Mitsubishi PAJERO IV Service Manual Download Page 39

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OPERATIONS INSIDE THE ENGINE COMPARTMENT

PERIODIC INSPECTION AND MAINTENANCE

2-15

NOTE: During the test, the engine speed and the fuel
pressure is 2, 000 r/min and 180MPa for 20 seconds
respectively.

16.Confirm there is no fuel leak from the joint for the

injection pipe.

A8. CHECK RADIATOR HOSES FOR
DAMAGE AND PROPER CONNECTION

M6020200900545

1. Check entire circumference and length of hoses,

using a mirror as required.

2. Check that hoses installed in grommets pass

through the centre of the grommets.

3. Check all clamps for tightness and connections

for leakage.

A9. CHECK ENGINE COOLANT LEVEL IN
RESERVOIR

M6020201000545

Check that the coolant level is between the "FULL"
and "LOW" lines when the engine is at the normal
operating temperature.

A10. CHANGE ENGINE COOLANT

M6020201100683

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 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 radiator condenser

tank.

6. Install the radiator condenser tank.

CAUTION

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

7. Depending upon conditions of operation,

determine the amount of long life coolant,
antifreeze or antirust to be added to the coolant.

Recommended antifreeze: DIA QUEEN
SUPER LONG LIFE COOLANT or equivalent

8. Fill the cooling system with soft water through the

filler port, and add long life coolant, if necessary.

9. Fill the radiator condenser tank with coolant.
10.Install the radiator cap and the radiator condenser

tank cap.

AC608822AB

<6G7>

AC608825AB

<4M4>

AC608829AB

Condenser tank

AC305655

AC305656

Summary of Contents for PAJERO IV

Page 1: ... AND DISASSEMBLY 0 2 SPECIAL TOOLS 0 3 PARTS TO BE REPLACED 0 3 PARTS 0 3 TUBES AND OTHER RUBBER PARTS 0 3 LUBRICANTS 0 3 BRAKE FLUID 0 3 SERVICING THE ELECTRICAL SYSTEM 0 4 APPLICATION OF ANTI CORROSION AGENTS AND UNDERCOATS 0 4 PRE INSPECTION CONDITION 0 4 VEHICLE WASHING 0 4 MULTI USE TESTER M U T III SUB ASSEMBLY 0 4 IN ORDER TO PREVENT VEHICLES FROM FIRE 0 5 ENGINE OILS 0 5 ...

Page 2: ...deration while they work REMOVAL AND DISASSEMBLY M6001000300023 When checking a malfunction find the cause of the problem If it is determined that removal and or dis assembly 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 wi...

Page 3: ...over gasket Packings O rings Lock washers Split pins Self locking nuts PARTS M6001000600024 When replacing parts use MITSUBISHI genuine parts TUBES AND OTHER RUBBER PARTS M6001000700021 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 M6001000800028 In accordance with the instructions in this manual...

Page 4: ... condition that the vehicle must be in before proper engine inspec tion can be carried out If you see the words Set the vehicle to the pre inspection condition In this man ual it means to set the vehicle to the following condi tion Engine coolant temperature 80 to 90 C Lamps electric cooling fan and all accessories OFF M T Neutral A T P range VEHICLE WASHING M6001001300123 If high pressure car was...

Page 5: ... systems for handling used engine oil and by degreasing components where practicable before handling them Other precautions Avoid prolonged and repeated contact with oils particularly used engine oils Wear protective clothing including impervious gloves where practicable Avoid contaminating clothes particularly under pants with oil Do not put oily rags in pockets the use of overalls without pocket...

Page 6: ...NOTES ...

Page 7: ...13 TYRE AND SPARE TYRE PRESSURES 1 10 14 SUSPENSION SYSTEM 1 10 15 STEERING LINKAGE AND SPLIT PINS 1 11 16 UNDER BODY 1 11 BEFORE ROAD TEST 1 11 17 SEAT ADJUSTERS AND SEATBACK LATCHES 1 11 18 INHIBITOR SWITCH 1 11 19 IDLE CONTROL KNOB 1 11 20 INSTRUMENT PANEL CONTROLS 1 12 21 METERS GAUGES WARNING LAMPS AND INDICATION LAMPS 1 12 22 AIR CONDITIONER HEATER AND DEFROSTER SYSTEM 1 12 23 WIPERS AND WAS...

