DOWNLOAD PDF Mitsubishi 2006 Pre-Delivery Inspection & Periodic Maintenance Manual

Pre-Delivery Inspection and Periodic Maintenance

GROUP INDEX General . . . . . . . . . . . . . . . . . . . . . . . . . . .

0

Pre-delivery Inspection . . . . . . . . . . . . . .

1

Periodic Inspection and Maintenance . .

2

FOREWORD This Inspection and Maintenance Manual explains the main points necessary for inspection and maintenance of Mitsubishi vehicles, combining Pre-Delivery Inspection and Periodic Inspection in one volume. It is intended to contain enough information to allow the user to conduct work quickly and with precision.

For checking procedures, specifications, tightening torques, etc., there may be instances in which reference to the Workshop Manual is necessary. If so, refer to the Workshop Manual applicable to that model.

All information, illustrations and product descriptions contained in this manual are current as of time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

©Mitsubishi Motors Europe B.V.

Sept. 2005

HOW TO USE THIS MANUAL CONTENTS

TEXT

The preceding page contains the GROUP INDEX which lists the group title and group number.

Information is provided regarding the pre-delivery inspection and periodic inspection and maintenance applicable to all models.

Make the inspection after selecting the items corresponding to the model to be inspected.

GROUP CONTENTS The first page in each main group has an index to the subjects included in that group and it lists the contents of that group.

PAGE NUMBERS All page numbers consist of two sets of digits separated by a dash. The digits preceding the dash identify the number of the main group. The digits following the dash represent the consecutive page number within the main group. The page numbers can be found on the top left or right of each page.

MAINTENANCE INTERVAL All inspection and maintenance must be conducted according to the table of "PERIODIC INSPECTION AND MAINTENANCE SCHEDULE" shown in GROUP 2.

Pa

Group title

Section title

Indicates the inspection to be made. The number preceding the indication of the inspection to be made is the same number as that used preceding in the periodic inspection and maintenance schedule.

6XEMHFW PRGHOV 7KLV PDQXDO LV IRU WKH IROORZLQJ PRGHOV Vehicle model

LANCER

Model code

Engine model

Total displacement ml

Transmission model

Transmission type

CS1A

4G13

1298

F5M41

5M/T

CS3A

4G18

1584

F5M41

5M/T

CS3A

4G18

1584

F4A4A

4A/T

CS9A

4G63

1997

F5M42

5M/T

CS3W

4G18

1584

F5M41

5M/T

CS3W

4G18

1584

F4A4A

4A/T

CS9W

4G63

1997

F5M42

5M/T

Wheel-drive system

FWD

Pre-Delivery Inspection and Periodic Maintenance

FOREWORD This Inspection and Maintenance Manual explains the main points necessary for inspection and maintenance of Mitsubishi vehicles, combining Pre-Delivery Inspection and Periodic Inspection in one volume. It is intended to contain enough information to allow the user to conduct work quickly and with precision.

For checking procedures, specifications, tightening torques, etc., there may be instances in which reference to the Workshop Manual is necessary. If so, refer to the Workshop Manual applicable to that model.

All information, illustrations and product descriptions contained in this manual are current as of time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

“GDI” is the registered mark of Mitsubishi Motors Corporation.

E Mitsubishi Motors Europe B.V.

August 2003

General . . . . . . . . . . . . . . . . . . . . . . . .

0

Pre-delivery Inspection . . . . . . . . . .

1

Periodic Inspection and Maintenance . . . . . . . . . . . . . . . . . . .

2

HOW TO USE THIS MANUAL CONTENTS The preceding page contains the GROUP INDEX which lists the group title and group number.

GROUP CONTENTS The first page in each main group has an index to the subjects included in that group and it lists the contents of that group.

PAGE NUMBERS All page numbers consist of two sets of digits separated by a dash. The digits preceding the dash identify the number of the main group. The digits following the dash represent the consecutive page number within the main group. The page numbers can be found on the top left or right of each page.

TEXT Information is provided regarding the pre-delivery inspection and periodic inspection and maintenance applicable to all models.

Make the inspection after selecting the items corresponding to the model to be inspected.

MAINTENANCE INTERVAL All inspection and maintenance must be conducted according to the table of “PERIODIC INSPECTION AND MAINTENANCE SCHEDULE” shown in GROUP 2.

Group title

ABBREVIATIONS A.B.S.: Anti-skid Brake System A/T: Automatic Transmission CO: Carbon Monoxide DOHC: Double Overhead Camshaft EGR: Exhaust Gas Recirculation FBC: Feed Back Carburettor (Electronic Control Carburettor) 4WD: Four Wheel Drive vehicles FWD: Front Wheel Drive vehicles GDI: Gasoline Direct Injection IRS: Independent Rear Suspension ISC: Idling Speed Control LSD: Limited slip differential LSPV: Load Sensing Proportioning Valve MAS: Mixture Adjusting Screw MIVEC: Mitsubishi Innovative Valve timing & lift Electronic Control system M.P.I.: Multi Point Injection MVV: Mitsubishi Vertical Vortex M/T: Manual Transmission PTO: Power Take Off RWD: Rear Wheel Drive vehicles SAS: Speed Adjusting Screw SRS: Supplemental Restraint System T/F: Transfer case VRV: Vacuum Regulator Valve VCU: Viscous Coupling Unit Section title

Page number

Indicates the inspection to be made. The number preceding the indication of the inspection to be made is the same number as that used preceding in the periodic inspection and maintenance schedule.

Subject models This manual is for the following models.

Vehicle model

Model code

Engine model

Total displacement ml

Transmission model

Transmission type

CS1A

4G13

1298

F5M41

5M/T

CS3A

4G18

1584

F5M41

5M/T

CS3A

4G18

1584

F4A41

4A/T

CS9A

4G63

1997

F5M42

5M/T

CS3W

4G18

1584

F5M41

5M/T

CS3W

4G18

1584

F4A41

4A/T

CS9W

4G63

1997

F5M42

5M/T

Wheel-drive system

FWD LANCER

FWD

NOTES

0-1

GENERAL CONTENTS PRECAUTIONS BEFORE SERVICE . . . . . . . . . . 2

Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Protecting the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 2

Servicing the Electrical System . . . . . . . . . . . . . . . . . 4

Doing Service Work in Groups of Two or More Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Application of Anti-Corrosion Agents and Undercoats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . 2

Pre-Inspections Condition . . . . . . . . . . . . . . . . . . . . . 4

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Parts to be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MUT-II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

In Order to Prevent Vehicles from Fire . . . . . . . . . . . 5

Tubes and Other Rubber Parts . . . . . . . . . . . . . . . . . 3

Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

0

0-2

GENERAL -- Precautions before Service

PRECAUTIONS BEFORE SERVICE PROTECTING THE VEHICLE If there is a likelihood of damaging interior or exterior parts during service operations, protect them with suitable covers (such as seat covers, fender covers, etc.).

DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS If the service work is to be done by two or more mechanics working together, all the mechanics involved should take safety into consideration while they work.

REMOVAL AND DISASSEMBLY When checking a malfunction, find the cause of the problem.

If it is determined that removal and/or disassembly is necessary, perform the work by following the procedures contained in this manual.

If punch marks or mating marks are made to avoid error in assembly and facilitate the assembly work, be sure to make them in locations which will have no detrimental effect on performance and/or appearance.

If an area having many parts, similar parts, and/or parts which are symmetrical right and left is disassembled, be sure to arrange the parts so that they do not become mixed during the assembly process.

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.

SPECIAL TOOLS If other tools are substituted for the special tools to do service of repair work, there is the danger that vehicle parts might be damaged, or the technician might be injured; therefore, be sure to use the special tool whenever doing any work for which the use of one is specified.

GENERAL -- Precautions before Service

0-3

PARTS TO BE REPLACED If any of the following parts are removed, they must be replaced with new parts.

1. Oil seals 2. Gaskets (except rocker cover gasket) 3. Packings 4. O-rings 5. Lock washers 6. Split pins 7. Self-locking nuts

PARTS When replacing parts, use MITSUBISHI genuine parts.

TUBES AND OTHER RUBBER PARTS Be careful to avoid spilling any petrol, oil, etc., because if it adheres to any tubes or other rubber parts, they might be adversely affected.

LUBRICANTS In accordance with the instructions in this Manual, apply the specified lubricants in the specified locations during assembly and installation.

BRAKE FLUID Be careful to avoid spilling any brake fluid, because if it adheres to the vehicle body, the paint coat might be discoloured.

0-4

GENERAL -- Precautions before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (--) cable from the battery in order to avoid damage caused by short-circuiting.

ACX00880AC

Caution Before connecting or disconnecting the negative (--) cable, be sure to turn off the ignition switch and the lighting switch.

(If this is not done, there is the possibility of semiconductor parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor.

Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITION “Pre-inspection condition” refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words “Set the vehicle to the pre-inspection condition”. in this manual, it means to set the vehicle to the following condition.

D Engine coolant temperature: 80 to 90_C D Lamps, electric cooling fan and all accessories: OFF D M/T: Neutral D A/T: P range

VEHICLE WASHING Approx.

40 cm

ACX00881AD

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.

D Spray nozzle distance: Approx. 40 cm or more D Spray pressure: 3,900 kPa or less D Spray temperature: 82_C or less D Time of concentrated spray to one point: within 30 sec.

GENERAL -- Precautions before Service

0-5

MUT-II

MUT-II sub-assembly

Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II OPERATING INSTRUCTIONS” for instructions on handling the MUT-II.

ROM pack ACX00882AD

MUT-II

Connect the MUT-II to the diagnosis connector as shown in the illustration.

Caution Turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting the MUT-II.

IN ORDER TO PREVENT VEHICLES FROM FIRE “Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMC’s information/Instructions”.

ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Recommended Precautions The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them.

Other precautions: D Avoid prolonged and repeated contact with oils, particularly used engine oils.

D Wear protective clothing, including impervious gloves where practicable.

D Avoid contaminating clothes, particularly underpants, with oil.

D Do not put oily rags in pockets, the use of overalls without pockets will avoid this.

D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing.

D Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

D Obtain First Aid treatment immediately for open cuts and wounds.

D Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised.

D Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.

D Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work.

D If skin disorders develop, obtain medical advice without delay.

NOTES

1-1

PRE-DELIVERY INSPECTION CONTENTS NOTES CONCERNING ENTRIES . . . . . . . . . . . . . 2 TABLE OF PRE-DELIVERY INSPECTION . . . . . 2 PAINTWORK TERMS . . . . . . . . . . . . . . . . . . . . . . . 4 FIRST STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connection of Dark Current Connector . . . . . . . . . . 5

BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wipers and Washers . . . . . . . . . . . . . . . . . . . . . . . . . 12 Operation of Service Brakes and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operation of Seat Belts, Shoulder Belts and Retractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1

Wrap Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation of Door Locking Systems and Door Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operation of Door Mirrors, Windows and Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine Performance and Exhaust Gas . . . . . . . . . 14 Transmission in All Ranges . . . . . . . . . . . . . . . . . . . 14 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Vibration and Rattles . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 15 Free Wheeling Hub . . . . . . . . . . . . . . . . . . . . . . . . . . 15

UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

AFTER ROAD TEST . . . . . . . . . . . . . . . . . . . . . . 16

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brake Master Cylinder Fluid Level . . . . . . . . . . . . . . 8 Clutch Master Cylinder Fluid Level . . . . . . . . . . . . . . 8 Washer Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Battery Condition and Connections . . . . . . . . . . . . . . 8 Power Steering Fluid Level . . . . . . . . . . . . . . . . . . . . 9 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tyre and Spare Tyre Pressures . . . . . . . . . . . . . . . . . 9 Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Steering Linkage and Split Pins . . . . . . . . . . . . . . . . 10 Under Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 16 Hoses, Fluid Lines and Connections Located under Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Manual Transmission and Transfer (4WD) Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Automatic Transmission Fluid Level . . . . . . . . . . . . 17 Engine, Transmission, Steering Gear Box and Differential for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 17 Front and Rear Differential Oil Levels . . . . . . . . . . . 17 Hoses, Fluid Lines and Connections Located under Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 17

BEFORE ROAD TEST . . . . . . . . . . . . . . . . . . . . . . 11

FINAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Seat Adjusters and Seat Back Latches . . . . . . . . . 11 Inhibitor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Idle Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Instrument Panel Controls . . . . . . . . . . . . . . . . . . . . 11 Meters, Gauges, Warning Lamps and Indication Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Air Conditioning, Heater and Defroster System . . 11

Headlamp Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Exterior and Interior . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Owner Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

UNDER VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1-2

Notes Concerning Entries/

PRE-DELIVERY INSPECTION -- Table of Pre-delivery Inspection

NOTES CONCERNING ENTRIES 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 (below).

Inspection methods are described following the TABLE OF PRE--DELIVERY INSPECTION. NOTE (1) The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in kilometres (miles), date of inspection, name of person conducting the inspection, and body colour must be completed without fail.

(2) The spaces for place of inspection, and name of owner should be completed as required.

TABLE OF PRE-DELIVERY INSPECTION Model Chassis number Engine number Distance Travelled

km

Owner Date of inspection Place of inspection Inspector Body colour Symbols to be used √

Good

Needs C cleaning

A

Needs adjustment

T

Needs retightening

L

Needs replenishment of lubricant, water, etc.

Needs X replacement or repair

INSPECTION PROCEDURE First Step 1.

Connection of the dark current connector Body 2.

Wrap film 3.

Exterior 4.

Operation of door locking systems and door hinges 5.

Operation of door mirrors, windows and sunroof Under Hood 6.

Engine oil level 7.

Brake master cylinder fluid level 8.

Clutch master cylinder fluid level 9.

Washer fluid level 10.

Battery condition and connections 11.

Power steering fluid level 12.

Electrical wiring

PRE-DELIVERY INSPECTION -- Table of Pre-delivery Inspection

Under Vehicle 13.

Tyre and spare tyre pressures 14.

Suspension system 15.

Steering linkage and split pins 16.

Under body Before Road Test 17.

Seat adjusters and seat back latches 18.

Inhibitor switch 19.

Idle control knob 20.

Instrument panel controls 21.

Meters, gauges, warning lamps and indication lamps 22.

Air conditioning, heater and defroster systems 23.

Wipers and washers 24.

Operation of service brakes and parking brakes 25.

Clutch operation 26.

Operation of seat belts, shoulder belts and retractors Road Test 27.

Engine performance and exhaust gas 28.

Transmission in all ranges 29.

Brakes 30.

Steering control 31.

Vibration and rattles 32.

Electrical equipment 33.

Free wheeling hub After Road Test 34.

Idle speed 35.

Ignition timing 36.

Radiator coolant level 37.

Hoses, fluid lines and connections located under hood 38.

Manual transmission and transfer (4WD) oil level 39.

Automatic transmission fluid level 40.

Engine, transmission, steering gear box and differential for leaks 41.

Front and rear differential oil levels 42.

Hoses, fluid lines and connections located under vehicle Final Steps 43.

Headlamp aiming 44.

Equipment 45.

Exterior and interior 46.

Owner instructions

1-3

1-4

ENGINE AND EMISSION CONTROL -- Paintwork Terms

PAINTWORK TERMS Term Blister

Change in tone Contact mark Crack Di t in Dirt i paintwork i t k Filed or ground traces O Orange peell P li Peeling Pin holes Runs Scratches Shrink Smears Spray mist Uneven lustre Uneven metallic dispersion Visibly incom incomplete topcoating

Definition A raised bubble in the paint (from the base or the undercoat) caused by abnormal moisture. moisture The bubble may contain either water or air.

The colour tone of the painted surface is not uniform uniform.

A mark on the painted surface as a result of contact by hands or clothing at the time of paint application.

A crack in the painted surface surface.

R Rough h surface f resulting lti ffrom fforeign i material t i l in i the th paint or from dust deposited on wet paint during painting or storage. storage Deep scratches in sheet metal surface, resulting from improper use of buffer or sander sander, are not completely covered, and are visible through paint coating.

Th painted The i t d surface f h has th the appearance off an orange peel.

Th paint The i fl flakes k off ff ((partly l or over a wide id area). ) Tiny holes in the painted surface.

A visible trickle of dried paint on the surface.

Scratches on the painted surface.

The painted surface “shrinks”, shrinks , causing wrinkles.

Spots of soot or other material deposited on the painted surface.

The painted surface includes fine particles of other paint paint.

The lustre of the painted surface is not uniform.

The metallic dispersion of the painted surface is not uniform.

A part of the undercoating visible visible.

Remarks

Including wrong colour colour, discoloration and decoloration.

Cracks may be either shallow or deep.

The peeling Th li may b be minor, i medium, di or major.

Either undercoat or top top-coat. coat.

Including stains and water spots.

ENGINE AND EMISSION CONTROL -- First Step/Body

1-5

FIRST STEP

Relay box

1. CONNECTION OF DARK CURRENT CONNECTOR Connecting Procedure Press down the storage connector.

Storage connector

BODY 2. WRAP FILM To protect the exterior finish of vehicles prior to 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 (see illustration).

Removal procedure Wrap film removal

Peel off slowly from corners keeping parallel to the body.

When the body temperature is high, lower it to 50_C or less by sprinkling water so that adhesive may not remain on the body.

Water washing

Cleaning of border

Wipe-off by kerosene or white gasoline, etc.

If it is considerably visible, use polishing compound.

Disposal of removed film: Burning is appropriate

1-6

ENGINE AND EMISSION CONTROL -- Body

Wrapping work No. 1 2 3 4

Process

Operation Content

Continuous peeling of film

The film is peeled off.

Water rinse

Sand and dust are removed from the vehicle body and it is dried thoroughly.

Parts where the film is to be reapplied are checked.

There should be no leftover adhesive, swelling or discoloration of the paint film, or other defects.

Treatment of parts where film is to be reapplied.

Treat the defects on the parts where film is to be reapplied. If a solvent is used to remove leftover adhesive, wipe off the solvent thoroughly.

Reapplication

1.

2.

5 3.

Basically, the parts where the film is to be applied should be the same as the film that is to be applied.

Apply the film from the lower portion of the body, working upward progressively. Apply pressure using a plastic squeegee or similar tool.

As necessary, cut the film at the various parts such as windshield washer nozzles, hood and trunk lid.

Cautions 1. Apply the film with the body at a temperature of 10 ~ 40_C. (Workability is good in this temperature range.)

2. If the outside surface of the film (the side with no adhesive) is brought into direct contact with the paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not get folded under or otherwise make contact with the paint film.

3. Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort should be made to prevent air bubbles from being trapped under the film by applying pressure from the center of the film outward toward the edges during application.

4. To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of the film securely.

3. EXTERIOR (1) Visually inspect the entire exterior.

1) Paint condition 2) Corrosion, scratches 3) Bent edges, dented panels (2) Coated surfaces maintenance Touch up minor paint chips and flaws.

NOTE For terms of paintwork, refer to page 1-4.

ENGINE AND EMISSION CONTROL -- Body

1-7

4. OPERATION OF DOOR LOCKING SYSTEMS AND DOOR HINGES (1) Open each door to check the release mechanism and ease of operation.

(2) Close the door to check the latch and striker.

(3) Open the door, operate the lock lever and close the door to check the lock.

(4) Partially close the door to check the open-door detent.

(5) Unlock each door with the key to check lock operation.

(6) Verify that all doors can be locked by the lock buttons.

Front

NOTE Adjust and lubricate the door latches, strikers and locks as required.

(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.

Caution Set the lock to the “FREE” position on child protection of both rear doors. (For four door models) Child-protection knob

5. OPERATION OF DOOR MIRRORS, WINDOWS AND SUNROOF (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 respective switches are operated. Check that when the lock switches are depressed, the respective door windows can no more be opened or closed.

(4) Slide window Close the slide window to the fully closed position to check operation.

(5) Sunroof Close the sunroof to the fully closed position to check operation.

1-8

ENGINE AND EMISSION CONTROL -- Under Hood

UNDER HOOD 6. ENGINE OIL LEVEL MAX

MIN

Check that the oil level is between “MAX” and “MIN”. If it is at or below MIN, add the necessary amount of the specified engine oil referring to GROUP 2, Periodic Inspection and Maintenance.

