FLUID LEVEL
M6010500300026 M6010500600072
AC305613 AC305616
Check the fluid level.

1. Check that the fluid level is between "MAX" and
If it is below the "MIN" mark, replenish fresh brake
"MIN".
fluid up to the "MAX" mark.
Specified Brake Fluid: DOT3 or DOT4
UNDER VEHICLE
2. If the fluid is added, start the engine and turn the 1. Each electrical wiring harness and connector
steering wheel from stop to stop several times to (1) Check each harness to be correctly routed
expel air from the system. and securely clipped.
Specified gear oil: Automatic transmission (2) Confirm that all connections are tight.
fluid DEXRON III or DEXRON II 2. Ignition cable
Be sure that all ignition cables are firmly attached
12. ELECTRICAL WIRING to the spark plugs, distributor cap (or crank angle
M6010500700024
sensor) and ignition coil.
AC305617
UNDER VEHICLE
13. TYRE AND SPARE TYRE PRESSURES 14. SUSPENSION SYSTEM
M6010600100041 M6010600200082
AC305618 AC305609
1. Tyre specification Check to be sure that each installation bolt and nut is
Check the correct tyre specification. tightened. If split pins are used, make sure that they
are properly installed.
2. Tyre pressures
Adjust each tyre pressure. 1. Lower arm, Upper arm
2. Stabilizer bar
NOTE: Recommended pressure is shown on the
tyre pressure label. 3. Strut assembly
3. Valve stem extensions
Verify that the valve stem extensions are installed
where necessary.
4. Install the wheel covers, wheel rings and hub
caps.
BEFORE ROAD TEST
1-11
REMOVE FRONT SPRING RESTRAINTS 1. Steering linkage retaining nuts and split pins
Check visually and by feel that the steering
CAUTION
linkage retaining nuts are correctly tightened and
It is very important that these restraints must be
the split pins are correctly installed.
removed during predelivery-inspection. Failure
to do so could cause ride and handling com- 2. Tie rods and relay rod
plaints. Check that the tie rods and relay rod of the
steering linkage are not bent and that the tie rod
Spring end lock nuts are securely tightened.
restraints 3. Steering components
(1) Check that each of the steering components is
tightened.
(2) Check the tie rod end, nuts and split pins for
proper installation.
(3) Check the condition of bellows-type dust
seals.
AC305605 4. Split pins
With the vehicle correctly positioned on the Check the front axle nuts and rear wheel spindle
sub-frame contact points, and the suspension fully nuts for split pins.
extended, remove the rubber restraints from the front
springs. 16. UNDER BODY
M6010600400020
Check under body and under body coating for dam-
15. STEERING LINKAGE AND SPLIT PINS age.
M6010600300023
AC305604
BEFORE ROAD TEST

17. SEAT ADJUSTERS AND SEATBACK 1. Mechanical adjusters of the seats
LATCHES 2. Operation of the latch for tilting the seatbacks
M6010700100082 forward and backward.
18. INHIBITOR SWITCH

M6010701100029
On models with an automatic transmission, be sure
the engine starts in both "P" and "N" position, and
does not start in other positions.
19. IDLE CONTROL KNOB

M6010700300020
Verify that the diesel engine revolution increases
AC305622 when the idle control knob is pulled out.
Check the operation of the various parts of the seats.
BEFORE ROAD TEST
20. INSTRUMENT PANEL CONTROLS

M6010700400083
Check the operation of the following
1. Horn
2. Headlamps
3. Exterior and interior lamps
4. Instrument panel lamps
5. Instrument brightness control
21. METERS, GAUGES, WARNING AC305626
LAMPS AND INDICATION LAMPS 2. Heater and defroster

M6010700500024
(1) After the engine has warmed up, turn on the
heater.
(2) Operate the blower motor switch in all ranges.
(3) Move the control to "Defrost" position.
A: From front and side defroster
B: From centre ventilators
C: From side ventilators
D: From under the instrument panel
E: From under the front seat (some models only)
AC305624
23. WIPERS AND WASHERS
1. Check the meters and gauges are functioning M6010700700028
properly.
2. Check each indicator lamp and warning lamp
functions properly.
22. AIR CONDITIONER, HEATER AND

DEFROSTER SYSTEM
M6010700600021
Check the systems for proper operation.
AC305627
1. Front wiper and washer

(1) Check operation of the front wipers in all
ranges.
(2) Check the aim of the front washer stream.
(3) Check the wiper blade-stop positions.
(4) Verify that the interval between cycles of
AC305625 wiping is shifted when timer knob is turned to
any position.
1. Air conditioner (5) Verify that the front wipers function by
(1) Operate the air conditioner system. operating the washer switch.
(2) Operate the air conditioner light. 2. Rear wiper and washer
(3) Operate the control lever in all ranges. (1) Check the operation of the rear wiper.
(4) Operate the blower motor switch in all ranges. (2) Check the aim of the rear washer stream.
(3) Check the wiper blade-stop positions.
BEFORE ROAD TEST
1-13
24. OPERATION OF SERVICE BRAKES 1. Check the clutch operation in all driving ranges.
AND PARKING BRAKES 2. Check the pedal to floorboard clearance when the
M6010700800274 clutch is just disengaged.
Depress the brake pedal

with approximately 500
N force
AC305628 AB
AC305631
1. Service brakes
3. Verify correct clutch pedal free play.
(1) Check the clearance between the brake pedal
NOTE: For inspection and adjustment of the
and the floor board when the brake pedal is
clutch pedal, refer to GROUP 2, Periodic Inspec-
depressed.
tion and Maintenance.
26. OPERATION OF SEAT BELTS,

SHOULDER BELTS AND RETRACTORS
M6010701000022
AC305629
(2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the
service brake, refer to GROUP 2, Periodic
AC305632
Inspection and Maintenance.
2. Parking brake
Check the parking brake drag and lever travel. 1. Verify that the seat belt warning lamp operates
NOTE: For inspection and adjustment of the park- properly.
ing brake, refer to GROUP 2, Periodic Inspection 2. Check all seat belts and harnesses to assure that
and Maintenance. they connect and hold properly.
3. Lean forward to check that the shoulder
25. CLUTCH OPERATION harnesses allow movement.
M6010700900282
4. Check the condition of the belts and anchors.
5. Check for proper seat belt retraction.
AC305630AC
ROAD TEST
ROAD TEST
27. ENGINE PERFORMANCE AND
EXHAUST GAS
M6010800100023
Button
AC305635 AB
2. Automatic transmission
AC305633 (1) Make sure shift indicator lines up properly in
all ranges.
1. Engine performance (2) Depress the accelerator completely to check
Check the engine for proper performance and that the manual kickdown is operating
accelerator pedal for smooth operation. correctly.
2. Exhaust system (3) Stop the vehicle on a steep incline.
Put the automatic transmission in "P" position
(1) Check the exhaust system components for
and slowly release the service brakes to see if
gas leaks. "P" position lock holds. If it does not hold, the
(2) Verify that no black smoking is emitted from transmission requires further service.
the end of the exhaust pipe (diesel-powered
vehicles). 29. BRAKES
M6010800300027
28. TRANSMISSION IN ALL RANGES 1. Service Brake

M6010800200020 Put the vehicle in gear and apply the brakes while
the vehicle is in motion. Be sure brake operation
is smooth and positive.
2. Parking Brake
(1) Stop the vehicle on a steep incline.
With the service brakes firmly applied, place
the transmission in "N" position, and set the
parking brakes.
(2) Slowly release the service brakes to see if the
parking brakes will hold.
AC305634
30. STEERING CONTROL
M6010800400024
1. Manual transmission
Check the transmission in all forward ranges and
in reverse.
AC305636
1. Check for excessive play or looseness.

2. Check the steering wheel centre.
AFTER ROAD TEST
1-15
31. VIBRATION AND RATTLES 1. Radio
M6010800500021
1. Locate squeaks, rattles and unusual vibrations. Tune the radio to a local broadcasting station and
check the following:
2. Verify that no noise occurs from the engine,
(1) Operate the volume, tone, balance and fader
transmission, axle and body.
controls, etc.
32. ELECTRICAL EQUIPMENT (2) Pull out the pushbuttons, dial another station
M6010800600028 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
AC305637 and fader controls, etc.
AFTER ROAD TEST

33. IDLE SPEED 35. RADIATOR COOLANT LEVEL
M6010900100172 M6010900300154
Check the engine idle speed. CAUTION
NOTE: For specific idle speed adjustment proce- Do not remove the radiator cap while the cooling
dure, refer to GROUP 2, Periodic Inspection and system is under pressure.
Maintenance. When removing the radiator cap, be careful of
steam and boiling water. Add coolant only to the
34. IGNITION TIMING reserve tank if it is required.
M6010900200179
AC305642
AC305641
Check the ignition timing. Except MPI vehicles with 1. Check that the coolant level in the reserve tank is
crankshaft-mounted crankshaft angle sensor. at or above "LOW" mark at normal engine
NOTE: For the inspection and adjustment of the igni- operating temperature. And check cooling system
tion timing, refer to GROUP 2, Periodic Inspection for leaks.
and Maintenance. 2. Check that the coolant concentration is 30% to
60%.
AFTER ROAD TEST
36. HOSES, FLUID LINES AND 38. AUTOMATIC TRANSMISSION FLUID

CONNECTIONS LOCATED UNDER HOOD LEVEL
M6010900400203 M6010900600230
CAUTION
Remember that the air conditioner system is
under pressure.
AC005861AD
1. Remove the dipstick and check the fluid level.

AC305643
2. Fluid level is okay if it is in the specified range as
illustration at normal engine operating
1. Check all brake, fuel, power steering and air temperature.
conditioner lines and connections; verify proper 3. If the level is below the lower notch, replenish fluid
routing, check connections for leaks, tighten loose until the level reaches the upper notch.
connector as required. NOTE: For the specified automatic transmission
2. Inspect routing and connections of all vacuum, fluid, refer to GROUP 2, Periodic Inspection and
and radiator and heater houses. Maintenance.
NOTE: Keep in mind that an oily residue around
an air conditioner connector does not necessarily 39. ENGINE, TRANSMISSION, STEERING
indicate a leak. Oil is used to lubricate fittings dur- GEAR BOX AND DIFFERENTIAL FOR
ing assembly. Be sure lines are not twisted or LEAKS
kinked. M6010900700055
Check the engine, transmission, steering gear box
37. MANUAL TRANSMISSION AND and differential for oil leaks.
TRANSFER (4WD) OIL LEVEL
M6010900500211 40. FRONT AND REAR DIFFERENTIAL
OIL LEVELS
M6010900800234
1. Remove the filler plug.
2. Check the oil level. If the oil level is at or slightly
Transmission oil
below the filler hole, it is in satisfactory condition.
•
TYPE 1 TYPE 2
AC305644 AB 8 mm Gear oil

Upper
limit
2. Check the oil level. If the oil level is at or slightly
Lower
below the filler hole, it is in satisfactory condition. limit
3. If the level is low, replenish the transmission and AC305646AC
transfer case with fresh oil by using a lubricator. Type 1 only: Remove the filler plug, and check the
NOTE: For the specified oil, refer to GROUP 2, gear oil level. Check that gear oil level is not 8
Periodic Inspection and Maintenance. mm below the bottom of filler plug hole.
3. If the level is low, replenish the front and/or rear
differential with fresh oil by using a lubricator.
FINAL STEPS
1-17
NOTE: For the specified oil, refer to GROUP 2, 1. Check all hoses, fluid lines and connections for
Periodic Inspection and Maintenance. leaks.
2. Check all hoses and fluid lines for proper routing
41. HOSES, FLUID LINES AND away from sharp edges and moving components.
CONNECTIONS LOCATED UNDER
VEHICLE
M6010901000145
AC305647
FINAL STEPS
42. HEADLAMP AIMING Check the installation of the various equipment.
M6011000100116 1. Floor mats
2. Spare tyre
Screen 3. Jack, jack handle and tool set
Headlamp
44. EXTERIOR AND INTERIOR
M6011000300187
Finally check and clean the exterior and interior.
1. Wash the vehicle to remove all traces of road
Level surface
grime and other dirt on the vehicle as a result of
new vehicle preparations.
AC305648 AB
2. Clean exterior and interior glass surface.
Check condition for headlamp aiming. 3. Remove all protective covers.
NOTE: For headlamp aiming procedures, refer to the 4. Remove undercoat overspray, excess window
Workshop Manual for that model. sealer, and excess weatherstrip adhesive.
5. Verify that the secondary key can not unlock the
43. EQUIPMENT glove box and tailgate/boot lid (if so equipped).
M6011000200050
6. Remove shipping and inspection stickers.
45. OWNER INSTRUCTIONS