Page 8: ...SION AND TRANSFER 4WD OIL LEVEL 1 16 38 AUTOMATIC TRANSMISSION FLUID LEVEL 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 17 ...

Page 9: ...g to the sequence described in the TABLE OF PRE DELIVERY INSPECTION Inspection methods are described following the TABLE OF PRE DELIVERY INSPECTION NOTE The spaces for model C Chassis number E engine number aggregate distance travelled in kilometres miles date of inspection name of person conducting the inspection and body colour must be completed without fail NOTE The spaces for place of inspecti...

Page 10: ...ne transmission steering gear box and differential for leaks 40 Front and rear differential oil levels 41 Hoses fluid lines and connections located under vehicle 28 Transmission in all ranges 29 Brakes 30 Steering control 31 Vibration and rattles 32 Electrical equipment 2 Wrap film 3 Exterior 4 Operation of door locking systems and door hinges 5 Operation of door mirrors windows and sunroof 6 Engi...

Page 11: ...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 The peeling may be minor medium or major Pin holes Tiny holes in the painted surface Runs A visible trickle of dried paint on the...

Page 12: ...connector BODY 2 WRAP FILM M6010400100100 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 AC608836AB Relay box Storage connector AC305606 ...

Page 13: ...ff 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 Appl...

Page 14: ...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 NOTE 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 M6010400400112 1 Door mirrors Check that th...

Page 15: ...YLINDER FLUID LEVEL M6010500300026 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 M6010500400108 Check the fluid level if it is low replenish the washer fluid 1 Windshield washer reservoir 2 Rear window washer reservoir 10 BATTERY CONDITION AND CONNECTIONS M6010500500042 Inspect the battery co...

Page 16: ...ached to the spark plugs distributor cap or crank angle sensor and ignition coil UNDER VEHICLE 13 TYRE AND SPARE TYRE PRESSURES M6010600100041 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 ...

Page 17: ...ts 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 Check under body and under body coating for dam age BEFORE ROAD TE...

Page 18: ...in all ranges 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 M6010700700028 1 Front wiper and washer 1...

Page 19: ...ON M6010700900282 1 Check the clutch operation in all driving ranges 2 Check the pedal to floorboard clearance when the clutch is just disengaged 3 Verify correct clutch pedal free play NOTE For inspection and adjustment of the clutch pedal refer to GROUP 2 Periodic Inspec tion and Maintenance 26 OPERATION OF SEAT BELTS SHOULDER BELTS AND RETRACTORS M6010701000022 1 Verify that the seat belt warni...

Page 20: ... 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 br...

Page 21: ...tc AFTER ROAD TEST 33 IDLE SPEED M6010900100172 Check the engine idle speed NOTE For specific idle speed adjustment proce dure refer to GROUP 2 Periodic Inspection and Maintenance 34 IGNITION TIMING M6010900200179 Check the ignition timing Except MPI vehicles with crankshaft mounted crankshaft angle sensor NOTE For the inspection and adjustment of the igni tion timing refer to GROUP 2 Periodic Ins...

Page 22: ... to GROUP 2 Periodic Inspection and Maintenance 38 AUTOMATIC TRANSMISSION FLUID LEVEL M6010900600230 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 NOTE For the specified automatic transmission ...

Page 23: ...ts 2 Spare tyre 3 Jack jack handle and tool set 44 EXTERIOR AND INTERIOR M6011000300187 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 we...

Page 24: ...NOTES ...

Page 25: ... A14 CHECK FLUID LEVEL IN CLUTCH RESERVOIR FOR HYDRAULIC TYPE CLUTCH ONLY 2 18 A15 CHANGE BRAKE FLUID 2 18 A16 CHECK BATTERY ELECTROLYTE LEVEL 2 19 A17 CHECK INJECTION NOZZLE IF DARK SMOKE IS EXHAUSTED OR ENGINE POWER IS LOW 4M40 2 20 A18 REPLACE FUEL FILTER 2 21 OPERATIONS UNDER THE VEHICLE 2 24 B1 CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS 2 24 B2 CHECK SUSPENSION ARM BALL JOINTS FOR PLAY ...

