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Mitsubishi Pajero Sport 2013 Inspection And Maintenance Manual

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HOW TO USE THIS MANUAL. . . . . .
PRECAUTIONS BEFORE
SERVICE . . . . . . . . . . . . . . . . . . . . . .
PROTECTING THE VEHICLE . . . . . . . . . .
DOING SERVICE WORK IN GROUPS
OF TWO OR MORE MECHANICS . . . . . . .
REMOVAL AND DISASSEMBLY . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . .
PARTS TO BE REPLACED . . . . . . . . . . . .
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBES AND OTHER RUBBER PARTS . . .
GROUP 0
GENERAL
CONTENTS
0-2
0-2
0-2
0-2
0-2
0-3
0-3
0-3
0-3
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . .
SERVICING THE ELECTRICAL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS . . . . . . . . . .
PRE-INSPECTION CONDITION . . . . . . . . .
VEHICLE WASHING . . . . . . . . . . . . . . . . . .
MULTI USE TESTER (M.U.T.-III)
SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
IN ORDER TO PREVENT VEHICLES
FROM FIRE . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . .
0-1
0-3
0-4
0-4
0-4
0-4
0-4
0-5
0-5
0-5

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Summary of Contents for Mitsubishi Pajero Sport 2013

  • Page 1 GROUP 0 GENERAL CONTENTS HOW TO USE THIS MANUAL..LUBRICANTS ..... . . BRAKE FLUID ..... . . PRECAUTIONS BEFORE SERVICING THE ELECTRICAL SYSTEM .

  • Page 2: How To Use This Manual

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

  • Page 3: Special Tools

    M6001000600024 AC305284 AC305593 If other tools are substituted for the special tools to When replacing parts, use MITSUBISHI genuine do service of repair work, there is the danger that parts. vehicle parts might be damaged, or the technician TUBES AND OTHER RUBBER PARTS might be injured;...

  • Page 4: Brake Fluid

    GENERAL PRECAUTIONS BEFORE SERVICE BRAKE FLUID APPLICATION OF ANTI-CORROSION M6001000900025 AGENTS AND UNDERCOATS M6001001100022 If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

  • Page 5: Sub Assembly

    GENERAL PRECAUTIONS BEFORE SERVICE MULTI USE TESTER (M.U.T.-III) SUB ENGINE OILS M6001001600180 ASSEMBLY HEALTH WARNING M6001001900158 Refer to the "M.U.T.-III OPERATING INSTRUC- Prolonged and repeated contact with mineral oil will TIONS" for instructions on handling the M.U.T.-III. result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis.
  • Page 6 NOTES...

  • Page 7: Table Of Contents

    GROUP 1 PRE-DELIVERY INSPECTION CONTENTS NOTES CONCERNING ENTRIES . . . UNDER VEHICLE ....1-14 13. TYRE AND SPARE TYRE PAINTWORK TERMS ... . PRESSURES .
  • Page 8 ROAD TEST ....1-18 37. MANUAL TRANSMISSION AND TRANSFER (4WD) OIL LEVEL ..1-20 27.

  • Page 9: Notes Concerning Entries

    PRE-DELIVERY INSPECTION NOTES CONCERNING ENTRIES NOTES CONCERNING ENTRIES M6010100100132 This section describes the details and the inspection methods employed for the pre-delivery inspection of vehicles. The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY INSPECTION.
  • Page 10 PRE-DELIVERY INSPECTION NOTES CONCERNING ENTRIES TABLE OF PRE-DELIVERY INSPECTION Model Chassis number Engine number Before Road Test Distance Travelled Seat adjusters and seat back latches Owner Choke system and inhibitor switch Date of inspection Idle control knob Place of inspection Instrument panel controls Inspector Meters, gauges, warning lamps and indication lamps...

  • Page 11: Paintwork Terms

    PRE-DELIVERY INSPECTION PAINTWORK TERMS PAINTWORK TERMS M6010200100139 Term Definition Remark Blister A raised bubble in the paint (from the base or the undercoat) caused by abnormal moisture. The bubble may contain either water or air. Change in tone The colour tone of the painted surface is not Including wrong colour, discoloration and uniform.

  • Page 12: First Step

    PRE-DELIVERY INSPECTION FIRST STEP FIRST STEP 1. CONNECTION OF DARK CURRENT CONNECTOR M6010300100471 CONNECTING PROCEDURE CAUTION Turn the ignition switch to the LOCK (OFF) posi- tion before connecting storage connector. AC510870 Junction block AC900074 4. When the "COMPASS CALIBRATION" screen is displayed, press the [SELECT] button.