M6011000400054
1. Verify that the owner's manual and service
booklet is in the glove box.
2. Place the spare keys in envelope in the glove box
before delivery.
AC305649
NOTES
2-1
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
PERIODIC INSPECTION AND A17. CHECK INJECTION NOZZLE [IF DARK

MAINTENANCE SCHEDULE . . . . . . 2-3 SMOKE IS EXHAUSTED OR ENGINE POWER
IS LOW] <4M40> . . . . . . . . . . . . . . . . . . . . . 2-20
OPERATIONS INSIDE THE ENGINE A18. REPLACE FUEL FILTER . . . . . . . . . . 2-21
COMPARTMENT . . . . . . . . . . . . . . . . 2-7
A1. CHECK V-BELT FOR CRACKS, FRAYING,
WEAR, AND ADJUST ITS TENSION . . . . . 2-7
OPERATIONS UNDER THE VEHICLE 2-24
B1. CHECK SUSPENSION SYSTEM FOR
A2. CHECK VACUUM PUMP OIL HOSE FOR
DAMAGE AND LOOSENESS . . . . . . . . . . . 2-24
DAMAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
B2. CHECK SUSPENSION ARM BALL JOINTS
A3. CHECK INTAKE AIR HOSE AND
FOR PLAY, AND DUST COVERS FOR
TURBOCHARGER OIL HOSE FOR DAMAGE 2-9
DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
A4. REPLACE ENGINE TIMING BELT
B3. LUBRICATE PROPELLER SHAFT WITH
<EXCEPT VEHICLES WITH TIMING CHAIN> 2-9
GREASE FITTING. . . . . . . . . . . . . . . . . . . . 2-25
A5. CHECK OPERATION OF CRANKCASE
B4. CHECK DRIVESHAFT BOOTS FOR
EMISSION CONTROL SYSTEM . . . . . . . . 2-10
DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
A6. REPLACE SPARK PLUGS. . . . . . . . . . 2-11
B5. CHECK STEERING LINKAGE FOR
A7. CHECK VALVE CLEARANCE (EXCEPT DAMAGE AND LOOSE CONNECTIONS
VEHICLES AUTO-LASH ADJUSTER) . . . . 2-11 (Including seals and boots). . . . . . . . . . . . . 2-25
A8. CHECK RADIATOR HOSES FOR DAMAGE B6. CHECK GEAR OIL LEVEL IN MANUAL
AND PROPER CONNECTION . . . . . . . . . . 2-15 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-26
A9. CHECK ENGINE COOLANT LEVEL IN B7. CHECK GEAR OIL LEVEL IN TRANSFER
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CASE (4WD) . . . . . . . . . . . . . . . . . . . . . . . . 2-26
A10. CHANGE ENGINE COOLANT . . . . . . 2-15 B8. CHANGE GEAR OIL IN MANUAL
A11. CHECK AIR CLEANER ELEMENT FOR TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-26
CLOGGING AND DAMAGE . . . . . . . . . . . . 2-17 B9. CHANGE GEAR OIL IN TRANSFER
A12. REPLACE AIR CLEANER ELEMENT 2-17 CASE (4WD) . . . . . . . . . . . . . . . . . . . . . . . . 2-27
A13. CHECK FLUID LEVEL IN BRAKE B10. CHECK GEAR OIL LEVEL IN FRONT
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 2-18 AND REAR DIFFERENTIAL . . . . . . . . . . . . 2-27
A14. CHECK FLUID LEVEL IN CLUTCH B11. CHANGE GEAR OIL IN FRONT AND
RESERVOIR (FOR HYDRAULIC TYPE REAR DIFFERENTIAL . . . . . . . . . . . . . . . . 2-27
CLUTCH ONLY) . . . . . . . . . . . . . . . . . . . . . 2-18 B12. CHECK EXHAUST PIPE CONNECTIONS
A15. CHANGE BRAKE FLUID . . . . . . . . . . 2-18 FOR GAS LEAKAGE, AND CHECK PIPE
A16. CHECK BATTERY ELECTROLYTE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 2-28
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Continued on next page
2-2
OPERATIONS INSIDE THE VEHICLE 2-28 OPERATIONS AFTER ENGINE IS

C1. CHECK BRAKE PEDAL AND CLUTCH WARMED UP . . . . . . . . . . . . . . . . . . . 2-37
PEDAL FOR FREE PLAY . . . . . . . . . . . . . . 2-28 E1. CHECK FLUID LEVEL IN AUTOMATIC
C2. CHECK PARKING BRAKE LEVER STROKE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-37
AND PLAY . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 E2. CHANGE AUTOMATIC TRANSMISSION
C3. REPLACE AIR PURIFIER FILTER. . . . 2-30 FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
E3. CHANGE ENGINE OIL . . . . . . . . . . . . . 2-39
OPERATIONS OUTSIDE THE VEHICLE 2-31 E4. REPLACE ENGINE OIL FILTER . . . . . 2-40
D1. CHECK WHEEL ALIGNMENT . . . . . . . 2-31 E5. CHECK ENGINE IDLING SPEED AND
D2. CHECK FRONT AND REAR WHEEL CO CONCENTRATION . . . . . . . . . . . . . . . . 2-41
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-33 E6. CHECK EXHAUST GAS RECIRCULATION
D3. CHECK BRAKE HOSES AND PIPES FOR (EGR) SYSTEM. . . . . . . . . . . . . . . . . . . . . . 2-44
LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
D4. CHECK BRAKE PADS AND DISCS FOR OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-48
WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 F1. CHECK BODY CONDITION FOR
D5. CHECK BRAKE SHOE LININGS AND DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
DISCS FOR WEAR. . . . . . . . . . . . . . . . . . . 2-35 F2. CHECK THE COMMON RAIL ENGINE
D6. CHECK FUEL HOSES AND PIPES FOR (small injection quantity learning) . . . . . . . . 2-48
LEAKAGE OR DETERIORATION . . . . . . . 2-36 F3. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-48
PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
2-3
M6020100100702
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
Maintenance item Maintenance Maintenance interval
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
A1 Check V-belt for cracks, fraying, wear, and Inspection First 1,000 km, thereafter every
adjust its tension 20,000 km or every 12 months
A2 Check vacuum pump oil hose for damage Inspection Every 20,000 km or every 12 months
(diesel-powered vehicles)
A3 Check intake air hose and turbocharger oil Inspection Every 40,000 km or every 2years (over
hose for damage (vehicles with turbocharger) 100,000 km, every 20,000 km for
turbocharger oil hose)
A4 Replace engine timing belt (except vehicles Replace Every 100,000 km
with timing chain)
A5 Check operation of crankcase emission Inspection Every 40,000 km or every 2 years
control system
A6 Replace spark plugs 3 earth Leaded Replace Every 40,000 km
electrodes petrol-pow
semi-surfa ered
ce vehicles
discharge Unleaded Replace Every 100,000 km
type petrol-pow
ered
vehicles
Iridium-tipp Unleaded Replace Every 100,000 km
ed type petrol-pow
ered
vehicles
A7 Check valve Except vehicles with Inspection First 1000 km, thereafter every 20,000
clearance (except 6G75 engine km or every 12 months
vehicles with Vehicles with 6G75 Inspection Every 40,000 km or every 2 years (If
auto-lash adjuster) (intake side) engine valve noise increases, check valve
clearance additionally to the
scheduled service.)
A8 Check radiator hoses for damage and proper Inspection Every 40,000 km or every 2 years
connection
A9 Check engine coolant level in reservoir Inspection First 1,000 km, thereafter every
20,000 km or every 12 months
A10 Change engine coolant Change Every 40,000 km or every 2 years
A11 Check air cleaner element for clogging and Inspection Norma Every 20,000 km or every 12
damage l usage months
Severe Every 10,000 km or every 6
usage months
2-4 PERIODIC INSPECTION AND MAINTENANCE

operation
A12 Replace air cleaner element Replace Norma Every 40,000 km or every 2
l usage years
Severe More frequently
usage
A13 Check fluid level in brake reservoir Inspection First 1,000 km, thereafter every
A14 Check fluid level in clutch reservoir (for Inspection First 1,000 km
hydraulic type clutch only)
A15 Change brake fluid Change Every 40,000 km or every 2 years
A16 Check battery electrolyte level Inspection First 1,000 km, thereafter every
A17 Check injection nozzle [If dark smoke is Inspection Every 50,000 km or every 2.5 years
exhausted or engine power is low]
A18 Replace fuel filter Petrol-powered Replace Every 60,000 km or every 3 years
vehicles
Diesel-powered Replace Every 20,000 km or every 12 months
vehicles
OPERATIONS UNDER THE VEHICLE
B1 Check suspension system for damage and Inspection First 1,000 km, thereafter every
looseness 20,000 km or every 12 months
B2 Check suspension arm ball joints for play, and Inspection Every 20,000 km or every 12 months
dust covers for damage
B3 Lubricate propeller shaft with grease fitting Lubrication Every 20,000 km or every 12 months
B4 Check driveshaft boots for damage Inspection Norma Every 20,000 km or every 12
l usage months
Severe First 1,000 km, thereafter
usage every 10,000 km or every 6
months
B5 Check steering linkage for damage and loose Inspection Every 20,000 km or every 12 months
connections (including seals and boots)
B6 Check gear oil level in manual transmission Inspection Every 20,000 km or every 12 months
B7 Check gear oil level in transfer case (4WD) Inspection Every 20,000 km or every 12 months
B8 Change gear oil in manual transmission Change Norma Every 100,000 km or every 5
l usage years
usage years
B9 Change gear oil in transfer case (4WD) Change Norma Every 100,000 km or every 5
l usage years
usage years
B10 Check gear oil level in front and rear Inspection Every 20,000 km or every 12 months
differential
2-5
operation
B11 Change gear oil in front and rear differential Change Norma Every 80,000 km or every 4
l usage years
usage years
B12 Check exhaust pipe connections for gas Inspection Every 20,000 km or every 12 months
leakage, and check pipe installation
OPERATIONS INSIDE THE VEHICLE
C1 Check brake pedal and clutch pedal for free Inspection Every 10,000 km or every 6 months
play
C2 Check parking brake lever stroke and play Inspection First 1,000 km, thereafter every
C3 Replace air purifier filter Replace Every 15,000 km or every 12 months
OPERATIONS OUTSIDE THE VEHICLE
D1 Check wheel alignment Inspection Every 20,000 km or every 12 months
D2 Check front and rear wheel bearings for play Inspection Every 60,000 km or every 3 years
D3 Check brake hoses and pipes for leakage Inspection Every 20,000 km or every 12 months
D4 Check brake pads and discs for wear Inspection Norma Every 20,000 km or every 12
l usage months
usage months
D5 Check brake shoe linings and discs for wear Inspection Norma Every 40,000 km or every 2
l usage years
usage months
D6 Check fuel hoses and pipes for leakage or Inspection Every 40,000 km or every 2 years
deterioration
OPERATIONS AFTER ENGINE IS WARMED UP
E1 Check fluid level in automatic transmission Inspection Every 20,000 km or every 12 months
E2 Change automatic transmission fluid Change Severe Every 40,000 km or every 2
usage years
E3 Change engine oil ACEA classification Change Norma Every 15,000 km or every 12
<6G7> "For service A1/B1, l usage months
A3/B3, A3/B4 or A5/B5" Severe Every 5,000 km
API classification "For usage
service SG" or higher
Change engine oil ACEA classification Change Norma Every 5,000 km or every 6
<4M40> "For service A1/B1, l usage months
service CD" or higher
Change engine oil ACEA classification Change Norma Every 15,000 km or every 12
<4M41> "For service A1/B1, l usage months
service CD" or higher

operation
E4 Replace engine oil filter <6G7> Replace Norma Every 15,000 km or every 12
l usage months
Severe Every 5,000 km
usage
Replace engine oil filter <4M40> Replace Norma Every 10,000 km or every 12
l usage months
usage
Replace engine oil filter <4M41> Replace Norma Every 15,000 km or every 12
l usage months
usage
E5 Check engine idling speed and CO Inspection First 1,000 km, thereafter every
concentration (petrol-powered vehicles) 20,000 km or every 12 months
Check engine idling speed (diesel-powered Inspection First 1,000 km, thereafter every
vehicles) 20,000 km or every 12 months
E6 Check exhaust gas recirculation (EGR) Inspection Every 20,000 km or every 12 months
system
OTHERS
F1 Check body condition for damage Inspection Every year
F2 Check the common rail engine (small injection Inspection Every 20,000 km or every 12 months
quantity learning)
F3 Road test Inspection First 1,000 km, thereafter every
NOTE: "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 in 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.
10. Operation under excessive load.
2-7
A1. CHECK V-BELT FOR CRACKS, <4M41>
FRAYING, WEAR, AND ADJUST ITS Item When When When
checked adjusted replaced
TENSION
M6020200100561 Vibration 150 −201 164 −190 190 −232
V-BELT CONDITION frequency
Check the whole rounds of the V-belt for cracks, fray- Hz
ing and wear. Tension N 245 −441 294 −392 392 −588
Deflection 9.1 −12.7 9.8 −11.7 7.2 −9.8
V-BELT TENSION mm
ALTERNATOR DRIVE BELT TENSION (Reference)
CHECK <6G7>
<WHEN THE VIBRATION FREQUENCY IS
CAUTION
Check the alternator drive belt tension after turn- MEASURED {SPECIAL TOOL (MB992080)
ing the crankshaft clockwise one turn or more. IS USED}: RECOMMENDATION>
Alternator drive belt NOTE: The vibration frequency measuring method is
auto-tensioner recommended for check and adjustment of the drive
belt tension.
Belt tension meter set (MB992080)
MB992081
Indicator mark
A
AC511210AB
1. Make sure that the indicator mark is within the