Page 26: ...CS FOR WEAR 2 34 D5 CHECK BRAKE SHOE LININGS AND DISCS FOR WEAR 2 35 D6 CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION 2 36 OPERATIONS AFTER ENGINE IS WARMED UP 2 37 E1 CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION 2 37 E2 CHANGE AUTOMATIC TRANSMISSION FLUID 2 37 E3 CHANGE ENGINE OIL 2 39 E4 REPLACE ENGINE OIL FILTER 2 40 E5 CHECK ENGINE IDLING SPEED AND CO CONCENTRATION 2 41 E6 CHECK EXHAU...

Page 27: ... crankcase emission control system Inspection Every 40 000 km or every 2 years A6 Replace spark plugs 3 earth electrodes semi surfa ce discharge type Leaded petrol pow ered vehicles Replace Every 40 000 km Unleaded petrol pow ered vehicles Replace Every 100 000 km Iridium tipp ed type Unleaded petrol pow ered vehicles Replace Every 100 000 km A7 Check valve clearance except vehicles with auto lash...

Page 28: ... every 20 000 km or every 12 months B2 Check suspension arm ball joints for play and dust covers for damage Inspection Every 20 000 km or every 12 months B3 Lubricate propeller shaft with grease fitting Lubrication Every 20 000 km or every 12 months B4 Check driveshaft boots for damage Inspection Norma l usage Every 20 000 km or every 12 months Severe usage First 1 000 km thereafter every 10 000 k...

Page 29: ...00 km or every 12 months Severe usage Every 5 000 km or every 6 months D5 Check brake shoe linings and discs for wear Inspection Norma l usage Every 40 000 km or every 2 years Severe usage Every 10 000 km or every 6 months D6 Check fuel hoses and pipes for leakage or deterioration Inspection Every 40 000 km or every 2 years OPERATIONS AFTER ENGINE IS WARMED UP E1 Check fluid level in automatic tra...

Page 30: ... E4 Replace engine oil filter 6G7 Replace Norma l usage Every 15 000 km or every 12 months Severe usage Every 5 000 km Replace engine oil filter 4M40 Replace Norma l usage Every 10 000 km or every 12 months Severe usage Every 6 000 km Replace engine oil filter 4M41 Replace Norma l usage Every 15 000 km or every 12 months Severe usage Every 7 500 km E5 Check engine idling speed and CO concentration...

Page 31: ...ommended for check and adjustment of the drive belt tension 1 Connect the Special tool microphone assembly MB992082 to the Special tool belt tension meter MB992081 of the Special tool belt tension meter set MB992080 2 Press the POWER button to turn on the power supply 3 Press number key 1 Check to ensure that No 01 appears on the upper left of the display and that the following numeric values are ...

Page 32: ...surface of the belt should be as close as possible to normal tem perature 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 valu...

Page 33: ... and belt deflection to the standard values 4 Tighten the nut for alternator pivot bolt Tightening torque 47 9 N m 5 Tighten the alternator fixing nut Tightening torque 24 4 N m 6 Tighten the adjusting bolt Tightening torque 5 0 1 0 N m A2 CHECK VACUUM PUMP OIL HOSE FOR DAMAGE M6020200400108 1 Inspect the surface of hose for evidence of heat and mechanical damage A3 CHECK INTAKE AIR HOSE AND TURBO...

Page 34: ...on or damage 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 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 i...

Page 35: ...the top dead centre on the compression stroke If rocker arms have a valve lash the piston in the cylinder corresponding to these rocker arms is at the top dead centre on the compression stroke 6 Valve clearance inspection and adjustment can be performed on rocker arms indicated by white arrow mark when the No 1 cylinder piston is at the top dead centre on the compression stroke and on rocker arms ...

Page 36: ...n by the following procedure White arrow When No 1 cylinder is at compression top dead centre position Black arrow When No 4 cylinder is at compression top dead centre position 1 Use a thickness gauge to measure the valve clearance If deviated from standard value make a note for the valve clearance Standard valve Cold engine Intake side 0 15 0 25 mm Exhaust side 0 25 0 35 mm NOTE There should be c...

