Mitsubishi Pajero Sport 2013 Inspection And Maintenance Manual Download Page 7

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1-1

GROUP 1

PRE-DELIVERY

INSPECTION

CONTENTS

NOTES CONCERNING ENTRIES . . .

1-3

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

1-5

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

1-6

1. CONNECTION OF DARK CURRENT

CONNECTOR . . . . . . . . . . . . . . . . . . . . . . .

1-6

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

1-7

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

1-7

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

1-12

4. OPERATION OF DOOR LOCKING

SYSTEMS AND DOOR HINGES . . . . . . . .

1-12

5. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF . . . . . . . . . . .

1-12

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

1-13

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

1-13

7. BRAKE MASTER CYLINDER FLUID

LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-13

8. CLUTCH MASTER CYLINDER

FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . .

1-13

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

1-13

10. BATTERY CONDITION AND

CONNECTIONS . . . . . . . . . . . . . . . . . . . . .

1-13

11. POWER STEERING FLUID LEVEL . . .

1-14

12. ELECTRICAL WIRING . . . . . . . . . . . . .

1-14

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

1-14

13. TYRE AND SPARE TYRE

PRESSURES . . . . . . . . . . . . . . . . . . . . . . .

1-14

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

1-14

15. STEERING LINKAGE AND

SPLIT PINS . . . . . . . . . . . . . . . . . . . . . . . . .

1-15

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

1-15

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

1-16

17. SEAT ADJUSTERS AND

SEATBACK LATCHES . . . . . . . . . . . . . . . .

1-16

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

1-16

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

1-16

20. INSTRUMENT PANEL CONTROLS . . .

1-16

21. METERS, GAUGES, WARNING

LAMPS AND INDICATION LAMPS . . . . . . .

1-16

22. AIR CONDITIONER, HEATER AND

DEFROSTER SYSTEM. . . . . . . . . . . . . . . .

1-16

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

1-17

24. OPERATION OF SERVICE BRAKES

AND PARKING BRAKES . . . . . . . . . . . . . .

1-17

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

1-17

26. OPERATION OF SEAT BELTS,

SHOULDER BELTS AND

RETRACTORS . . . . . . . . . . . . . . . . . . . . . .

1-18

Continued on next page

Summary of Contents for Pajero Sport 2013

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 4 SERVICING THE ELECTRICAL SYSTEM 0 4 APPLICATION OF ANTI CORROSI...

Page 2: ...eration 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 w...

Page 3: ...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 PARTS M6001000600024 When replacing parts use MITSU...

Page 4: ...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 M6001001200115 Pre inspection...

Page 5: ...t 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 the...

Page 6: ...NOTES...

Page 7: ...ND CONNECTIONS 1 13 11 POWER STEERING FLUID LEVEL 1 14 12 ELECTRICAL WIRING 1 14 UNDER VEHICLE 1 14 13 TYRE AND SPARE TYRE PRESSURES 1 14 14 SUSPENSION SYSTEM 1 14 15 STEERING LINKAGE AND SPLIT PINS 1...

Page 8: ...LANT LEVEL 1 20 36 HOSES FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD 1 20 37 MANUAL TRANSMISSION AND TRANSFER 4WD OIL LEVEL 1 20 38 AUTOMATIC TRANSMISSION FLUID LEVEL 1 21 39 ENGINE TRANSMISSION ST...

Page 9: ...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 n...

Page 10: ...e 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...

Page 11: ...cratches 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 a...

Page 12: ...ION NOTE Perform compass calibration in a space where the vehicle can turn around with the engine running 1 The COMPASS SETTING screen is displayed with the user customisation function in the RV meter...

Page 13: ...s may be shipped from the assembly plant to the distributors with a white plastic film or coating wrap film applied for the purpose of protecting the painted exterior from environmental elements where...

Page 14: ...re or low temperature may cause wrap film to become brittle For easier removal the recommended Wrap Film temperature is below 40 C i e If the surface of the vehicle is hot lower it to 40 C or less by...

Page 15: ...will not damage the paint you can avoid trapping air by adhering the wrap film from the centre to the out side of the vehicle Use a tool such as a squeezer to adhere the wrap film firmly to the vehic...

Page 16: ...BODY PRE DELIVERY INSPECTION 1 10...

Page 17: ...BODY PRE DELIVERY INSPECTION 1 11...

Page 18: ...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 plung...

Page 19: ...Specified Brake Fluid DOT3 or DOT4 8 CLUTCH MASTER CYLINDER 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...