7. BRAKE MASTER CYLINDER FLUID LEVEL Check the fluid level.

If it is below the “MIN” or “A” marks, replenish fresh brake fluid up to the “MAX” mark.

Specified Brake Fluid: DOT3 or DOT4

8. CLUTCH MASTER CYLINDER FLUID LEVEL Check the fluid level.

If it is below the “MIN” mark, replenish fresh brake fluid up to the “MAX” mark.

Specified Brake Fluid: DOT3 or DOT4

9. WASHER FLUID LEVEL Check the fluid level; if it is low, replenish the washer fluid at the up to MAX mark.

(1) Windshield washer reservoir (2) Rear window washer reservoir

10. BATTERY CONDITION AND CONNECTIONS Inspect the battery connections. Verify that they are tightened.

NOTE Do not wipe the lubricant from the battery posts and cable clamps.

ENGINE AND EMISSION CONTROL -- Under Hood/Under Vehicle

1-9

11. POWER STEERING FLUID LEVEL (1) Check that the fluid level is between “MAX” and “MIN”.

(2) If the fluid is added, start the engine and turn the steering wheel from stop to stop several times to expel air from the system.

Specified gear oil: Automatic transmission fluid DEXRON II

12. ELECTRICAL WIRING (1) Each electrical wiring harness and connector 1) Check each harness to be correctly routed and securely clipped.

2) Confirm that all connections are tight.

(2) Ignition cable Be sure that all ignition cables are firmly attached to the spark plugs, distributor cap (or crank angle sensor) and ignition coil.

UNDER VEHICLE 13. TYRE AND SPARE TYRE PRESSURES (1) Tyre specification Check the correct tyre specification.

(2) Tyre pressures Adjust each tyre pressure.

NOTE Recommended pressure is shown on the tyre pressure label.

(3) Valve stem extensions Verify that the valve stem extensions are installed where necessary.

(4) Install the wheel covers, wheel rings and hub caps.

1-10

ENGINE AND EMISSION CONTROL -- Under Vehicle 14. SUSPENSION SYSTEM Check to be sure that each installation bolt and nut is tightened. If split pins are used, make sure that they are properly installed.

(1) Lower arm, Upper arm (2) Stabilizer bar (3) Strut assembly

REMOVE FRONT SPRING RESTRAINTS Spring restraints

With the vehicle correctly positioned on the sub-frame contact points, and the suspension fully extended, remove the rubber restraints from the front springs.

Caution It is very important that these restraints must be removed during predelivery-inspection. Failure to do so could cause ride and handling complaints.

15. STEERING LINKAGE AND SPLIT PINS (1) Steering linkage retaining nuts and split pins Check visually and by feel that the steering linkage retaining nuts are correctly tightened and the split pins are correctly installed.

(2) Tie rods and relay rod Check that the tie rods and relay rod of the steering linkage are not bent and that the tie rod end lock nuts are securely tightened.

(3) Steering components 1) Check that each of the steering components is tightened.

2) Check the tie rod end, nuts and split pins for proper installation.

3) Check the condition of bellows-type dust seals.

(4) Split pins Check the front axle nuts and rear wheel spindle nuts for split pins.

16. UNDER BODY Check under body and under body coating for damage.

ENGINE AND EMISSION CONTROL -- Before Road Test

1-11

BEFORE ROAD TEST 17. SEAT ADJUSTERS AND SEAT BACK LATCHES Check the operation of the various parts of the seats.

(1) Mechanical adjusters of the seats (2) Operation of the latch for tilting the seatbacks forward and backward.

18. INHIBITOR SWITCH 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 Verify that the diesel engine revolution increases when the idle control knob is pulled out.

20. INSTRUMENT PANEL CONTROLS Check the operation of the following (1) Horn (2) Head lamps (3) Exterior and interior lamps (4) Instrument panel lamps (5) Instrument brightness control

21. METERS, GAUGES, WARNING LAMPS AND INDICATION LAMPS (1) Check the meters and gauges are functioning properly.

(2) Check each indicator lamp and warning lamp functions properly.

22. AIR CONDITIONING, HEATER AND DEFROSTER SYSTEM Check the systems for proper operation.

(1) Air conditioning 1) Operate the air conditioning system.

2) Operate the air conditioning light.

3) Operate the control lever in all ranges.

4) Operate the blower motor switch in all ranges.

1-12

ENGINE AND EMISSION CONTROL -- Before Road Test (2) Heater and defroster 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)

23. WIPERS AND WASHERS (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 wiping is shifted when timer knob is turned to any position.

5) Verify that the front wipers function by operating the washer switch.

(2) Rear wiper and washer 1) Check the operation of the rear wiper.

2) Check the aim of the rear washer stream.

3) Check the wiper blade-stop positions.

24. OPERATION OF SERVICE BRAKES AND PARKING BRAKES

Depress the brake pedal with approximately 500 N force

(1) Service brakes 1) Turn up the carpet, etc under the brake pedal.

Check the clearance between the brake pedal and the toeboard when the brake pedal is depressed. If the clearance does not meet the specifications, check for air in the system, brake fluid leakage, and/or a malfunction of the pedal itself.

Clearance between the brake pedal and the toeboard: (From the surface of melting seat to the face of pedal pad) Standard value: 90 mm or more

2) Verify correct brake pedal free play.

NOTE For inspection and adjustment of the brake pedal free play, refer to GROUP 2 -- Periodic Inspection and Maintenance.

(2) Parking brake Check the parking brake drag and lever travel.

NOTE For inspection of the parking brake lever, refer to GROUP 2 -- Periodic Inspection and Maintenance.

ENGINE AND EMISSION CONTROL -- Before Road Test

1-13

25. CLUTCH OPERATION (1) Check the clutch operation in all driving ranges.

(2) Turn up the carpet, etc under the clutch pedal.

Check the pedal-to-toeboard clearance when the clutch is just disengaged.

Clearance to toeboard when clutch disengaged: (From the surface of melting seat to the face of pedal pad) Standard value: 105 mm or more (3) Verify correct clutch pedal free play.

NOTE For inspection and adjustment of the free play of the clutch pedal, refer to GROUP 2 -- Periodic Inspection and Maintenance.

26. OPERATION OF SEAT BELTS, SHOULDER BELTS AND RETRACTORS (1) Verify that the seat belt warning lamp operates properly.

(2) Check all seat belts and harnesses to assure that they connect and hold properly.

(3) Lean forward to check that the shoulder harnesses allow movement.

(4) Check the condition of the belts and anchors.

(5) Check for proper seat belt retraction.

1-14

ENGINE AND EMISSION CONTROL -- Road Test

ROAD TEST 27. ENGINE PERFORMANCE AND EXHAUST GAS (1) Engine performance Check the engine for proper performance and accelerator pedal for smooth operation.

(2) Exhaust system 1) Check the exhaust system components for gas leaks.

2) Verify that no black smoking is emitted from the end of the exhaust pipe (diesel-powered vehicles).

28. TRANSMISSION IN ALL RANGES (1) Manual transmission Check the transmission in all forward ranges and in reverse.

Button

(2) Automatic transmission 1) Make sure shift indicator lines up properly in all ranges.

2) Depress the accelerator completely to check that the manual kickdown is operating correctly.

3) Stop the vehicle on a steep incline.

Put the automatic transmission in “P” position and slowly release the service brakes to see if “P” position lock holds. If it does not hold, the transmission requires further service.

29. BRAKES (1) Service Brake Put the vehicle in gear and apply the brakes while the vehicle is in motion. Be sure brake operation is smooth and positive.

(2) Parking Brake 1) Stop the vehicle on a steep incline.

With the service brakes firmly applied, place the transmission in “N” position, and set the parking brakes.

2) Slowly release the service brakes to see if the parking brakes will hold.

30. STEERING CONTROL (1) Check for excessive play or looseness.

(2) Check the steering wheel centre.

31. VIBRATION AND RATTLES (1) Locate squeaks, rattles and unusual vibrations.

(2) Verify that no noise occurs from the engine, transmission, axle and body.

ENGINE AND EMISSION CONTROL -- Road Test

1-15

32. ELECTRICAL EQUIPMENT (1) Radio Tune the radio to a local broadcasting station and check the following: 1) Operate the volume, tone, balance and fader controls, etc.

2) Pull out the pushbuttons, dial another station and set each pushbuttons.

3) Operate the AM/FM switch.

(2) Tape player Insert a cassette tape in the tape player and check as follows: 1) Check the operation of the tape feeder and rewind.

2) Check the ejection.

3) Check the operation of volume, tone, balance and fader controls, etc.

33. FREE WHEELING HUB (1) Manual free wheeling hub Verify that the revolution effort of wheel is heavier at the “LOCK” position than at the “FREE” position with the front wheels raised.

(2) Auto free wheeling hub 1) Shift the transfer lever from “2H” to “4H”, and start the vehicle. Check that the vehicle is changed to the four-wheel drive.

2) Shift the transfer lever from “4H” to “2H”, and drive the vehicle in the reverse direction (or in the forward direction if the vehicle has been driven in reverse direction) for 1 or 2 meters. Check that the vehicle is changed to the rear-wheel drive.

1-16

ENGINE AND EMISSION CONTROL -- After Road Test SAS

AFTER ROAD TEST 34. IDLE SPEED Check the engine idle speed.

Increase engine speed

MAS

NOTE For specific idle speed adjustment procedure, refer to GROUP 2 -- Periodic Inspection and Maintenance.

Lean mixture

35. IGNITION TIMING Check the ignition timing.

Except MPI vehicles with crankshaft-mounted crankshaft angle sensor.

NOTE For the inspection and adjustment of the ignition timing, refer to GROUP 2 -- Periodic Inspection and Maintenance.

36. RADIATOR COOLANT LEVEL (1) Check that the coolant level in the reserve tank is at or above “LOW” mark at normal engine operating temperature. And check cooling system for leaks.

(2) Check that the coolant concentration is 30% to 60%.

Caution Do not remove the radiator cap while the cooling system is under pressure.

When removing the radiator cap, be careful of steam and boiling water.

Add coolant only to the reserve tank if it is required.

37. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD (1) Check all brake, fuel, power steering and air conditioner lines and connections; verify proper routing, check connections for leaks, tighten loose connector as required.

(2) Inspect routing and connections of all vacuum, and radiator and heater houses.

Caution Remember that the air conditioner system is under pressure.

NOTE Keep in mind that an oily residue around an air conditioner connector does not necessarily indicate a leak.

Oil is used to lubricate fittings during assembly.

Be sure lines are not twisted or kinked.

ENGINE AND EMISSION CONTROL -- After Road Test

1-17

38. MANUAL TRANSMISSION AND TRANSFER (4WD) OIL LEVEL (1) Remove the filler plug.

(2) Check the oil level. If the oil level is at or slightly below the filler hole, it is in satisfactory condition.

(3) If the level is low, replenish the transmission and transfer case with fresh oil by using a lubricator.

Transmission oil

NOTE For the specified oil, refer to GROUP 2 -- Periodic Inspection and Maintenance.

39. AUTOMATIC TRANSMISSION FLUID LEVEL (1) Remove the dipstick and check the fluid level.

(2) Fluid level is okay if it is in the specified range as illustration at normal engine operating temperature.

(3) If the level is below the lower notch, replenish fluid until the level reaches the upper notch.

Automatic transmission fluid: DIA QUEEN ATF SP III Caution Do not overfill.

40. ENGINE, TRANSMISSION, STEERING GEAR BOX AND DIFFERENTIAL FOR LEAKS Check the engine, transmission, steering gear box and differential for oil leaks.

41. FRONT AND REAR DIFFERENTIAL OIL LEVELS (1) Remove the filler plug.

(2) Check the oil level. If the oil level is at or slightly below the filler hole, it is in satisfactory condition.

TYPE 1

Upper limit

TYPE 2

8 mm

Gear oil

TYPE 1 Remove the filler plug, and check the gear oil level.

Check that gear oil level is not 8 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.

NOTE For the specified oil, refer to GROUP 2 -- Periodic Inspection and Maintenance.

Lower limit

42. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE (1) Check all hoses, fluid lines and connections for leaks.

(2) Check all hoses and fluid lines for proper routing away from sharp edges and moving components.

1-18

ENGINE AND EMISSION CONTROL -- Final Steps

FINAL STEPS Screen

Headlamp

43. HEADLAMP AIMING Check condition for headlamp aiming.

NOTE For headlamp aiming procedures, refer to the Workshop Manual for that model.

Level surface

44. EQUIPMENT Check the installation of the various equipment.

(1) Floor mats (2) Spare tyre (3) Jack, jack handle and tool set

45.EXTERIOR AND INTERIOR Finally check and clean the exterior and interior.

(1) Wash the vehicle to remove all traces of road grime and other dirt on the vehicle as a result of new vehicle preparations.

(2) Clean exterior and interior glass surface.

(3) Remove all protective covers.

(4) Remove undercoat overspray, excess window sealer, and excess weatherstrip adhesive.

(5) Verify that the secondary key can not unlock the glove box and tailgate/boot lid (if so equipped).

(6) Remove shipping and inspection stickers.

46.OWNER INSTRUCTIONS (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.

2-1

PERIODIC INSPECTION AND MAINTENANCE CONTENTS PERIODIC INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 3 OPERATIONS INSIDE THE ENGINE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

A15. CHANGE BRAKE FLUID . . . . . . . . . . . . . . . . 15 A16. CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 A18. REPLACE FUEL FILTER . . . . . . . . . . . . . . . . 16

A1.

CHECK V-BELT FOR CRACKS, FRAYING, WEAR, AND ADJUST ITS TENSION . . . . . . 7

A3.

HECK IGNITION CABLES FOR DAMAGE . . 9

B1.

CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS . . . . . . . . . . . . 18

A6.

REPLACE ENGINE TIMING BELT (EXCEPT VEHICLES WITH TIMING CHAIN) . . . . . . . . . 9

B2.

CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR DAMAGE . . . . . . . . . . . . . . . . 19

B4.

CHECK DRIVE SHAFT BOOTS FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

OPERATIONS UNDER THE VEHICLE . . . . . . 18

A7.

CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM . . . . . . . . . 10

A8.

REPLACE SPARK PLUGS . . . . . . . . . . . . . . 11

A9.

CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION . . . . . . . . . . . 11

B5.

CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS . . 19

A10. CHECK ENGINE COOLANT LEVEL IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 11

B6.

CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 20

A11. CHANGE ENGINE COOLANT . . . . . . . . . . . . 12

B8.

CHANGE GEAR OIL IN MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 20

A12. CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE . . . . . . . . . . . . . 14 A13. REPLACE AIR CLEANER ELEMENT . . . . . 14 A14. CHECK FLUID LEVEL IN BRAKE RESERVOIR AND CLUTCH RESERVOIR . . 14

B12. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 20

2

2-2 OPERATIONS INSIDE THE VEHICLE . . . . . . . 21 C1. CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY . . . . . . . . . . . . . . . 21 C2. CHECK PARKING BRAKE LEVER STROKE AND PLAY . . . . . . . . . . . . . . . . . . . . 22

OPERATIONS AFTER ENGINE IS WARMED UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 E1.

CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 32

E2.

CHANGE AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

E3.

CHANGE ENGINE OIL . . . . . . . . . . . . . . . . . . 35

C3. REPLACE AIR PURIFIER FILTER . . . . . . . . 22 C4. CHECK SRS AIRBAG SYSTEM . . . . . . . . . . 23

E4.

REPLACE ENGINE OIL FILTER . . . . . . . . . 36

OPERATIONS OUTSIDE THE VEHICLE . . . . . 27

E5.

CHECK ENGINE IDLING SPEED . . . . . . . . 37

D1. CHECK UNEVEN TYRE WEAR . . . . . . . . . . 27

E6.

CHECK CO CONCENTRATION . . . . . . . . . . 37

D2. CHECK FRONT WHEEL BEARINGS FOR PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

E8.

CHECK EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 38

D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

D4. CHECK BRAKE PADS AND DISCS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

F1.

CHECK BODY CONDITION FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

D5. CHECK BRAKE SHOE LININGS AND DRUMS FOR WEAR . . . . . . . . . . . . . . . . . . . 31

F2.

ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION . . . . . . . . 31

2-3

Inspection and PRE-DELIVERY INSPECTION -- Periodic Maintenance Schedule

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance operation code I : Inspection L : Lubrication R : Replace or change C : Clean

LANCER

For items which indicate both distance and time (in months), the inspection should be made at whichever (distance or time) comes first.

None : Not applicable F : Applicable

Service Intervals (Odometer reading or months, whichever occurs first) Months

Items

Odometer Reading

× 1000 km

12

24

36

48

60

72

84

96

108

120

132

144

156

168

180

192

204

216

228

240

15

30

45

60

75

90

105

120

135

150

165

180

195

210

225

240

255

270

285

300

I

I

I

I

I

I

I

I

I

I

OPERATIONS INSIDE THE ENGINE COMPARTMENT A1

Check V-belt for cracks, fraying, wear, and adjust its tension

A2

Check condition of distributor, cap and rotor

A3

Check ignition cables for damage

A4

Check vacuum pump oil hose for damage (diesel - powered vehicles)

A5

Check intake air hose and turbocharger oil hose for damage (vehicles with turbocharger)

A6

Replace engine timing belt *1 (except vehicles with timing chain)

A7

Check operation of crankcase emission control system (petrol-powered vehicles)

A8

Replace p spark p plugs l

I

I

I

I

I

I

I

I I I

I I

I

I

I

I

I I

I

I I

I

I

I

I I

I

I

I I

I

I

I

I I

I

I

I I

I

I

I

I I

I

I

I I

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I

I I

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F

I

Standard type

R : Every 45,000 km

Platinum-tipped type or Iridium-tipped type

R : Every 90,000 km

F

I

R : Every 90,000 km I

F

I

I

I

I

F F

A9

Check radiator hoses for damage and proper connection

I

I

I

I

I

I

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I

F

A10

Check engine coolant level in reservoir

I

I

I

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F

R

F

I

F

A11

Change engine coolant

A12

Check air cleaner element for clogging gg g and damage g

A13

Replace air cleaner element

R Normal usage

I

I

I

I

R I

I

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Severe usage

I

R I

R

R

R

Severe usage Check fluid level in brake reservoir and clutch reservor (for hydraulic type clutch)

A15

Change brake fluid

A16

Check battery electrolyte level

A17

Check injection nozzle [If dark smoke is exhausted or engine power is low ] (diesel-powered vehicles)

A18

Replace p fuel filt ter

A19

Removal of water from the fuel filter (vehicle with F9Q engine)

A20

Clean brake booster vacuum nipple (PAJERO PININ with GDI engine)

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R I

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*1: Including timing belt B with 4G6/4D5 engine

R I

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F

R

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F

R

F

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R I

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R I

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R I

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Petrol-powered vehicles

NOTE:

I

R : More frequently

R

Diesel-powered vehicles

I

I : Every 7,500 km or every 6 months

Normal usage

A14

I

I

I R

I

I

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R

R

R

R

C

C

F

R

F

I

F

R R

R

R

R

Removal : Every 15,000 km C

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I

I

R R

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C

C

C

R

F

2-4

Maintenance operation code I : Inspection L : Lubrication R : Replace or change F : Applicable

LANCER

Inspection and PRE-DELIVERY INSPECTION -- Periodic Maintenance Schedule

None : Not applicable

Service Intervals (Odometer reading or months, whichever occurs first) Months

Items

Odometer Reading

× 1000 km

12

24

36

48

60

72

84

96

108

120

132

144

156

168

180

192

204

216

228

240

15

30

45

60

75

90

105

120

135

150

165

180

195

210

225

240

255

270

285

300

OPERATIONS UNDER THE VEHICLE B1

Check suspension system for damage and looseness

I

I

I

I

I

I

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I

F

B2

Check suspension arm ball joints for play, and dust covers for damage

I

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F

B3

Lubricate suspension arm, steering linkage and propeller shaft with grease fitting

L

L

L

L

L

L

L

L

L

L

B4

Check drive shaft boots for damage g

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B5

Check steering linkage for damage and loose connections (including seals and boots)

B6

Check gear oil level in manual transmission

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B7

Check gear oil level in transfer case (4WD)