  • Page 13: Body

    PRE-DELIVERY INSPECTION BODY AC900079 7. "COMPASS CALIBRATION COMPLETE" is indicated with a blip, and the compass calibration is completed. When three seconds have elapsed after completion, the information screen is displayed. BODY 2. WRAP FILM M6010400100241 AC305606 Vehicles may be shipped from the assembly plant to the distributors with a white plastic film or coating (wrap film) applied for the purpose of protecting the painted exterior from environmental elements where...
  • Page 14 PRE-DELIVERY INSPECTION BODY REMOVAL PROCEDURE Flow Chart of Wrap Film Removal Wrap film removal Peel off from the corners of the wrap film. High temperature or low temperature may cause wrap film to become brittle. For easier removal, the recommended Wrap Film temperature is below 40˚C.
  • Page 15 PRE-DELIVERY INSPECTION BODY Steps. Process Tips Remove old wrap film Follow the "flow chart of removing the wrap film" Prepare the surface to adhere the wrap Make sure there is no debris such as sand or dust. Dry film the surface thoroughly. The temperature of the area to apply the wrap film should be below 40°C for workability.
  • Page 16 PRE-DELIVERY INSPECTION 1-10 BODY...
  • Page 17 PRE-DELIVERY INSPECTION 1-11 BODY...

  • Page 18: Exterior

    PRE-DELIVERY INSPECTION 1-12 BODY 3. EXTERIOR 6. Verify that all doors can be locked by the lock M6010400200215 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.

  • Page 19: Under Hood

    PRE-DELIVERY INSPECTION 1-13 UNDER HOOD UNDER HOOD 6. ENGINE OIL LEVEL If it is below the "MIN" mark, replenish fresh brake fluid up to the "MAX" mark. M6010500100271 Specified Brake Fluid: DOT3 or DOT4 9. WASHER FLUID LEVEL M6010500400090 AC702169 Check that the oil level is between "MAX"...

  • Page 20: Power Steering Fluid Level

    PRE-DELIVERY INSPECTION 1-14 UNDER VEHICLE 11. POWER STEERING FLUID LEVEL 12. ELECTRICAL WIRING M6010500600072 M6010500700024 AC305616 AC305617 1. Check that the fluid level is between "MAX" and 1. Each electrical wiring harness and connector "MIN". (1) Check each harness to be correctly routed and securely clipped.

  • Page 21: Steering Linkage And Split Pins

    PRE-DELIVERY INSPECTION 1-15 UNDER VEHICLE REMOVE FRONT SPRING RESTRAINTS 15. STEERING LINKAGE AND SPLIT PINS M6010600300023 CAUTION It is very important that these restraints must be removed during pre-delivery inspection. Failure to do so could cause ride and handling com- plaints.

  • Page 22: Before Road Test

    PRE-DELIVERY INSPECTION 1-16 BEFORE ROAD TEST BEFORE ROAD TEST 17. SEAT ADJUSTERS AND SEATBACK 21. METERS, GAUGES, WARNING LATCHES LAMPS AND INDICATION LAMPS M6010700100082 M6010700500024 AC305624 AC305622 Check the operation of the various parts of the seats. 1. Check the meters and gauges are functioning 1.

  • Page 23: Wipers And Washers

    PRE-DELIVERY INSPECTION 1-17 BEFORE ROAD TEST 24. OPERATION OF SERVICE BRAKES AND PARKING BRAKES M6010700800360 Depress the brake pedal with approximately 500 N force AC305626 2. Heater and defroster (1) After the engine has warmed up, turn on the AC305628 heater.

  • Page 24: Operation Of Seat Belts, Shoulder Belts And Retractors

    PRE-DELIVERY INSPECTION 1-18 ROAD TEST 26. OPERATION OF SEAT BELTS, 2. Check the pedal-to- floorboard clearance when the clutch is just disengaged. SHOULDER BELTS AND RETRACTORS M6010701000022 AC305631 AC305632 3. Verify correct clutch pedal free play. 1. Verify that the seat belt warning lamp operates NOTE: For inspection and adjustment of the properly.

  • Page 25: Brakes

    PRE-DELIVERY INSPECTION 1-19 ROAD TEST 30. STEERING CONTROL M6010800400024 Button AC305635 AC305636 2. Automatic transmission 1. Check for excessive play or looseness. (1) Make sure shift indicator lines up properly in 2. Check the steering wheel centre. all ranges. (2) Depress the accelerator completely to check 31.

