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Vehicle Maintenance and Repair Manual

This document provides instructions and guidelines for maintenance and inspections for various vehicle systems. It outlines 24 maintenance items to inspect, such as the fuel system, spark plugs, drive belts, engine oil, brakes, and tires. For each item, it specifies the inspection procedure and recommended replacement schedule.

Uploaded by

Tedy Anto
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
154 views58 pages

Vehicle Maintenance and Repair Manual

This document provides instructions and guidelines for maintenance and inspections for various vehicle systems. It outlines 24 maintenance items to inspect, such as the fuel system, spark plugs, drive belts, engine oil, brakes, and tires. For each item, it specifies the inspection procedure and recommended replacement schedule.

Uploaded by

Tedy Anto
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

00-1

GROUP 00

GENERAL <BODY
AND CHASSIS>
CONTENTS

HOW TO USE THIS MANUAL. . . . . . 00-3 1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTIONS, AND FUEL TANK FILLER
TUBE CAP) (Check for leaks) . . . . . . . . . 00-39
TROUBLESHOOTING GUIDELINES 00-6
2. FUEL HOSES (CHECK CONDITION). . . 00-39
3. AIR CLEANER ELEMENT (Replace) . . . 00-39
HOW TO USE
TROUBLESHOOTING/INSPECTION 4. EVAPORATIVE EMISSION SYSTEM (CHECK
SERVICE POINTS . . . . . . . . . . . . . . . 00-6 FOR LEAKS AND CLOGGING) - EXCEPT
EVAPORATIVE EMISSION CANISTER . 00-40
5. SPARK PLUGS (REPLACE) . . . . . . . . . . 00-40
VEHICLE IDENTIFICATION . . . . . . . 00-15
6. IGNITION CABLES (REPLACE) . . . . . . . 00-40
VEHICLE IDENTIFICATION . . . . . . . . . . . . 00-15
7. TIMING BELT (REPLACE) . . . . . . . . . . . 00-40
VEHICLE INFORMATION CODE PLATE. . 00-17
8. DRIVE BELT (FOR GENERATOR AND WATER
PUMP, POWER STEERING PUMP) (CHECK
PRECAUTIONS BEFORE SERVICE. 00-22 CONDITION) . . . . . . . . . . . . . . . . . . . . . . 00-41
9. EXHAUST SYSTEM (CONNECTION PORTION
TREATMENT BEFORE/AFTER DRIVING OF MUFFLER, PIPINGS AND CONVERTER
THROUGH WATER . . . . . . . . . . . . . . 00-25 HEAT SHIELDS) (CHECK AND SERVICE AS
REQUIRED) . . . . . . . . . . . . . . . . . . . . . . 00-42
TOWING AND HOISTING . . . . . . . . . 00-27 10. ENGINE OIL (CHANGE) . . . . . . . . . . . . 00-42
11. ENGINE OIL FILTER (REPLACE) . . . . 00-43
GENERAL DATA AND SPECIFICATIONS 12. TRANSMISSION FLUID . . . . . . . . . . . . 00-43
................................. 00-30 13. TRANSFER OIL . . . . . . . . . . . . . . . . . . 00-46
14. ENGINE COOLANT (CHANGE) . . . . . . 00-46
TIGHTENING TORQUE . . . . . . . . . . . 00-31 15. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT). . . . . . . . . . 00-48
16. DISC BRAKE PADS (INSPECT FOR
LUBRICATION AND MAINTENANCE 00-32
WEAR). . . . . . . . . . . . . . . . . . . . . . . . . . . 00-48
17. BRAKE HOSES (CHECK FOR
RECOMMENDED LUBRICANTS AND DETERIORATION OR LEAKS) . . . . . . . . 00-48
LUBRICANT CAPACITIES TABLE . . 00-33
18. BALL JOINT AND STEERING LINKAGE
SEALS (INSPECT FOR GREASE LEAKS
SCHEDULED MAINTENANCE AND DAMAGE) . . . . . . . . . . . . . . . . . . . . 00-48
TABLE . . . . . . . . . . . . . . . . . . . . . . . . 00-36 19. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE). . . . . . 00-49
MAINTENANCE SERVICE . . . . . . . . 00-39
Continued on next page
00-2