MB992082
area marked with A in the illustration.
AC507219AB
2. If the mark is out of the area, replace the drive
belt. 1. Connect the Special tool microphone assembly
NOTE: The alternator drive belt tension check is (MB992082) to the Special tool belt tension meter
not necessary as alternator drive belt auto-ten- (MB992081) of the Special tool belt tension meter
sioner is adopted. set (MB992080).
ALTERNATOR DRIVE BELT TENSION 2. Press the "POWER" button to turn on the power
CHECK AND ADJUSTMENT <4M4> supply.
Check the drive belt tension in the following proce- 3. Press number key 1. Check to ensure that "No.
dure. 01" appears on the upper left of the display and
that the following numeric values are displayed for
STANDARD VALUE: individual items (M, W, and S):
<4M40> M 000.9 g/m
Item When When When W 010.0 mm/R
checked adjusted replaced S 0100 mm
Vibration 103 −132 111 −125 132 −156
If numeric values have not been entered (new
frequency
tool), set them according to the belt specifications
Hz
as shown below. Once you set them, you do not
Tension N 294 −490 343 −441 490 −686 have to set them again. The settings remain
Deflection 8.0 −11.0 9.0 −11.0 8.0 −9.0 undeleted even after battery replacement.
mm
(Reference)
NOTE: This operation is to temporarily set the CAUTION

preset data such as the belt specifications, • The temperature of the surface of the belt
because if the measurement is taken without input should be as close as possible to normal tem-
of the belt specifications, conversion to tension perature.
value (N) cannot be made, resulting in judgement • Do not let any contaminants such as water or
of error.
oil get onto the microphone.
<Setting procedure> • If strong gusts of wind blow against the
(1) Press down the "MASS" button till the belt microphone or if there is loud sources of
mass select display appears. noise nearby, the values measured by the
(2) Press the "UP" or "DOWN" button to select "01 microphone may not correspond to actual
1.5GT 0.9" and press the "MEASURE" button values.
to decide it. • If the microphone is touching the belt while
Check to ensure that "M 000.9 g/m" is the measurement is being made, the values
displayed. measured by the microphone may not corre-
(3) Press the "WIDTH" button to change to the spond to actual values.
belt width input display. • Do not take the measurement while the vehi-
(4) Press number keys 0, 1, 0, and 0 sequentially, cle's engine is running.
and press the "SELECT" button to apply them. MB992080 Water pump
Check to ensure that "W 010.0 mm/R" (Microphone) 15˚ pulley
appears on the display.
(5) Press the "SPAN" button to change to the 15˚
span length input display. 10 – 15 mm
(6) Press number keys 0, 1, 0, and 0 sequentially, Gentry tap
and press the "SELECT" button to apply them. with your
Check to ensure that "S 0100 mm" appears on finger
the display. Alternator
pulley
4. Press "Hz" button twice to change the display to AC600283AB
the frequency display (Hz).

5. Hold the microphone to the middle of the drive
belt between the pulleys (at the place indicated by
the arrow), about 10 −15 mm away from the rear
surface of the belt and so that it is perpendicular
to the belt (within an angle of ± 15 ° ).
6. Press the "MEASURE" button.
7. Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and check
that the vibration frequency of the belt is within the
standard value.
NOTE: To take the measurement repeatedly, fillip
the belt again.
8. After the completion of the measurement, press
and hold the "POWER" button to turn off the
power supply.
2-9
<WHEN USING THE TENSION GAUGE> 4. Tighten the nut for alternator pivot bolt.
Tightening torque: 47 ± 9 N⋅ m
Water pump
pulley 5. Tighten the alternator fixing nut.
Tension
gauge Tightening torque: 24 ± 4 N⋅ m
6. Tighten the adjusting bolt.
Tightening torque: 5.0 ± 1.0 N⋅ m
A2. CHECK VACUUM PUMP OIL HOSE

Alternator FOR DAMAGE
pulley AC600285AB M6020200400108
Use a belt tension gauge to check that the belt ten-

sion is within the standard value.
<BELT DEFLECTION CHECK>
Approximately Water pump

100N pulley
Hose
Crankshaft AC502483AE
pulley
1. Inspect the surface of hose for evidence of heat
Deflection and mechanical damage.
Alternator pulley
AK500540AB
A3. CHECK INTAKE AIR HOSE AND
TURBOCHARGER OIL HOSE FOR
Apply approximately 100 N of force to the middle of
the drive belt between the pulleys (at the place indi- DAMAGE
M6020200500235
cated by the arrow) and check that the amount of
deflection is within the standard value.
When the belt tension is adjusted by measuring the
deflection, adjust it with a tool for vibration frequency
measurement or tension measurement afterward. Turbocharger
If not within the standard value, adjust the belt ten-

sion by the following procedure.
AC305652 AB
Adjusting 1. Inspect the intake air hoses for cracks or dam-

bolt
age.
Alternator
fixing nut 2. Inspect the turbocharger oil hoses for cracks or
damage.
A4. REPLACE ENGINE TIMING BELT

Alternator pivot bolt AC702321AB <EXCEPT VEHICLES WITH TIMING
1. Loosen the nut of the alternator pivot bolt. CHAIN>
M6020200600306
2. Loosen the alternator fixing nut. For information concerning the replacement proce-
3. Use the adjusting bolt to adjust the belt tension dures, refer to the Workshop Manual.
and belt deflection to the standard values.
A5. CHECK OPERATION OF 1. Remove the ventilation hose from the PCV
CRANKCASE EMISSION CONTROL (Positive crankcase ventilation) valve.
SYSTEM 2. Remove the PCV valve from the rocker cover.
M6020200700347 3. Reinstall the PCV valve at the ventilation hose.
BREATHER HOSE 4. Start the engine and run at idle.
<6G72>
Breather hose
PCV valve
AC610025AB AC305653AD
1. Inspect the breather hose for cracks or damage. <6G75>

2. Clean the inside of the breather hose if neces-
sary.
3. Inspect the ventilation filter for clogging.
VENTILATION HOSE
1. Check entire circumference and length of hoses
using a mirror as required.
PCV valve
2. Check all clamps for tightness and the connec-
tions for leakage. AC609736AC
3. Hoses should be replaced immediately if there is
5. Place finger at the opening of the PCV valve and
any evidence of deterioration or damage.
check that vacuum of the intake manifold is felt.
POSITIVE CRANKCASE VENTILATION NOTE: At this moment, the plunger in the PCV
valve moves back and forth.
SYSTEM CHECK
6. If vacuum is not felt, clean the PCV valve or
replace it.
7. Apply a small amount of new engine oil to the
O-ring on the PCV valve, and tighten to the
Ventilation hose specified torque. <6G75>
PCV valve
AC610047 AB
2-11
PCV VALVE CHECK 5. Move the rocker arms on the No. 1 and No. 4
cylinders up and down by hand to determine
<6G72>
which cylinder has its piston at the top dead
centre on the compression stroke. If rocker arms
have a valve lash, the piston in the cylinder
PCV valve
corresponding to these rocker arms is at the top
dead centre on the compression stroke.
Exhaust side
Right bank
AC305654AD
<6G75>
PCV valve
No. 1 No. 3 No. 5

Intaake side
No. 2 No. 4 No. 6
AC609737AC
1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
that the plunger moves. Left bank
Exhaust side
2. If the plunger does not move, there is clogging in AK404086 AE
the PCV valve. In this case, clean or replace the

6. Valve clearance inspection and adjustment can be
PCV valve.
performed on rocker arms indicated by white
A6. REPLACE SPARK PLUGS arrow mark when the No. 1 cylinder piston is at
M6020200800281 the top dead centre on the compression stroke,
After removing old spark plugs, install new ones and and on rocker arms indicated by black arrow mark
tighten them at the specified torque. when the No. 4 cylinder piston is at the top dead
centre on the compression stroke.
A7. CHECK VALVE CLEARANCE 7. Measure the valve clearance.
(EXCEPT VEHICLES AUTO-LASH
If the valve clearance is not as specified, loosen
ADJUSTER) the rocker arm lock nut and adjust the clearance
M6020202400137
using a thickness gauge while turning the
VALVE CLEARANCE (Intake side) CHECK adjusting screw.
AND ADJUSTMENT <6G75> Standard value (cold engine):
NOTE: The valve clearance check and adjustment Intake valve: 0.10 mm
should be done when the engine is cold. NOTE: Valve clearance check and adjustment is
1. Turn the ignition switch to the "LOCK" (OFF) unnecessary for exhaust side due to auto lash
position. adjuster installed.
2. Remove all ignition coils. 8. Turn the crankshaft through 360 degree angle to
3. Remove the rocker cover. line up the notch on the crankshaft pulley with the
"T" mark on the timing indicator.
4. Turn the crankshaft clockwise until the notch on
9. Repeat steps 7 and 8 on other valves for
the pulley is lined up with the "T" mark on the
clearance adjustment.
timing indicator.
10.Install the rocker cover.
11.Install the ignition coils.
VALVE CLEARANCE CHECK AND

ADJUSTMENT <4M40> Intake Intake Intake Intake
No. 1 No. 2 No. 3 No. 4
NOTE: Perform the valve clearance check and
adjustment at the engine cold state.
1. Remove the rocker cover.
2. Remove the glow plug plate and all of the glow
plugs from the cylinder head.
Exhaust Exhaust Exhaust Exhaust
CAUTION No. 1 No. 2 No. 3 No. 4
Never turn the crankshaft anticlockwise (the AK603846AB
opposite direction) as the tensioner, which adjust
the timing chain tension at the timing gear, may 4. Check the valve clearances at the places by
be damaged. If so, remove and reinstall the ten- arrows in the illustration by the following
sioner. procedure.
White arrow: When No. 1 cylinder is at compression
top dead centre position
"0" Black arrow: When No. 4 cylinder is at compression
top dead centre position
Valve
clearance
Crankshaft pulley
AK601576AB
3. Align the notch of the crankshaft pulley with the

"0" timing mark to set the No. 1 or No. 4 cylinder
to the compression top dead centre position. AK603982AB
(1) Use a thickness gauge to measure the valve

Dent clearance. If deviated from standard value,
make a note for the valve clearance.
Standard valve (Cold engine):
Intake side 0.15 −0.25 mm
Exhaust side 0.25 −0.35 mm
NOTE: There should be certain amount of
resistance against the thickness gauge when
AK601577AB
taking the measurements. If the thickness
gauge is moving too smoothly, a correct meas-
NOTE: If the dent on the camshaft is pointing directly urement cannot be obtained.
upwards, the No. 1 cylinder will be at the compres- (2) Use the measured values as a reference for
sion top dead centre position. If the crankshaft is selecting adjustment shims which will bring the
then turned once, the No. 4 cylinder will then be at incorrect valve clearance to the standard
the compression top dead centre position. value.
A: thickness of newly installed shim
B: thickness of removed shim
C: measured valve clearance
Equation
Intake valve: A = B + (C −0.2) mm
Exhaust valve: A = B + (C −0.3) mm
NOTE: The thicknesses of the adjustment
shims are between 2,250 −3,150 mm (37types
which increase in thickness by 0.025 mm)
2-13
2. Use the special tool fuel injection pipe wrench
Identification
size mark (MB992188) to remove the fuel injection pipe.
3. Remove the rocker cover.
CAUTION
The crankshaft should always be turned in a
clockwise direction.
Timing marks
AK603848AB
NOTE: Size identification mark: "2775" = 2.775

mm thickness
(3) Remove the camshaft and install the shim
which was selected in step (2).
(4) Re-measure the valve clearances and check Camshaft sprocket
that they are all at the standard value.
5. Turn the crankshaft once to align the notch of the Timing marks
crankshaft pulley with the timing mark "0".
6. Check and adjust the other valve clearances
according to the step 4.
VALVE CLEARANCE CHECK AND

ADJUSTMENT <4M41>
NOTE: The valve clearance check and adjustment
should be done when the engine is cold. Crankshaft pulley
AC610704AB
1. Remove the EGR pipe.
4. Align the camshaft sprocket timing marks and set
CAUTION
the No. 1 cylinder at top dead centre.
Leaked fuel on parts causes a decrease in func-
tion and burning. Therefore, place waste to Exhaust valve side
absorb leaked fuel.
MB992188
Intake valve side AK500544AB
5. Measure the valve clearance.