  • Page 26: After Road Test

    PRE-DELIVERY INSPECTION 1-20 AFTER ROAD TEST AFTER ROAD TEST 33. IDLE SPEED 36. HOSES, FLUID LINES AND M6010900100149 CONNECTIONS LOCATED UNDER HOOD Check the engine idle speed. M6010900400195 NOTE: For specific idle speed adjustment proce- CAUTION dure, refer to GROUP 2, Periodic Inspection and Remember that the air conditioner system is Maintenance.

  • Page 27: Fluid Level

    PRE-DELIVERY INSPECTION 1-21 AFTER ROAD TEST 38. AUTOMATIC TRANSMISSION FLUID TYPE 1 TYPE 2 LEVEL M6010900600207 Gear oil 8 mm Upper limit Lower limit AC305646 Type 1 only: Remove the filler plug, and check the gear oil level. Check that gear oil level is not 8 mm AC005861AD below the bottom of filler plug hole.

  • Page 28: Final Steps

    PRE-DELIVERY INSPECTION 1-22 FINAL STEPS FINAL STEPS 42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR M6011000100116 M6011000300176 Finally check and clean the exterior and interior. 1. Wash the vehicle to remove all traces of road Screen grime and other dirt on the vehicle as a result of Headlamp new vehicle preparations.

  • Page 29: Continued On Next Page

    GROUP 2 PERIODIC INSPECTION AND MAINTENANCE CONTENTS PERIODIC INSPECTION AND A12. REPLACE AIR CLEANER ELEMENT ......2-31 MAINTENANCE SCHEDULE .
  • Page 30 B7. CHECK TRANSFER FOR OIL LEAKAGE D3. CHECK BRAKE HOSES AND (In case of leakage, check the oil level) . . . 2-40 PIPES FOR LEAKAGE ....2-48 B8.

  • Page 31: Periodic Inspection And Maintenance Schedule

    PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE M6020100102054 For items which indicate both distance and time (in months), the inspection should be made at whichever (distance or time) comes first. FOR GENERAL EXPORT Maintenance item Maintenance Maintenance interval...
  • Page 32 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation A12 Replace air cleaner element Replace Normal Every 40,000 km or every 2 usage years Severe More frequently usage A13 Check fluid level in brake reservoir and Inspection Every 10,000 km or every 6 months clutch reservoir...
  • Page 33 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation B11 Change gear oil in Conventional Change Normal Every 80,000 km front and rear differential usage differential Severe Every 40,000 km usage Hybrid type LSD Change Normal Every 40,000 km...
  • Page 34 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation Replace engine oil Petrol-powered Replace Normal Every 15,000 km or every 12 filter vehicles usage months Severe Every 5,000 km usage Diesel-powered Replace Normal Every 10,000 km or every 12 vehicles usage months...
  • Page 35 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation Check engine coolant Petrol-powered Inspection Every 40,000 km or every 2 years level in reservoir vehicles Diesel-powered Inspection Every 20,000 km or every 12 months vehicles A10 Change engine coolant Petrol-powered Change...
  • Page 36 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation Check transfer for oil leakage Inspection Every 20,000 km or every 12 months (In case of leakage, check the oil level) Change gear oil in manual transmission Change Normal Every 100,000 km...
  • Page 37 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation OPERATIONS AFTER ENGINE IS WARMED UP Check fluid level in automatic transmission Inspection Every 20,000 km or every 12 months Change automatic transmission fluid Change Normal Every 80,000 km usage...