20. SUSPENSION SYSTEM (INSPECT FOR 23. SRS AIR BAG (INSPECT FOR
LOOSENESS AND DAMAGE) . . . . . . . . 00-49 SRS SYSTEM) . . . . . . . . . . . . . . . . . . . . 00-50
21. REAR AXLE OIL (CHECK OIL 24. TIRES (ROTATE) . . . . . . . . . . . . . . . . . 00-56
LEVEL) . . . . . . . . . . . . . . . . . . . . . . . . . . 00-49
22. PROPELLER SHAFT JOINTS WITH MAIN SEALANT AND ADHESIVE TABLE
GREASE NIPPLE (LUBRICATE WITH ................................. 00-56
GREASE) . . . . . . . . . . . . . . . . . . . . . . . . 00-49
GENERAL <BODY AND CHASSIS>
HOW TO USE THIS MANUAL
00-3
HOW TO USE THIS MANUAL
M1001000100615

MAINTENANCE, REPAIR AND REFERENCE VALUE


SERVICING EXPLANATIONS Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
This manual provides explanations, etc. concerning
adjustment procedures, and so they can be com-
procedures for the inspection, maintenance, repair
pleted in a shorter time).
and servicing of the subject model. Unless otherwise
specified, each service procedure covers all models. .

Procedures covering specific models are identified DANGER, WARNING, AND CAUTION
by the model codes, or similar designation (engine DANGER, WARNING, and CAUTION call special
type, transmission type, etc.). A description of these attention to a necessary action or to an action that
designations is covered in this manual under "VEHI- must be avoided. The differences among DANGER,
CLE IDENTIFICATION." WARNING, and CAUTION are as follows:
. • If a DANGER is not followed, the result is severe
ON-VEHICLE SERVICE bodily harm or even death.
"ON-VEHICLE SERVICE" are procedures for per- • If a WARNING is not followed, the result could be
forming inspections and adjustments of particularly bodily injury.
important locations with regard to the construction • If a CAUTION is not followed, the result could be
and for maintenance and servicing, but other inspec- damage to the vehicle, vehicle components or
tions (for looseness, play, cracking, damage, etc.) service equipment.
must also be performed.
.
TIGHTENING TORQUE INDICATION
SERVICE PROCEDURES The tightening torque indicates a median and its tol-
The service steps are arranged in numerical order. erance by a unit of N⋅m (in-lb) or N⋅m (ft-lb). For fas-
Attention must to be paid in performing vehicle ser- teners with no assigned torque value, refer to
vice are described in detail in SERVICE POINTS. P.00-31.

DEFINITION OF TERMS SPECIAL TOOL NOTE


Only MMC special tool part numbers are called out in
.

STANDARD VALUE
Indicates the value used as the standard for judging the repair sections of this manual. Please refer to the
the quality of a part or assembly on inspection or the special tool cross reference chart, which is located in
value to which the part or assembly is corrected and the service manual at the beginning of each group,
adjusted. It is given by tolerance. for a cross reference from the MMC special tool
number to the special tool number that is available in
your market.
.

LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum MODEL INDICATIONS
or minimum value within which the part or assembly The following abbreviations are used in this manual
must be kept functionally or in strength. It is a value for classification of model types.
established outside the range of standard value. A/T:Indicates automatic transmission, or models
equipped with automatic transmission.
.

MFI:Indicates multiport fuel injection, or engines


equipped with multiport fuel injection.
A/C:Indicates air conditioning.
3.8L Engine:Indicates the 3.8 liter <6G75> engine, or
a model equipped with such an engine.

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00-4 GENERAL <BODY AND CHASSIS>
HOW TO USE THIS MANUAL

when

when

<<A>>
>>A<<

ACX00859 AC

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GENERAL <BODY AND CHASSIS>
HOW TO USE THIS MANUAL
00-5

(continued)