I

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B8

Change gear oil in manual transmission

B9

Change gear oil in transfer case ((4WD))

Normal usage Severe usage

R

R

Conventional differential or VCU type LSD

Normal usage

Mechanical type LSD or Hybrid type LSD

Normal usage

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I

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R R

F R

R

R

R

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I

I

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R

R

R

R

F

R

R

Severe usage

F

I

R

R

I

F

R

R I

I

R

R

Change gear oil in transfer case (4WD) (OUTLANDER/SPACE WAGON)

Change gear oil in front and rear differential

I

R

Severe usage

Check gear oil level in front and rear differential

I

I

R

Normal usage

B11

I

R

Severe usage

B12

I

Normal usage

B10

F

I : Every 7,500 km I

F

R

R

I

R R

R

R R

R

Severe usage

R

R

R

R

R

R

R

R

R

R

Check exhaust pipe connections for gas leakage, and check pipe installation

I

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F

OPERATIONS INSIDE THE VEHICLE C1

Check brake pedal and clutch pedal for free play

I

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F

C2

Check parking brake lever stroke and play

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F

C3

Replace air purifier filter (pollen filter)

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

F

C4

Check SRS airbag system

F

I : At 10 years

OPERATIONS OUTSIDE THE VEHICLE D1

Check uneven tyre wear

D2

Check front wheel bearings for play

D3

Check brake hoses and pipes for leakage

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2-5

Maintenance operation code I : Inspection L : Lubrication R : Replace or change F : Applicable

LANCER

Inspection and PRE-DELIVERY INSPECTION -- Periodic Maintenance Schedule

None : Not applicable

Service Intervals (Odometer reading or months, whichever occurs first)

Months

12

24

36

48

60

72

84

96

108

120

132

144

156

168

180

192

204

216

228

240

× 1000 km

15

30

45

60

75

90

105

120

135

150

165

180

195

210

225

240

255

270

285

300

Check brake p pads and discs for wear

Normal usage

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Check brake shoe linings g and d drums ffor wear

Normal usage

Odometer Reading

Items D4

D5

D6

Severe usage

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Check fuel hoses and pipes for leakage or deterioration

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Severe usage

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OPERATIONS AFTER ENGINE IS WARMED UP E1

Check fluid level in automatic transmission

E2

Change g automatic t transmission i i flfluid id

2WD *1

Normal usage

4WD

Normal usage

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ACEA and API classifications “ACEA A1 A1, A2 A2, A3” / “For service SG” or higher

Change engine oil (Diesel-powered sel powered vehicles )

ACEA and API classifications “ACEA ACEA B1, B2, B3, B4” / “For service CD” or higher

Replace engine oil filter (petrol pow (petrol-powered vehicles)

ACEA and API classifications “ACEA A1 A1, A2 A2, A3” / “For service SG” or higher

Replace engine oil filter (Diesel-pow(Diesel pow ered vehicles)

ACEA and API classifications “ACEA ACEA B1, B2, B3, B4” / “For service CD” or higher

Normal usage

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Severe usage

Change engine oil (petrol powered rol-powered vehicles)

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R : Every 4,000 km

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Severe usage

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Severe usage

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F F

R : Every 7,500 km

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Severe usage

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R : Every 7,500 km or every 6 months

Normal usage

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Normal usage

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R : Every 7,500 km

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Severe usage

Normal usage

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Severe usage

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E5

Check engine idling speed

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E6

Check CO concentration (petrol-powered vehicles)

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E7

Check ignition timing (vehicle with distributor) (except vehicle with crankshaft-mounted crankshaft angle sensor)

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Check exhaust gas recirculation (EGR) system

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E9

Check valve clearance (except vehicles with auto-lash adjuster)

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NOTE: *1: Replacement is not required for RWD vehicles used in normal operating conditions.

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2-6

Maintenance operation code I : Inspection L : Lubrication R : Replace or change F : Applicable

LANCER

Inspection and PRE-DELIVERY INSPECTION -- Periodic Maintenance Schedule

None : Not applicable

Service Intervals (Odometer reading or months, whichever occurs first) Months Odometer Reading

Items

× 1000 km

12

24

36

48

60

72

84

96

108

120

132

144

156

168

180

192

204

216

228

240

15

30

45

60

75

90

105

120

135

150

165

180

195

210

225

240

255

270

285

300

OTHERS F1

Check body condition for damage

F2

Road test

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NOTE: “Severe usage” specifications apply to only vehicles used under severe operating conditions.

Severe operating conditions include the following: (1)

Driving in a dusty area.

(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)

When more than 50% of driving is in heavy city traffic and the

(9)

ambient temperature is 32°C or more.

When more than 50% of driving is at 120km/h or more and the ambient temperature is 30°C or more.

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inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

2-7

OPERATIONS INSIDE THE ENGINE COMPARTMENT A1.

CHECK V-BELT FOR CRACKS, FRAYING, WEAR, AND ADJUST ITS TENSION

V-BELT CONDITION Check the whole rounds of the V-belt for cracks, fraying and wear.

DRIVE BELT TENSION CHECK AND ADJUSTMENT <4G1> ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension in the following procedure.

Standard value:

Alternator pulley

Water pump pulley

MB991668 (Microphone) 15° 15°

Tap lightly with a finger

Crankshaft pulley

Vibration frequency Hz

142 -- 173

Tension N

392 -- 588

Deflection mm (Reference)

8.1 -- 10.2

<When using the MUT-II> (1) Connect the special tool (belt tension meter set) to the MUT-II. (2) Connect the MUT-II to the diagnosis connector.

(3) Turn the ignition switch to “ON” position and select “Belt Tension Measurement” from the menu screen.

(4) Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 -- 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15°).

(5) 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.

Caution (1) The temperature of the surface of the belt should be as close as possible to normal temperature.

(2) Do not let any contaminants such as water or oil get onto the microphone.

(3) If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

(4) If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values.

(5) Do not take the measurement while the vehicle’s engine is running.

2-8

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

Alternator pulley

Water pump pulley

<When using a tension gauge> Use a belt tension gauge to check that the belt tension is within the standard value.

Belt tension gauge

Crankshaft pulley

Alternator pulley

Water pump pulley

Deflection

<Belt deflection check> Apply approx. 100 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Crankshaft pulley Approx. 100 N

Adjusting bolt

Lock bolt

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT (1) Loosen the nut of the alternator pivot bolt.

(2) Loosen the lock bolt.

(3) Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

Standard value:

Pivot bolt

Item

When adjusted

When replaced

Vibration frequency Hz

150 -- 166

200 -- 224

Tension N

441 -- 539

785 -- 981

Deflection mm (Reference)

8.6 -- 9.7

5.4 -- 6.6

(4) Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 ± 10 N·m (5) Tighten the lock bolt.

Tightening torque: 23 ± 2 N·m (6) Tighten the adjusting bolt.

Tightening torque: 5 ± 1 N·m

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

Indicator mark

2-9

DRIVE BELT TENSION CHECK AND ADJUSTMENT <4G6> (1) Check that the indicator marking of the auto-tensioner is within the range as shown in the illustration A of the tensioner bracket.

Caution Inspection must be carried out after turning the crankshaft clockwise for more than once.

(2) If the marking is outside the range as shown in the illustration A, replace the drive belt.

NOTE Due to the adoption of the auto-tensioner, no adjustment for belt tension is required.

A3.

CHECK IGNITION CABLES FOR DAMAGE

(1) Check the ignition cable and rubber cap for damage or weakness, and check the installation condition.

(2) Check the ignition cable and spark plug, distributor, and ignition coil connections for contamination, dirt, etc.

(3) If dirty, clean it; if damaged, replace it.

A6.

REPLACE ENGINE TIMING BELT (EXCEPT VEHICLES WITH TIMING CHAIN)

For information concerning the replacement procedures, refer to the Workshop Manual.

2-10

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

A7.

Ventilation hose

Breather hose

CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM (PETROL-POWERED VEHICLES)

BREATHER HOSE (1) Inspect the blow-by hose for cracks or damage.

(2) Clean the inside of the blow-by gas hoses if necessary.

(3) Inspect the ventilation filter for clogging.

VENTILATION HOSE (1) Check entire circumference and length of hoses using a mirror as required.

(2) Check all clamps for tightness and the connections for leakage.

(3) Hoses should be replaced immediately if there is any evidence of deterioration or damage.

Ventilation hose

Breather hose

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK (1) Remove the ventilation hose from the PCV (Positive crankcase ventilation) valve.

(2) Remove the PCV valve from the rocker cover.

Ventilation hose PCV valve

Ventilation hose

PCV valve

PCV valve

(3) Reinstall the PCV valve at the ventilation hose.

(4) Start the engine and run at idle.

(5) Place finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt.

NOTE At this moment, the plunger in the PCV valve moves back and forth.

(6) If vacuum is not felt, clean the PCV valve or replace it.

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

PCV valve

2-11

PCV VALVE CHECK (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.

(2) If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve.

A8.

REPLACE SPARK PLUGS

After removing old spark plugs, install new ones and tighten them at the specified torque.

A9.

CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION

(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.

A10. CHECK ENGINE COOLANT LEVEL IN RESERVOIR Check that the coolant level is between the “FULL” and “LOW” lines when the engine is at the normal operating temperature.

Full

Reserve tank

Low AC210258AB

2-12

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

A11. CHANGE ENGINE COOLANT (1) Stop the engine after it is fully warmed up.

(2) Add detergent to the engine coolant in order to flush the cooling system, and start the engine.

(3) Loosen the drain plug, remove the radiator cap and drain the coolant.

(4) Feed fresh water into the cooling system through the filler port of the radiator in order to wash the cooling system, and then tighten the drain plug.

(5) Drain the coolant from the reserve tank.

(6) Install the reserve tank.

(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 Caution Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol antifreeze. The use of an improper anti-freeze can cause the corrosion of the aluminium components.

(8) Fill the cooling system with soft water through the filler port, and add long life coolant, if necessary.

(9) Fill the reserve tank with coolant.

(10)Install the radiator cap and the reserve tank cap.

(11)Recheck the engine coolant level after a road test.

Full

Reserve tank

Low AC210258AB

Caution When removing the radiator cap, be careful to blow out steam and boiling water.

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

2-13

REMOVAL OF ENGINE COOLANT FROM THE CYLINDER BLOCK DRAIN PLUG (1) Drain the engine coolant by removing the drain plug and then the radiator cap.

(2) Remove the cylinder block drain plug from the cylinder block to drain the engine coolant.

(3) Remove the reserve tank to drain the engine coolant.

(4) When the engine coolant has drained, pour in water from the radiator cap to clean the engine coolant line.

(5) Coat the thread of the cylinder block drain plug with the specified sealant and tighten to the specified torque.

<4G1> Inlet side

Cylinder block drain plug

Specified sealant: 3M Nut Locking Part No.4171 or equivalent

<4G6> Inlet side

Tightening torque: 40 ± 5 N·m <4G1> 44 ± 5 N·m <4G6> (6) Securely tighten the radiator drain plug.

(7) Install the reserve tank.

(8) Use special tool LLC changer (MB991871) to refill the coolant.

Cylinder block drain plug

NOTE For how to use special tool MB991871, refer to its manufacturer’s instructions.

AC104528AD

MB991871 Air hose

Recommended antifreeze: DIA QUEEN SUPER LONG LIFE COOLANT or equivalent Quantity: 5.0 L <4G1> 7.0 L <4G6> Caution Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol antifreeze. The use of an improper anti-freeze can cause the corrosion of the aluminium components.

(9) Install the radiator cap securely.

(10)Start the engine and warm the engine until the thermostat opens. (Touch the radiator hose with your hand to check that warm water is flowing.)

(11)After the thermostat opens, race the engine several times, and then stop the engine.

(12)Cool down the engine, and then pour engine coolant into the reserve tank until the level reaches the FULL line. If the level is low, repeat the operation from step 9.

2-14

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

A12. CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE (1) Check air cleaner element for clogging and damage.

(2) Clean deposited dust from the element in the following manner.

1) Lightly tap the element against the top of a bench.

2) Blow compressed air from inside the element.

(3) Wipe off dust on the air cleaner interior.

(4) Install the air cleaner body.

A13. REPLACE AIR CLEANER ELEMENT

Air cleaner element

The air cleaner element will become dirty and loaded with dust during use, and the filtering effect will be substantially reduced. Replace it with a new one.

(1) Unclasp the air cleaner cover clip.

(2) Remove the air cleaner element and install a new one.

(3) Be sure to close the air cleaner cover completely when clamping it.

A14. CHECK FLUID LEVEL IN BRAKE RESERVOIR AND CLUTCH RESERVOIR (for hydraulic-type clutch only) (1) Check that the fluid level is between the “MAX” and “MIN” or “A” marks.

(2) If it is below the “MIN” or “A” marks, replenish with fresh brake fluid up to the “MAX” mark.

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

2-15

A15. CHANGE BRAKE FLUID (1) Remove the cap of the bleeder screw, connect a vinyl tube, and place its other end in a receptacle.

(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.

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.

Specified brake fluid: DOT3 or DOT4 Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. If brake fluid is exposed to the air, it will absorb moisture; as water is absorbed from the atmosphere, the boiling point of the brake fluid will decrease and the braking performance will be seriously impaired. For this reason use a hermetically sealed 1 lit. or 0.5 lit. brake fluid container. Firmly close the cap of the brake fluid container after use.

( ):R.H. drive vehicle

(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 color of fluid that flows out.

(4) Repeat above steps for other bleeder screws.

NOTE The operating steps for each bleeder screws are illustrated on this page.

AC000876AC

MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.)

(1) Fill the reserve tank with brake fluid.

(2) Keep the brake pedal depressed.

(3) Have another person cover the master cylinder outlet with a finger.

(4) With the outlet still closed, release the brake pedal.

(5) Repeat steps (2) - (4) three or four times to fill the inside of the master cylinder with brake fluid.

2-16

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

A16. CHECK BATTERY ELECTROLYTE LEVEL (1) Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.

Good

Caution (1) If the battery fluid is below the LOWER LEVEL, the battery could explode in using.

(2) If the battery fluid is over the UPPER LEVEL, leakage could result.

Thermometer

(2) Use a hydrometer and thermometer to check the specific gravity of the battery fluid.

Standard value: 1.220 -- 1.290 [20_C] Hydrometer

The specific gravity of the battery fluid varies with the temperature, so use the following formula to calculate the specific gravity for 20_C. Use the calculated value to determine whether or not the specific gravity is satisfactory.

D20 = (t -- 20) × 0.0007 + Dt D20: Specific gravity of the battery fluid calculated for 20_C. AC102027AC

Dt: Actually measured specific gravity t: Actually measured temperature

Fuel high-pressure hose

Fuel tank hose Fuel tank pump connector

A18. REPLACE FUEL FILTER (1) Remove the rear seat cushion.

(2) Remove the service hole cover mounting screws and remove the service hole cover.

(3) Disconnect the fuel tank pump assembly connector, fuel high-pressure hose and fuel tank hose.

(4) Remove the mounting nuts and fuel pump bracket plate, and remove the fuel pump assembly from the service hole.

inside the PRE-DELIVERY INSPECTION -- Operations Engine Compartment

2-17

FUEL PUMP MODULE

Fuel filter assembly (Replace fuel filter assembly)

Grommet

Fuel pump

O--ring

Suction filter (Not replace suction filter)

Fuel high-pressure hose

(5) Install the fuel pump assembly to the fuel tank through the service hole.

(6) Install the fuel pump bracket plate to the fuel tank and tighten the mounting nuts to the specified torque.

Tightening torque: 2.5 ± 0.5 N·m (7) Connect the fuel tank pump assembly connector, fuel high-pressure hose and fuel tank hose.

Fuel tank hose Fuel tank pump connector

Caution After connecting the fuel high-pressure hose, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.

(8) Tighten the service hole cover mounting screws and install the service hole cover.

(9) Install the rear seat cushion.

Corresponding side Fuel high-pressure hose

Quick connector

2-18

PRE-DELIVERY INSPECTION -- Operations under the Vehicle

OPERATIONS UNDER THE VEHICLE B1. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS FRONT SUSPENSION Deterioration and sagging

Bends and damage Noise and oil leakage

Cracks, bends and dents Cracks, bends and dents

REAR SUSPENSION

Deterioration and sagging

Bends and damage Noise and oil leakage

Cracks, bends and dents

Cracks, bends and dents

PRE-DELIVERY INSPECTION -- Operations inside the Vehicle B2.

Dust cover

Lower arm AC210260AB

2-19

CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR DAMAGE

LOWER ARM BALL JOINT END PLAY CHECK (1) Raise the vehicle.

(2) Remove the stabilizer bar from the lower arm assembly.

(3) Move the lower arm up and down with your hands to check for an excessive play in the axial direction of the ball joint. If there is an excessive play, replace the lower arm assembly.

DUST COVERS FOR DAMAGE Check dust covers for damage.

B4.

CHECK DRIVE SHAFT BOOTS FOR DAMAGE

Check the drive shaft boots for damage.

B5.

CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS (INCLUDING SEALS AND BOOTS)

(1) Move the steering wheel bit by bit to the left or right, and check to be sure that there is no play or looseness in the linkage coupling, that the installation is not loose, and that the rod or arm is not bent or damaged.

(2) Check to be sure that the seal and boot of the ball joint are correctly installed (in the correct position), and that they are not damaged.

(3) Check tie-rod end lock nut for looseness. If lock nut is loose, adjust toe-in and then tighten lock nut to the specified torque.

Tightening torque: 40 ± 5 N·m

AC210261AB

2-20

PRE-DELIVERY INSPECTION -- Operations under the Vehicle B6.

Filler plug

CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION

(1) Remove the filler plug of the transmission case.

Drain plug

Filler plug hole Transmission oil

(2) Oil level should be at the lower portion of the filler plug hole.

(3) Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity.

(4) Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N·m

Filler plug

B8.

Filler plug

CHANGE GEAR OIL IN MANUAL TRANSMISSION

(1) Remove oil filler plug and oil drain plug.

(2) Drain the gear oil.

(3) Before installing the plug, remove iron powder attached to the magnet of the drain plug.

Tighten the oil drain plug to the specified torque.

Drain plug

Filler plug hole Transmission oil

Filler plug

Tightening torque: 32 ± 2 N·m

(4) Fill the transmission fresh oil by using a lubricator.

(5) 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 or higher SAE 75W--85W or 75W--90 Quantity: 2.1 L <F5M41>, 2.2 L <F5M42> (6) Tighten the oil filler plug to the specified torque.

Tightening torque: 32 ± 2 N·m

B12. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE INSTALLATION (1) Confirm that the exhaust pipe does not interfere with any body components.

(2) Check the exhaust pipe for damage by stones, etc.

(3) Start the engine and check for gas leaks from the exhaust pipe connections.

PRE-DELIVERY INSPECTION -- Operations inside the Vehicle

2-21

OPERATIONS INSIDE THE VEHICLE C1.

AC102353AC

CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY

BRAKE PEDAL FREE PLAY (1) With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value.

Standard value (B): 3 – 8 mm (2) If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: D Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod D Brake pedal height D Installation position of the stop lamp switch, etc.

CLUTCH PEDAL FREE PLAY (1) Measure the clutch pedal free play (including the play at the clutch pedal clevis pin).

Standard value: 4 -- 13 mm (2) If the clutch pedal free play do not meet the standard value, probably there is air in the hydraulic system or a malfunction of the clutch itself, so bleed out the air or disassemble and inspect the clutch.

2-22

PRE-DELIVERY INSPECTION -C2.

Operations inside the Vehicle

CHECK PARKING BRAKE LEVER STROKE AND PLAY

(1) Pull the parking brake lever with a force of approx. 200 N and count the number of notches.

Standard value: 5 -- 7 notches

Adjusting nut

Adjuster

Cable rod

(2) If the parking brake lever stroke is not the standard value, adjust as described below.

1) Remove the floor console assembly.

2) Loosen the adjusting nut to move it to the cable rod end so that the cable will be free.

3) Remove the rear wheel hub plug, and then use a flat-tipped screwdriver to turn the shoe slack adjuster in the direction of the arrow (the direction which expands the shoe) so that the disc will not rotate.