  • Page 38: Operations Inside The Engine Compartment

    PERIODIC INSPECTION AND MAINTENANCE 2-10 OPERATIONS INSIDE THE ENGINE COMPARTMENT OPERATIONS INSIDE THE ENGINE COMPARTMENT A1. CHECK DRIVE BELT FOR CRACKS, 2. Press the "POWER" button to turn on the power supply. FRAYING, WEAR, AND ADJUST ITS 3. Press number key 1. Check to ensure that "No. TENSION 01"...
  • Page 39 PERIODIC INSPECTION AND MAINTENANCE 2-11 OPERATIONS INSIDE THE ENGINE COMPARTMENT <WHEN USING THE TENSION GAUGE> CAUTION • The temperature of the surface of the belt Water pump should be as close as possible to normal tem- pulley perature. Tension gauge •...
  • Page 40 PERIODIC INSPECTION AND MAINTENANCE 2-12 OPERATIONS INSIDE THE ENGINE COMPARTMENT DRIVE BELT TENSION CHECK 4. Tighten the nut for alternator pivot bolt. Tightening torque: 47 ± 9 N⋅m <6G74, 6B31> 5. Tighten the alternator fixing bolt. CAUTION Tightening torque: 24 ± 4 N⋅m Check the alternator drive belt tension after turn- ing the crankshaft clockwise one turn or more.
  • Page 41 PERIODIC INSPECTION AND MAINTENANCE 2-13 OPERATIONS INSIDE THE ENGINE COMPARTMENT DRIVE BELT TENSION CHECK AND 2. Press the "POWER" button to turn on the power supply. ADJUSTMENT<4G64> 3. Press number key 1. Check to ensure that "No. ALTERNATOR DRIVE BELT TENSION 01"...
  • Page 42 PERIODIC INSPECTION AND MAINTENANCE 2-14 OPERATIONS INSIDE THE ENGINE COMPARTMENT <When using the tension gauge> CAUTION • Do not let any contaminants such as water or oil get onto the microphone. Alternator Water pump pulley pulley • If strong gusts of wind blow against the microphone or if there is loud sources of noise nearby, the values measured by the microphone may not correspond to actual...
  • Page 43 PERIODIC INSPECTION AND MAINTENANCE 2-15 OPERATIONS INSIDE THE ENGINE COMPARTMENT <When the tension is measured> 4. Tighten the nut of the pivot bolt. Tightening torque: 22 ± 2 N⋅m Use a belt tension gauge to check that the drive belt tension is within the standard value at the middle of 5.

  • Page 44: A2. Check Vacuum Pump Oil Hose For Damage

    PERIODIC INSPECTION AND MAINTENANCE 2-16 OPERATIONS INSIDE THE ENGINE COMPARTMENT <When the deflection is measured> CAUTION When checking the power steering oil pump CAUTION drive belt tension, turn the crankshaft clockwise • When measuring the deflection, make sure one turn or more. that the engine is cold.

  • Page 45: A3. Check Intake Air Hose And Turbocharger Oil Hose For Damage (Vehicles With Turbocharger)

    PERIODIC INSPECTION AND MAINTENANCE 2-17 OPERATIONS INSIDE THE ENGINE COMPARTMENT A3. CHECK INTAKE AIR HOSE AND VENTILATION HOSE TURBOCHARGER OIL HOSE FOR 1. Check entire circumference and length of hoses using a mirror as required. DAMAGE 2. Check all clamps for tightness and the (Vehicles with turbocharger) connections for leakage.

  • Page 46: A6. Replace Spark Plugs

    PERIODIC INSPECTION AND MAINTENANCE 2-18 OPERATIONS INSIDE THE ENGINE COMPARTMENT PCV VALVE CHECK CAUTION Leaked fuel on parts causes a decrease in func- <6G74> tion and burning. Therefore, place waste to absorb leaked fuel. PCV valve MB992188 AC305654 AE 1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation AK600671 side), and move the rod back and forth to check...
  • Page 47 PERIODIC INSPECTION AND MAINTENANCE 2-19 OPERATIONS INSIDE THE ENGINE COMPARTMENT 4. Align the camshaft sprocket timing marks and set 7. Turn the crankshaft 360° clockwise to bring No. 4 the No. 1 cylinder at top dead centre. cylinder to the top dead centre position. Exhaust valve side Exhaust valve side Intake valve side...
  • Page 48 PERIODIC INSPECTION AND MAINTENANCE 2-20 OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION CAUTION • The reinstallation histories of the removed Degrease the area between the flare nut and the injection pipe are up to five times. To count pipe of the fuel injection pipe by fully spraying how many times the injection pipe is rein- the parts cleaner.
  • Page 49 PERIODIC INSPECTION AND MAINTENANCE 2-21 OPERATIONS INSIDE THE ENGINE COMPARTMENT 16.Start up the personal computer. CAUTION Before connecting or disconnecting the 17.Connect special tool M.U.T.-III USB cable M.U.T.-III, turn the ignition switch to the "LOCK" (MB991827) to V.C.I. (MB991824) and the (OFF) position.
  • Page 50 PERIODIC INSPECTION AND MAINTENANCE 2-22 OPERATIONS INSIDE THE ENGINE COMPARTMENT <4D56> CAUTION The crankshaft should always be turned in a NOTE: The valve clearance check and adjustment clockwise direction. should be done when the engine is cold. 1. Remove the engine air intake pipe. Timing marks 2.
  • Page 51 PERIODIC INSPECTION AND MAINTENANCE 2-23 OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION Pay special attention that the tightening torque is not beyond this valve. If the tightening torque is beyond the valve, the valve stem would possibly bend. AK202860AB MB992046 10 mm Thickness gauge AK500381 8.
  • Page 52 PERIODIC INSPECTION AND MAINTENANCE 2-24 OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION CAUTION • The reinstallation histories of the removed Degrease the area between the flare nut and the injection pipe are up to five times. To count pipe of the fuel injection pipe by fully spraying how many times the injection pipe is rein- the parts cleaner.
  • Page 53 PERIODIC INSPECTION AND MAINTENANCE 2-25 OPERATIONS INSIDE THE ENGINE COMPARTMENT 21.Start up the personal computer. CAUTION Before connecting or disconnecting the 22.Connect special tool M.U.T.-III USB cable M.U.T.-III, turn the ignition switch to the "LOCK" (MB991827) to V.C.I. (MB991824) and the (OFF) position.
  • Page 54 PERIODIC INSPECTION AND MAINTENANCE 2-26 OPERATIONS INSIDE THE ENGINE COMPARTMENT <6B31 (intake side)> NOTE: If the rocker arm of No. 6 cylinder at the inlet side is moved up and down and the rocker NOTE: Perform the valve clearance check and arm is moved, No.