Page 37: ...ecrease in func tion and burning Therefore place waste to absorb leaked fuel 2 Use the special tool fuel injection pipe wrench MB992188 to remove the fuel injection pipe 3 Remove the rocker cover CAUTION The crankshaft should always be turned in a clockwise direction 4 Align the camshaft sprocket timing marks and set the No 1 cylinder at top dead centre 5 Measure the valve clearance If the valve c...

Page 38: ...ved injection pipe are up to five times To count how many times the injection pipe is rein stalled record the number of the reinstalla tion histories on the service booklet by adding this latest number of the histories which is usually 1 to the previous one Use a new injection pipe when the total reinstalla tion history numbers reach five times or when the injector or common rail is replaced In th...

Page 39: ...der to flush the cooling system and start the engine 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 radiator condenser tank 6 Install the radiator condenser tank CAUTION Do not use alcohol or metha...

Page 40: ... coolant inside the water jacket 4M4 4 Remove the radiator condenser tank and drain the coolant 5 Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area 6 Apply the designated sealant to the screw area of the cylinder block drain plug and then tighten to the standard torque 6G7 Specified sealant 3M Nut Locking Part No 4171 or equivalent...

Page 41: ...ll the radiator cap 12 Start the engine and let it warm up until the thermostat opens 13 After repeatedly revving the engine up to 3 000 r min several times then stop the engine 14 Remove the radiator cap after the engine has become cold and pour in coolant up to the brim Reinstall the cap CAUTION Do not overfill the radiator condenser tank 15 Add coolant to the radiator condenser tank between the...

Page 42: ...nd replenish as necessary 2 Loosen the bleeder screw and depress the brake pedal supply new brake fluid when the level of the fluid within the reservoir tank decreases Specified brake fluid DOT3 or DOT4 CAUTION Use the specified brake fluid Avoid using a mix ture 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 ...

Page 43: ...hat the pump motor stops per one air bleeding If the brake fluid level in the reservoir has been dropped air may enter the pump motor accidentally To avoid this always maintain the brake fluid between the MIN and MAX marks While the ignition switch is turned ON and the brake pedal is depressed bleed air from the right and left rear brake calipers A16 CHECK BATTERY ELECTROLYTE LEVEL M6020201700577 ...

Page 44: ...on initial pressure increases by approximately 1 177 2 157 kPa INJECTION SPRAY CONDITION CHECK 1 Move the lever of the nozzle tester rapidly 4 6 times per second to eject the fuel continuously Check to be sure that the injection spray comes out evenly in a cone shape injection spray comes out evenly in a cone shape injection spray angle is 0 The injection spray patterns shown in the illustration a...

Page 45: ...uel tank pump module assembly connector fuel tank suction hose fuel high pressure tube CAUTION After connecting the fuel high pressure tube slightly pull it to ensure that it is installed securely Also confirm that there is a play approximately 3 mm 9 Install the service hole cover 10 Spread the floor carpet ant then install the front scuff plate R H and outer seat belt front anchor bolt R H LONG ...

Page 46: ...tly pull it to ensure that it is installed securely Also confirm that there is a play approximately 3 mm 10 Install the service hole cover lower side 11 Install the service hole cover upper side 12 Restore the second seat R H 4M4 1 Remove the fuel tank cap to release the pressure inside the fuel tank 2 Disconnect the connector and the fuel hose and then remove the fuel filter assembly from the bra...

Page 47: ...n the fuel filter cartridge when fuel filter indi cator lamp illuminates Evacuate water by the follow ing procedures 4M40 1 Loosen the water level sensor 2 After water is evacuated by using a hand pump tighten the water level sensor to the specified torque Tightening torque 2 5 0 5 N m 4M41 1 Loosen the drain plug 2 After water is evacuated by using an hand pump tighten the drain plug WATER LEVEL ...

Page 48: ...EHICLE B1 CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS M6020300100342 AC608833 Bends and damage Cracks bends and dents AB Deterioration and sagging REAR SUSPENSION FRONT SUSPENSION Noise and oil leakage Cracks bends and dents Deterioration and sagging Noise and oil leakage Bends and damage ...

Page 49: ... 3 Press the upper arm ball joint cover with your finger to check that there are no cracks or damage in the upper arm ball joint cover 4 If the upper arm ball joint cover is cracked or damaged replace the upper arm ball joint assembly NOTE If the upper arm ball joint cover is cracked or damaged it is possible that there may also be damage to the ball joint B3 LUBRICATE PROPELLER SHAFT WITH GREASE ...