Page 20: ...ure 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 M6010600100041 1 Tyre specifi...

Page 21: ...heck 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...

Page 22: ...ses when the idle control knob is pulled out 20 INSTRUMENT PANEL CONTROLS M6010700400083 Check the operation of the following 1 Horn 2 Headlamps 3 Exterior and interior lamps 4 Instrument panel lamps...

Page 23: ...ront 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...

Page 24: ...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 ROAD TEST 27 ENGINE PERFORMANCE...

Page 25: ...n 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 1 Check for excessive play or looseness 2 Check th...

Page 26: ...that the coolant concentration is 30 to 60 36 HOSES FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD M6010900400195 CAUTION Remember that the air conditioner system is under pressure 1 Check all brake f...

Page 27: ...RONT AND REAR DIFFERENTIAL OIL LEVELS M6010900800320 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 only...

Page 28: ...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 Remov...

Page 29: ...AND PROPER CONNECTION 2 27 A9 CHECK ENGINE COOLANT LEVEL IN RESERVOIR 2 27 A10 CHANGE ENGINE COOLANT 2 27 A11 CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE 2 30 A12 REPLACE AIR CLEANER ELEMENT 2...

Page 30: ...THE VEHICLE 2 46 D1 CHECK WHEEL ALIGNMENT 2 46 D2 CHECK FRONT AND REAR WHEEL BEARINGS FOR PLAY 2 48 D3 CHECK BRAKE HOSES AND PIPES FOR LEAKAGE 2 48 D4 CHECK BRAKE PADS AND DISCS FOR WEAR 2 49 D5 CHECK...

Page 31: ...00 km A5 Check operation of crankcase emission control system Inspection Every 40 000 km or every 2 years A6 Replace spark plugs Iridium tipped type Standard type Leaded petrol powered vehicles Replac...

Page 32: ...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 Normal usage Every 20 000 km or every 12 mont...

Page 33: ...rings for play Inspection Every 60 000 km or every 3 years D3 Check brake hoses and pipes for leakage Inspection Every 20 000 km or every 12 months D4 Check brake pads and discs for wear Inspection No...

Page 34: ...nce item Maintenance operation Maintenance interval OPERATIONS INSIDE THE ENGINE COMPARTMENT A1 Check drive belt for cracks fraying wear and adjust its tension Petrol powered vehicles Inspection Every...

Page 35: ...Every 20 000 km or every 12 months A14 Change brake fluid Change Every 40 000 km or every 2 years A15 Check battery condition Inspection Every 20 000 km or every 12 months A16 Replace fuel filter Petr...

Page 36: ...00 km or every 2 years OPERATIONS INSIDE THE VEHICLE C1 Check brake pedal and clutch pedal for free play Inspection Every 20 000 km or every 12 months C2 Check parking brake lever stroke and play Insp...

Page 37: ...re than 50 of operation time at speeds of 120 km h or higher in hot temperatures of 30 C or higher 10 Operation under excessive load OPERATIONS AFTER ENGINE IS WARMED UP E1 Check fluid level in automa...

Page 38: ...wn below Once you set them you do not have to set them again The settings remain undeleted even after battery replacement NOTE This operation is to temporarily set the preset data such as the belt spe...

Page 39: ...he belt is within the standard value NOTE To take the measurement repeatedly fillip the belt again 8 After the completion of the measurement press and hold the POWER button to turn off the power suppl...

Page 40: ...illustration 2 If the mark is out of the area A replace the drive belt NOTE The drive belt tension check is not neces sary as auto tensioner is adopted DRIVE BELT TENSION CHECK 6G74 6B31 CAUTION Chec...

Page 41: ...wn below Once you set them you do not have to set them again The settings remain undeleted even after battery replacement NOTE This operation is to temporarily set the preset data such as the belt spe...

Page 42: ...ator drive belt is within the standard value NOTE To take the measurement repeatedly fillip the alternator drive belt again 8 After the completion of the measurement press and hold the POWER button to...

Page 43: ...9 257 Hz NOTE Refer to Alternator Drive Belt Tension Check for information regarding the vibration frequency measurement method using special tool belt tension meter set MB992080 When the tension is m...

Page 44: ...e in the middle of the A C compressor drive belt between the pulleys shown in the figure at the place indicated by the arrow to check that the drive belt tension is within the standard value Standard...

Page 45: ...lter 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 replac...

Page 46: ...hten them at the specified torque A7 CHECK VALVE CLEARANCE Except vehicles with auto lash adjuster M6020202400870 4M41 NOTE The valve clearance check and adjustment should be done when the engine is c...