  • Page 55: A8. Check Radiator Hoses For Damage And Proper Connection

    PERIODIC INSPECTION AND MAINTENANCE 2-27 OPERATIONS INSIDE THE ENGINE COMPARTMENT A8. CHECK RADIATOR HOSES FOR A9. CHECK ENGINE COOLANT LEVEL IN DAMAGE AND PROPER CONNECTION RESERVOIR M6020200901140 M6020201001098 <4M41> Air cleaner Condenser tank AC503024 AC702330 AC Check that the coolant level is between the "FULL" <4D56>...
  • Page 56 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: MITSUBISHI Engine oil MOTORS GENUINE SUPER LONG LIFE cooler water feed hose COOLANT or equivalent...
  • Page 57 PERIODIC INSPECTION AND MAINTENANCE 2-29 OPERATIONS INSIDE THE ENGINE COMPARTMENT <6B31-Left bank> <4M41> Engine oil cooler assembly Engine oil cooler water drain plug 29 ± 5 N·m Power steering oil pump AC903246 AC AC712143 6. Install the engine oil cooler water drain plug and <6B31-Right bank>...

  • Page 58: A11. Check Air Cleaner Element For Clogging And Damage

    PERIODIC INSPECTION AND MAINTENANCE 2-30 OPERATIONS INSIDE THE ENGINE COMPARTMENT Recommended antifreeze: MITSUBISHI <6B31-Left bank> MOTORS GENUINE SUPER LONG LIFE COOLANT or equivalent Quantity (includes 0.65 L in the radiator con- denser tank): <4M41> 8.5 L <4D56> 8.2 L <6G74> 8.8 L 29 ±...

  • Page 59: A12. Replace Air Cleaner Element

    PERIODIC INSPECTION AND MAINTENANCE 2-31 OPERATIONS INSIDE THE ENGINE COMPARTMENT A12. REPLACE AIR CLEANER ELEMENT A14. CHANGE BRAKE FLUID M6020201301011 M6020201601119 The air cleaner element will become dirty and loaded with dust during use, and the filtering effect will be substantially reduced.

  • Page 60: A15. Check Battery Condition

    PERIODIC INSPECTION AND MAINTENANCE 2-32 OPERATIONS INSIDE THE ENGINE COMPARTMENT MASTER CYLINDER BLEEDING 2. Use a hydrometer and thermometer to check the specific gravity of the battery fluid. The master cylinder used has no check valve, so if Standard value: 1.220 − 1.290 [20°C] bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become 3.
  • Page 61 PERIODIC INSPECTION AND MAINTENANCE 2-33 OPERATIONS INSIDE THE ENGINE COMPARTMENT <Diesel powered vehicles with plastic fuel filter case> 1. Remove the fuel tank cap to release the pressure inside the fuel tank. 2. Remove the fuel filter protector B. 3. Loosen the drain plug to drain the fuel. Then. tighten the drain plug.
  • Page 62 PERIODIC INSPECTION AND MAINTENANCE 2-34 OPERATIONS INSIDE THE ENGINE COMPARTMENT REMOVAL OF WATER FROM THE FUEL FILTER Water is in the fuel filter cartridge when fuel filter indicator lamp illuminates. Under 2 mm Remove water by the following procedures. <TYPE1> Hand pump ACB02187AB 9.
  • Page 63 PERIODIC INSPECTION AND MAINTENANCE 2-35 OPERATIONS INSIDE THE ENGINE COMPARTMENT WATER LEVEL SENSOR CHECK Fuel tank Fuel high- pump and pressure hose <Steel filter case> gauge assembly Float connector Fuel tank hose (vapour) AC806807 AC502835 4. Disconnect the fuel tank pump and gauge assembly connector and fuel high-pressure hose.
  • Page 64 PERIODIC INSPECTION AND MAINTENANCE 2-36 OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION Fuel tank Fuel high- • Pay attention not to damage and the float of pump and pressure hose gauge the fuel tank gauge unit when installing it to assembly connector the fuel tank.