Page 50: ...IN TRANSFER CASE 4WD M6020300700236 1 Remove the filler plug 2 Check that oil level is up to the lower edge of the filler plug hole 3 Check that the oil is not noticeably dirty 4 Tighten the filler plug to the specified torque Tightening torque 32 2 N m B8 CHANGE GEAR OIL IN MANUAL TRANSMISSION M6020300800244 1 Remove the oil filler plug 2 Remove the drain plug and drain the oil 3 Tighten the fill...

Page 51: ...e filler plug 2 Check that gear oil level is not 5 mm below the bottom of filler plug hole 3 Tighten the filler plug to the specified torque Tightening torque 50 10 N m B11 CHANGE GEAR OIL IN FRONT AND REAR DIFFERENTIAL M6020301100356 FRONT DIFFERENTIAL 1 Remove the under cover and filler plug 2 Remove the drain plug and drain oil 3 Tighten the drain plug to the specified torque Tightening torque ...

Page 52: ...ps When the brake fluid is accu mulated in the accumulator the pump motor does not run 2 Operate the pedal by hand and check that the pedal stroke free play meets the standard value at the point where resistance is felt Standard value B 3 mm or less 3 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 ped...

Page 53: ... 3 mm CAUTION Do not push in the master cylinder pushrod at this time otherwise the clutch will not operate properly 4 If the clutch pedal height is not within the standard value loosen the setting nut and the locking nut vehicles with auto cruise control to adjust the clutch pedal height to the standard value and move the pushrod and the clutch switch vehicles with auto cruise control 5 If the cl...

Page 54: ...ase 3200 3800 and then use a flat tip screwdriver to turn the adjuster in the direction of the arrow the direction which expands the shoe so that the disc will not rotate 4 Return the adjuster six notches Short wheelbase Long wheelbase 2800 3000 or eight notches Long wheelbase 3200 3800 in the direction opposite to the direction of the arrow CAUTION If the parking brake lever stroke is below the s...

Page 55: ...e is turned toward the rear of the vehicle 2 Install the clip and tighten the lock nut to the specified torque Tightening torque 93 15 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 CAMBER CASTER AND KINGPIN INCLINATION Standard value NOTE Difference between right and left wheels must be l...

Page 56: ...d tires must be serviced to normal condition before measuring the wheel alignment 2 Measure the wheel alignment with the vehicle parked on a level surface CAMBER Standard value 0 00 30 difference between right and left wheels must be less than 30 NOTE For vehicles with aluminium wheels attach the camber caster kingpin gauge by using a compen sator If camber is not within the standard value adjust ...

Page 57: ...HECK FRONT AND REAR WHEEL BEARINGS FOR PLAY M6020500900041 Front 1 Remove the caliper assembly 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 mm 4 If the play exceeds the limit value disassemble hub knuckle to check each component If the fron...

Page 58: ...00507 1 Check the brake pad thickness through the caliper body check port Standard value 2 When the thickness is less than the limit always replace the pads at an axle set AC608397AB Hydraulic brake booster HBB Front disc brake Rear disc brake AC102396AF Item Brake pad thickness Limit Front Short wheelbase Long wheelbase 2800 3000 10 0 mm 2 0 mm Long wheelbase 3200 3800 11 5 mm 2 0 mm Rear Short w...

Page 59: ...base 2800 3000 3 0 mm Long wheelbase 3200 3800 4 0 mm Limit 1 0 mm 3 If the thickness of the brake lining has worn down to the limit value or more replace the shoe and lining assemblies on both sides of the vehicle BRAKE DISC INSIDE DIAMETER CHECK 1 Remove the brake disc 2 Measure the inside diameter of the brake disc in two places or more Standard value Short wheelbase Long wheelbase 2800 3000 19...

Page 60: ...ES FOR LEAKAGE OR DETERIORATION M6020500600352 1 Check entire circumference and length of hoses and pipes 2 Check all clamps for tightness and connections for leakage AC609411 Fuel injector Fuel tank assembly Petrol powered vehicles Diesel powered vehicles Fuel injector assembly AB Fuel tank assembly ...