Page 47: ...d possibly bend 6 While holding the adjusting screw with a screwdriver to prevent it from turning tighten the lock nut to the specified torque using a valve adjusting socket MB992046 Tightening torque...

Page 48: ...ly check for fuel leak NOTE The oil leak detection agent detects oil leak by colour change when it is applied to the area to be checked For details on how to use the product refer to the instruction m...

Page 49: ...T III 24 Select SPECIAL FUNCTION from MPI GDI DIESEL Screen 25 Select FUEL LEAKAGE CHECK from Test Screen Carry out the fuel leakage check during the test the engine speed and the fuel pressure is 2...

Page 50: ...iming belt cover 5 Remove the rocker cover CAUTION The crankshaft should always be turned in a clockwise direction 6 Align the camshaft sprocket timing marks and set the No 1 cylinder at top dead cent...

Page 51: ...position 10 Measure the valve clearances at the places indicated by arrows in the illustration If the clearance is not within the standard value repeat steps 7 and 8 above 11 Apply specified sealant t...

Page 52: ...supply pump pipe connec tion visually check for fuel leak NOTE The oil leak detection agent detects oil leak by colour change when it is applied to the area to be checked For details on how to use the...

Page 53: ...T III 29 Select SPECIAL FUNCTION from MPI GDI DIESEL Screen 30 Select FUEL LEAKAGE CHECK from Test Screen Carry out the fuel leakage check during the test the engine speed and the fuel pressure is 2...

Page 54: ...oved No 1 cylinder is at top dead centre on compression stroke If the rocker arm of No 6 cylinder at the inlet side is moved up and down and the rocker arm is not moved No 4 cylinder is at top dead ce...

Page 55: ...the FULL and LOW lines when the engine is at the normal operating temperature A10 CHANGE ENGINE COOLANT M6020201101761 1 Stop the engine after it is fully warmed up 2 Add detergent to the engine cool...

Page 56: ...Install the radiator cap and the radiator condenser tank cap CAUTION When removing the radiator cap be careful to blow out steam and boiling water 11 Recheck the engine coolant level after a road test...

Page 57: ...M41 Tightening torque 31 2 N m 7 Connect the engine oil cooler water feed hose of the engine oil cooler 4D56 8 Apply the designated sealant to the screw area of the cylinder block drain plug and then...

Page 58: ...65 L in the radiator con denser tank 4M41 8 5 L 4D56 8 2 L 6G74 8 8 L 6B31 11 0 L 4G64 7 5 L NOTE For how to use special tool refer to its manufacturer s instructions 13 Remove the special tool and th...

Page 59: ...out of fluid during operation air will find way into the brake line Pay attention therefore to the fluid level and replenish as necessary 2 Loosen the bleeder screw and depress the brake pedal supply...

Page 60: ...ect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks 2 Use a hydrometer and thermometer to check the specific gravity of the battery fluid Standard value 1 220 1 290 2...

Page 61: ...filter and pump the hand pump until the hand pump becomes stiff Diesel powered vehicles with plastic fuel filter case 1 Remove the fuel tank cap to release the pressure inside the fuel tank 2 Remove t...

Page 62: ...pump operation becomes stiff REMOVAL OF WATER FROM THE FUEL FILTER Water is in the fuel filter cartridge when fuel filter indicator lamp illuminates Remove water by the following procedures 1 Loosen t...

Page 63: ...floor inspection lid 4 Disconnect the fuel tank pump and gauge assembly connector and fuel high pressure hose 5 Remove the fuel tank pump and gauge assembly mounting nuts CAUTION Pay attention not to...

Page 64: ...thly 7 Tighten the fuel tank pump and gauge assembly mounting nuts to the specified torque Tightening torque 2 5 0 5 N m 8 Connect the fuel tank pump and gauge assembly connector and fuel high pressur...

Page 65: ...k each portion of suspension for damage visually 2 Check each installation bolt and nut for looseness by spanner or similar tool AC801750AB REAR SUSPENSION FRONT SUSPENSION Deterioration and sagging N...

Page 66: ...ball joint 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 damag...

Page 67: ...20302300449 Check oil leakage Check the transmission case for oil leakage visually or by touching it with hand NOTE If an oil leakage is not detected the oil level check is necessary Check oil level 1...

Page 68: ...SMISSION M6020300801117 1 Remove the filler plug and gasket 2 Remove the drain plug and gasket and then drain the oil 3 Install the drain plug and new gasket then tighten them to the specified torque...