  • Page 65: Operations Under The Vehicle

    PERIODIC INSPECTION AND MAINTENANCE 2-37 OPERATIONS UNDER THE VEHICLE OPERATIONS UNDER THE VEHICLE B1. CHECK SUSPENSION SYSTEM FOR 2. Check each installation bolt and nut for looseness by spanner or similar tool. DAMAGE AND LOOSENESS M6020300100579 1. Check each portion of suspension for damage visually.

  • Page 66: B2. Check Suspension Arm Ball Joints For Play, And Dust Covers For Damage

    PERIODIC INSPECTION AND MAINTENANCE 2-38 OPERATIONS UNDER THE VEHICLE B2. CHECK SUSPENSION ARM BALL B3. LUBRICATE PROPELLER SHAFT JOINTS FOR PLAY, AND DUST COVERS WITH GREASE FITTING M6020301300082 FOR DAMAGE M6020300200554 BALL JOINTS FOR PLAY AC503034AB Fill the multi-purpose grease fitting of the propeller shaft joints.

  • Page 67: B6. Check Manual Transmission For Oil Leakage (In Case Of Leakage, Check The Oil Level)

    PERIODIC INSPECTION AND MAINTENANCE 2-39 OPERATIONS UNDER THE VEHICLE Check oil level <R5MB1, V5MB1> Filler plug Drain plug AC508162AB AC502641AB 2. Check to be sure that the seal and boot of the ball joint are correctly installed (in the correct Filler plug <R5M21>...

  • Page 68: B7. Check Transfer For Oil Leakage (In Case Of Leakage, Check The Oil Level)

    4. Fill with specified oil till the level comes to the lower portion of oil filler plug hole. Specified transmission oil: MITSUBISHI MOTORS GENUINE MTF API classification GL-3 SAE 75W-85 <R5MB, V5MB and R5M2> or MIT- SUBISHI MOTORS GENUINE Multi Gear oil API classification GL-4 SAE 75W-85 <R5M2 only>...

  • Page 69: B9. Change Gear Oil In Transfer

    Specified transfer oil: 2. Check that gear oil level is not 8 mm below the MITSUBISHI MOTORS GENUINE MTF API bottom of filler plug hole. classification GL-3 SAE 75W-85 or 3. If the gear oil level is lower than the lower limit,...

  • Page 70: B11. Change Gear Oil In Front And Rear Differential

    4. Add the oil until the level comes to the lower portion of the filter plug hole. CAUTION Specified gear oil: Be careful not to drop the inspection tool into the MITSUBISHI MOTORS GENUINE Super differential. Hypoid Gear Oil API classification GL-5 SAE 80 Amount to use: 1.2 L Inspection tool 5.

  • Page 71: Operations Inside The Vehicle

    PERIODIC INSPECTION AND MAINTENANCE 2-43 OPERATIONS INSIDE THE VEHICLE OPERATIONS INSIDE THE VEHICLE C1. CHECK BRAKE PEDAL AND CLUTCH CLEARANCE BETWEEN BRAKE PEDAL PEDAL FOR FREE PLAY AND DASH PANEL M6020400100800 1. Turn up the carpet, etc. under the brake pedal. BRAKE PEDAL FREE PLAY AC502988AB 1.

  • Page 72: C2. Check Parking Brake Lever Stroke And Play

    PERIODIC INSPECTION AND MAINTENANCE 2-44 OPERATIONS INSIDE THE VEHICLE CLUTCH PEDAL CHECK AND ADJUSTMENT Clutch pedal free play 1. Turn back the carpet etc. under the clutch pedal. Clutch pedal height Clutch pedal clevis pin play Distance between the clutch pedal and the floorboard when the clutch AC001133 is disengaged...