AC609910 AB
If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance
using a thickness gauge between the camshaft
and the roller while turning the adjusting screw.
Standard value (cold engine):
Intake valve: 0.10 mm
Exhaust valve: 0.15 mm
MB992188
AK600672 AB
CAUTION
Pay special attention that the tightening torque is
not beyond this value. If the tightening torque is
beyond the value, the value stem would possibly
MB992188
bend.
AC609910 AB
Thickness
MB992046 gauge
AK500542 AB
6. While holding the adjusting screw with a

screwdriver to prevent it from turning, tighten the
lock nut to the specified torque using a valve
adjusting socket. (MB992046) MB992188
AK600672 AB
Tightening torque: 9.8 ± 1 N⋅ m
7. Turn the crankshaft 360° clockwise to bring No. 4 10.Use the special tool fuel injection pipe wrench
cylinder to the top dead centre position. (MB992188) to tighten the fuel injection pipe to
the specified torque.
Exhaust valve side
CAUTION
• The reinstallation histories of the removed
injection pipe are up to five times. To count
how many times the injection pipe is rein-
stalled, record the number of the reinstalla-
tion histories on the service booklet by
adding this latest number of the histories,
Intake valve side AK500544AC which is usually "1", to the previous one. Use
a new injection pipe when the total reinstalla-
8. Measure the valve clearances at the places tion history numbers reach five times, or
indicated by arrows in the illustration. If the when the injector or common rail is replaced.
clearance is not within the standard value, repeat In this case, record "a new injection pipe, the
steps 5 and 6 above. number of the reinstallation histories is zero"
9. Install the rocker cover. on the service booklet.
• When the injection pipe is reinstalled, confirm
there is no foreign material on the seal sur-
face or in the pipe and then install it not to
deviate from the axis, fitting the seal surface.
11.Install the EGR pipe.
12.After the ignition switch is in "LOCK" (OFF)
position, connect the M.U.T.-III to the diagnosis
connector.
13.Start the engine, and let it run at idle.
14.Select SPECIAL FUNCTION from the function
menu.
15.Select FUEL LEAKAGE CHECK from SPECIAL
FUNCTION menu to execute the test.
2-15
NOTE: During the test, the engine speed and the fuel A10. CHANGE ENGINE COOLANT
pressure is 2, 000 r/min and 180MPa for 20 seconds M6020201100683
respectively. 1. Stop the engine after it is fully warmed up.

16.Confirm there is no fuel leak from the joint for the 2. Add detergent to the engine coolant in order to
injection pipe. flush the cooling system, and start the engine.
A8. CHECK RADIATOR HOSES FOR

DAMAGE AND PROPER CONNECTION
M6020200900545
<6G7>
AC305655
3. Loosen the drain plug, remove the radiator can

and drain the coolant.
AC608822AB 4. Feed fresh water into the cooling system through
the filler port of the radiator in order to wash the
<4M4> cooling system, and then tighten the drain plug.
5. Drain the coolant from the radiator condenser
tank.
6. Install the radiator condenser tank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
AC608825AB can cause the corrosion of the aluminium com-
ponents.
1. Check entire circumference and length of hoses,
using a mirror as required.
2. Check that hoses installed in grommets pass
through the centre of the grommets.
3. Check all clamps for tightness and connections
for leakage.
A9. CHECK ENGINE COOLANT LEVEL IN

RESERVOIR
M6020201000545
AC305656
7. Depending upon conditions of operation,

determine the amount of long life coolant,
antifreeze or antirust to be added to the coolant.
Recommended antifreeze: DIA QUEEN
SUPER LONG LIFE COOLANT or equivalent
8. Fill the cooling system with soft water through the
filler port, and add long life coolant, if necessary.
Condenser tank
AC608829AB 9. Fill the radiator condenser tank with coolant.
Check that the coolant level is between the "FULL" 10.Install the radiator cap and the radiator condenser
and "LOW" lines when the engine is at the normal tank cap.
operating temperature.
CAUTION <4M40>
When removing the radiator cap, be careful to
blow out steam and boiling water.
11.Recheck the engine coolant level after a road test.
REMOVAL OF ENGINE COOLANT FROM
THE CYLINDER BLOCK DRAIN PLUG
1. Drain the water from the radiator, heater core and 29 N·m Engine oil filter
engine after unplugging the radiator drain plug Water drain plug
and removing the radiator cap. AC610385 AB
<6G7-Left bank>
<4M41>
31 ± 2 N·m Engine
oil cooler
assembly
Water drain plug
AC609816 AB
AC503525AC
<6G7-Right bank> 3. Remove the water drain plug of engine oil cooler
to drain the coolant inside the water jacket.
<4M4>.
4. Remove the radiator condenser tank and drain
the coolant.
5. Drain the coolant then clean the path of the
coolant by injecting water into the radiator from
the radiator cap area.
AC609817AB
Cylinder block
2. Drain the water in the water jacket by unplugging drain plug
the drain plug of the cylinder block <6G7>.
AC200625 AC
6. Apply the designated sealant to the screw area of

the cylinder block drain plug, and then tighten to
the standard torque <6G7>.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent
7. Replace the gasket and tighten the water drain
plug to the specified torque <4M4>.
Tightening torque:
<4M40> 29 N⋅ m
<4M41> 31 ± 2 N⋅ m
2-17
8. Securely tighten the drain plug of the radiator. A11. CHECK AIR CLEANER ELEMENT
9. Reinstall the radiator condenser tank. FOR CLOGGING AND DAMAGE
M6020201200475
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium compo-
nents.
MB991871
AC608830
1. Check air cleaner element for clogging and

damage.
2. Clean deposited dust from the element in the
following manner.
AC602117 AB (1) Lightly tap the element against the top of a
10.By referring to the section on coolant, select an bench.
appropriate concentration for safe operating (2) Blow compressed air from inside the element.
temperature within the range of 30 to 60%. Use 3. Wipe off dust on the air cleaner interior.
special tool LLC changer (MB991871) to refill the 4. Install the air cleaner body.
coolant. A convenient mixture is a 50% water and
50% antifreeze solution (freezing point: −31° C). A12. REPLACE AIR CLEANER ELEMENT
M6020201300524
Recommended antifreeze: DIA QUEEN SUPER The air cleaner element will become dirty and loaded
LONG LIFE COOLANT or equivalent with dust during use, and the filtering effect will be
Quantity (including 0.65 L in the radiator con- substantially reduced. Replace it with a new one.
denser tank):
<Short wheelbase, Long wheelbase (vehi-
cles without rear heater)> 9.0 L
<Long wheelbase (vehicles with rear
heater)> 10.5 L
NOTE: For how to use special tool (MB991871),
refer to its manufacturer’s instructions.
11.Reinstall the radiator cap.
12.Start the engine and let it warm up until the
thermostat opens. AC608831
13.After repeatedly revving the engine up to 3,000

1. Unclasp the air cleaner cover clip.
r/min several times, then stop the engine.
2. Remove the air cleaner element and install a new
14.Remove the radiator cap after the engine has
one.
become cold, and pour in coolant up to the brim.
Reinstall the cap. 3. Be sure to close the air cleaner cover completely
when clamping it.
CAUTION
Do not overfill the radiator condenser tank.
15.Add coolant to the radiator condenser tank
between the "FULL" and "LOW" mark if
necessary.
A13. CHECK FLUID LEVEL IN BRAKE A15. CHANGE BRAKE FLUID

M6020201600581
RESERVOIR
M6020202200230
<Vehicles with ABS>
AC305659
AC608832 AC 1. Remove the cap of the bleeder screw, connect a

<Vehicles without ABS> vinyl tube, and place its other end in a receptacle.
CAUTION
If the reservoir tank completely runs out of fluid
during operation, air will find way into the 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.
AC609839AB Specified brake fluid: DOT3 or DOT4
1. Check that the fluid level is between the "MAX" CAUTION
and "MIN" mark. Use the specified brake fluid. Avoid using a mix-
2. If it is below the "MIN" marks, replenish with fresh ture of the specified brake fluid and other fluid. If
brake fluid up to the "MAX" mark. brake fluid is exposed to the air, it will absorb
moisture; as water is absorbed from the atmos-
A14. CHECK FLUID LEVEL IN CLUTCH phere, the boiling point of the brake fluid will
RESERVOIR (FOR HYDRAULIC TYPE decrease and the braking performance will be
CLUTCH ONLY) seriously impaired. For this reason use a hermet-
M6020201500205 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.
NOTE: This change from existing to fresh fluid
can be judged by change in colour of fluid that
flows out.
3 (4) 2
AC609400
1. Check that the fluid level is between the "MAX"

and "MIN" mark.
2. If it is below the "MIN" marks, replenish with fresh
brake fluid up to the "MAX" mark.
4 (3) 1
( ): RH drive vehicles AC608770AB
4. Repeat above steps for other bleeder screws.

2-19
MASTER CYLINDER BLEEDING <VEHI- A16. CHECK BATTERY ELECTROLYTE
CLES WITHOUT ABS> LEVEL
M6020201700577
The master cylinder used has no check valve, so if
bleeding is carried out by the following procedure, CAUTION
bleeding of air from the brake pipeline will become • If the battery fluid is below the LOWER
easier (When brake fluid is not contained in the mas- LEVEL, the battery could explode in using.
ter cylinder). • If the battery fluid is over the UPPER LEVEL,
1. Fill the reservoir with brake fluid. leakage could result.
2. Keep the brake pedal depressed. Thermometer Hydrometer
Battery fluid
AC504567AB
AC608769AB 1. Inspect whether or not the battery fluid is between

the UPPER LEVEL and LOWER LEVEL marks.
3. Have another person cover the master cylinder
outlet with a finger. 2. Use a hydrometer and thermometer to check the
specific gravity of the battery fluid.
4. With the outlet still closed, release the brake
pedal. Standard value: 1.220 −1.290 (electrolyte
5. Repeat steps 2 −4 three or four times to fill the temperature 20° C)
inside of the master cylinder with brake fluid. 3. The specific gravity of the battery fluid varies with
the temperature, so use the following formula to
HBB SYSTEM AIR BLEEDING <VEHICLES calculate the specific gravity for 20° C. Use the
WITH ABS> calculated value to determine whether or not the
specific gravity is satisfactory.
1. Air bleeding from front brake system
Turn the ignition switch to the LOCK (OFF) posi- D20 = (t - 20) × 0.0007 + Dt
tion. Bleed air from the front brake calipers (right D20: Specific gravity converted to a value for
and left) by pumping the brake pedal. electrolyte temperature of 20° C.
t: Electrolyte temperature at the time of meas-
2. Air bleeding from rear brake system
urement
CAUTION Dt: Actual specific gravity
• If too much brake fluid is drained at a time,
the accumulator pressure may be dropped
abnormally. So limit drain amount at a time to
100 cm3 or less, and check that the pump
motor stops per one air-bleeding.
• If the brake fluid level in the reservoir has
been dropped, air may enter the pump motor
accidentally. To avoid this, always maintain
the brake fluid between the MIN and MAX
marks.
While the ignition switch is turned ON and the
brake pedal is depressed, bleed air from the right
and left rear brake calipers.
A17. CHECK INJECTION NOZZLE [IF 1. Move the lever of the nozzle tester rapidly (4 −6
DARK SMOKE IS EXHAUSTED OR times per second) to eject the fuel continuously.
Check to be sure that the injection spray comes
ENGINE POWER IS LOW] <4M40>
M6020201800080 out evenly in a cone shape (injection spray comes
FUEL INJECTION INITIAL PRESSURE out evenly in a cone shape (injection spray angle
is 0° ). The injection spray patterns shown in the
CHECK illustration.
a. Injection angle is tool large
b. Bias
c. Intermittent fuel injection
AK500622 AB
1. Install the injection nozzle to a nozzle tester.