Page 61: ... low add more A T fluid until the level reaches between the HOT marks A T fluid DIA QUEEN ATF SP III NOTE If the A T fluid level is too low the oil pump draws air into the system along with the A T fluid and air bubbles will thus from 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 A T fluid level is too ...

Page 62: ...T fluid is contam inated repeat steps 6 and 7 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 P position 11 Check that the A T fluid level on the oil level gauge is at the COLD mark if it is not up to this mark add ...

Page 63: ... out the procedure in CHANGE PROCEDURE from step 2 onwards E3 CHANGE ENGINE OIL M6020600300637 6G7 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C CAUTION Use care as engine oil could be hot 2 Remove the engine oil filler cap 3 Remove the engine oil pan drain plug to drain engine oil 4 Install a new engine oil pan drain plug gasket so that it fa...

Page 64: ...g to drain engine oil 4 Remove the under cover 5 Use the special tool oil filter wrench MB991610 to remove the 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 Oil filter number MD352626 8 Once the O ring of the oil filter is touching the flange use the special tool oil filter wrench MB991610 to tighten to the spec...

Page 65: ...check to be sure that no engine oil leaks from installation section of the oil filter 11 Install the under cover E5 CHECK ENGINE IDLING SPEED AND CO CONCENTRATION M6020600500545 IDLE SPEED AND MIXTURE CHECK AND ADJUSTMENT 6G72 VEHICLES WITHOUT CATALYTIC CON VERTER 1 Before inspection set the vehicle to the pre inspection condition 2 Turn the ignition switch to the LOCK OFF position and then connec...

Page 66: ...ture adjusting screw 11 Remove the timing light 12 Turn the ignition switch to the LOCK OFF position and then remove the M U T III VEHICLES WITH CATALYTIC CONVERTER 1 Before inspection set the vehicle to the pre inspection condition 2 Turn the ignition switch to the LOCK OFF position and then connect the M U T III to the diagnosis connector 3 Set a timing light to the power supply line terminal No...

Page 67: ...t run at idle 5 Check that ignition timing is at the standard value Standard value approximately 10 BTDC NOTE The ignition timing may fluctuate within 7 This is normal NOTE In higher altitude the ignition timing is more advanced than the standard value by approximately 5 NOTE Wait till approximately 1 minute passes after the engine started and check the ignition timing when the engine stabilized 6...

Page 68: ... set the vehicle to the pre inspection condition 2 Turn the ignition switch to the LOOK OFF position and then connect the M U T III to the diagnosis connector 3 Start the engine and let it run at idle 4 Check the idle speed Standard value 700 30 r min 5 If the idle speed is not within the standard value inspect the diesel system Refer to WORKSHOP MANUAL GROUP 13 Troubleshooting 6 Turn the ignition...

Page 69: ...oid valve and without applying voltage 5 Measure the resistance between the terminals of the solenoid valve Standard value 29 35 Ω at 20 C EGR VALVE STEPPER MOTOR CHECK 6G75 Checking the Operation Sound 1 Check that the operation sound of the stepper motor can be heard from the exhaust gas recirculation valve when the ignition switch is turned ON without starting the engine 2 If the operation soun...

Page 70: ...vibrates with a slight shudder indicating that the stepper motor is operating CAUTION Connecting battery voltage to the exhaust gas recirculation valve for a long term could damage the coil 5 Connect the positive terminal of the battery to terminal No 5 6 Connect terminals No 4 and No 6 to the negative terminal of the battery in order to test whether the stepper motor vibrates with a slight shudde...

Page 71: ...e is to be 5 V When the valve is not opened increase the voltage 1 V by 1 V For each voltage current is to be applied within 5 seconds Once the valve is opened the voltage is not to be increased any more 5 Confirm the voltage is changed between the terminal No 1 and No 2 together with the exhaust gas recirculation valve opening movement 6 By the voltage changed the DC is recognized as being normal...

Page 72: ...tion menu 4 Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNCTION menu to execute learning CAUTION If the vehicle conditions go out of the learning conditions during idling learning is inter rupted To reexecute learning the ignition switch must once be turned off 5 Continue idling for about 3 minutes before learning is completed 6 Confirm that the engine warning lamp is off If it stil...

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