Return the shoe slack adjuster 5 notches in the direction opposite to the direction of the arrow.

4) Turn the adjusting nut to adjust the parking brake lever stroke to the standard value. After adjusting, check that there is no space between the adjusting nut and the parking brake lever. Check that the adjusting nut is secured with the nut holder.

Caution If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag.

5) Release the parking brake and turn the rear wheels to check that the rear brakes are not dragging.

Air purifier filter

C3.

REPLACE AIR PURIFIER FILTER (POLLEN FILTER)

(1) Remove the glove box.

(2) Remove the two screws as shown, and replace the air purifier filter.

(3) Install the glove box.

PRE-DELIVERY INSPECTION -- Operations inside the Vehicle

2-23

C4. CHECK SRS AIRBAG SYSTEM SRS WARNING LAMP CHECK Turn the ignition key to the ON position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly.

SRS warning lamp

SRS COMPONENT VISUAL CHECK Insulating tape

Battery

Turn the ignition key to the LOCK position, disconnect the negative battery cable and tape the terminal.

Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work.

Battery (--) cable ACX00583AE

SRS-ECU

SRS CONTROL UNIT (SRS-ECU) (1) Check SRS-ECU case and brackets for dents, cracks, deformation or rust.

Caution The SRS may not activate if the SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger.

(2) Check connector for damage, and terminals for deformation or rust.

Replace SRS-ECU if it fails visual check.

<Driver’s side> Inflator case

Connector

<Passenger’s side>

Connector Inflator case

AIR BAG MODULES, STEERING WHEEL AND CLOCK SPRING (1) Remove the air bag modules, steering wheel and clock spring.

Caution The removed air bag modules should be stored in a clean, dry place with the pad cover face up.

(2) Check pad cover for dents, cracks or deformation.

(3) Check connector for damage, terminals for deformation, and harness for binds.

(4) Check air bag inflator case for dents, cracks or deformation.

(5) Check harness and connectors for damage, and terminals for deformation.

(6) Check clock spring connectors and protective tube for damage, and terminals for deformation.

(7) Visually check the clock spring case for damage.

REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION.

2-24

PRE-DELIVERY INSPECTION -- Operations inside the Vehicle (8) Align the mating marks of the clock spring, and after turning the vehicle’s front wheels to straight-ahead position, install the clock spring to the column switch.

Case

Mating Mark Alignment

Protective tubes Mating mark AC100446AD

Turn the clock spring clockwise fully, and then turn it back approx. 3 3/4 turns counterclockwise to align the mating marks.

Caution If the clock spring’s mating mark is not properly aligned, the steering wheel may not be completely rotational during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle’s driver or front passenger.

(9) Install the steering column covers, steering wheel and the air bag module.

(10)Check steering wheel for noise, binds of difficult operation.

(11)Check steering wheel for excessive free play.

Caution The SRS may not activate if any of the above components is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger.

FRONT SEATBACK ASSEMBLY WITH SIDE AIR BAG MODULE (1) Check the side air bag module deployment section in the seat for dents and deformation.

(2) Check the harness for binds, the connector for damage and the terminals for deformation.

Air bag module deployment section

Center pillar

Side impact sensor (Front)

Quarter panel inner Side impact sensor (Rear)

SIDE IMPACT SENSORS FRONT (1) Check the center piller for deformation or rust.

(2) Check the side impact sensors for dents, cracks, deformation or rust.

(3) Check the connectors for damage and the terminals for deformation.

REAR (1) Check the quarter panel inner for deformation or rust.

(2) Check the side impact sensors for dents, cracks, deformation or rust.

(3) Check the connectors for damage and the terminals for deformation.

PRE-DELIVERY INSPECTION -- Operations inside the Vehicle

2-25

CURTAIN AIR BAG MODULE (1) Check the curtain air bag module deployment section in the headlining for dents and deformation.

(2) Check the inflator surface for cracks, dents, and deformation.

(3) Check the harness for binds, the connector for damage and the terminals for deformation.

Curtain air bag module deployment section

SEAT BELT WITH PRE-TENSIONER (1) Check the seat belt pre-tensioner for dents or deformation.

(2) Check that the seat belt pre-tensioner is installed correctly to the vehicle body.

INSTRUMENT PANEL WIRING HARNESS/FLOOR WIRING HARNESS/ROOF WIRING HARNESS Air bag module connector

Instrument panel wiring harness Air bag module connector

Clock spring connector

Instrument panel wiring harness

SRS-ECU connector

2-26

PRE-DELIVERY INSPECTION -- Operations inside the Vehicle Curtain air bag module connector (RH)

Seat belt pre-tensioner connector (RH)

Side impact sensor connector (Rear : RH)

Side impact sensor connector (Front : RH)

Curtain air bag module connector (LH) Roof wiring harness

Side air bag module connector (RH)

Side impact sensor connector (Rear : LH) Side impact sensor connector (Front : LH) Seat belt pre-tensioner connector (LH) Instrument panel wiring harness

Side air bag module connector (LH) Floor wiring harness

(1) Check connector for poor connection.

(2) Check harnesses for binds, connectors for damage, and terminals for deformation.

REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION. Caution The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected, which could result in serious injury or death to the vehicle’s driver or front passenger.

POST-INSTALLATION INSPECTION Reconnect the negative battery terminal. Turn the ignition key to the ON position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly.

SRS warning lamp

PRE-DELIVERY INSPECTION -- Operations outside the Vehicle

2-27

OPERATIONS OUTSIDE THE VEHICLE D1.

CHECK UNEVEN TYRE WEAR

Check the entire periphery of the tyres for uneven wear.

If any tyre shows uneven wear, check the toe-in and toe-out, and adjust as necessary.

TOE-IN Using a toe-in gauge, measure toe-in.

Toe-in = B -- A Standard value: At the centre of tyre tread: 1 ± 2 mm Toe angle (per wheel): 0_ 03’ ± 06’

(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).

Clip

Lock nut AC102578AD

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.

Tightening torque: 40 ± 5 N·m (3) Confirm that the toe-in is at the standard value.

(4) Use a turning radius gauge to check that the steering angle is at the standard value.

Standard value: Item Inner wheels h l

Outer wheels h l (reference)

Specifications Comfort

39_30’ ± 1_30’

Sport (L.H. drive vehicles)

33_40’ + 1_00’/-2_00’

Sport (R.H. drive vehicles)

37_00’ + 1_00’/-2_00’

Comfort

32_30’

Sport (L.H. drive vehicles)

28_46’

Sport (R.H. drive vehicles)

30_00’

2-28

PRE-DELIVERY INSPECTION -- Operations outside the Vehicle TOE-OUT ANGLE ON TURNS To check the steering linkage, especially after the vehicle has been involved in an accident or if an accident is presumed, it is advisable to check the toe-out angle on turns in addition to the wheel alignment.

Conduct this test on the left turn as well as on the right turn.

Standard value: Item Toe-out angle on turns (inner wheel when outer wheel at 20_)

Specifications 21_42’ ± 1_30’

CAMBER, CASTER AND KINGPIN INCLINATION Standard value: MB991004

Item Camber Caster Kingpin inclination

Specifications Comfort 0_05’ ± 30’* 2_45’ ± 30’* 12_30’ ± 1_30’

Sport -- 0_05’ ± 30’* 2_55’ ± 30’* 12_40’ ± 1_30’

NOTE (1) *: difference between right and left wheels must be less than 30’.

(2) Camber and caster are preset at the factory and cannot be adjusted.

(3) For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment (MB991004).

Tighten the special tool to the same torque 245 ± 29 N·m as the driveshaft nut.

Caution To prevent the wheel bearing from damage, never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened.

REAR TOE-IN Toe adjusting bolt

Control link

120 ± 10 N·m

Control link

Standard value: At the centre of tyre tread: 3 ± 2 mm Toe angle (per wheel): 0_08’ ± 05’ (1) Be sure to adjust the camber before making toe adjustment.

(2) Carry out adjustment by turning the toe adjusting bolt (control link mounting bolt which is located on the inner side of the body).

Left wheel: Turning clockwise (+) toe-in Right wheel: Turning clockwise (--) toe-in NOTE The scale has gradations of approximately 2.6 mm (single side toe angle equivalent to 16’).

Caution To prevent bushings from breakage, the control link mounting nut should be temporarily tightened, and then fully tightened to 120 ± 10 N·m with the vehicle on the ground in the unladen condition.

PRE-DELIVERY INSPECTION -- Operations outside the Vehicle 2-29 <Vehicles with aluminium wheels>

REAR CAMBER

MB991014

Standard value: --0_40’ ± 30’ (difference between right and left wheel: less than 30’) NOTE For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the trailing arm spindle by using special tool wheel alignment gauge attachment (MB991014). Tighten the special tool to the same torque 175 ± 25 N·m as the rear wheel hubnut (self--locking nut).

If camber is not within the standard value, adjust by following procedures.

Camber adjusting bolt Lower arm assembly

(1) Disconnect the conjunction of the control link and the trailing arm.

(2) Carry out adjustment by turning the camber adjusting bolt (lower arm assembly mounting bolt which is located on the inner side of the body).

Left wheel: Turning clockwise (+) camber Right wheel: Turning clockwise (--) camber NOTE The scale has gradations of approximately 14’.

(3) Tighten the control link to the trailing arm.

Caution To prevent bushings from breakage, the connecting bolt should be temporarily tightened, and then fully tightened to 90 ± 10 N·m with the vehicle on the ground in the unladen condition.

(4) After adjusting the camber, the toe should be adjusted.

Connecting bolt

D2.

CHECK FRONT WHEEL BEARINGS FOR PLAY

(1) Remove the disc brake caliper and suspend it with a wire.

(2) Remove the brake disc from the front hub.

(3) Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction.

Limit: 0.05 mm AC102438AB

(4) If axial play exceeds the limit, replace the front hub assembly.

2-30 D3.

PRE-DELIVERY INSPECTION -- Operations outside the Vehicle CHECK BRAKE HOSES AND PIPES FOR LEAKAGE (1) Check entire circumference and length of hoses and pipes.

(2) Check all clamps for tightness and connections for leakage.

D4.

CHECK BRAKE PADS AND DISCS FOR WEAR

(1) Check the brake pad thickness through the caliper body check port.

Standard value: 10.0 mm Limit: 2.0 mm (2) When the thickness is less than the limit, always replace the pads at an axle set.

AC102396AD

ACX00668AD

(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: 26.0 mm <Front> 10.0 mm <Rear> Limit: 24.4 mm <Front> 8.4 mm <Rear> (4) If the disc thickness is less than the limits, replace it with a new one.

BRAKE DISC RUN-OUT CHECK (1) Remove the brake assembly, and then hold it with wire.

(2) Temporarily install the disc with the hub nut.

(3) Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.

Limit: 0.04 mm

ACX00669AD

PRE-DELIVERY INSPECTION -- Operations outside the Vehicle 2-31 D5.

ACX00708AD

CHECK BRAKE SHOE LININGS AND DRUMS FOR WEAR

BRAKE LINING THICKNESS CHECK (1) Remove the brake disc.

(2) Measure the thickness of the brake lining at several places.

Standard value (A): 2.8 mm Limit (A): 1.0 mm (3) If the thickness of the brake lining is below the limit, replace the shoe and lining assemblies on both sides of the vehicle. Never replace only one side.

BRAKE DRUM INSIDE DIAMETER CHECK (1) Remove the brake disc.

(2) Measure the inside diameter of the brake disc in two places or more.

Standard value (A): 168.0 mm Limit (A): 169.0 mm (3) If the inside diameter exceeds the limit, or if it is excessively worn on one side, replace the brake disc.

D6.

CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION (1) Check entire circumference and length of hoses and pipes.

(2) Check all clamps for tightness and connections for leakage.

2-32

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

OPERATIONS AFTER ENGINE IS WARMED UP E1.

CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION

(1) Drive the vehicle until the ATF temperature reaches the normal temperature (70 -- 80_C).

Fluid level (mm)

Oil level gauge Fluid temperature (°C)

AC002477AE

NOTE 1) Measure ATF temperature using MUT-II/III. 2) Check the oil level referring to the characteristics chart shown at left if it takes some time to reach the normal operation temperature of ATF (70 -- 80_C).

(2) Park the vehicle on a level surface.

(3) Move the selector lever to all positions to fully charge the torque converter and the fluid lines with ATF, and then move the selector lever to the N position.

(4) After wiping away any dirt from around the oil level gauge, pull out the oil level gauge and check the level of ATF. NOTE If the ATF has a burnt smell, or if it has become very contaminated or dirty, it means that the ATF has become contaminated by minute particles from bushings (metal) or worn parts. In such a case, the transmission needs to be overhauled and the ATF cooler line needs to be flushed out.

(5) Check that the ATF level is between the HOT marks on the oil level gauge. If the ATF level is too low, add more ATF until the level reaches between the HOT marks.

Automatic transmission fluid: DIA QUEEN ATF SP III

AC005861AC

NOTE If the ATF level is too low, the oil pump draws air into the system along with the ATF, and air bubbles will thus form in the fluid circuit. This will cause a drop in fluid pressure and cause the shift points to change and the clutches and brakes to slip.

If the ATF level is too high, the gear will churn the ATF and cause bubbles to develop, which can then cause the same problems as when the ATF fluid is too low.

In either case, the air bubbles can cause overheating and oxidation of the ATF, and also prevent the valves, clutches and brakes from operating normally. In addition, if bubbles develop in the ATF, the ATF can overflow from the transmission vent holes and be mistaken for leaks.

(6) Securely re-insert the oil level gauge.

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

E2.

Radiator

2-33

CHANGE AUTOMATIC TRANSMISSION FLUID

SPECIFICATIONS Automatic transmission fluid

Quantity

Remark

DIA QUEEN ATF SP III

7.7 L

F4A41

CHANGE PROCEDURE If you have an ATF changer, use the ATF changer to flush the ATF. If you do not have an ATF changer, follow the procedure given below.

(1) Remove the hose shown in the illustration which allows the ATF to flow from the ATF cooler (built into the radiator) to the transmission.

(2) Start the engine and discharge the ATF. Driving conditions: N range, idling Caution The engine should be stopped within one minute of it being started. If the ATF has all been discharged before this, stop the engine at that point.

Discharge amount: Approx. 3.5 L (3) Remove the drain plug at the bottom of the transmission case to drain out the remaining ATF. Discharge amount: Approx. 2.0 L (4) Install the drain plug with a gasket in between, and tighten it to the specified torque.

Tightening torque: 32 ± 2 N·m (5) Pour in new ATF through the oil filler tube.

Drain plug

Amount to add: Approx. 2.0 L AC103691AF

Caution Stop pouring in the ATF once 5.5 L has been poured in.

(6) Repeat the operation in step 2.

(7) Pour in new ATF through the oil filler tube.

Amount to add: Approx. 3.5 L NOTE Carry out steps 2 and 7 so that at least 8.0 L has been discharged from the cooler hose. After this, discharge a small quantity of ATF and check for contamination. If the ATF is contaminated, repeat steps 6 and 7.

Radiator

(8) Connect the hose which was disconnected in step 1, and then securely re-insert the oil level gauge.

(9) Start the engine, and let it run at idle for 1 -- 2 minutes.

(10)Move the selector lever to all positions once, and then return it to the N position.

2-34

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

(11)Check that the ATF level on the oil level gauge is at the COLD mark. If it is not up to this mark, add more ATF. (12)Drive the vehicle until the ATF temperature reaches the normal temperature (70 -- 80_C), and then re-check the ATF level.

The ATF level must be between the HOT marks.

AC005861AC

Fluid level (mm)

Oil level gauge Fluid temperature (°C)

AC002477AE

Radiator

NOTE 1) The COLD mark is for reference only; the HOT marks should be used as the standard for judgment.

2) Measure ATF temperature using MUT-II/III. 3) Check the oil level referring to the characteristics chart shown at left if it takes some time until reaching the normal operation temperature of ATF (70 -80_C.) (13)When ATF is under the specified level, top up ATF. When ATF is over the specified level, drain the excessive ATF from the drain plug to adjust ATF level to the specified level.

(14)Securely insert the oil level gauge into the oil filler tube.

AUTOMATIC TRANSMISSION FLUID COOLER LINE FLUSHING (1) Remove the hose shown in the illustration which allows the ATF to flow from the ATF cooler (built into the radiator) to the transmission.

(2) Start the engine and discharge the ATF. Driving conditions: N range, idling Caution The engine should be stopped within one minute of it being started. If the ATF has all been discharged before this, stop the engine at that point.

Discharge amount: Approx. 3.5 L (3) Pour in new ATF through the oil filler tube.

Amount to add: Approx. 3.5 L Caution Stop pouring in the ATF once 3.5 L has been poured in.

(4) Repeat the operation in step 2 and 3.

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 ATF and check for contamination. If the ATF is contaminated, repeat steps 2 and 3.

(5) Carry out the procedure in “CHANGE PROCEDURE” from step 2 onwards.

after PRE-DELIVERY INSPECTION -- Operations Engine is warmed up

E3.

Engine oil Engine oip panpan drain plug

Engine oil pan side

2-35

CHANGE ENGINE OIL

(1) Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. (2) Stop the engine and remove the engine oil filler cap.

(3) Remove the drain plug to drain oil.

Caution Use care as oil could be hot.

Engine oip pan drain plug

(4) Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque.

Tightening torque: 39 ± 5 N·m (5) Refil with specified quantity of oil.

Special Engine Oil Total quantity (Includes volume inside oil filter): 3.3 L <4G1> 4.3 L <4G6> (6) Remove the dipstick from the engine, and check whether or not the engine oil level is within the range between MAX and MIN. (7) Install the engine oil filer cap.

(8) Start the engine and run it for a few minutes.

(9) Stop the engine and check the oil level.

<Petrol-powered vehicles>

Selection of engine oil (1) Use engine oil conforming to the following classification: ACEA and API classifications “ACEA A1, A2, A3”/ “FOR SERVICE SG” or higher (2) Select engine oil of the proper SAE viscosity number according to the atmospheric temperature.

<Diesel-powered vehicles>

2-36

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

E4.

MB991396 <4G1>, MB991828 <4G1>, MB991610 <4G6> or commerciallyavailable tool

REPLACE ENGINE OIL FILTER

(1) Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. (2) Remove the engine oil filler cap.

(3) Remove the drain plug to drain oil.

Caution Use care as oil could be hot.

(4) Remove the under cover.

(5) Use the respective tool in the following table to remove the engine oil filter.

(6) Clean the filter bracket side mounting surface.

(7) Apply a small amount of engine oil to the O-ring of the new oil filter.

(8) Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque.

(9) Install the 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 the oil filter.

O-ring

Number

Tool

Tightening torque

MD348631, MD365876 <4G1>

Oil filter wrench (MB991828) or equivalent

Approx. 3/4 turn (16 ± 4 N·m)

MD360935 <4G1>

Oil filter wrench (MB991396) or equivalent

Approx. 1 turn (14 ± 2 N·m)

MD136466, MD322508 <4G6>

Commercially-available tool

Approx. 3/4 turn (17 ± 3 N·m)

MD356000 <4G6>

Oil filter wrench (MB991610) or equivalent

Approx. 3/4 turn (14 ± 2 N·m)

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

MUT-II

E5.

2-37

CHECK ENGINE IDLING SPEED

(1) Before inspection, set the vehicle to the pre-inspection condition.

(2) Turn the ignition switch to “LOCK” (OFF) position.

(3) Connect the MUT-II/III to the diagnosis connector or connect a tachometer to the engine speed detection connector.

(4) Connect a timing light.

(5) Start the engine and let it run at idle.

(6) Check that ignition timing is at the standard value.

Standard value: approximately 10_ BTDC <4G1> approximately 5_ BTDC <4G6> (7) Check the idle speed.

Standard value: 750 ± 100 r/min NOTE 1. The idle speed is controlled automatically by the idle speed control system.

2. When using the MUT-II, select item No.22 and take a reading of the idle speed.

(8) If the idle speed is outside the standard value, inspect the MPI system (Refer to WORKSHOP MANUAL GROUP 13 -- Troubleshooting).

MUT-II

E6.