  • Page 73: C3. Replace Air Purifier Filter

    PERIODIC INSPECTION AND MAINTENANCE 2-45 OPERATIONS INSIDE THE VEHICLE Backing plate Adjuster assembly Cable rod Adjusting nut AC800895 AC808025AB 2. Loosen the adjuster to move it to the cable rod 4. Remove the backing plate adjusting hole plug. end so that the cable will be free. Then insert a flat-tipped screwdriver to turn the adjuster to the arrow direction (to expand the 3.

  • Page 74: Operations Outside The Vehicle

    PERIODIC INSPECTION AND MAINTENANCE 2-46 OPERATIONS OUTSIDE THE VEHICLE OPERATIONS OUTSIDE THE VEHICLE D1. CHECK WHEEL ALIGNMENT Standard value: M6020500100937 36°50' ± 2°00' Inner wheels FRONT WHEEL ALIGNMENT (Left/right deviation Measure wheel alignment with alignment equipment within 2°00’) on a level surface. The front suspension, steering Outer wheels (reference 32°40' system, wheels, and tires should be serviced to nor-...
  • Page 75 PERIODIC INSPECTION AND MAINTENANCE 2-47 OPERATIONS OUTSIDE THE VEHICLE 2. How to read this table (example). If the camber difference −0°35' and the caster difference is 0°17' 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 opposite direction against the "A"...

  • Page 76: D2. Check Front And Rear Wheel Bearings For Play

    PERIODIC INSPECTION AND MAINTENANCE 2-48 OPERATIONS OUTSIDE THE VEHICLE D2. CHECK FRONT AND REAR WHEEL <Rear wheel> BEARINGS FOR PLAY M6020500200354 <Front wheel> 1. Remove the caliper assembly and brake disc, and retain the caliper assembly with a wire and the like to prevent from falling.

  • Page 77: D4. Check Brake Pads And Discs For Wear

    PERIODIC INSPECTION AND MAINTENANCE 2-49 OPERATIONS OUTSIDE THE VEHICLE D4. CHECK BRAKE PADS AND DISCS FOR WEAR M6020500400767 <Front> ACX00668AF 3. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 AC801465AC mm in from the outer edge of the disc. Standard value: <Rear>...

  • Page 78: D5. Check Brake Shoe Linings And Drums (Drum In Disc) For Wear

    PERIODIC INSPECTION AND MAINTENANCE 2-50 OPERATIONS OUTSIDE THE VEHICLE D5. CHECK BRAKE SHOE LININGS AND BRAKE DRUM (DRUM IN DISC) INSIDE DRUMS (DRUM IN DISC) FOR WEAR DIAMETER CHECK M6020500500678 1. Remove the brake drum (drum in disc). BRAKE LINING THICKNESS CHECK 1.

  • Page 79: Operations After Engine Is Warmed Up

    M6020600100707 1. Drive the vehicle until the A/T fluid temperature reaches between the HOT marks. reaches the normal temperature (70 − 80°C). Automatic transmission fluid: MITSUBISHI NOTE: Use M.U.T.-III. to measure the A/T fluid MOTORS GENUINE ATF SP III temperature.
  • Page 80 PERIODIC INSPECTION AND MAINTENANCE 2-52 OPERATIONS AFTER ENGINE IS WARMED UP 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.

  • Page 81: E3. Change Engine Oil

    PERIODIC INSPECTION AND MAINTENANCE 2-53 OPERATIONS AFTER ENGINE IS WARMED UP 4. Repeat the operation in steps 2 and 3. Fluid level (mm) NOTE: Carry out steps 2 and 3 so that at least 8.0 L has been discharged from the cooler hose. After this, discharge a small quantity of A/T fluid and check for contamination.
  • Page 82 PERIODIC INSPECTION AND MAINTENANCE 2-54 OPERATIONS AFTER ENGINE IS WARMED UP <6G74> AC511675AD AC903479 7. Refill with specified quantity of engine oil. <6B31> <FOR GENERAL EXPORT> Specified Engine Oil • ACEA classification: "For service A1/B1, A3/B3, A3/B4 or A5/B5" • API classification: "For service CD" or higher Total quantity (includes volume inside oil filter and oil cooler): 9.3 L (4M41), 6.4 L (4D56)