2. Move the lever of the nozzle tester 2 −3 times to
inject fuel and to bleed the air. AK500624
3. Gently press down the lever of the nozzle tester,
and take a reading of the indication value on the 2. Check to be sure that no fuel drips after injection
pressure gauge at the point where the needle is completed.
slowly rises and then suddenly drops. 3. If there are any drips, disassemble the nozzle,
clean it and reinspect, or replace the nozzle.
Standard value (Fuel injection initial pres-
sure): 14,710 −15,690 kPa
NOZZLE FUEL-TIGHT CHECK
4. If the fuel injection initial pressure is outside the
standard value, disassembly the nozzle holder to
clean it, and the change the thickness of the shim
to adjust the fuel injection initial pressure.
NOTE: When the shim thickness is increased by
0.1 mm, the fuel injection initial pressure
increases by approximately 1,177 −2,157 kPa.
INJECTION SPRAY CONDITION CHECK

AK500625 AB
A B C
1. Gently raise the lever of the nozzle tester until the
pressure inside the nozzle (value displayed on
pressure gauge) becomes 12,750 −13,730 kPa,
and after holding this pressure for approximately
10 seconds, check to be sure that there are no
fuel leaks from the nozzle.
2. If there are any leaks, disassemble the injection
AK500623 AB nozzle, clean it and re-inspect, or replace the
nozzle.
2-21
A18. REPLACE FUEL FILTER 7. Install the retainer plate to the fuel tank and
M6020201900582 tighten the mounting nuts.
<6G7> 8. Connect the fuel tank pump module assembly
SHORT WHEELBASE connector, fuel tank suction hose, fuel
1. Remove the front scuff plate (R.H.) and outer seat high-pressure tube.
belt (front) anchor bolt (R.H.), and then turn the
Fuel tank pump
floor carpet.
module assembly Fuel high-pressure tube
Floor carpet
Quick connector
3 mm
AC703276 AB
CAUTION
Service hole cover AC609842 AB
After connecting the fuel high-pressure tube,
2. Remove the service hole cover. slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
Fuel tank Fuel tank pump module approximately 3 mm.
suction hose assembly connector
9. Install the service hole cover.
10.Spread the floor carpet, ant then install the front
scuff plate (R.H.) and outer seat belt (front)
anchor bolt (R.H.).
LONG WHEELBASE
Fuel high-pressure
1. Tumble the second seat (R.H.).
tube AC703247 AB Service hole cover
(upper side)
3. Disconnect the fuel tank pump module assembly
connector, fuel suction hose, fuel high-pressure
tube.
4. Remove the mounting nuts and retainer plate, and
remove the fuel tank pump module assembly from
the service hole.
FUEL PUMP
MODULE Second seat (R.H.) AC609845 AB
2. Remove the service hole cover (upper side).

Fuel tank
Service hole cover
pump
Fuel tank filter (lower side)
assembly
assembly
Packing
AC703246 AB
5. Replace the fuel tank filter assembly and packing

with a new one.
6. Install the fuel tank pump module assembly to the AC609846AB
fuel tank through the service hole.
3. Remove the service hole cover (lower side).
Fuel high-pressure CAUTION

tube After connecting the fuel high-pressure tube,
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm.
10.Install the service hole cover (lower side).
11.Install the service hole cover (upper side).
Fuel tank suction 12.Restore the second seat (R.H.).
Fuel tank pump module hose
assembly connector AC703272 AB
<4M4>
4. Disconnect the fuel tank pump module assembly 1. Remove the fuel tank cap to release the pressure
connector, fuel tank suction hose, fuel inside the fuel tank.
high-pressure tube.
<4M40> Fuel filter assembly
5. Remove the mounting nuts and retainer plate, and
remove the fuel pump module assembly from the
service hole.
FUEL PUMP
MODULE
Fuel tank
pump
Fuel tank filter AC610457AB
assembly
assembly
<4M41>
Packing
AC703246 AB
6. Replace the fuel tank filter assembly and packing

with a new one.
Fuel filter
7. Install the fuel tank pump module assembly to the assembly
fuel tank through the service hole.
8. Install the retainer plate to the fuel tank and
AC608826AB
tighten the mounting nuts.
9. Connect the fuel tank pump module assembly 2. Disconnect the connector and the fuel hose, and
connector, fuel tank suction hose, fuel then remove the fuel filter assembly from the
high-pressure tube. bracket.
3. Remove the water level sensor.
Fuel tank pump
module assembly Fuel high-pressure tube
Quick connector
3 mm
AC703276 AB
AC609422
4. Use an oil filter wrench to remove the fuel filter

cartridge from the fuel filter pump body.
2-23
5. Install a new filter, and bleed the air from fuel line. <4M40>
<4M40>
Hand pump
Hand pump
Air plug
Fuel filter assembly
Water level sensor

Fuel filter
assembly AC610094AB
AC610095AB
1. Loosen the water level sensor.
(1) Loosen the Air plug. 2. After water is evacuated by using a hand pump,
(2) Cover the circumference of the air plug tighten the water level sensor to the specified
with cloth and use a hand pump repeatedly torque.
until no bubbles come out of the air plug hole.
(3) Replace the air plug and O-ring with a new
one. Tighten the air plug to the specified <4M41>
torque.
Hand pump
(4) Repeat until the hand pump operation
becomes stiff.
<4M41>
Hand pump Battery
Drain plug
AC608828AB
Battery 1. Loosen the drain plug.

2. After water is evacuated by using an hand pump,
Fuel feed
tighten the drain plug.
hose
AC608827 AB
WATER LEVEL SENSOR CHECK
(1) Connect the all fuel feed hose to the fuel
filter, and pump the hand pump until the hand 1 2
Float
pump becomes stiff.
REMOVAL OF WATER FROM THE FUEL
FILTER
Water is in the fuel filter cartridge when fuel filter indi-
cator lamp illuminates. Evacuate water by the follow-
ing procedures.
AC609849AB
1. Connect the circuit tester to the water level

sensor.
2. There should be continuity when the float is
raised, while there is no continuity when it is
lowered.
3. Replace the water level sensor if it is faulty.

B1. CHECK SUSPENSION SYSTEM FOR
DAMAGE AND LOOSENESS
M6020300100342
FRONT SUSPENSION
Deterioration
and sagging
Noise and
oil leakage
Bends and
damage
Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Deterioration
and sagging
Bends and
damage
Cracks, bends
and dents
AC608833 AB
2-25
B2. CHECK SUSPENSION ARM BALL B3. LUBRICATE PROPELLER SHAFT
JOINTS FOR PLAY, AND DUST COVERS WITH GREASE FITTING
M6020300300023
FOR DAMAGE
M6020300200349
BALL JOINTS FOR PLAY Front propeller shaft
AC608835AB
Fill the multi-purpose grease fitting of the propeller

AC502481
shaft joints.
1. With the vehicle unladen, check the top end of B4. CHECK DRIVESHAFT BOOTS FOR
tyre for the amount of movement. DAMAGE
2. Remove the stabilizer link from the lower arm. M6020300400343
3. Jack up the lower arm and move the bottom of

tyre to check the amount of movement.
DUST COVER FOR DAMAGE
AC305661
Check the driveshaft boots for damage.
B5. CHECK STEERING LINKAGE FOR

AC608834 AB
DAMAGE AND LOOSE CONNECTIONS
1. Press the lower arm ball joint cover with your (Including seals and boots)
finger to check that there are no cracks or M6020300500351
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.
B7. CHECK GEAR OIL LEVEL IN

TRANSFER CASE (4WD)
M6020300700236
Filler plug hole
AC608838AB
2. Check to be sure that the seal and boot of the ball Filler plug
Transfer oil
joint are correctly installed (in the correct AC604825AC
position), and that they are not damaged.
3. Check tie-rod end lock nut for looseness. If lock 1. Remove the filler plug.
nut is loose, adjust toe-in and then tighten lock nut 2. Check that oil level is up to the lower edge of the
to the specified torque. filler plug hole.
Tightening torque: 93 ± 15 N⋅ m 3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.
B6. CHECK GEAR OIL LEVEL IN MANUAL Tightening torque: 32 ± 2 N⋅ m
TRANSMISSION
M6020300600206
B8. CHANGE GEAR OIL IN MANUAL
TRANSMISSION
M6020300800244
Filler plug hole
Filler plug
Filler plug
Transmission oil
AC604825AB

Drain plug AC604827AB
2. Check that oil level is up to the lower edge of the
filler plug hole. 1. Remove the oil filler plug.
3. Check that the oil is not noticeably dirty. 2. Remove the drain plug and drain the oil.
4. Tighten the filler plug to the specified torque. 3. Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 N⋅ m Tightening torque: 32 ± 2 N⋅ m
4. Fill with specified oil till the level comes to the
lower portion of oil filler plug hole.
Specified transmission oil:
Gear oil API classification GL-4 SAE 75W−
85W
Quantity: 3.2 L
2-27
B9. CHANGE GEAR OIL IN TRANSFER
CASE (4WD)
M6020300900252
Gear oil
Filler plug Upper

limit
Lower 5 mm
limit
Drain plug
AC102739 AG
2. Check that gear oil level is not 5 mm below the

AC604828AB bottom of filler plug hole.
Tightening torque : 50 ± 10 N⋅ m
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque. B11. CHANGE GEAR OIL IN FRONT AND
Tightening torque: 32 ± 2 N⋅ m REAR DIFFERENTIAL
M6020301100356
4. Fill with specified oil till the level comes to the
lower portion of oil filler plug hole. <Front> <Rear>
Specified transfer oil: Filler plug

Gear oil API classification GL-4 SAE 75W−
85W Filler plug
Quantity: 2.8 L
5. Tighten the oil filler plug to the specified torque.
Drain plug Drain plug
B10. CHECK GEAR OIL LEVEL IN FRONT AC608839AB
AND REAR DIFFERENTIAL FRONT DIFFERENTIAL

M6020301000315
FRONT DIFFERENTIAL 1. Remove the under cover and filler plug.

1. Remove the under cover and filler plug. 2. Remove the drain plug and drain oil.
3. Tighten the drain plug to the specified torque
Tightening torque : 65 ± 5 N⋅ m
Gear oil 4. Add the oil until the level comes to the lower
portion of the filler plug hole.
Specified lubricant:
Upper
limit
8 mm Gear oil API classification GL-5 or higher
Lower Above 10° C: SAE 90
limit Below 10° C: SAE 80W
Quantity: 1.15 L
AC102739 AB
2. Check that gear oil level is not 8 mm below the Tightening torque : 50 ± 10 N⋅ m
bottom of filler plug hole
3. Tighten the filler plug to the specified torque. REAR DIFFERENTIAL
Tightening torque : 50 ± 10 N⋅ m 1. Remove the filler plug.
2. Remove the drain plug and drain oil.
REAR DIFFERENTIAL 3. Tighten the drain plug to the specified torque.
1. Remove the filler plug. Tightening torque : 65 ± 5 N⋅ m
4. Add the oil until the level comes to the lower B12. CHECK EXHAUST PIPE
portion of the filler plug hole. CONNECTIONS FOR GAS LEAKAGE,
Specified lubricant : AND CHECK PIPE INSTALLATION
Gear oil API classification GL-5 or higher M6020301200331
Above 10° C: SAE 90 1. Confirm that the exhaust pipe does not interfere
Below 10° C: SAE 80W with any body components.
Quantity: 1.6 L 2. Check the exhaust pipe for damage by stones,
5. Tighten the filler plug to the specified torque. etc.
Tightening torque : 50 ± 10 N⋅ m 3. Start the engine and check for gas leaks from the
exhaust pipe connections.