CHECK CO CONCENTRATION

(1) Before inspection, set the vehicle to the pre-inspection condition.

(2) Turn the ignition switch to “LOCK” (OFF) position.

(3) Connect the MUT-II/III to the diagnosis connector or connect a tachometer to the engine speed detection connector.

(4) Connect a timing light.

(5) Start the engine and let it run at idle.

(6) Check that ignition timing is at the standard value.

Standard value: approximately 10_ BTDC <4G1> approximately 5_ BTDC <4G6> (7) Run the engine at 2,500 r/min for 2 minutes.

(8) Set the CO, HC tester.

2-38

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

(9) Check the CO contents and the HC contents at idle.

Standard value CO contents: 0.5% or less <4G1> 0.6% or less <4G6> HC contents: 100 ppm or less (10)If there is a deviation from the standard value, check the following items: D Diagnosis output D Fuel pressure D Injector D Ignition coil, spark plug cable, spark plug D EGR control system D Evaporative emission control system D Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

E8.

CHECK EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR CONTROL VALVE CHECK (1) Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found clean with a suitable solvent so that the valve seats correctly.

(2) Connect a hand vacuum pump to the EGR 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 EGR passage.

Vacuum

Passage of air

5.3 kPa or less

Air is not blown out

27 kPa or more

Air is blown out

(5) Replace the gasket, and tighten to the specified torque.

Tightening torque: 21 ± 4 N·m <4G1> 20 ± 2 N·m <4G6>

after PRE-DELIVERY INSPECTION -- Operations Engine is Warmed up

2-39

EGR CONTROL SOLENOID VALVE CHECK <4G1> 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.

(3) Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left).

(4) Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.

Battery voltage

Normal condition

Applied

Vacuum leaks

Not applied

Vacuum maintained

(5) Measure the resistance between the terminals of the solenoid valve.

Standard value: 29 -- 35 Ω (at 20 °C)

EGR CONTROL SOLENOID VALVE CHECK <4G6> NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.

Battery

(1) Disconnect the vacuum hose from the solenoid valve.

(2) Disconnect the harness connector.

(3) Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left).

(4) Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.

Battery voltage

B nipple condition

Normal condition

Not applied

Open

Vacuum maintained

Applied pp

Open

Vacuum leaks

Closed

Vacuum maintained

(5) Measure the resistance between the terminals of the solenoid valve.

Standard value: 29 – 35 Ω (at 20 °C)

2-40

PRE-DELIVERY INSPECTION -- Others

OTHERS F1.

CHECK BODY CONDITION FOR DAMAGE

(1) Check underbody coating for damage.

(2) Check body painting for damage.

F2.

AC304203

ROAD TEST

Drive the vehicle and check for conditions.

(1) Check free play of steering wheel.

(2) Check efficiency of service brakes and parking brakes system.

(3) Check driveability of engine.

(4) Check condition of instruments, gauges indicators, exterior lamps, heater and ventilators.

(5) Check abnormal noise of each part.

(6) Check the tyres for wear and for the correct air pressure.

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

DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS . . . . . . . . . .

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS . . . . . . . . . .

0-4

0-2

PRE-INSPECTION CONDITION . . . . . . . . .

0-4

REMOVAL AND DISASSEMBLY . . . . . . . .

0-2

VEHICLE WASHING . . . . . . . . . . . . . . . . . .

0-4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . .

0-3

PARTS TO BE REPLACED . . . . . . . . . . . .

0-3

MULTI USE TESTER (M.U.T.-II/III) SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

0-4

PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-3

TUBES AND OTHER RUBBER PARTS . . .

0-3

IN ORDER TO PREVENT VEHICLES FROM FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-5

ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . .

0-5

0-2

GENERAL HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL This manual contains Pre-delivery inspection and Periodic inspection and maintenance.

M6000000100026

Group 0 and 1 have the contents for all vehicle models, and Group 2 has contents for the relevant vehicle models.

PRECAUTIONS BEFORE SERVICE PROTECTING THE VEHICLE

REMOVAL AND DISASSEMBLY M6001000100029

AC305590

If there is a likelihood of damaging interior or exterior parts during service operations, protect them with suitable covers (such as seat covers, fender covers, etc.).

M6001000300023

AC305591

When checking a malfunction, find the cause of the problem. If it is determined that removal and/or disassembly is necessary, perform the work by following the procedures contained in this manual.

DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS M6001000200026

AC305592

AC305283

If the service work is to be done by two or more mechanics working together, all the mechanics involved should take safety into consideration while they work.

If punch marks or mating marks are made to avoid error in assembly and facilitate the assembly work, be sure to make them in locations which will have no detrimental effect on performance and/or appearance. If an area having many parts, similar parts, and/or parts which are symmetrical right and left is disassembled, be sure to arrange the parts so that they do not become mixed during the assembly process.

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.

0-3

GENERAL PRECAUTIONS BEFORE SERVICE

SPECIAL TOOLS M6001000400031

When replacing parts, use MITSUBISHI genuine 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 vehicle parts might be damaged, or the technician might be injured; therefore, be sure to use the special tool whenever doing any work for which the use of one is specified.

Be careful to avoid spilling any petrol, oil, etc., because if it adheres to any tubes or other rubber parts, they might be adversely affected.

PARTS TO BE REPLACED

LUBRICANTS

AC305595

M6001000800028

M6001000500027

AC305596

AC305594

If any of the following parts are removed, they must be replaced with new parts.

• Oil seals • Gaskets (except rocker cover gasket) • Packings • O-rings • Lock washers • Split pins • Self-locking nuts

In accordance with the instructions in this manual, apply the specified lubricants in the specified locations during assembly and installation.

BRAKE FLUID M6001000900025

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 PRECAUTIONS BEFORE SERVICE

SERVICING THE ELECTRICAL SYSTEM M6001001000025

• Engine coolant temperature: 80 to 90°C • Lamps, electric cooling fan and all accessories: OFF • M/T: Neutral • A/T: P range

VEHICLE WASHING M6001001300037

ACX00880AD

Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (-) cable from the battery in order to avoid damage caused by short-circuiting.

CAUTION Before connecting or disconnecting the negative (-) cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semiconductor parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS M6001001100022

If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor.

Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITION M6001001200029

"Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words "Set the vehicle to the pre-inspection condition" in this manual, it means to set the vehicle to the following condition.

Approx.

40 cm

ACX00881AE

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: Approx. 40 cm or more • Spray pressure: 3,900 kPa or less • Spray temperature: 82°C or less • Time of concentrated spray to one point: within 30 sec.

MULTI USE TESTER (M.U.T.-II/III) SUB ASSEMBLY M6001002000028

Refer to the "M.U.T.-II/III OPERATING INSTRUCTIONS" for instructions on handling the M.U.T.-II/III.

GENERAL PRECAUTIONS BEFORE SERVICE

0-5

ENGINE OILS M6001001600027

Steering shaft

Health Warning

M.U.T.-II

AC300830AD

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Recommended Precautions

Steering shaft

The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them.

16-PIN

MB991911 MB991824

MB991827

AK302282AB

Connect the M.U.T.-II/III to the diagnosis connector as shown in the illustration.

CAUTION Turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting the M.U.T.-II/III.

IN ORDER TO PREVENT VEHICLES FROM FIRE M6001001500020

"Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/ repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMC's information/Instructions".

Other precautions: • Avoid prolonged and repeated contact with oils, particularly used engine oils.

• Wear protective clothing, including impervious gloves where practicable.

• Avoid contaminating clothes, particularly underpants, with oil.

• Do not put oily rags in pockets, the use of overalls without pockets will avoid this.

• Do not wear heavily soiled clothing and oilimpregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing.

• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

• Obtain First Aid treatment immediately for open cuts and wounds.

• Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised.

• Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.

• Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work.

• If skin disorders develop, obtain medical advice without delay.

NOTES

1-1

GROUP 1

PRE-DELIVERY INSPECTION CONTENTS NOTES CONCERNING ENTRIES . . .

1-3

PAINTWORK TERMS . . . . . . . . . . . .

1-5

FIRST STEP . . . . . . . . . . . . . . . . . . . .

1-6

15. STEERING LINKAGE AND SPLIT PINS

1-11

16. UNDER BODY. . . . . . . . . . . . . . . . . . . .

1-11

BEFORE ROAD TEST . . . . . . . . . . . .

1-11

17. SEAT ADJUSTERS AND SEAT BACK LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . .

1-11

18. INHIBITOR SWITCH . . . . . . . . . . . . . . .

1-11

1. CONNECTION OF DARK CURRENT CONNECTOR . . . . . . . . . . . . . . . . . . . . . . .

1-6

19. IDLE CONTROL KNOB . . . . . . . . . . . . .

1-11

BODY . . . . . . . . . . . . . . . . . . . . . . . . .

1-6

20. INSTRUMENT PANEL CONTROLS . . .

1-11

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . .

1-6

3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . .

1-7

21. METERS, GAUGES, WARNING LAMPS AND INDICATION LAMPS . . . . . . . . . . . . .

1-12

4. OPERATION OF DOOR LOCKING SYSTEMS AND DOOR HINGES . . . . . . . .

1-8

22. AIR CONDITIONING, HEATER AND DEFROSTER SYSTEM. . . . . . . . . . . . . . . .

1-12

5. OPERATION OF DOOR MIRRORS, WINDOWS AND SUNROOF . . . . . . . . . . .

23. WIPERS AND WASHERS. . . . . . . . . . .

1-12

1-8

24. OPERATION OF SERVICE BRAKES AND PARKING BRAKES . . . . . . . . . . . . . . . . . . .

1-12

UNDER HOOD . . . . . . . . . . . . . . . . . .

1-9

25. CLUTCH OPERATION . . . . . . . . . . . . .

1-13

6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . .

1-9

7. BRAKE MASTER CYLINDER FLUID LEVEL

1-9

26. OPERATION OF SEAT BELTS, SHOULDER BELTS AND RETRACTORS .

1-13

8. CLUTCH MASTER CYLINDER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-9

ROAD TEST . . . . . . . . . . . . . . . . . . . .

1-14

9. WASHER FLUID LEVEL. . . . . . . . . . . . .

1-9

10. BATTERY CONDITION AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . .

27. ENGINE PERFORMANCE AND EXHAUST GAS . . . . . . . . . . . . . . . . . . . . . .

1-14

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

31. VIBRATION AND RATTLES . . . . . . . . .

1-15

32. ELECTRICAL EQUIPMENT . . . . . . . . .

1-15

UNDER VEHICLE . . . . . . . . . . . . . . .

1-10

13. TYRE AND SPARE TYRE PRESSURES

1-10

14. SUSPENSION SYSTEM. . . . . . . . . . . .

1-10

Continued on next page

1-2 AFTER ROAD TEST . . . . . . . . . . . . .

1-15

33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . .

1-15

34. IGNITION TIMING. . . . . . . . . . . . . . . . .

1-15

35. RADIATOR COOLANT LEVEL . . . . . . .

1-15

36. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD . . . . . . . . . . . . .

1-16 37. MANUAL TRANSMISSION AND TRANSFER (4WD) OIL LEVEL . . . . . . . . .

38. AUTOMATIC TRANSMISSION FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-16 1-16

39. ENGINE, TRANSMISSION, STEERING GEAR BOX AND DIFFERENTIAL FOR LEAKS . .

1-16

40. FRONT AND REAR DIFFERENTIAL OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-16

41. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE . . . . . . . . . . .

1-17

FINAL STEPS . . . . . . . . . . . . . . . . . . .

1-17

42. HEADLAMP AIMING . . . . . . . . . . . . . . .

1-17

43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . .

1-17

44. EXTERIOR AND INTERIOR . . . . . . . . .

1-17

45. OWNER INSTRUCTIONS . . . . . . . . . . .

1-18

PRE-DELIVERY INSPECTION NOTES CONCERNING ENTRIES

1-3

NOTES CONCERNING ENTRIES M6010100100080

This section describes the details and the inspection methods employed for the pre-delivery inspection of vehicles.

The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY INSPECTION. Inspection methods are described following the TABLE OF PRE-DELIVERY INSPECTION. NOTE: .

1. The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in kilometres (miles), date of inspection, name of person conducting the inspection, and body colour must be completed without fail.

2. The spaces for place of inspection, and name of owner should be completed as required.

1-4

PRE-DELIVERY INSPECTION NOTES CONCERNING ENTRIES TABLE OF PRE-DELIVERY INSPECTION

Model Chassis number Engine number Distance Travelled Owner Date of inspection Place of inspection Inspector Body colour

Before Road Test

km

Symbols to be used Good

C

Needs cleaning

A

Needs adjustment

L

Needs replenishment of lubricant, water, etc.

T

Needs retightening

X

Needs replenishment of repair

INSPECTION PROCEDURE First Step 1.

Connection of the dark current connector

Body 2.

Wrap film

3.

Exterior

4.

Operation of door locking systems and door hinges

5.

Operation of door mirrors, windows and sunroof

Under Hood 6.

Engine oil level

7.

Brake master cylinder fluid level

8.

Clutch master cylinder fluid level

9.

Washer fluid level

10.

Battery condition and connections

11.

Power steering fluid level

12.

Electrical wiring

Under Vehicle

17.

Seat adjusters and seat back latches

18.

Choke system and inhibitor switch

19.

Idle control knob

20.

Instrument panel controls

21.

Meters, gauges, warning lamps and indication lamps

22.

Air conditioning, heater and defroster systems

23.

Wipers and washers

24.

Operation of service brakes and parking brakes

25.

Clutch operation

26.

Operation of seat belts, shoulder belts and retractors

Road Test 27.

Engine performance and exhaust gas

28.

Transmission in all ranges

29.

Brakes

30.

Steering control

31.

Vibration and rattles

32.

Electrical equipment

After Road Test 33.

Idle speed

34.

Ignition timing

35.

Radiator coolant level

36.

Hoses, fluid lines and connections located under hood

37.

Manual transmission and transfer (4WD) oil level

38.

Automatic transmission fluid level

39.

Engine, transmission, steering gear box and differential for leaks

40.

Front and rear differential oil levels

41.

Hoses, fluid lines and connections located 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

1-5

PRE-DELIVERY INSPECTION PAINTWORK TERMS

PAINTWORK TERMS M6010200100032

Term

Definition

Remarks

Blister

A raised bubble in the paint (from the base or the undercoat) caused by abnormal moisture. The bubble may contain either water or air.

Change in tone

The colour tone of the painted surface is not Including wrong colour, discoloration and uniform. decoloration.

Contact mark

A mark on the painted surface as a result of contact by hands or clothing at the time of paint application.

Crack

A crack in the painted surface.

Dirt in paintwork

Rough surface resulting from foreign material in the paint or from dust deposited on wet paint during painting or storage.

Filed or ground traces

Deep scratches in sheet metal surface, 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 area).

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 dispersion

The metallic dispersion of the painted surface is not uniform.

Visibly incomplete topcoating

A part of the undercoating visible.

Cracks may be either shallow or deep.

The peeling may be minor, medium, or major.

1-6

PRE-DELIVERY INSPECTION FIRST STEP

FIRST STEP 1. CONNECTION OF DARK CURRENT CONNECTOR

Press down the storage connector.

M6010300100095

Connecting Procedure AC210252

Relay box

Storage connector AC303992AB

BODY 2. WRAP FILM M6010400100025

To protect the exterior finish of vehicles prior to 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.

Removal procedure

AC305606

Wrap film removal

Peel off slowly from corners keeping parallel to the body. When 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

Cleaning of border

Wipe-off by kerosene or white gasoline, etc.

If it is considerably visible, use polishing compound.

Disposal of removed film: Burning is appropriate AC306352 AB

PRE-DELIVERY INSPECTION BODY

1-7

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 checked.

There should be no leftover adhesive, swelling or discoloration of the paint film, or other defects.

4

Treatment of parts where film is to be reapplied.

Treat the defects on the parts where film is to be reapplied. If a solvent is used to remove leftover adhesive, wipe off the solvent thoroughly.

5

Reapplication

1. Basically, the parts where the film is to be applied should be the same as the film that is to be applied.

2. Apply the film from the lower portion of the body, working upward progressively. Apply pressure using a plastic squeegee or similar tool.

3. As necessary, cut the film at the various parts such as windshield washer nozzles, hood and trunk lid.

CAUTION 1. Apply the film with the body at a temperature of 10 − 40°C. (Workability is good in this temperature range.)

2. If the outside surface of the film (the side with no adhesive) is brought into direct contact with the paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not get folded under or otherwise make contact with the paint film.

3. Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort should be made to prevent air bubbles from being trapped under the film by applying pressure from the center of the film outward toward the edges during application.

4. To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of the film securely.

3. EXTERIOR M6010400200022

AC305607

1. Visually inspect the entire exterior.

(1) Paint condition (2) Corrosion, scratches (3) Bent edges, dented panels 2. Coated surfaces maintenance Touch up minor paint chips and flaws.

NOTE: For terms of paintwork, refer to P.1-5.

1-8

PRE-DELIVERY INSPECTION BODY

4. OPERATION OF DOOR LOCKING SYSTEMS AND DOOR HINGES M6010400300029

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.

CAUTION Set the lock to the "FREE" position on child protection of both rear doors. (For four door models)

5. OPERATION OF DOOR MIRRORS, WINDOWS AND SUNROOF M6010400400026

Front AC305608 AB

AC305607

1. Door mirrors AC210253AB

1. Open each door to check the release mechanism and ease of operation.

2. Close the door to check the latch and striker.

3. Open the door, operate the lock lever and close the door to check the lock.

4. Partially close the door to check the open-door detent.

5. Unlock each door with the key to check lock operation.

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

NOTE: Adjust and lubricate the door latches, strikers and locks as required.

Child-protection knob AC305610 AB

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 respective switches are operated. Check that when the lock switches are depressed, the respective door windows can no more be opened or closed.

4. Slide window Close the slide window to the fully closed position to check operation.

5. Sunroof Close the sunroof to the fully closed position to check operation.

1-9

PRE-DELIVERY INSPECTION UNDER HOOD

UNDER HOOD 6. ENGINE OIL LEVEL

9. WASHER FLUID LEVEL M6010500100022

M6010500400023

MAX

MIN

AC305611 AB

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

If it is at or below MIN, add the necessary amount of the specified engine oil referring to GROUP 2, Periodic Inspection and Maintenance P.2-3.

7. BRAKE MASTER CYLINDER FLUID LEVEL M6010500200029

AC305614

Check the fluid level; if it is low, replenish the washer fluid at the up to MAX mark.

1. Windshield washer reservoir 2. Rear window washer reservoir

10. BATTERY CONDITION AND CONNECTIONS M6010500500020

AC305612

Check the fluid level.

If it is below the "MIN" mark, replenish fresh brake fluid up to the "MAX" mark.

Specified Brake Fluid: DOT3 or DOT4

8. CLUTCH MASTER CYLINDER FLUID LEVEL M6010500300026

AC305615

Inspect the battery connections. Verify that they are tightened.

NOTE: Do not wipe the lubricant from the battery posts and cable clamps.

11. POWER STEERING FLUID LEVEL M6010500600102

AC305613

Check the fluid level.

If it is below the "MIN" mark, replenish fresh brake fluid up to the "MAX" mark.

Specified Brake Fluid: DOT3 or DOT4

AC305616

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

1-10

PRE-DELIVERY INSPECTION UNDER VEHICLE

2. If the fluid is added, start the engine and turn the steering wheel from stop to stop several times to expel air from the system.

Specified gear oil: Automatic transmission fluid DEXRON III or DEXRON II

12. ELECTRICAL WIRING M6010500700024

1. Each electrical wiring harness and connector (1) Check each harness to be correctly routed and securely clipped.

(2) Confirm that all connections are tight.

2. Ignition cable Be sure that all ignition cables are firmly attached to the spark plugs, distributor cap (or crank angle sensor) and ignition coil.

AC305617

UNDER VEHICLE 13. TYRE AND SPARE TYRE PRESSURES

14. SUSPENSION SYSTEM

M6010600100029

AC305618

1. Tyre specification Check the correct tyre specification.

2. Tyre pressures Adjust each tyre pressure.

NOTE: Recommended pressure is shown on the tyre pressure label.