Page 69: ...w gasket then tighten them to the specified torque Tightening torque 32 2 N m B10 CHECK FRONT AND REAR DIFFERENTIAL FOR OIL LEAKAGE IN CASE OF LEAKAGE CHECK THE OIL LEVEL M6020301000542 CHECK OIL LEAK...

Page 70: ...gear oil MITSUBISHI MOTORS GENUINE Super Hypoid Gear Oil API classification GL 5 SAE 80 Amount to use 1 2 L 5 Tighten the filler plug to the specified torque Tightening torque 50 10 N m Rear different...

Page 71: ...on of the stop lamp switch etc CLEARANCE BETWEEN BRAKE PEDAL AND DASH PANEL 1 Turn up the carpet etc under the brake pedal 2 Pierce a needle or similar material to the silencer and melting sheets and...

Page 72: ...hrod to adjust 8 After 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 floorbo...

Page 73: ...to move it to the cable rod end so that the cable will be free 3 Raise the vehicle and remove the rear wheels 4 Remove the backing plate adjusting hole plug Then insert a flat tipped screwdriver to tu...

Page 74: ...rned 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 r...

Page 75: ...NT 1 Before the wheel alignment measurement adjust the rear suspension wheel and tyres in good condition 2 Park the vehicle on a level surface to measure the wheel alignment Standard value Toe in 0 mm...

Page 76: ...the axial direction Limit 0 mm 3 If the play exceeds the limit value check the front hub assembly If the wheel bearing is faulty replace the front hub assembly Rear wheel 1 Measure the axle shaft axi...

Page 77: ...hickness at eight positions approximately 45 apart and 10 mm in from the outer edge of the disc Standard value 28 0 mm Front 18 0 mm Rear Limit 26 4 mm Front 16 4 mm Rear 4 If the disc thickness is le...

Page 78: ...IN DISC INSIDE DIAMETER CHECK 1 Remove the brake drum drum in disc 2 Measure the inside diameter of the brake drum drum in disc at two or more locations Vehicles with rear drum in disc brake Standard...

Page 79: ...l reaches between the HOT marks Automatic transmission fluid MITSUBISHI MOTORS GENUINE 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...

Page 80: ...T fluid 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 A...

Page 81: ...e Amount to add Approx 3 5 L 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...

Page 82: ...4 L 8 Install the engine oil filler cap 9 Check oil level 6G74 6B31 4G64 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...

Page 83: ...tool oil filter wrench MH061590 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 engine oil filter Oil fil...

Page 84: ...late and engine room under cover 6B31 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C WARNING Use care as oil could be hot 2 Remove the engine oil...

Page 85: ...in the following table to tighten to the specified torque 9 Install the engine oil pan drain plug and refill the engine oil 10 Install the engine oil filler cap 11 Race the engine 2 3 times and check...

Page 86: ...tion set the vehicle to the pre inspection condition 2 Turn the ignition switch to the LOOK OFF position and connect the M U T III to the diagnosis connector 3 Set the timing light to the terminal No...

Page 87: ...ng 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 st...

Page 88: ...alue inspect the MPI system Refer to WORKSHOP MANUAL GROUP 13 Troubleshooting 8 Remove the timing light 9 Turn the ignition switch to the LOCK OFF position and then disconnect the M U T III E6 CHECK C...

Page 89: ...d 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 NOT...

Page 90: ...andard value inspect the MPI system Refer to WORKSHOP MANUAL GROUP 13 Troubleshooting 10 Remove the timing light 11 Turn the ignition switch to the LOCK OFF position and then disconnect the M U T III...

Page 91: ...d as being normal 7 Use a new gasket and tighten the installation bolt to the tightening torque Tightening torque 48 6 N m CLEANING THE EGR VALVE CAUTION Do not use a solvent or detergent which could...

Page 92: ...R valve and then connect a hand vacuum pump via the three way terminal 2 When the engine is hot or cold check the condition of vacuum by racing the engine When engine is cold Engine coolant temperatur...

Page 93: ...nd connect a hand vacuum pump to the nipple 2 Start the engine 3 Measure engine vacuum at 2 500 r min Standard value 51 kPa or more 4 Reset the vacuum pump to 0 Release vacuum 5 Using a stop watch mea...

Page 94: ...d all accessories OFF Transmission Neutral M T P range A T Power steering Static state 3 Select SPECIAL FUNCTION from the function menu 4 Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNC...

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Mitsubishi Pajero Sport 2013, Inspection And Maintenance Manual

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