  • Page 83: E4. Replace Engine Oil Filter

    PERIODIC INSPECTION AND MAINTENANCE 2-55 OPERATIONS AFTER ENGINE IS WARMED UP Specified Engine Oil • ACEA classification : "For service A1/B1, A3/B3, A3/B4 or A5/B5" • API classification: "For service SG" or higher Total quantity (Includes volume inside oil fil- ter and oil cooler): <6G74>...
  • Page 84 PERIODIC INSPECTION AND MAINTENANCE 2-56 OPERATIONS AFTER ENGINE IS WARMED UP WARNING Use care as oil could be hot. 2. Remove the engine oil filler cap. Commercially- 3. Remove the engine oil pan drain plug to drain available tool engine oil. MB991828, ACX00395AD MB991396...
  • Page 85 PERIODIC INSPECTION AND MAINTENANCE 2-57 OPERATIONS AFTER ENGINE IS WARMED UP 6. Clean the engine oil filter bracket side mounting Number Special tool Tightening surface. torque MD332687 or MB991828 or Approximately (Engine oil) 3/4 turn (16 ± 4 MD365876 equivalent N⋅m) O-ring MD360935...

  • Page 86: E5. Check Engine Idling Speed

    PERIODIC INSPECTION AND MAINTENANCE 2-58 OPERATIONS AFTER ENGINE IS WARMED UP E5. CHECK ENGINE IDLING SPEED M6020601300641 <4D56, 4M41> 1. Before inspection, set the vehicle to the pre-inspection condition. Diagnosis connector MB991910 Diagnosis MB991824 connector MB991910 MB991824 MB991827 AC807654 2. Turn the ignition switch to the "LOOK" (OFF) position, and connect the M.U.T.-III to the diagnosis connector.
  • Page 87 PERIODIC INSPECTION AND MAINTENANCE 2-59 OPERATIONS AFTER ENGINE IS WARMED UP 6. Check the idle speed. 3. Set the timing light to the timing pick-up loop (white) of No. 1 ignition coil. Standard value: 700 ± 100 r/min 4. Start the engine and let it run at idle. NOTE: The idle speed is controlled automatically 5.

  • Page 88: E6. Check Co Concentration (Petrol-Powered Vehicles)

    PERIODIC INSPECTION AND MAINTENANCE 2-60 OPERATIONS AFTER ENGINE IS WARMED UP 2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the M.U.T.-III to the diagnosis connector. No.1 Ignition coil Diagnosis connector MB991910 MB991824 AK600245AB 3. Set the timing light to the terminal No. 3 power supply line (white) of the ignition coil No.
  • Page 89 PERIODIC INSPECTION AND MAINTENANCE 2-61 OPERATIONS AFTER ENGINE IS WARMED UP 8. Check the CO contents and the HC contents at 4. Start the engine and let it run at idle. idle. 5. Check that ignition timing is at the standard value. Standard value Standard value: approximately 10°...

  • Page 90: E7. Check Exhaust Gas Recirculation (Egr) System

    PERIODIC INSPECTION AND MAINTENANCE 2-62 OPERATIONS AFTER ENGINE IS WARMED UP E7. CHECK EXHAUST GAS 2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the M.U.T.-III to the RECIRCULATION (EGR) SYSTEM diagnosis connector. M6020600800999 <4D56, 4M41> CHECK ON OPERATING SOUND No.1 Ignition coil Carry out this check after checking that the diagnosis...
  • Page 91 PERIODIC INSPECTION AND MAINTENANCE 2-63 OPERATIONS AFTER ENGINE IS WARMED UP OPERATION CHECK 5. Confirm the voltage is changed between the terminal No. 1 and No. 2 together with the EGR valve opening movement. 6. By the voltage changed, the DC is recognized as being normal 7.
  • Page 92 PERIODIC INSPECTION AND MAINTENANCE 2-64 OPERATIONS AFTER ENGINE IS WARMED UP EGR control solenoid valve check <4G64> EGR SYSTEM CHECK NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at <4G6> original position. EGR valve Three-way 1.
  • Page 93 PERIODIC INSPECTION AND MAINTENANCE 2-65 OPERATIONS AFTER ENGINE IS WARMED UP EGR VALVE CHECK 1. Remove the EGR valve and inspect for sticking, 1.0 SECOND carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. VACUUM 2.

  • Page 94: Others

    PERIODIC INSPECTION AND MAINTENANCE 2-66 OTHERS 2. Disconnect the harness connector. Battery B nipple Normal 3. Connect a hand vacuum pump to nipple (A) of the voltage condition condition solenoid valve (refer to the illustration at left). Not applied Open Vacuum 4.

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