3. Valve stem extensions Verify that the valve stem extensions are installed where necessary.

4. Install the wheel covers, wheel rings and hub caps.

M6010600200026

AC305609

Check to be sure that each installation bolt and nut is tightened. If split pins are used, make sure that they are properly installed.

1. Lower arm, Upper arm 2. Stabilizer bar 3. Strut assembly

REMOVE FRONT SPRING RESTRAINTS Spring restraints

AC305605

PRE-DELIVERY INSPECTION BEFORE ROAD TEST

With the vehicle correctly positioned on the sub-frame contact points, and the suspension fully extended, remove the rubber restraints from the front springs.

CAUTION It is very important that these restraints must be removed during predelivery-inspection. Failure to do so could cause ride and handling complaints.

15. STEERING LINKAGE AND SPLIT PINS M6010600300023

1-11

1. Steering linkage retaining nuts and split pins Check visually and by feel that the steering linkage retaining nuts are correctly tightened and the split pins are correctly installed.

2. Tie rods and relay rod Check that the tie rods and relay rod of the steering linkage are not bent and that the tie rod end lock nuts are securely tightened.

3. Steering components (1) Check that each of the steering components is tightened.

(2) Check the tie rod end, nuts and split pins for proper installation.

(3) Check the condition of bellows-type dust seals.

4. Split pins Check the front axle nuts and rear wheel spindle nuts for split pins.

16. UNDER BODY M6010600400020

AC305604

Check under body and under body coating for damage.

BEFORE ROAD TEST 17. SEAT ADJUSTERS AND SEAT BACK LATCHES M6010700100026

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 when the idle control knob is pulled out.

20. INSTRUMENT PANEL CONTROLS AC305622

Check the operation of the various parts of the seats.

1. Mechanical adjusters of the seats 2. Operation of the latch for tilting the seatbacks forward and backward.

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

M6010700400027

1-12

PRE-DELIVERY INSPECTION BEFORE ROAD TEST

21. METERS, GAUGES, WARNING LAMPS AND INDICATION LAMPS M6010700500024

(2) Operate the blower motor switch in all ranges.

(3) Move the control to "Defrost" position.

A: From front and side defroster B: From centre ventilators C: From side ventilators D: From under the instrument panel E: From under the front seat (some models only)

23. WIPERS AND WASHERS M6010700700028

AC305624

1. Check the meters and gauges are functioning properly.

2. Check each indicator lamp and warning lamp functions properly.

22. AIR CONDITIONING, HEATER AND DEFROSTER SYSTEM Check the systems for proper operation.

M6010700600021

AC305625

1. Air conditioning (1) Operate the air conditioning system.

(2) Operate the air conditioning light.

(3) Operate the control lever in all ranges.

(4) Operate the blower motor switch in all ranges.

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 wiping is shifted when timer knob is turned to any position.

(5) Verify that the front wipers function by operating the washer switch.

2. Rear wiper and washer (1) Check the operation of the rear wiper.

(2) Check the aim of the rear washer stream.

(3) Check the wiper blade-stop positions.

24. OPERATION OF SERVICE BRAKES AND PARKING BRAKES M6010700800155

Depress the brake pedal with approximately 500 N force

AC305626

2. Heater and defroster (1) After the engine has warmed up, turn on the heater.

AC305628 AB

1. Service brakes

1-13

PRE-DELIVERY INSPECTION BEFORE ROAD TEST

(1) Check the clearance between the brake pedal and the floor board when the brake pedal is depressed.

AC305631

AC305629

(2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the service brake, refer to GROUP 2, Periodic Inspection and Maintenance.

2. Parking brake Check the parking brake drag and lever travel.

NOTE: For inspection and adjustment of the parking brake, refer to GROUP 2, Periodic Inspection and Maintenance.

3. Verify correct clutch pedal free play.

NOTE: For inspection and adjustment of the clutch pedal, refer to GROUP 2, Periodic Inspection and Maintenance.

26. OPERATION OF SEAT BELTS, SHOULDER BELTS AND RETRACTORS M6010701000022

25. CLUTCH OPERATION M6010700900152

AC305632

AC305630

1. Check the clutch operation in all driving ranges.

2. Check the pedal-to-floor board clearance when the clutch is just disengaged.

1. Verify that the seat belt warning lamp operates properly.

2. Check all seat belts and harnesses to assure that they connect and hold properly.

3. Lean forward to check that the shoulder harnesses allow movement.

4. Check the condition of the belts and anchors.

5. Check for proper seat belt retraction.

1-14

PRE-DELIVERY INSPECTION ROAD TEST

ROAD TEST 27. ENGINE PERFORMANCE AND EXHAUST GAS M6010800100023

Button

AC305635 AB

AC305633

1. Engine performance Check the engine for proper performance and accelerator pedal for smooth operation.

2. Exhaust system (1) Check the exhaust system components for gas leaks.

(2) Verify that no black smoking is emitted from the end of the exhaust pipe (diesel-powered vehicles).

28. TRANSMISSION IN ALL RANGES M6010800200020

AC305634

1. Manual transmission Check the transmission in all forward ranges and in reverse.

2. Automatic transmission (1) Make sure shift indicator lines up properly in all ranges.

(2) Depress the accelerator completely to check that the manual kickdown is operating correctly.

(3) Stop the vehicle on a steep incline.

Put the automatic transmission in "P" position and slowly release the service brakes to see if "P" position lock holds. If it does not hold, the transmission requires further service.

29. BRAKES M6010800300027

1. Service Brake Put the vehicle in gear and apply the brakes while the vehicle is in motion. Be sure brake operation is smooth and positive.

2. Parking Brake (1) Stop the vehicle on a steep incline.

With the service brakes firmly applied, place the transmission in "N" position, and set the parking brakes.

(2) Slowly release the service brakes to see if the parking brakes will hold.

30. STEERING CONTROL M6010800400024

AC305636

1. Check for excessive play or looseness.

2. Check the steering wheel centre.

1-15

PRE-DELIVERY INSPECTION AFTER ROAD TEST

31. VIBRATION AND RATTLES

1. Radio M6010800500021

1. Locate squeaks, rattles and unusual vibrations.

2. Verify that no noise occurs from the engine, transmission, axle and body.

32. ELECTRICAL EQUIPMENT M6010800600028

AC305637

Tune the radio to a local broadcasting station and check the following: (1) Operate the volume, tone, balance and fader controls, etc.

(2) Pull out the pushbuttons, dial another station and set each pushbuttons.

(3) Operate the AM/FM switch.

2. Tape player Insert a cassette tape in the tape player and check as follows: (1) Check the operation of the tape feeder and rewind.

(2) Check the ejection.

(3) Check the operation of volume, tone, balance and fader controls, etc.

AFTER ROAD TEST 33. IDLE SPEED

35. RADIATOR COOLANT LEVEL M6010900100053

Check the engine idle speed.

NOTE: For specific idle speed adjustment procedure, refer to GROUP 2, Periodic Inspection and Maintenance P.2-3.

M6010900300068

34. IGNITION TIMING M6010900200061

AC305642

AC305641

Check the ignition timing. Except MPI vehicles with crankshaft-mounted crankshaft angle sensor.

NOTE: For the inspection and adjustment of the ignition timing, refer to GROUP 2, Periodic Inspection and Maintenance P.2-3.

1. Check that the coolant level in the reserve tank is at or above "LOW" mark at normal engine operating temperature. And check cooling system for leaks.

2. Check that the coolant concentration is 30% to 60%.

CAUTION Do not remove the radiator cap while the cooling system is under pressure.

When removing the radiator cap, be careful of steam and boiling water. Add coolant only to the reserve tank if it is required.

1-16

PRE-DELIVERY INSPECTION AFTER ROAD TEST

36. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD

38. AUTOMATIC TRANSMISSION FLUID LEVEL

M6010900400065

M6010900600081

AC005861AD

AC305643

1. Check all brake, fuel, power steering and air conditioner lines and connections; verify proper routing, check connections for leaks, tighten loose connector as required.

2. Inspect routing and connections of all vacuum, and radiator and heater houses.

CAUTION Remember that the air conditioner system is under pressure.

NOTE: Keep in mind that an oily residue around an air conditioner connector does not necessarily indicate a leak. Oil is used to lubricate fittings during assembly. Be sure lines are not twisted or kinked.

37. MANUAL TRANSMISSION AND TRANSFER (4WD) OIL LEVEL M6010900500073

1. Remove the dipstick and check the fluid level.

2. Fluid level is okay if it is in the specified range as illustration at normal engine operating temperature.

3. If the level is below the lower notch, replenish fluid until the level reaches the upper notch.

Automatic transmission fluid: DIA QUEEN ATF SP III

CAUTION Do not overfill.

39. ENGINE, TRANSMISSION, STEERING GEAR BOX AND DIFFERENTIAL FOR LEAKS M6010900700066

Check the engine, transmission, steering gear box and differential for oil leaks.

40. FRONT AND REAR DIFFERENTIAL OIL LEVELS M6010900800063

1. Remove the filler plug.

2. Check the oil level. If the oil level is at or slightly below the filler hole, it is in satisfactory condition.

Transmission oil

•

TYPE 1

TYPE2

AC305644 AB

1. Remove the filler plug.

2. Check the oil level. If the oil level is at or slightly below the filler hole, it is in satisfactory condition.

3. If the level is low, replenish the transmission and transfer case with fresh oil by using a lubricator.

NOTE: For the specified oil, refer to GROUP 2, Periodic Inspection and Maintenance P.2-3.

Upper limit

8 mm

Gear oil

Lower limit AC305646 AB

Type 1 only: Remove the filler plug, and check the gear oil level. Check that gear oil level is not 8 mm below the bottom of filler plug hole.

1-17

PRE-DELIVERY INSPECTION FINAL STEPS

3. If the level is low, replenish the front and/or rear differential with fresh oil by using a lubricator.

NOTE: For the specified oil, refer to GROUP 2, Periodic Inspection and Maintenance P.2-3.

41. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE M6010901000060

AC305647

1. Check all hoses, fluid lines and connections for leaks.

2. Check all hoses and fluid lines for proper routing away from sharp edges and moving components.

FINAL STEPS 42. HEADLAMP AIMING M6011000100064

Screen

Check the installation of the various equipment.

1. Floor mats 2. Spare tyre 3. Jack, jack handle and tool set

Headlamp

44. EXTERIOR AND INTERIOR M6011000300068

Level surface

AC305648 AB

Check condition for headlamp aiming.

NOTE: For headlamp aiming procedures, refer to the Workshop Manual for that model.

AC305650

43. EQUIPMENT M6011000200061

AC305649

Finally check and clean the exterior and interior.

1. Wash the vehicle to remove all traces of road grime and other dirt on the vehicle as a result of new vehicle preparations.

2. Clean exterior and interior glass surface.

3. Remove all protective covers.

4. Remove undercoat overspray, excess window sealer, and excess weatherstrip adhesive.

5. Verify that the secondary key can not unlock the glove box and tailgate/boot lid (if so equipped).

6. Remove shipping and inspection stickers.

1-18

PRE-DELIVERY INSPECTION FINAL STEPS

45. OWNER INSTRUCTIONS M6011000400065

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.

2-1

GROUP 2

PERIODIC INSPECTION AND MAINTENANCE CONTENTS PERIODIC INSPECTION AND MAINTENANCE SCHEDULE . . . . . .

OPERATIONS INSIDE THE ENGINE COMPARTMENT . . . . . . . . . . . . . . . .

2-3

OPERATIONS UNDER THE VEHICLE

2-16

B1. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS . . . . . . . . . . .

2-16

2-7

A1. CHECK V-BELT FOR CRACKS, FRAYING, WEAR, AND ADJUST ITS TENSION . . . . .

B2. CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-17

2-7

A3. CHECK IGNITION CABLES FOR DAMAGE

2-9

B4. CHECK DRIVESHAFT BOOTS FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .

A6. REPLACE ENGINE TIMING BELT <EXCEPT VEHICLES WITH TIMING CHAIN>

2-9

A7. CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM . . . . . . . .

2-9

A8. REPLACE SPARK PLUGS. . . . . . . . . .

2-10

A9. CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION . . . . . . . . . .

2-10 A10. CHECK ENGINE COOLANT LEVEL IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . .

2-11

A11. CHANGE ENGINE COOLANT . . . . . .

2-11

A12. CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE . . . . . . . . . . . .

2-12

A13. REPLACE AIR CLEANER ELEMENT

2-12

A14. CHECK FLUID LEVEL IN BRAKE RESERVOIR AND CLUTCH RESERVOIR (for hydraulic-type clutch only) . . . . . . . . . .

2-13

A15. CHANGE BRAKE FLUID . . . . . . . . . .

2-13

A16. CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14

A18. REPLACE FUEL FILTER . . . . . . . . . .

2-14

2-17

B5. CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS (INCLUDING SEALS AND BOOTS) . . . . . . . . . . . . . . . . .

2-17 B6. CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . .

2-17

B8. CHANGE GEAR OIL IN MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . .

2-18

B12. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

2-18

OPERATIONS INSIDE THE VEHICLE

2-19

C1. CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY . . . . . . . . . . . . . .

2-19

C2. CHECK PARKING BRAKE LEVER STROKE AND PLAY . . . . . . . . . . . . . . . . . .

2-20

C3. REPLACE AIR PURIFIER FILTER . . . .

2-21

Continued on next page

2-2 OPERATIONS OUTSIDE THE VEHICLE 2-22 D1. CHECK UNEVEN TYRE WEAR. . . . . .

2-22

D2. CHECK FRONT WHEEL BEARINGS FOR PLAY . . . . . . . . . . . . . . . . . . . . . . . . .

2-24

D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE. . . . . . . . . . . . . . . . . . . . . .

2-24

E1. CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . .

2-26

E2. CHANGE AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-27

E3. CHANGE ENGINE OIL . . . . . . . . . . . . .

2-29

E4. REPLACE ENGINE OIL FILTER . . . . .

2-29

E5. CHECK ENGINE IDLING SPEED. . . . .

2-30 2-31

D4. CHECK BRAKE PADS AND DISCS FOR WEAR. . . . . . . . . . . . . . . . . . . . . . . . .

2-25

E6. CHECK CO CONCENTRATION . . . . . .

D5. CHECK BRAKE SHOE LININGS AND DRUMS FOR WEAR. . . . . . . . . . . . . . . . . .

2-25

E8. CHECK EXHAUST GAS RECIRCULATION (EGR) SYSTEM. . . . . . . . . . . . . . . . . . . . . .

2-32

D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION . . . . . . .

2-26

OPERATIONS AFTER ENGINE IS WARMED UP . . . . . . . . . . . . . . . . . . .

2-26

OTHERS . . . . . . . . . . . . . . . . . . . . . . .

2-33

F1. CHECK BODY CONDITION FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . .

2-33

F2. ROAD TEST . . . . . . . . . . . . . . . . . . . . .

2-33

2-3

PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE M6020100100230

For items which indicate both distance and time (in months), the inspection should be made at whichever (distance or time) comes first.

•: Applicable for LANCER Maintenance item

Maintenance Maintenance interval operation

Application

OPERATIONS INSIDE THE ENGINE COMPARTMENT A1

Check V-belt for cracks, fraying, wear, and adjust its tension

Inspection

Every 15,000 km or every 12 months

A2

Check condition of distributor, cap and rotor

Inspection

Every 60,000 km or every 4 years

A3

Check ignition cables for damage

Inspection

Every 30,000 km or every 2 years

A4

Check vacuum pump oil hose for damage (diesel - powered vehicles)

Inspection

Every 15,000 km or every 12 months

A5

Check intake air hose and turbocharger oil hose Inspection for damage (vehicles with turbocharger)

Every 30,000 km or every 2 years

A6

Replace engine timing belt [including timing belt Replace B with 4G6/4D5 engine] (except vehicles with timing chain)

Every 90,000 km

•

A7

Check operation of crankcase emission control Inspection system (petrol-powered vehicles)

Every 30,000 km or every 2 years

•

A8

Replace spark plugs

Replace

Every 45,000 km

•

Platinum-tipped type Replace or Iridium-tipped type

Every 90,000 km

•

Inspection

Every 30,000 km or every 2 years

•

A10 Check engine coolant level in reservoir

Inspection

Every 30,000 km or every 2 years

•

A11 Change engine coolant

Change

Every 60,000 km or every 4 years

•

A12 Check air cleaner element for clogging and damage

Inspection

Normal usage

Every 15,000 km or every 12 months

•

Severe usage

Every 7,500 km or every 6 months

•

Normal usage

Every 45,000 km or every 3 years

•

Severe usage

More frequently

•

A9

Standard type

Check radiator hoses for damage and proper connection

A13 Replace air cleaner element

Replace

•

•

A14 Check fluid level in brake reservoir and clutch reservoir (for hydraulic type clutch)

Inspection

Every 15,000 km or every 12 months

•

A15 Change brake fluid

Change

Every 30,000 km or every 2 years

•

A16 Check battery electrolyte level

Inspection

Every 15,000 km or every 12 months

•

2-4

PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

Maintenance item

Maintenance Maintenance interval operation

A17 Check injection nozzle [If dark smoke is exhausted or engine power is low] (dieselpowered vehicles)

Inspection

Every 60,000 km or every 4 years

A18 Replace fuel filter

Petrol-powered vehicles

Replace

Every 150,000 km or every 10 years

Diesel-powered vehicles

Replace

Every 30,000 km or every 2 years

A19 Removal of water from the fuel filter (vehicle with F9Q engine)

Removal

Every 15,000 km

A20 Clean brake booster vacuum nipple (PAJERO PININ with GDI engine)

Clean

Every 45,000 km or every 3 years

Application

•

OPERATIONS UNDER THE VEHICLE B1

Check suspension system for damage and looseness

Inspection

Every 30,000 km or every 2 years

•

B2

Check suspension arm ball joints for play, and dust covers for damage

Inspection

Every 30,000 km or every 2 years

•

B3

Lubricate suspension arm, steering linkage and Lubrication Every 30,000 km or every 2 propeller shaft with grease fitting years

B4

Check driveshaft boots for damage

Inspection

Normal usage

Every 30,000 km or every 2 years

•

Severe usage

Every 7,500 km

•

B5

Check steering linkage for damage and loose connections (including seals and boots)

Inspection

Every 60,000 km or every 4 years

•

B6

Check gear oil level in manual transmission

Inspection

Every 15,000 km or every 12 months

•

B7

Check gear oil level in transfer case (4WD)

Inspection

Every 15,000 km or every 12 months

B8

Change gear oil in manual transmission

Change

Normal usage

Every 105,000 km or • every 7 years

Severe usage

Every 45,000 km or every 3 years

Normal usage

Every 105,000 km or every 7 years

Severe usage

Every 45,000 km or every 3 years

B9

Change gear oil in transfer case (4WD)

Change gear oil in transfer case (4WD) (OUTLANDER)

Change

Change

B10 Check gear oil level in front and rear differential Inspection

Every 75,000 km or every 5 years Every 30,000 km or every 2 years

•

2-5

PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item

B11 Change gear oil in front and rear differential

Maintenance Maintenance interval operation

Conventional differential or VCU type LSD

Change

Mechanical type LSD Change or Hybrid type LSD

B12 Check exhaust pipe connections for gas leakage, and check pipe installation

Normal usage

Every 90,000 km or every 6 years

Severe usage

Every 45,000 km or every 3 years

Normal usage

Every 60,000 km or every 4 years

Severe usage

Every 30,000 km or every 2 years

Application

Inspection

Every 30,000 km or every 2 years

•

OPERATIONS INSIDE THE VEHICLE C1

Check brake pedal and clutch pedal for free play

Inspection

Every 15,000 km or every 12 months

•

C2

Check parking brake lever stroke and play

Inspection

Every 15,000 km or every 12 months

•

C3

Replace air purifier filter

Replace

Every 15,000 km or every 12 months

•

OPERATIONS OUTSIDE THE VEHICLE D1

Check uneven tyre wear

Inspection

Every 30,000 km or every 2 years

•

D2

Check front wheel bearings for play

Inspection

Every 60,000 km or every 4 years

•

D3

Check brake hoses and pipes for leakage

Inspection

Every 30,000 km or every 2 years

•

D4

Check brake pads and discs for wear

Inspection

Normal usage

Every 15,000 km or every 12 months

•

Severe usage

Every 7,500 km or every 6 months

•

Normal usage

Every 30,000 km or every 2 years

•

Severe usage

Every 15,000 km or every 12 months

•

D5

D6

Check brake shoe linings and drums for wear

Check fuel hoses and pipes for leakage or deterioration

Inspection

Inspection

Every 30,000 km or every 2 years

•

Inspection

Every 15,000 km or every 12 months

•

OPERATIONS AFTER ENGINE IS WARMED UP E1

Check fluid level in automatic transmission

2-6

PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

Maintenance item

E2

Change automatic transmission fluid

2WD

4WD

4WD E3

E4

Maintenance Maintenance interval operation

Application

Change

Change

Change

Normal usage

Every 90,000 km or every 6 years

•

Severe usage

Every 45,000 km or every 3 years

•

Normal usage

Every 90,000 km or every 6 years

Severe usage

Every 45,000 km or every 3 years

Every 45,000 km or every 3 years

Change engine oil (petrol-powered vehicles)

ACEA and API Change classifications "ACEA A1, A2, A3" / "For service SG" or higher

Normal usage

Every 15,000 km or every 12 months

•

Severe usage

Every 7,500 km

•

Change engine oil (diesel-powered vehicles)

ACEA and API classifications "ACEA B1, B2, B3, B4" / "For service CD" or higher

Normal usage

Every 7,500 km or every 6 months

Severe usage

Every 4,000 km

Replace engine oil filter (petrol-powered vehicles)

ACEA and API Replace classifications "ACEA A1, A2, A3" / "For service SG" or higher

Normal usage

Every 15,000 km or every 12 months

•

Severe usage

Every 7,500 km

•

Replace engine oil filter (diesel-powered vehicles)

ACEA and API classifications "ACEA B1, B2, B3, B4" / "For service CD" or higher

Normal usage

Every 15,000 km or every 12 months

Severe usage

Every 8,000 km

Change

Replace

E5

Check engine idling speed

Inspection

Every 15,000 km or every 12 months

•

E6

Check CO concentration (petrol-powered vehicles)

Inspection

Every 15,000 km or every 12 months

•

E7

Check ignition timing (vehicles with distributor) (except vehicles with crankshaft mountedcrankshaft angle sensor)

Inspection

Every 60,000 km or every 4 years

E8

Check exhaust gas recirculation (EGR) system Inspection

Every 15,000 km or every 12 months

E9

Check valve clearance (except vehicles with auto-lash adjuster)

Inspection

Every 15,000 km or every 12 months

•

OTHERS F1

Check body condition for damage

Inspection

Every year

•

F2

Road test

Inspection

Every 15,000 km or every 12 months

•

2-7

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

NOTE: .