C1. CHECK BRAKE PEDAL AND CLUTCH • Brake pedal height
PEDAL FOR FREE PLAY • Installation position of the stop lamp switch, etc.
M6020400100509
BRAKE PEDAL FREE PLAY <VEHICLES BRAKE PEDAL FREE PLAY <VEHICLES
WITH ABS> WITHOUT ABS>
1. Turn the ignition switch ON, and fully accumulate
the brake fluid in the HBB accumulator.
NOTE: If the brake fluid is not fully accumulated in
the accumulator, the pump motor will start to run.
When the accumulator is fully accumulated, the
pump motor stops. When the brake fluid is accu-
mulated in the accumulator, the pump motor does
not run.
B
AC606585AB
1. Turn the ignition switch to the "LOCK" (OFF)

position, depress the brake pedal two or three
times. After eliminating the vacuum in the brake
booster, press the pedal down by hand, and
confirm that the amount of movement before
resistance is met (free play) is within the standard
B value range.
AC606585AB Standard value (B): 3 − 8 mm
2. Operate the pedal by hand, and check that the 2. If the brake pedal play is not within the standard
pedal stroke (free play) meets the standard value value, check the following, and adjust or replace if
at the point where resistance is felt. necessary:
Standard value (B): 3 mm or less • Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the
3. If the brake pedal play is not within the standard
brake booster operating rod
value, check the following, and adjust or replace if
• Brake pedal height
necessary:
• Installation position of the stop lamp switch, etc.
• Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the
brake booster operating rod
2-29
CLEARANCE BETWEEN BRAKE PEDAL CAUTION
AND FLOORBOARD Do not push in the master cylinder pushrod at
1. Turn up the carpet etc. under the brake pedal. this time, otherwise the clutch will not operate
properly.
Clutch switch
Pushrod
Locking nut
C
Setting nut
AC606587AB
12 ± 3 N·m AC704095 AB
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the 4. If the clutch pedal height is not within the standard
clearance between the brake pedal and the value, loosen the setting nut and the locking nut
floorboard. (vehicles with auto-cruise control) to adjust the
clutch pedal height to the standard value and
Standard value (C): move the pushrod and the clutch switch (vehicles
<Short wheelbase, Long wheelbase-2800, with auto-cruise control).
3000> 85 mm or more
5. If the clutch pedal clevis pin play is not within the
<Long wheelbase-3200, 3800> 80 mm or
standard value, loosen the setting nut and move
more
the pushrod to adjust.
3. If the clearance is outside the standard value,
check for air trapped in the brake line and Clutch pedal free play
thickness of the disc brake pad.
4. Return the carpet, etc.
CLUTCH PEDAL CHECK AND ADJUST-

C
MENT
1. Turn back the carpet etc. under the clutch pedal. Distance between the clutch pedal
and the floorboard when the clutch
Clutch pedal height Clutch pedal clevis pin is disengaged
play
D
AC604553AB
A B
6. After the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal
AC604551AB pad) and the distance between the clutch pedal
(the face of the pedal pad) and the floorboard
2. Measure the clutch pedal height. If the height is
when the clutch is disengaged are within the
outside the standard value, go to step 4.
standard value ranges.
Standard value (A):
Standard value (C): 4 −13 mm
<LHD> 202.7 −205.7 mm
Standard value (D):
<RHD> 195.7 −198.7 mm
<LHD> 125 mm or more
3. Measure the clutch pedal clevis pin play. If the <RHD> 120 mm or more
play is outside the standard value, go to Step 5.
Standard value (B): 1 −3 mm
7. If the measured free play and distance do not (3) Remove the adjustment hole plug of the rear
agree with the standard value ranges, it is brake backing plate <Short wheelbase, Long
probably the result of either air in the hydraulic wheelbase-2800, 3000> or the rear brake disc
system or a faulty master cylinder or clutch. Bleed <Long wheelbase-3200, 3800>, and then use
the air, or disassemble and inspect the master a flat-tip screwdriver to turn the adjuster in the
cylinder or clutch. direction of the arrow (the direction which
8. Reinstall the carpet, etc. expands the shoe) so that the disc will not
rotate.
C2. CHECK PARKING BRAKE LEVER (4) Return the adjuster six notches <Short
STROKE AND PLAY wheelbase, Long wheelbase-2800, 3000> or
M6020400200540 eight notches <Long wheelbase-3200, 3800>
1. Pull the parking brake lever with a force of approx. in the direction opposite to the direction of the
200 N and count the number of notches. arrow.
Standard value: 6 −7 notches CAUTION
2. If the parking brake lever stroke is not the If the parking brake lever stroke is below the
standard value, adjust as described below. standard value and the braking is too firm, the
rear brakes may drag.
(5) Turn the adjusting nut to adjust the parking
brake lever stroke to the standard value. After
Cable rod adjusting, check that there is no space
between the adjusting nut and the parking
brake lever.
(6) Release the parking brake and turn the rear
wheels to check that the rear brakes are not
dragging.
Adjusting nut
AC608399AB
C3. REPLACE AIR PURIFIER FILTER
(1) Remove the cup holder, and then loosen the M6020400300280
adjusting nut to move it to the cable rod end so

that the cable will be free.
(2) Remove the rear wheels.
<Short wheelbase, Long wheelbase-2 800, 3 000>
Backing
plate AC608840 AB
Adjuster
assembly 1. Remove the glove box.
AC604648AC
2. Loosen the two screw as shown to replace the air
<Long wheelbase-3 200, 3 800>
purifier filter.
3. Install the glove box.
Adjuster
assembly
Brake disc
AC604649AD
2-31
D1. CHECK WHEEL ALIGNMENT
M6020500100487 Inner Short wheelbase 36° 49' ± 1° 30'
FRONT WHEEL ALIGNMENT wheels Long wheelbase 36° 01' ± 1° 30'
Measure wheel alignment with alignment equipment Outer Short wheelbase 32° 06'
on a level surface. The front suspension, steering wheels Long wheelbase 32° 18'
system, wheels, and tires should be serviced to nor- (reference)
mal condition before measuring wheel alignment.
TOE-IN CAMBER, CASTER AND KINGPIN
Standard value: INCLINATION
At the centre of tyre tread: 0 −5 mm Standard value:
Toe angle (per wheel): 0 ° 00’ −0 ° 12’
Item Standard value
Camber 0° 00' ± 0° 30'*
Clip Caster Short 3° 39' ± 1° 00'*
wheelbase
Long 3° 31' ± 1° 00'*
wheelbase
Lock nut Kingpin inclination 11° 30'
NOTE: *: Difference between right and left wheels
AC603507AB
must be less than 30'
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).
Compensator
NOTE: The toe will move out as the left turnbuckle
is turned toward the front of the vehicle and the
right turnbuckle is turned toward the rear of the
vehicle.
2. Install the clip and tighten the lock nut to the
specified torque. AC603508 AB
Tightening torque: 93 ± 15 N⋅ m NOTE: For vehicles with aluminium wheels, attach

3. Confirm that the toe-in is at the standard value. the camber/caster/kingpin gauge by using a compen-
sator.
CAMBER AND CASTER REFERENCE

TABLE
B A
AC306798
Vehicles Outside of
4. Use a turning radius gauge to check that the centre vehicles
steering angle is at the standard value.
Standard value:
AC603509 AB
1. Adjust the camber and caster until they meets the 2. How to read this table (example). If the camber
standard value by turning the lower arm camber difference 0° 36' and the caster difference is
adjusting bolt. −0° 13' by comparing the measurement value with
the standard value, rotate the front adjusting cam
by 1.5 graduations and the rear adjusting cam by
2.5 graduations to the "B" direction.
Front side
adjust bolt scale
Direction A
+5
+4
+3
+2
+1
Rear side
adjust bolt scale Direction A
+5 +4 +3 +2 +1 0 –1 –2 –3 –4 –5
Direction B
'
06
0˚
–1
36
1˚
'
'
0˚
53
–2
29
0˚
'
'
40
0˚
–3
22
0˚
'
'
0˚
26
–4
15
0˚
'
0˚
'
13
07
–5
0˚
'
–0
–0
6'
–0
3'
0'
–0
–0
6'
'
0˚
3'
00
˚0
˚1
˚4
˚3
˚2
˚5
˚2
˚1
˚0
˚2
00
0˚
–1
–0
–0
6'
–0
–0
2'
5'
7'
9'
'
Direction B : Caster angle

: Camber angle
AC702880 AB
NOTE: Solid lines show caster, broken lines show

camber.
REAR WHEEL ALIGNMENT Compensator

1. The rear suspension, wheel and tires must be
serviced to normal condition before measuring the
wheel alignment.
2. Measure the wheel alignment with the vehicle
parked on a level surface.
ACX00712AD
CAMBER
Standard value: 0° 00' ± 30' (difference NOTE: For vehicles with aluminium wheels, attach
between right and left wheels must be less the camber/caster/kingpin gauge by using a compen-
than 30')
sator.
If camber is not within the standard value, adjust by
following procedures.
2-33
2. Remove the brake disc from the front hub.
Adjusting bolt
Lower arm AC603223AB
1. Adjust by turning the adjusting bolt of the lower

arm.
AC602402AB
Left wheel: Turning clockwise (+) camber
Right wheel: Turning clockwise (-) camber 3. Attach a dial gauge as shown in the illustration,
2. After adjusting the camber, the toe-in should be and then measure the axial play while moving the
adjusted. hub in the axial direction.
Limit : 0 mm
TOE-IN 4. If the play exceeds the limit value, disassemble
Standard value: hub knuckle to check each component. If the front
At the centre of tyre tread: 3 ± 3 mm hub bearing is faulty, replace the front hub
Toe angle (per wheel): 0° 06' ± 0° 06' assembly.
If toe-in is not within the standard value, adjust as fol-
lows. <Rear>
1. Be sure to adjust the camber before making toe 1. Remove the rear brake assembly and remove the
adjustment. brake disc while holding it with wires to prevent it
from falling.
Toe control
arm
Adjusting
bolt
AC603222 AB
ACX01084 AC
2. Adjust by turning the adjusting bolt (toe control
arm mounting bolt which faces the inside of the 2. Fit the dial gauge as shown in the diagram and
body). move the hub in the axial direction to measure the
Left wheel: Turning clockwise (+) toe-in play.
Right wheel: Turning clockwise (-) toe-in Limit : 0 mm
3. If the play exceeds the limit, replace the rear hub
D2. CHECK FRONT AND REAR WHEEL assembly.
BEARINGS FOR PLAY
M6020500900041
<Front>
1. Remove the caliper assembly and suspend it with
a wire.
D3. CHECK BRAKE HOSES AND PIPES

FOR LEAKAGE
M6020500300351
Hydraulic brake booster (HBB)
Rear disc brake
Front disc brake AC608397AB
1. Check entire circumference and length of hoses Item Brake pad Limit
and pipes. thickness
2. Check all clamps for tightness and connections Front Short wheelbase, 10.0 mm 2.0 mm
for leakage. Long
wheelbase-2800,
D4. CHECK BRAKE PADS AND DISCS
3000
FOR WEAR
M6020500400507 Long 11.5 mm 2.0 mm
wheelbase-3200,
3800
Rear Short wheelbase, 10.0 mm 2.0 mm
Long
wheelbase-2800,
3000
Long 10.0 mm 2.0 mm
wheelbase-3200,
3800
AC102396AF
2. When the thickness is less than the limit, always
1. Check the brake pad thickness through the caliper replace the pads at an axle set.
body check port.
Standard value:
ACX00668AF
2-35
3. Using a micrometer, measure disc thickness at
eight positions, approximately 45° apart and 10
mm in from the outer edge of the disc.
Standard value:
Item Brake disc Limit
thickness
Front Short wheelbase, 26.0 mm 24.4 mm
Long
wheelbase-2800,
ACX00708
3000
Long 28.0 mm 26.0 mm 2. Measure the thickness of the brake lining at
wheelbase-3200, several places.
3800 Standard value:
Rear Short wheelbase, 22.0 mm 20.4 mm <Short wheelbase, Long wheelbase-2800,
Long 3000> 3.0 mm
wheelbase-2800, <Long wheelbase-3200, 3800> 4.0 mm
3000 Limit: 1.0 mm
Long 18.0 mm 16.0 mm 3. If the thickness of the brake lining has worn down
wheelbase-3200, to the limit value or more, replace the shoe and
3800 lining assemblies on both sides of the vehicle.
4. If the disc thickness is less than the limits, replace
it with a new one. BRAKE DISC INSIDE DIAMETER CHECK
BRAKE DISC RUN-OUT CHECK 1. Remove the brake disc.
1. Remove the brake assembly, and then hold it with
wire.
ACX00709
2. Measure the inside diameter of the brake disc in

ACX00669AF two places or more.
2. Place a dial gauge approximately 5 mm from the Standard value:
outer circumference of the brake disc, and <Short wheelbase, Long wheelbase-2800,
measure the run-out of the disc. 3000> 199.0 mm
<Long wheelbase-3200, 3800> 210.0 mm
Limit: 0.06 mm or less
Limit:
D5. CHECK BRAKE SHOE LININGS AND <Short wheelbase, Long wheelbase-2800,
3000> 200.0 mm
DISCS FOR WEAR <Long wheelbase-3200, 3800> 211.0 mm
M6020500500311
BRAKE LINING THICKNESS CHECK 3. If the inside of the brake disc has worn down to
1. Remove the brake disc. the limit value or more, of if it is excessively worn
on one side, replace the brake disc.
D6. CHECK FUEL HOSES AND PIPES