• "Severe usage" specifications apply to only vehicles used under severe operating conditions.

Severe operating conditions include the followings: 1. Driving in a dusty area.

2. Driving on rough roads, on submerged roads, or hilly areas.

3. Driving cold zones.

4. Engine idling for a long time or short-distance travel during cold weather.

5. Frequent, sudden application of brakes.

6. Towing of a trailer.

7. Use as a taxi or as a rent-a-car.

8. When more than 50% of driving is in heavy city traffic and the ambient temperature is 32°C or more.

9. When more than 50% of driving is at 120 km/h or more and the ambient temperature is 30°C or more.

OPERATIONS INSIDE THE ENGINE COMPARTMENT A1. CHECK V-BELT FOR CRACKS, FRAYING, WEAR, AND ADJUST ITS TENSION M6020200100204

V-BELT CONDITION Check the whole rounds of the V-belt for cracks, fraying and wear.

DRIVE BELT TENSION CHECK AND ADJUSTMENT <4G1> Check the drive belt tension in the following procedure.

Standard value: Vibration frequency Hz 142 − 173 Tension N

392 − 588

Deflection mm (Reference)

8.1 − 10.2

<When using the M.U.T.-II> 1. Connect the special tool belt tension meter set (MB991668) to the M.U.T.-II. 2. Connect the M.U.T.-II to the diagnosis connector.

3. Turn the ignition switch to the "ON" position and select "Belt Tension Measurement" from the menu screen.

4. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 − 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15 °).

Alternator pulley

Water pump pulley

10 – 20 mm MB991668 (Microphone) 15˚

Crankshaft 15˚ pulley

AK101474 AD

5. 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. <When using the Vehicle communication interface (V.C.I.)> 1. Connect the special tool belt tension meter set (MB991668) to the special tool V.C.I. (MB991824).

2. Connect the special tool V.C.I. (MB991824) to the diagnosis connector.

3. Turn the ignition switch to the "ON" position and select "Belt Tension Measurement" from the menu screen.

4. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 − 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15 °).

2-8

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

<Belt deflection check>

Alternator pulley

Water pump pulley

Alternator pulley

Water pump pulley

10 – 20 mm

Crankshaft pulley

Deflection MB991668 (Microphone) 15˚

Crankshaft 15˚ pulley

5. 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.

CAUTION • The temperature of the surface of the belt should be as close as possible to normal temperature.

• Do not let any contaminants such as water or oil get onto the microphone.

• If strong gusts of wind blow against the microphone or if there is loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values.

• Do not take the measurement while the vehicle's engine is running. <When using the tension gauge> Alternator pulley

Water pump pulley

Tension Gauge Crankshaft pulley

Approximately 100 N

AK101474 AD

AK101481 AD

Use a belt tension gauge to check that the belt tension is within the standard value.

AC505095AB

Apply approx. 100 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT Lock bolt

Adjusting bolt

Pivot bolt

AK101483AD

1. Loosen the nut of the alternator pivot bolt.

2. Loosen the lock bolt.

3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

Standard value: Items When When adjusted replaced Vibration frequency 150 − 166 Hz

195 − 218

Tension N

441 − 539

785 − 981

Deflection mm (Reference)

8.6 − 9.7

5.4 − 6.6

4. Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 ± 10 N⋅m 5. Tighten the lock bolt.

Tightening torque: 23 ± 2 N⋅m 6. Tighten the adjusting bolt.

Tightening torque: 5.0 ± 1.0 N⋅m

2-9

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

DRIVE BELT TENSION CHECK <4G6>

2. Check the ignition cable and spark plug, distributor, and ignition coil connections for contamination, dirt, etc.

3. If dirty, clean it; if damaged, replace it.

A6. REPLACE ENGINE TIMING BELT <EXCEPT VEHICLES WITH TIMING CHAIN>

A

M6020200600050

Indicator mark

AC102125AC

1. Make sure that the indicator mark is within the area marked with A in the illusttation.

CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or more.

2. If the mark is out of the area, replace the drive belt.

NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.

For information concerning the replacement procedures, refer to the Workshop Manual.

A7. CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM M6020200700091

BREATHER HOSE < 4G1 >

Ventilation hose

A3. CHECK IGNITION CABLES FOR DAMAGE

Breather hose

M6020200300059 AC303995AB

< 4G1 > < 4G6 >

Ventilation hose

Breather hose

AC303993AB AC300829AE

< 4G6 >

1. Inspect the breather hose for cracks or damage.

2. Clean the inside of the breather hose if necessary.

3. Inspect the ventilation filter for clogging.

VENTILATION HOSE

AC300827AE

1. Check the ignition cable and rubber cap for damage or weakness, and check the installation condition.

1. Check entire circumference and length of hoses using a mirror as required.

2. Check all clamps for tightness and the connections for leakage.

3. Hoses should be replaced immediately if there is any evidence of deterioration or damage.

2-10

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK

6. If vacuum is not felt, clean the PCV valve or replace it.

PCV VALVE CHECK

< 4G1 >

Ventilation hose PCV valve

PCV valve

AC303994AB

< 4G6 >

AC305654 AB

Ventilation hose

PCV valve

AC300828AE

1. Remove the ventilation hose from the PCV (Positive crankcase ventilation) valve.

2. Remove the PCV valve from the rocker cover.

3. Reinstall the PCV valve at the ventilation hose.

4. Start the engine and run at idle.

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.

2. If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve.

A8. REPLACE SPARK PLUGS M6020200800021

After removing old spark plugs, install new ones and tighten them at the specified torque.

A9. CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION M6020200900095

PCV valve

AC305653 AB AC303996AB

5. Place finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt.

NOTE: At this moment, the plunger in the PCV valve moves back and forth.

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.

2-11

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

A10. CHECK ENGINE COOLANT LEVEL IN RESERVOIR M6020201000028

Full

Reserve tank

Low AC210258AC

Check that the coolant level is between the "FULL" and "LOW" lines when the engine is at the normal operating temperature.

A11. CHANGE ENGINE COOLANT M6020201100092

1. Stop the engine after it is fully warmed up.

2. Add detergent to the engine coolant in order to flush the cooling system, and start the engine.

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

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 the corrosion of the aluminium components.

8. Fill the cooling system with soft water through the filler port, and add long life coolant, if necessary.

9. Fill the reserve tank with coolant.

10.Install the radiator cap and the reserve tank cap.

11.Recheck the engine coolant level after a road test.

CAUTION When removing the radiator cap, be careful to blow out steam and boiling water.

REMOVAL OF ENGINE COOLANT FROM THE CYLINDER BLOCK DRAIN PLUG 1. Drain the engine coolant by removing the drain plug and then the radiator cap. <4G1> Inlet side

AC305655

3. Loosen the drain plug, remove the radiator can and drain the coolant.

4. Feed fresh water into the cooling system through the filler port of the radiator in order to wash the cooling system, and then tighten the drain plug.

5. Drain the coolant from the reserve tank.

6. Install the reserve tank.

Cylinder block drain plug

AC208283 AC

<4G6> Inlet side

Cylinder block drain plug AC303355 AB

AC305656

2. Remove the cylinder block drain plug from the cylinder block to drain the engine coolant.

3. Remove the reserve tank to drain the engine coolant.

2-12

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

4. When the engine coolant has drained, pour in water from the radiator cap to clean the engine coolant line.

AC104528AE

5. Coat the thread of the cylinder block drain plug with the specified sealant and tighten to the specified torque.

Specified sealant: 3M Nut Locking Part No.4171 or equivalent Tightening torque: 40 ± 5 N⋅m <4G1> 44 ± 5 N⋅m <4G6>

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 the corrosion of the aluminium components.

9. Install the radiator cap securely.

10.Start the engine and warm the engine until the thermostat opens. (Touch the radiator hose with your hand to check that warm water is flowing.)

11.After the thermostat opens, race the engine several times, and then stop the engine.

12.Cool down the engine, and then pour engine coolant into the reserve tank until the level reaches the FULL line. If the level is low, repeat the operation from step 10.

A12. CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE M6020201200022

6. Securely tighten the radiator drain plug.

7. Install the reserve tank.

MB991871

Air hose AC305657

AC210658AB

8. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Use special tool LLC changer (MB991871) to refill the coolant. A convenient mixture is a 50% water and 50% antifreeze solution (freezing point: −31°C) NOTE: For How to use special tool MB991871, refer to its manufacturer’s instructions.

Recommended antifreeze: DIA QUEEN SUPER LONG LIFE COOLANT or equivalent Quantity: 5.0L <4G1> 7.0L <4G6>

1. Check air cleaner element for clogging and damage.

2. Clean deposited dust from the element in the following manner.

(1) Lightly tap the element against the top of a bench.

(2) Blow compressed air from inside the element.

3. Wipe off dust on the air cleaner interior.

4. Install the air cleaner body.

A13. REPLACE AIR CLEANER ELEMENT M6020201300029

The air cleaner element will become dirty and loaded with dust during use, and the filtering effect will be substantially reduced. Replace it with a new one.

2-13

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

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.

Air cleaner element

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.

Specified brake fluid: DOT3 or DOT4

AC210259AD

1. Unclasp the air cleaner cover clip.

2. Remove the air cleaner element and install a new one.

3. Be sure to close the air cleaner cover completely when clamping it.

A14. CHECK FLUID LEVEL IN BRAKE RESERVOIR AND CLUTCH RESERVOIR (for hydraulic-type clutch only) M6020201400026

CAUTION Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. If brake fluid is exposed to the air, it will absorb moisture; as water is absorbed from the atmosphere, the boiling point of the brake fluid will decrease and the braking performance will be seriously impaired. For this reason use a hermetically 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 color of fluid that flows out.

AC305658

1. Check that the fluid level is between the "MAX" and "MIN" or "A" mark.

2. If it is below the "MIN" or "A" marks, replenish with fresh brake fluid up to the "MAX" mark.

A15. CHANGE BRAKE FLUID M6020201600194

( ):R.H. drive vehicle

AC305660 AB

4. Repeat above steps for other bleeder screws.

NOTE: The operating steps for each bleeder screws are illustrated on this page.

MASTER CYLINDER BLEEDING

AC305659

1. Remove the cap of the bleeder screw, connect a vinyl tube, and place its other end in a receptacle.

The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.)

1. Fill the reserve tank with brake fluid.

2. Keep the brake pedal depressed.

2-14

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

CAUTION 1. If the battery fluid is below the LOWER LEVEL, the battery could explode in using.

2. If the battery fluid is over the UPPER LEVEL, leakage could result.

2. Use a hydrometer and thermometer to check the specific gravity of the battery fluid.

Standard value: 1.220 − 1.290 [20°C] AC000876AD

3. Have another person cover the master cylinder outlet with a finger.

4. With the outlet still closed, release the brake pedal.

5. Repeat steps (2) - (4) three or four times to fill the inside of the master cylinder with brake fluid.

A16. CHECK BATTERY ELECTROLYTE LEVEL M6020201700210

3. The specific gravity of the battery fluid varies with the temperature, so use the following formula to calculate the specific gravity for 20°C. Use the calculated value to determine whether or not the specific gravity is satisfactory.

D20 = (t - 20) × 0.0007 + Dt D20: Specific gravity of the battery fluid calculated for 20°C. t: Actually measured temperature Dt: Actually measured specific gravity

A18. REPLACE FUEL FILTER M6020201900106

Thermometer Hydrometer

1. Remove the rear seat cushion assembly.

2. Remove the service hole cover mounting screws and remove the service hole cover.

Fuel high-pressure hose

Battery fluid

AC504567AB

1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.

Fuel tank hose Fuel tank pump connector

AC303087AB

3. Disconnect the fuel tank pump assembly connector, fuel high-pressure hose and fuel tank hose.

4. Remove the mounting nuts and fuel pump bracket plate, and remove the fuel pump assembly from the service hole.

2-15

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT

FUEL PUMP MODULE

Fuel filter assembly (Replace fuel filter assembly) Grommet N Fuel pump O-ring N

Suction filter (Not replace suction filter)

AC303094AC

5. Install the fuel pump assembly to the fuel tank through the service hole.

6. Install the fuel pump bracket plate to the fuel tank and tighten the mounting nuts to the specified torque.

Tightening torque: 2.5 ± 0.5 N⋅m Fuel high-pressure hose

Corresponding side Fuel high-pressure hose

3 mm

Quick connector AC300047AD

Fuel tank hose Fuel tank pump connector

AC303087AB

7. Connect the fuel tank pump assembly connector, fuel high-pressure hose and fuel tank hose.

CAUTION After connecting the fuel high-pressure hose, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.

8. Tighten the service hole cover mounting screws and install the service hole cover.

9. Install the rear seat cushion assembly.

2-16

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE

OPERATIONS UNDER THE VEHICLE B1. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS M6020300100085

FRONT SUSPENSION

Deterioration and sagging

Bends and damage

Cracks, bends and dents

Noise and oil leakage

Cracks, bends and dents

REAR SUSPENSION Deterioration and sagging

Bends and damage

Noise and oil leakage

Cracks, bends and dents

Cracks, bends and dents

AC304376AD

2-17

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE

B2. CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR DAMAGE

B5. CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS (INCLUDING SEALS AND BOOTS)

M6020300200145

M6020300500083

LOWER ARM BALL JOINT AXIAL PLAY CHECK Dust cover

AC305662

Lower arm AC210260AC

1. Raise the vehicle.

2. Remove the stabilizer bar from the lower arm assembly.

3. Move the lower arm up and down with your hands to check for an excessive play in the axial direction of the ball joint. If there is an excessive play, replace the lower arm assembly.

1. Move the steering wheel bit by bit to the left or right, and check to be sure that there is no play or looseness in the linkage coupling, that the installation is not loose, and that the rod or arm is not bent or damaged.

DUST COVERS FOR DAMAGE Check dust covers for damage.

B4. CHECK DRIVESHAFT BOOTS FOR DAMAGE M6020300400127

AC305661

AC210261AC

2. Check to be sure that the seal and boot of the ball joint are correctly installed (in the correct position), and that they are not damaged.

3. Check tie-rod end lock nut for looseness. If lock nut is loose, adjust toe-in and then tighten lock nut to the specified torque.

Tightening torque: 40 ± 5 N⋅m

B6. CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION M6020300600046

Check the driveshaft boots for damage.

Filler plug

Drain plug AC203434AC

2-18

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE

1. Remove the filler plug of the transmission case.

Filler plug hole Filler plug hole

Transmission oil

Transmission oil

Filler plug Filler plug AC103664AG AC103664AG

2. Oil level should be at the lower portion of the filler plug hole.

3. Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity.

4. Tighten the filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅m

B8. CHANGE GEAR OIL IN MANUAL TRANSMISSION M6020300800147

Filler plug

3. Before installing the plug, remove iron powder attached to the magnet of the drain plug. Tighten the oil drain plug to the specified torque.

Tightening torque: 32 ± 2 N⋅m 4. Fill the transmission fresh oil by using a lubricator.

5. Fill with specified oil till the level comes to the lower portion of oil filler plug hole.

Specified transmission oil: DiaQueen NEW MULTI GEAR OIL API classification GL-3, SAE 75W−80 or Gear oil API classification GL-4, SAE 75W−85W / 75W−90 Quantity: 2.1 L <F5M41> 2.2 L <F5M42> 6. Tighten the oil filler plug to the specified torque.

Tightening torque: 32 ± 2 N⋅m

Drain plug AC203434AC

1. Remove oil filler plug and oil drain plug.

2. Drain the gear oil.

B12. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE INSTALLATION M6020301200029

1. Confirm that the exhaust pipe does not interfere with any body components.

2. Check the exhaust pipe for damage by stones, etc.

3. Start the engine and check for gas leaks from the exhaust pipe connections.

2-19

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE

OPERATIONS INSIDE THE VEHICLE C1. CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY M6020400100156

Brake pedal free play

Standard value (C): 90 mm or more (From the surface of floor board to the face of pedal pad) 3. If the clearance is outside the standard value, check for air trapped in the brake line, thickness of the disc brake pad and dragging in the parking brake. And then adjust and replace defective parts as required.

4. Return the carpet etc. to its original position.

Clutch pedal check and adjustment 1. For RH drive vehicles, turn up the carpet, etc. under the clutch pedal.

B AC102353AD

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 value range.

Standard value (B): 3 − 8 mm

Clutch pedal height <LH drive vehicles>

A Clutch pedal stopper <RH drive vehicles>

2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: • Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod • Brake pedal height • Installation position of the stop lamp switch, etc.

Clearance between brake pedal and floor board 1. Turn up the carpet, etc. under the brake pedal.

A

Carpet Dash pad AC310574 AB

2. Measure the clutch pedal height.

Standard value (A): 206.4 − 210.4 mm <LH drive vehicles>, 201.8 − 205.8 mm <RH drive vehicles> Clutch pedal clevis pin play

C AC006220 AC

2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floor board.

B AC100355 AB

3. Measure the clutch pedal clevis pin play.

Standard value (B): 1 − 3 mm

2-20

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE

Setting nut

Clutch pedal 13 ± 2 N·m AC100356 AB

4. If the clutch pedal height and clutch pedal clevis pin play are not within the standard value, loosen the setting nut to adjust the clutch pedal height and clevis pin play to the standard value.

CAUTION Do not push in the master cylinder pushrod at this time, otherwise the clutch will not operate properly.

Clutch pedal free play

5. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the clutch pedal stopper or dash pad when the clutch is disengaged are within the standard value ranges.

Standard value (C): 4 − 13 mm Standard value (D): 105 mm or more 6. If the clutch pedal free play and the distance between the clutch pedal and the clutch pedal stopper or dash pad when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder, release cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder, release cylinder or clutch.

C2. CHECK PARKING BRAKE LEVER STROKE AND PLAY M6020400200119

C AC100355 AC

<LH drive vehicles>

AC303998AB

1. Pull the parking brake lever with a force of approx.

200 N and count the number of notches.

Standard value: 5 − 7 notches

D

Cable rod Clutch pedal stopper <RH drive vehicles>

Adjusting nut

D AC107239 AD

AC310575 AB

2. If the parking brake lever stroke is not the standard value, adjust as described below.

(1) Remove the floor console assembly.

(2) Loosen the adjusting nut to move it to the cable rod end so that the cable will be free.

2-21

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE

CAUTION If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag.

(5) After adjusting the parking brake lever stroke, jack up the rear end of the vehicle, and then release the parking brake and turn the rear wheels to check that the rear brakes are not dragging.

Adjuster

AC202320AC

(3) Remove the rear brake adjusting hole plug.

Then insert a flat-tipped screwdriver to turn the adjuster to the arrow direction (to expand the shoe) until the parking brake shoe makes contact and the disc can no longer be turned.

Back off the adjuster to the opposite direction by five notches.

(4) Adjust the parking brake lever stroke to the standard value by turning the adjusting nut.

After the adjustment, ensure that there is no free play between the adjusting nut and the parking brake lever.

C3. REPLACE AIR PURIFIER FILTER M6020400300086

Air purifier filter

AC303997AB

1. Remove the glove box.

2. Remove the two screws as shown, and replace the air purifier filter.

3. Install the glove box.

2-22

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE

OPERATIONS OUTSIDE THE VEHICLE D1. CHECK UNEVEN TYRE WEAR M6020500100205

Check the entire periphery of the tyres for uneven wear. If any tyre shows uneven wear, check the toein and toe-out, and adjust if necessary.

TOE-IN

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.

Tightening torque: 40 ± 5 N⋅m 3. Confirm that the toe-in is at the standard value.

AC306798

4. Use a turning radius gauge to check that the steering angle is at the standard value.

Standard value: Item

AC305666

Using a toe-in gauge, measure toe-in.

Toe-in = B - A Standard value: At the centre of tyre tread: 1 ± 2 mm Toe angle (per wheel): 0°03’± 0°06’

Clip

Lock nut AC102578AE

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).

Inner wheels

Specifications Invite

39°30' ± 1°30'

Intense (L.H. drive vehicles)

33°40' + 1°00'/−2°00’

Intense (R.H. drive vehicles)

37°00' + 1°00'/−2°00’

Outer Invite wheels Intense (L.H. (for drive vehicles) reference) Intense (R.H. drive vehicles)

32°30' 28°46' 30°00'

TOE-OUT ANGLE ON TURNS To check the steering linkage, especially after the vehicle has been involved in an accident or if an accident is presumed, it is advisable to check the toe-out angle on turns in addition to the wheel alignment.

Conduct this test on the left turn as well as on the right turn.

Standard value: Item

Specifications

Toe-out angle on turns (inner 21°42' ± 1°30' wheel when outer wheel at 20°)

2-23

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE

CAMBER, CASTER AND KINGPIN INCLINATION MB991004

AC001079 AB

Standard value: Item

Specifications Invite

Intense

Camber

0°05' ± 0° 30'*

−0°05' ± 0° 30'*

Caster

2°45' ± 0° 30'*

2°55' ± 0° 30'*

Kingpin inclination

12°30' ± 1°30'

12°40' ± 1°30'

NOTE: .

1. *: difference between right and left wheels must be less than 30' 2. Camber and caster are preset at the factory and cannot be adjusted.

3. For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment (MB991004). Tighten the special tool to the same torque 245 ± 29 N⋅m as the driveshaft nut.

2. Carry out adjustment by turning the toe adjusting bolt (control link mounting bolt which is located on the inner side of the body).

Left wheel: Turning clockwise (+) toe-in Right wheel: Turning clockwise (−) toe-in NOTE: The scale has gradations of approximately 2.6 mm (single side toe angle equivalent to 16')

CAUTION To prevent bushings from breakage, the control link mounting nut should be temporarily tightened, and then fully tightened to 120 ± 10 N⋅m with the vehicle on the ground in the unladen condition.

REAR CAMBER <Vehicles with aluminium wheels> MB991014

AC001079 AG

CAUTION To prevent the wheel bearing from damage, never subject the wheel bearings to the vehicle load when the drive shaft nuts are loosened.

Standard value: −0°40' ± 0°30' (Left / right deviation within 30') NOTE: For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the trailing arm spindle by using special tool wheel alignment gauge attachment (MB991014). Tighten the special tool to the same torque. 175 ± 25 N⋅m as the rear wheel hub nut (self-locking nut).

REAR TOE-IN Standard value: At the centre of tyre tread: 3 ± 2 mm Toe angle (per wheel): 0°08’ ± 0°05’

If camber is not within the standard value, adjust by following procedures.

1. Disconnect the conjunction of the control link and the trailing arm.

1. Be sure to adjust the camber before making toe adjustment.

Toe adjusting bolt

Camber adjusting bolt Lower arm assembly

120 ± 10 N·m

AC006159 AC

Control link

Control link AC102499AD

2-24

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE

2. Carry out adjustment by turning the camber adjusting bolt (lower arm assembly mounting bolt which is located on the inner side of the body).

Left wheel: Turning clockwise (+) camber Right wheel: Turning clockwise (−) camber NOTE: The scale has gradations of approximately 14’.

D2. CHECK FRONT WHEEL BEARINGS FOR PLAY M6020500200020

1. Remove the disc brake caliper and suspend it with a wire.

2. Remove the brake disc from the front hub.

Connecting bolt AC102438AD AC006160 AC

3. Tighten the control link to the trailing arm.

CAUTION To prevent bushings from breakage, the connecting bolt should be temporarily tightened, and then fully tightened to 90 ± 10 N⋅m with the vehicle on the ground in the unladen condition.

4. After adjusting the camber, the toe should be adjusted.

3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction.

Limit: 0.05 mm 4. If axial play exceeds the limit, replace the front hub assembly.

D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE M6020500300072

Brake booster assembly

Brake modulator hydraulic unit

Rear disc brake

Front disc brake

1. Check entire circumference and length of hoses and pipes.

AC304027AC

2. Check all clamps for tightness and connections for leakage.

2-25

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE

D4. CHECK BRAKE PADS AND DISCS FOR WEAR

2. Temporarily install the disc with the hub nut.

M6020500400198

ACX00669AF

AC102396AF

1. Check the brake pad thickness through the caliper body check port.

Standard value: 10.0 mm Minimum limit: 2.0 mm 2. When the thickness is less than the limit, always replace the pads at an axle set.

3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.

Limit: <Front> 0.015 mm <Rear> 0.04 mm

D5. CHECK BRAKE SHOE LININGS AND DRUMS FOR WEAR M6020500500021

BRAKE LINING THICKNESS CHECK 1. Remove the brake disc.

ACX00668AF

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: <Front> 26.0 mm <Rear> 10.0 mm Minimum limit: <Front> 24.4 mm <Rear> 8.4 mm 4. If the disc thickness is less than the limits, replace it with a new one.

BRAKE DISC RUN-OUT CHECK 1. Remove the brake assembly, and then hold it with wire.

A

ACX00708AE

2. Measure the thickness of the brake lining at several places.

Standard value (A): 2.8 mm Limit (A): 1.0 mm 3. If the thickness of the brake lining is below the limit, replace the shoe and lining assemblies on both sides of the vehicle. Never replace only one side.

2-26

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

BRAKE DRUM INSIDE DIAMETER CHECK 1. Remove the brake disc.

2. Measure the inside diameter of the brake disc in two places or more.

Standard value (A): 168.0 mm Limit (A): 169.0 mm 3. If the inside diameter exceeds the limit, or if it is excessively worn or one side, replace the brake disc.

A

ACX00709AD

D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION M6020500600073

Fuel filler neck

Fuel vapour canister Fuel delivery pipe

Fuel tank assembly Fuel line pipes AC303014AC

1. Check entire circumference and length of hoses and pipes.

2. Check all clamps for tightness and connections for leakage.

OPERATIONS AFTER ENGINE IS WARMED UP E1. CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION M6020600100020

1. Drive the vehicle until the ATF temperature reaches the normal temperature (70 − 80°C).

2-27

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

NOTE: .

1. Measure ATF temperature using M.U.T.-II/III. Fluid level (mm ) 10 0 -10 -20 -30 80 60 40 Fluid temperature (˚C )

Oil level gauge AC002477AG

2. Check the oil level referring to the characteristics chart if it takes some time to reach the normal operation temperature of ATF (70 − 80°C.) 2. Park the vehicle on a level surface.

3. Move the selector lever to all positions to fully charge the torque converter and the fluid lines with ATF, and then move the selector lever to the N position.

4. After wiping away any dirt from around the oil level gauge, pull out the oil level gauge and check the level of ATF. NOTE: If the ATF has a burnt smell, or if it has become very contaminated or dirty, it means that the ATF has become contaminated by minute particles from bushings (metal) or worn parts. In such a case, the transmission needs to be overhauled and the ATF cooler line needs to be flushed out.

NOTE: If the ATF level is too low, the oil pump draws air into the system along with the ATF, and air bubbles will thus form in the fluid circuit. This will cause a drop in fluid pressure and cause the shift points to change and the clutches and brakes to slip. If the ATF level is too high, the gear will churn the ATF and cause bubbles to develop, which can then cause the same problems as when the ATF is too low. In either case, the air bubbles can cause overheating and oxidation of the ATF, and also prevent the valves, clutches and brakes from operating normally. In addition, if bubbles develop in the ATF, the ATF can overflow from the transmission vent holes and be mistaken for leaks.

6. Securely re-insert the oil level gauge.

E2. CHANGE AUTOMATIC TRANSMISSION FLUID M6020600200232

SPECIFICATIONS Automatic transmission Quantity fluid

Remark

DIA QUEEN ATF SP III 7.7 L

F4A4A

CHANGE PROCEDURE If you have an ATF changer, use the ATF changer to flush the ATF. If you do not have an ATF changer, follow the procedure given below.

Radiator

AC005861AD

5. Check that the ATF level is between the HOT marks on the oil level gauge. If the ATF level is too low, add more ATF until the level reaches between the HOT marks.

Automatic transmission fluid: DIA QUEEN ATF SP III

AC211000 AF

1. Remove the hose shown in the illustration which allows the ATF to flow from the ATF cooler (built into the radiator) to the transmission.

2. Start the engine and discharge the ATF. Driving conditions: N range, idling

CAUTION The engine should be stopped within one minute of it being started. If the ATF has all been discharged before this, stop the engine at that point.

Discharge amount: Approx. 3.5 L

2-28

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

10.Move the selector lever to all positions once, and then return it to the N position.

11.Check that the ATF level on the oil level gauge is at the COLD mark. If it is not up to this mark, add more ATF.

Drain plug

AC103691AG

3. Remove the drain plug at the bottom of the transmission case to drain out the remaining ATF. Discharge amount: Approx. 2.0 L 4. Install the drain plug with a gasket in between, and tighten it to the specified torque.

Tightening torque: 32 ± 2 N⋅m 5. Pour in new ATF through the oil filler tube.

Amount to add: Approx. 5.5 L

CAUTION Stop pouring in the ATF once 5.5 L has been poured in.

6. Repeat the operation in step 2.

7. Pour in new ATF through the oil filler tube.

Amount to add: Approx. 3.5 L NOTE: Carry out steps 2 and 7 so that at least 8.0 L has been discharged from the cooler hose. After this, discharge a small quantity of ATF and check for contamination. If the ATF is contaminated, repeat steps 6 and 7.

Radiator

AC211000 AF

8. Connect the hose which was disconnected in step 1, and then securely re-insert the oil level gauge.

9. Start the engine, and let it run at idle for 1 − 2 minutes.

AC005861AD

12.Drive the vehicle until the ATF temperature reaches the normal temperature (70 − 80°C), and then re-check the ATF level.

The ATF level must be between the HOT marks.

NOTE: .

1. The COLD mark is for reference only; the HOT marks should be used as the standard for judgment.

2. Measure ATF temperature using M.U.T.-II/III. Fluid level (mm ) 10 0 -10 -20 -30 80 60 40 Fluid temperature (˚C )

Oil level gauge AC002477AG

3. Check the oil level referring to the characteristics chart if it takes some time until reaching the normal operation temperature of ATF (70 − 80°C.) 13.When ATF is under the specified level, top up ATF. When ATF is over the specified level, drain the excessive ATF from the drain plug to adjust ATF level to the specified level.

14.Securely insert the oil level gauge into the oil filler tube.

2-29

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

AUTOMATIC TRANSMISSION FLUID COOLER LINE FLUSHING

CAUTION Use care as oil could be hot.

Engine oil pan Engine oip pan drain plug

Radiator

Engine oil pan side

AC208299 AC

AC211000 AF

1. Remove the hose shown in the illustration which allows the ATF to flow from the ATF cooler (built into the radiator) to the transmission.

2. Start the engine and discharge the ATF. Driving conditions: N range, idling

Engine oip pan drain plug

4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque.

Tightening torque: 39 ± 5 N⋅m

CAUTION The engine should be stopped within one minute of it being started. If the ATF has all been discharged before this, stop the engine at that point.

Discharge amount: Approx. 3.5 L 3. Pour in new ATF through the oil filler tube.

Amount to add: Approx. 3.5 L

CAUTION Stop pouring in the ATF once 3.5 L has been poured in.

4. Repeat the operation in steps 2 and 3.

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 ATF and check for contamination. If the ATF is contaminated, repeat steps 2 and 3.

5. Carry out the procedure in "CHANGE PROCEDURE" from step 2 onwards.

E3. CHANGE ENGINE OIL M6020600300109

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C to 90°C. 2. Stop the engine and remove the engine oil filler cap.

3. Remove the drain plug to drain oil.

AC301513

5. Refill with specified quantity of engine oil.

Specified Engine Oil ACEA and API classifications: "ACEA A1, A2, A3"/"FOR SERVICE SG" or higher Total quantity (Includes volume inside oil filter): 3.3 L <4G1> 4.3 L <4G6> 6. Remove the dipstick from the engine, and check whether or not the engine oil level is within the range between MAX and MIN. 7. Install the engine oil fiIler cap.

8. Start the engine and run it for a few minutes.

9. Stop the engine and check the oil level.

E4. REPLACE ENGINE OIL FILTER M6020600400076

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C to 90°C. 2. Remove the engine oil filler cap.

3. Remove the drain plug to drain oil.

CAUTION Use care as oil could be hot.

2-30

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

4. Remove the under cover.

Number MB991396 <4G1>, MB991828 <4G1>, MB991610 <4G6> or commerciallyavailable tool

AC000093 AI

5. Use the respective tool in the following table to remove the engine oil filter.

Special tool

MD348631 <4G1>

Oil filter wrench (MB991828) or equivalent

MD360935 <4G1>

Oil filter wrench (MB991396) or equivalent

MD136466 <4G6>

Commercially- available tool

MD136466 Commercially<4G6> available tool

Approximately 3/4 turn (17 ± 3 N⋅m)

MD322508 <4G6> MD356000 Oil filter wrench Approximately 3/4 <4G6> (MB991610) or turn (14 ± 2 N⋅m) equivalent 9. Install the 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 the oil filter.

M6020600500255

1. Before inspection, set the vehicle to the preinspection condition.

2. Turn the ignition switch to "LOCK" (OFF) position.

Steering shaft

MD322508 <4G6> MD356000 <4G6>

Tightening torque

E5. CHECK ENGINE IDLING SPEED

Number MD365876 <4G1>

Special tool

Oil filter wrench (MB991610) or equivalent

6. Clean the filter bracket side mounting surface.

M.U.T.-II

AC300830AD

Steering shaft 16-PIN O-ring AC103250AD

7. Apply a small amount of engine oil to the O-ring of the new oil filter.

8. Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque.

Number

Special tool

Tightening torque

MB991911 MB991824

MD348631 Oil filter wrench Approximately 3/4 <4G1> (MB991828) or turn (16 ± 4 N⋅m) MD365876 equivalent <4G1> MD360935 Oil filter wrench Approximately 1 turn <4G1> (MB991396) or (14 ± 2 N⋅m) equivalent

MB991827

AK302282AB

2-31

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

3. Connect the M.U.T.-II/III to the diagnosis connector or connect a tachometer to the engine speed detection connector.

4. Connect a timing light.

5. Start the engine and let it run at idle.

6. Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC <4G1> approximately 5° BTDC <4G6> 7. Check the idle speed.

Standard value: 750 ± 100 r/min NOTE: .

1. The idle speed is controlled automatically by the idle speed control system.

2. When using the M.U.T.-II/III, select item No.22 and take a reading of the idle speed.

8. If the idle speed is outside the standard value, inspect the MPI system. (Refer to WORKSHOP MANUAL GROUP 13 − Troubleshooting)

E6. CHECK CO CONCENTRATION M6020601000134

Before inspection, set the vehicle to the preinspection condition.

1. Turn the ignition switch to "LOCK" (OFF) position.

Steering shaft

M.U.T.-II

AC300830AD

Steering shaft 16-PIN

MB991911 MB991824

MB991827

AK302282AB

2. Connect the M.U.T.-II/III to the diagnosis connector or connect a tachometer to the engine speed detection connector.

3. Connect a timing light.

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 <4G1> approximately 5° BTDC <4G6> 6. Run the engine at 2,500 r/min for 2 minutes.

7. Set the CO, HC tester.

8. Check the CO contents and the HC contents at idle.

Standard value CO contents: 0.5% or less <4G1> 0.6% or less <4G6> HC contents: 100 ppm or less

2-32

PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP

9. If there is a deviation from the standard value, check the following items: • Diagnosis output • Fuel pressure • Injector • Ignition coil, spark plug cable, spark plug • EGR control system • Evaporative emission control system • Compression pressure NOTE: Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

EGR CONTROL SOLENOID VALVE CHECK <4G1> 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.

A

B

E8. CHECK EXHAUST GAS RECIRCULATION (EGR) SYSTEM M6020600800096

Battery

EGR CONTROL VALVE CHECK 1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found clean with a suitable solvent so that the valve seats correctly.

AKX00351AE

3. Connect a hand vacuum pump to nipple (A) of the solenoid valve.

4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.

Battery voltage

Normal condition

Applied

Vacuum leaks

Not applied

Vacuum maintained

AKX00348

2. Connect a hand vacuum pump to the EGR 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 EGR passage.

Vacuum

Passage of air

5.3 kPa or less

Air is not blown out

27 kPa or more

Air is blown out

5. Replace the gasket, and tighten to the specified torque.

Tightening torque: 21 ± 4 N⋅m <4G1> 20 ± 2 N⋅m <4G6>

AKX00352

5. Measure the resistance between the terminals of the solenoid valve.

Standard value: 29 − 35 Ω (at 20°C)

2-33

PERIODIC INSPECTION AND MAINTENANCE OTHERS

EGR CONTROL SOLENOID VALVE CHECK <4G6> 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.

4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.

Battery voltage

B nipple condition

Normal condition

Not applied

Open

Vacuum maintained

Applied

Open

Vacuum leaks

Closed

Vacuum maintained

A

B C Battery AK201251AB AK100016

3. Connect a hand vacuum pump to nipple (A) of the solenoid valve.

5. Measure the resistance between the terminals of the solenoid valve.

Standard value: 29 − 35 Ω (at 20°C)

OTHERS F1. CHECK BODY CONDITION FOR DAMAGE M6020700100027

1. Check underbody coating for damage.

2. Check body painting for damage.

F2. ROAD TEST M6020700200080

AC401471

Drive the vehicle and check for conditions.

1. Check free play of steering wheel.

2. Check efficiency of service brakes and parking brakes system.

3. Check driveability of engine.

4. Check condition of instruments, gauges indicators, exterior lamps, heater and ventilators.

5. Check abnormal noise of each part.

6. Check the tyres for wear and for the correct air pressure.

NOTES