FOR LEAKAGE OR DETERIORATION
M6020500600352
<Petrol-powered vehicles>
Fuel tank assembly
Fuel injector
<Diesel-powered vehicles>
Fuel injector
assembly
Fuel tank assembly
AC609411AB
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
2-37
E1. CHECK FLUID LEVEL IN AUTOMATIC 5. Check that the A/T fluid level is between the HOT
TRANSMISSION marks on the oil level gauge. If the A/T fluid level
M6020600100439 is too low, add more A/T fluid until the level
1. Drive the vehicle until the A/T fluid temperature reaches between the HOT marks.
reaches the normal temperature (70 −80° C) A/T fluid: DIA QUEEN ATF SP III
NOTE: Use M.U.T.-III. measure the A/T fluid tem- NOTE: If the A/T fluid level is too low, the oil pump
perature. draws air into the system along with the A/T fluid,
Fluid level (mm)
Oil level
and air bubbles will thus from in the fluid circuit.
20
gauge This will cause a drop in fluid pressure and cause
10
the shift points to change and the clutches and
0 brakes to slip. If the A/T fluid level is too high, the
HOT
-10 gear will churn the A/T fluid and cause bubbles to
-20 develop, which can then cause the same prob-
-30 lems as when the A/T fluid is too low. In either
-40 case, the air bubbles can cause overheating and
40 60 80
oxidation of the A/T fluid, and also prevent the
AC100600AD valves, clutches and brakes from operating nor-
mally. In addition, if bubbles develop in the A/T
NOTE: Check the fluid level referring to the char- fluid, the A/T fluid can overflow from the transmis-
acteristics chart shown if it takes some time to sion vent holes and be mistaken for leaks.
reach the normal operation temperature of A/T
6. Securely re-insert the oil level gauge.
fluid (70 −80° C).
2. Park the vehicle on a level surface. E2. CHANGE AUTOMATIC
3. Move the selector lever to all positions to fully TRANSMISSION FLUID
charge the torque converter and the fluid lines M6020600200511
with A/T fluid, and then move the selector lever to SPECIFICATIONS
the P position.
4. After wiping away any dirt from around the oil Automatic transmission Quantity Remarks
level gauge, pull out the oil level gauge and check fluid
the level of A/T fluid. DIA QUEEN ATF SP III 9.7 L V4A5A,
NOTE: If the A/T fluid has a burnt smell, or if it has V5A5A
become very contaminated or dirty, it means that
the A/T fluid has become contaminated by minute CHANGE PROCEDURE
particles form bushings (metal) or worn parts. In If you have an A/T fluid changer, use the A/T fluid
such a case, the transmission needs to be over- changer to flush the A/T fluid. If you do not have an
hauled and the A/T fluid cooler line needs to be A/T fluid changer, follow the procedure given below.
flushed out.
ACX01184 AB
AC000846AB
1. Remove the hose shown in the illustration which
allows the A/T fluid to flow from the A/T fluid
cooler to the transmission.
CAUTION 8. Connect the hose which was disconnected in step

The engine should be stopped within one minute 1, and then securely re-insert the oil level gauge.
of it being started. If the A/T fluid has all been dis- 9. Start the engine, and let it run at idle for 1 −2
charged before this, stop the engine at that point. minutes.
2. Start the engine and discharge the A/T fluid. 10.Move the selector lever to all positions once, and
then return it to the P position.
Driving conditions: N range, idling
Discharge amount: Approx. 3.5 L
AC000846AB
ACX01185AB 11.Check that the A/T fluid level on the oil level
gauge is at the COLD mark. if it is not up to this
3. Remove the drain plug at the bottom of the mark, add more A/T fluid.
transmission case to drain out the remaining A/T 12.Drive the vehicle until the A/T fluid temperature
fluid. reaches the normal temperature (70 −80° C), and
Discharge amount: Approx. 2.0 L then re check the A/T fluid level.
4. Install the drain plug with a gasket in between, NOTE: The COLD mark is for reference only; the
and tighten it to the specified torque. HOT marks should be used as the standard for
Tightening torque: 32 ± 2 N⋅ m judgment.
NOTE: Use M.U.T.-III. measure the A/T fluid tem-
CAUTION
perature.
Stop pouring in the A/T fluid once 5.5 L has been
poured in. Fluid level (mm)
20 Oil level
gauge
5. Pour the new A/T fluid in through the oil filler tube. 10
Amount to add: Approx. 5.5 L 0
HOT
6. Repeat the operation in step 2. -10
-20
7. Pour in new A/T fluid through the oil filler tube.
-30
Amount to add: Approx. 3.5 L
-40
NOTE: Carry out steps 2 and 7 so that at least 8.0 40 60 80
L has been discharged from the cooler hose. After AC100600AD
this, discharge a small quantity of A/T fluid and
check for contamination. If the A/T fluid is contam- NOTE: Check the fluid level referring to the char-
inated, repeat steps 6 and 7. acteristics chart shown if it takes some time until
reaching the normal operation temperature of A/T
fluid (70 −80° C.)
13.When A/T fluid is under the specified level, top up
A/T fluid. When A/T fluid is over the specified
level, drain the excessive A/T fluid from the drain
plug to adjust A/T fluid level to the specified level.
14.Securely insert the oil level gauge into the oil filler
tube.
ACX01184 AB
2-39
AUTOMATIC TRANSMISSION FLUID 3. Remove the engine oil pan drain plug to drain
COOLER LINE FLUSHING engine oil.
Engine
oil pan
side
Engine oil pan

drain plug gasket
AC607505AB AC603625 AD
1. Remove the hose shown in the illustration which 4. Install a new engine oil pan drain plug gasket so
allows the A/T fluid to flow from the A/T fluid that it faces in the direction shown in the
cooler to the transmission. illustration, and then tighten the engine oil pan
drain plug to the specified torque.
CAUTION
The engine should be stopped within one minute
of it being started. If the A/T fluid has all been dis-
charged before this, stop the engine at that point.
2. Start the engine and discharge the A/T fluid.
Driving conditions: N range, idling
Discharge amount: Approx. 3.5 L
CAUTION
Stop pouring in the A/T fluid once 3.5 L has been
poured in.
AC609878
3. Pour in new A/T fluid through the oil filler tube.
Amount to add: Approx. 3.5 L 5. Refill with specified quantity of engine oil.
4. Repeat the operation in step 2 and 3. Specified Engine Oil
• ACEA classification: "For service
NOTE: Carry out steps 2 and 3 so that at least 8.0
A1/B1, A3/B3, A3/B4 or A5/B5"
L has been discharged from the cooler hose. After
• API classification: "For service SG" or
this, discharge a small quantity of A/T fluid and
higher
check for contamination. If the A/T fluid is contam-
Total quantity (Includes volume inside oil fil-
inated, repeat steps 2 and 3.
ter): 4.9 L
5. Carry out the procedure in "CHANGE
PROCEDURE" from step 2 onwards. 6. Install the engine oil filler cap.
7. Check engine oil level.
E3. CHANGE ENGINE OIL
M6020600300637 <4M4>
<6G7> 1. Start the engine and allow it to warm up until the
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 ° C to 90
temperature of the coolant reaches 80° C to 90° C. ° C.
CAUTION CAUTION
Use care as engine oil could be hot. Use care as engine oil could be hot.
2. Remove the engine oil filler cap. 2. Remove the engine oil filler cap.
3. Remove the drain plug to drain engine oil.
Engine oil pan side

MB991610
Engine oil pan

drain plug gasket
AC609881AB
AC609879 AB
4. Install a new engine oil pan drain plug gasket so 5. Use the special tool oil filter wrench (MB991610)
that it faces in the direction shown in the to remove the oil filter.
illustration, and then tighten the engine oil pan 6. Clean the filter bracket side mounting surface.
drain plug to the specified torque.
O-ring
AC609882 AB
7. Apply a small amount of engine oil to the O-ring of

AC609880
the new oil filter.
5. Refill with specified quantity of engine oil. Oil filter number: MD352626
Specified Engine Oil 8. Once the O-ring of the oil filter is touching the
• ACEA classification: "For service flange, use the special tool oil filter wrench
A1/B1, A3/B3, A3/B4 or A5/B5" (MB991610) to tighten to the specified torque.
• API classification: "For service CD" or Tightening torque: Approximately 3/4 turn
higher (14 ± 2 N⋅ m)
Total quantity (Includes volume inside oil filter
and oil cooler): 9.8 L 9. Install the engine oil pan drain plug and refill the
engine oil.
6. Install the engine oil filler cap.
10.Race the engine 2−3 times, and check to be sure
7. Check engine oil level. that no engine oil leaks from installation section of
the oil filter.
E4. REPLACE ENGINE OIL FILTER
M6020600400526 11.Install the under cover.
<6G7>
1. Start the engine and allow it to warm up until the
<4M4>
temperature of the coolant reaches 80 ° C to 90 1. Start the engine and allow it to warm up until the
° C. temperature of the coolant reaches 80 ° C to 90
° C.
CAUTION
Use care as engine oil could be hot. CAUTION
Use care as engine oil could be hot.
2. Remove the oil filler cap.
3. Remove the engine oil pan drain plug to drain 2. Remove the oil filler cap.
engine oil. 3. Remove the engine oil pan drain plug to drain
4. Remove the under cover. engine oil.
4. Remove the under cover.
2-41
E5. CHECK ENGINE IDLING SPEED AND
CO CONCENTRATION
M6020600500545
IDLE SPEED AND MIXTURE CHECK AND

MH061590
ADJUSTMENT <6G72>
<VEHICLES WITHOUT CATALYTIC CON-
VERTER>
1. Before inspection, set the vehicle to the
AC609883AB pre-inspection condition.
5. Use the special tool oil filter wrench (MH061590)

to remove the engine oil filter.
Diagnosis
6. Clean the filter bracket side mounting surface. connector
MB991910
MB991824
O-ring
AC609884 AB
7. Apply a small amount of engine oil to the O-ring of

the new engine oil filter.
Oil filter number:
<4M40> ME013307
<4M41> 1230A046 MB991827 AC608423AC
8. Once the O-ring of the oil filter is touching the

flange, use the special tool (MH061590) to tighten
position and then connect the M.U.T.-III to the
to the specified torque.
diagnosis connector.
Tightening torque:
<4M40> Approximately 5/8 turn (20 ± 2 N⋅ m)
<4M41> Approximately 3/4 turn (20 ± 2 N⋅ m)
9. Install the engine oil pan drain plug and refill the
engine oil.
10.Race the engine 2−3 times, and check to be sure
that no engine oil leaks from installation section of No. 1 Ignition coil
the oil filter.
11.Install the under cover.
AK602718AC
3. Set a timing light to the power supply line

(terminal No. 3) of the ignition coil No. 1.
4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
NOTE: The ignition timing may fluctuate within
± 7° . This is normal.
NOTE: In higher altitude, the ignition timing is more

advanced than the standard value by approximately
5° . Diagnosis
NOTE: Wait till approximately 1 minute passes after connector
the engine started, and check the ignition timing
when the engine stabilized.
6. Check the idle speed.
Standard value: 700 ± 100 r/min MB991910
NOTE: The idle speed is controlled automatically

by the idle speed control system.
MB991824
NOTE: When using the M.U.T.-III, select item No.
02 and take a reading of the idle speed.
7. If the idle speed is outside the standard value,
inspect the MPI system (Refer to WORKSHOP
MANUAL GROUP 13 −Troubleshooting).
8. Set the CO tester.
9. Check the CO contents at idle.
Standard value: 1.0 ± 0.5% MB991827 AC608423AC

MD998299 position and then connect the M.U.T.-III to the
diagnosis connector.
Mixture
adjusting
screw
Air flow sensor

AK603844 AB
No. 1 Ignition coil
10.If there is deviation from the standard value, set
the idle mixture to the specified value by adjusting
the mixture adjusting screw (variable resister). AK602718AC
Use the special tool MAS screwdriver
(MD998299) to turn the mixture adjusting screw. 3. Set a timing light to the power supply line
(terminal No. 3) of the ignition coil No. 1.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-III. 5. Check that ignition timing is at the standard value.
Standard value: approximately 10° BTDC
<VEHICLES WITH CATALYTIC NOTE: The ignition timing may fluctuate within ± 7° .
CONVERTER> This is normal.
1. Before inspection, set the vehicle to the NOTE: In higher altitude, the ignition timing is more
pre-inspection condition. advanced than the standard value by approximately
5° .
NOTE: Wait till approximately 1 minute passes after
the engine started, and check the ignition timing
when the engine stabilized.
Standard value: 700 ± 100 r/min
NOTE: The idle speed is controlled automatically
2-43
NOTE: When using the, M.U.T.-III select item No.
7. If the idle speed is outside the standard value,
8. Run the engine at 2,500 r/min for 2 minutes.
9. Set the CO, HC tester.
10.Check the CO contents and the HC contents at
No.1 Ignition coil
idle.
AK602719AC
Standard value
CO contents: 0.5% or less 3. Set a timing light to the power supply line
HC contents: 100 ppm or less (terminal No. 3) of the ignition coil No. 1.
11.If there is a deviation from the standard value, 4. Start the engine and let it run at idle.
inspect the MPI system (Refer to WORKSHOP 5. Check that ignition timing is at the standard value.
MANUAL GROUP 13 −Troubleshooting). Standard value: approximately 10° BTDC
12.Remove the timing light. NOTE: The ignition timing may fluctuate within ± 7° .
13.Turn the ignition switch to the "LOCK" (OFF) This is normal.
position and then remove the M.U.T.-III.
NOTE: In higher altitude, the ignition timing is more
advanced than the standard value by approximately
IDLE SPEED AND MIXTURE CHECK AND 5° .
ADJUSTMENT <6G75> NOTE: Wait till approximately 1 minute passes after
1. Before inspection, set the vehicle to the the engine started, and check the ignition timing
pre-inspection condition. when the engine stabilized.
Diagnosis
connector NOTE: The idle speed is controlled automatically
NOTE: When using the M.U.T.-III, select item No.
MB991910 7. If the idle speed is outside the standard value,
MB991824 8. Run the engine at 2,500 r/min for 2 minutes.
9. Set the CO, HC tester.
10.Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
11.If there is a deviation from the standard value,
MB991827 AC608423AC inspect the MPI system (Refer to WORKSHOP
2. Turn the ignition switch to the "LOCK" (OFF) 12.Remove the timing light.
position and then connect the M.U.T.-III to the
diagnosis connector. 13.Turn the ignition switch to the "LOCK" (OFF)
IDLE SPEED CHECK <4M40>

NOTE: Check that the injection timing is normal.
Diagnosis
1. Before inspection, set the vehicle to the connector
pre-inspection condition.
CAUTION
When the speedometer is connected to the injec-
tion pipe, the pipe mounting clamps should all be MB991910
removed.
MB991824
Speedometer
Injection
nozzle AK603857AB
MB991827 AC608423AC
2. Connect the speedometer to the injection nozzle
ore the injection pipe. 2. Turn the ignition switch to the "LOOK" (OFF)
3. Start the engine and run it at idle. position, and then connect the M.U.T.-III to the
4. Check the idle speed. diagnosis connector.
Acceleratorlever
5. If the idle speed is not within the standard value,
inspect the diesel system (Refer to WORKSHOP
Locking nut
Idle speed
adjusting screw
E6. CHECK EXHAUST GAS
AK603858 AB RECIRCULATION (EGR) SYSTEM
M6020600800375
5. If not within the standard value, loosen idle EGR VALVE CHECK <6G72>
adjusting screw lock nut and adjust the idle speed 1. Remove the exhaust gas recirculation valve and
by rotating adjusting screw. And tighten locking inspect for sticking, carbon deposits, etc. If found,
nut. clean with a suitable solvent so that the valve
seats correctly.
IDLE SPEED CHECK <4M41>
1. Before inspection, set the vehicle to the
pre-inspection condition.
AKX00348
2-45
2. Connect a hand vacuum pump to the exhaust gas
recirculation valve.
3. Apply 67 kPa of vacuum, and check that the
vacuum is maintained.
4. Apply a vacuum and check the passage of air by
blowing through one side of the exhaust gas
recirculation passage.
Vacuum Passage of air
5.6 kPa or less Air is not blown out AK100016
29 kPa or more Air is blown out

5. Measure the resistance between the terminals of
5. Replace the gasket, and tighten to the specified the solenoid valve.
torque.
Standard value: 29 − 35 Ω (at 20° C)
EGR VALVE (STEPPER MOTOR) CHECK
EGR CONTROL SOLENOID VALVE <6G75>
CHECK <6G72>
Checking the Operation Sound
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.
1. Disconnect the vacuum hose from the solenoid
valve.
2. Disconnect the harness connector.
B
Exhaust gas
recirculation valve
A (stepper motor) AK602173AB
1. Check that the operation sound of the stepper

C motor can be heard from the exhaust gas
Battery recirculation valve when the ignition switch is
turned ON (without starting the engine).
AK100015 AF 2. If the operation sound cannot be heard, inspect
the drive circuit of the stepper motor.
3. Connect a hand vacuum pump to nipple (A) of the
NOTE: If the circuit is normal, either the stepper
solenoid valve.
motor or the engine-ECU <M/T> or engine-A/T-ECU
4. Check air tightness by applying a vacuum with <A/T> may have failed.
voltage applied directly from the battery to the
exhaust gas recirculation control solenoid valve Checking the Coil Resistance
and without applying voltage. 1. Remove the exhaust gas recirculation valve.
Battery Nipple Normal condition
voltage condition
Applied Open Vacuum leaks
B nipple Vacuum maintained
closed
1 2 3
Not applied Open Vacuum leaks 4 5 6
C nipple Vacuum maintained

1 2 3
closed 4 5 6
AK200805 AC
2. Measure the resistance between terminal No. 2 4. Connect terminals No. 1 and No. 3 to the negative
and either terminal No. 1 or terminal No. 3 of the (−) terminal of the battery, in order to test whether
connector at the exhaust gas recirculation valve. the stepper motor vibrates (with a slight shudder),
Standard value: 20 −24 Ω (at 20° C) indicating that the stepper motor is operating.
3. Measure the resistance between terminal No. 5 CAUTION
and either terminal No. 6 or terminal No. 4 of the Connecting battery voltage to the exhaust gas
connector at the exhaust gas recirculation valve. recirculation valve for a long term could damage
Standard value: 20 −24 Ω (at 20° C) the coil.
4. Using a new gasket, install the exhaust gas

recirculation valve by tightening its mounting bolts
Tightening Torque: 23 ± 6 N⋅ m
Operation Check
MB991658 Battery
AK304039 AB
5. Connect the positive (+) terminal of the battery to

1 2 3
terminal No. 5.
4 5 6 6. Connect terminals No. 4 and No. 6 to the negative
Exhaust gas (−) terminal of the battery, in order to test whether
recirculation valve the stepper motor vibrates (with a slight shudder),
AK502151 AE indicating that the stepper motor is operating.
7. If a vibration can be felt during the test, the
1. Remove the exhaust gas recirculation valve. stepper motor is normal.
2. Attach a test wiring harness (special tool 8. Using a new gasket, install the exhaust gas
MB991658) to the connector at the exhaust gas recirculation valve by tightening its mounting bolts
recirculation valve. to the specified torque.
CAUTION Tightening torque: 23 ± 6 N⋅ m
Connecting battery voltage to the exhaust gas
recirculation valve for a long term could damage Cleaning the EGR Valve
the coil.
CAUTION
Do not use a solvent or detergent, which could
enter the motor and cause it to malfunction.
1. Remove the exhaust gas recirculation valve and
check that the exhaust gas recirculation valve is
not stuck or clogged with carbon deposits. Use a
wire brush to clean the valve if necessary.
MB991658 2. Using a new gasket, install the exhaust gas
Battery recirculation valve by tightening its mounting bolts
AK302886 AB
3. Connect the positive (+) terminal of the battery to
terminal No. 2.
2-47
EGR VALVE (DC MOTOR) CHECK <4M41> 3. A tester is to be connected between the terminal
System Check No.1 and No. 2.
4. Connect the terminal (+) of the power supply with
Exhaust gas recircilation valve the terminal No. 6 of the exhaust gas recirculation
(Exhaust gas recircilation sensor built)
valve connector, and connect the terminal (−) of
the power supply with the terminal No. 4. Confirm
the exhaust gas recirculation valve is opened.
NOTE: At this time, the power supply voltage is to
be 5 V. When the valve is not opened, increase
the voltage 1 V by 1 V. For each voltage, current is
to be applied within 5 seconds. Once the valve is
opened, the voltage is not to be increased any
AK602177AB
more.
1. Connect the M.U.T.-III to the diagnosis connector
to check for date list item No. 16.
2. Start the engine, and warm up the engine.
3. Raise the engine speed gradually, and make sure
that the valve open degree changes from 0 % to
100 %.
Operation Check
Valve open
AK500442AB
5. Confirm the voltage is changed between the

terminal No. 1 and No. 2 together with the exhaust
1 2 3 gas recirculation valve opening movement.
Exhaust gas
4 5 6 recirculation 6. By the voltage changed, the DC is recognized as
valve being normal.
7. Use a new gasket and tighten the installation bolt
to the tightening torque.
AK500440AC
1. Remove the exhaust gas recirculation valve.
Cleaning the EGR Valve
CAUTION
5V Do not use a solvent or detergent, which could
enter the motor and cause it to malfunction.
1 2 3 1. Remove the exhaust gas recirculation valve and
4 5 6 check that the exhaust gas recirculation valve is
not stuck or clogged with carbon deposits. Use a
5V wire brush to clean the valve if necessary.
2. Using a new gasket, install the exhaust gas
AK603110 AB
recirculation valve by tightening its mounting bolts
2. Connect the terminal (+) of the sensor power to the specified torque.
supply (5 V) with the terminal No. 3 of the exhaust Tightening torque: 48 ± 6 N⋅ m
gas recirculation valve connector, and connect the
terminal (−) of the sensor power supply (5 V) with
the terminal No. 2.
OTHERS
OTHERS
F1. CHECK BODY CONDITION FOR • Power steering: Static state
DAMAGE 3. Select SPECIAL FUNCTION from the function
M6020700100254 menu.
1. Check underbody coating for damage. 4. Select SMALL INJECTION QUANTITY
2. Check body painting for damage. LEARNING from the SPECIAL FUNCTION menu
to execute learning.
F2. CHECK THE COMMON RAIL ENGINE
CAUTION
(small injection quantity learning) • If the vehicle conditions go out of the learning
M6020700400017
LEARNING PROCEDURE conditions during idling, learning is inter-

rupted.
• To reexecute learning, the ignition switch
must once be turned off.
Diagnosis
connector 5. Continue idling for about 3 minutes before
learning is completed.
6. Confirm that the engine warning lamp is off. If it
still blinks, reexecute learning.
MB991910
F3. ROAD TEST
M6020700200325
MB991824
AC609417
MB991827 AC608423AC
Drive the vehicle and check for conditions.
1. After the ignition switch is in "LOCK" (OFF)
1. Check free play of steering wheel.
position, connect the M.U.T.-III to the diagnosis
connector. 2. Check efficiency of service brakes and parking
brakes system.
2. Put the vehicle in the following idling stable
conditions: 3. Check driveability of engine.
• Engine coolant temperature: 80 −90° C 4. Check condition of instruments, gauges
• Automatic transmission fluid temperature: 60° C indicators, exterior lamps, heater and ventilators.
or higher 5. Check abnormal noise of each part.
• Lamps, A/C condenser fan and all accessories: 6. Check the tyres for wear and for the correct air
OFF pressure.
• Transmission: Neutral <M/T>, "P" range <A/T>

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0-1

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

HOW TO USE THIS MANUAL

PRECAUTIONS BEFORE SERVICE

DOING SERVICE WORK IN GROUPS OF

If punch marks or mating marks are made to avoid

TUBES AND OTHER RUBBER PARTS

If other tools are substituted for the special tools to

PARTS TO BE REPLACED LUBRICANTS

Be careful to avoid spilling any brake fluid, because if

SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING

If high-pressure car-washing equipment or steam

HEALTH WARNING gles or face shields; in addition an eye wash

8. CLUTCH MASTER CYLINDER FLUID LEVEL 1-9

AFTER ROAD TEST . . . . . . . . . . . . . 1-15 39. ENGINE, TRANSMISSION, STEERING

TABLE OF PRE-DELIVERY INSPECTION

Term Definition Remark

Wipe-off by kerosene or white gasoline, etc.

Disposal of removed film: Burning is appropriate

3. EXTERIOR 6. Verify that all doors can be locked by the lock

4. OPERATION OF DOOR LOCKING

7. Verify that the rear doors can't be opened by the

Check the fluid level. AC305615

Check the fluid level.

BEFORE ROAD TEST

18. INHIBITOR SWITCH

19. IDLE CONTROL KNOB

20. INSTRUMENT PANEL CONTROLS

21. METERS, GAUGES, WARNING AC305626

LAMPS AND INDICATION LAMPS 2. Heater and defroster

22. AIR CONDITIONER, HEATER AND

1. Front wiper and washer

Depress the brake pedal

26. OPERATION OF SEAT BELTS,

(2) Verify correct brake pedal free play.

28. TRANSMISSION IN ALL RANGES 1. Service Brake

1. Check for excessive play or looseness.

AFTER ROAD TEST

36. HOSES, FLUID LINES AND 38. AUTOMATIC TRANSMISSION FLUID

1. Remove the dipstick and check the fluid level.

AC305644 AB 8 mm Gear oil

45. OWNER INSTRUCTIONS

PERIODIC INSPECTION AND A17. CHECK INJECTION NOZZLE [IF DARK

OPERATIONS INSIDE THE VEHICLE 2-28 OPERATIONS AFTER ENGINE IS

Maintenance item Maintenance Maintenance interval

Maintenance item Maintenance Maintenance interval

1. Make sure that the indicator mark is within the

NOTE: This operation is to temporarily set the CAUTION

the frequency display (Hz).

A2. CHECK VACUUM PUMP OIL HOSE

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

<BELT DEFLECTION CHECK>

Approximately Water pump

If not within the standard value, adjust the belt ten-

Adjusting 1. Inspect the intake air hoses for cracks or dam-

A4. REPLACE ENGINE TIMING BELT

1. Inspect the breather hose for cracks or damage. <6G75>