ACX00860 AC

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00-6 GENERAL <BODY AND CHASSIS>
TROUBLESHOOTING GUIDELINES

TROUBLESHOOTING GUIDELINES
M1001008800157
FIND THE PROBLEM
VERIFY THE COMPLAINT After the symptoms have been confirmed, and prob-
• Make sure the customer's complaint and the ser- able causes have been identified, the next step is to
vice writer's work order description are under- make step-by-step checks of the suspected system
stood before starting work. components, junctions, and links in logical order.
• Make sure the correct operation of the system is Use the diagnostic procedures in the service manual
understood. Read the service manual description whenever possible. Follow these procedures care-
to verify any aspect of normal system operation. fully to avoid missing an important step in the diagno-
• Operate the system to see the symptoms. Look sis sequence. It might be the skipped step that leads
for other symptoms that were not reported by the to the solution of the problem.
customer, or on the work order, that may be If the service manual doesn't have step-by-step pro-
related to the problem. cedures to help diagnose the problem, come up with
a series of checks based on the ranked list of proba-
DETERMINE POSSIBLE CAUSES ble causes. Troubleshooting checks should be made
Compare the confirmed symptoms to the diagnostic in the order that the list of causes was ranked:
symptom indexes to get to the right diagnosis proce- • general to specific
dure. • most-likely to least-likely
If the confirmed symptoms can not be found on any • easy-to-check to hard-to-check
symptom index, determine other possible causes.
• Analyze the system diagrams and list all possible REPAIR THE PROBLEM
causes for the problem symptoms. When the step-by-step troubleshooting checks find a
• Rank all these possible causes in order of proba- fault, perform the proper repairs. Make sure to fix the
bility, based on how much of the system they root cause of the problem, not just the symptom. Just
cover, how likely they are to be the cause, and fixing the symptom, without fixing the root cause, will
how easy they will be to check. Be sure to take cause the symptom to eventually return.
experience into account. Consider the causes of
similar problems seen in the past. The list of VERIFY THE REPAIR
causes should be ranked in order from general to After repairs are made, recheck the operation of the
specific, from most-likely to least-likely, and from system to confirm that the problem is eliminated.
easy-to-check to hard-to-check. Make sure to check the system thoroughly. Some-
times new problems are revealed after repairs have
been made.

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE


POINTS
M1001000200515
Troubleshooting of electronic control systems for 2. SYSTEM OPERATION AND SYMPTOM
which the scan tool can be used follows the basic VERIFICATION TESTS
outline described below. Even in systems for which If verification of the symptoms is difficult, procedures
the scan tool cannot be used, part of these systems for checking operation and verifying symptoms are
still follow this outline. shown.

TROUBLESHOOTING CONTENTS
.

3. DIAGNOSTIC FUNCTION
.

The following trouble code diagnosis are shown.


1. STANDARD FLOW OF DIAGNOSTIC TROU-
• How to read diagnostic trouble codes
BLESHOOTING
• How to erase diagnostic trouble codes
Troubleshooting strategy are shown.
• Input inspection service points
.

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GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-7
4. DIAGNOSTIC TROUBLE CODE CHART NOTE: Measure voltage with the ECU connectors
If the scan tool displays a diagnostic trouble code, connected.
retrieve an applicable inspection procedure accord- You may find it convenient to pull out the ECU to
ing to this chart. make it easier to reach the connector terminals.
.
Checks don't have to be carried out in the order
5. SYMPTOM CHART given in the chart.
If there are symptoms, even though the results of 3. If voltage readings differ from normal condition
inspection using the scan tool show that all diagnos- values, check related sensors, actuators, and
tic trouble codes are normal, inspection procedures wiring, then replace or repair.
for each symptom will be found by using this chart. 4. After repair or replacement, recheck with the
.
voltmeter to confirm that the repair has corrected
6. DIAGNOSTIC TROUBLE CODE PROCEDURES the problem.
Indicates the inspection procedures corresponding to .

each diagnostic trouble code. (Refer to P.00-6.) Terminal Resistance and Continuity Checks
. 1. Turn the ignition switch to the "LOCK" (OFF)
7. SYMPTOM PROCEDURES position.
Indicates the inspection procedures corresponding to 2. Disconnect the ECU connector.
each symptoms classified in the Symptom Chart.
(Refer to P.00-6) CAUTION
If resistance and continuity checks are per-
.

formed on the wrong terminals, damage to the


8. SERVICE DATA REFERENCE TABLE
vehicle wiring, sensors, ECU, and/or ohmmeter
Inspection items and normal judgment values have
may occur. Use care to prevent this!
been provided in this chart as reference information.
3. Measure the resistance and check for continuity
between the terminals of the ECU harness-side
.

9. CHECK AT ECU TERMINALS


Terminal numbers for the ECU connectors, inspec- connector while referring to the check chart.
tion items and standard values have been provided NOTE: Checks don't have to be carried out in the
in this chart as reference information. order given in the chart.
.
4. If the ohmmeter shows any deviation from the
Terminal Voltage Checks Normal Condition value, check the corresponding
1. Connect a needle-nosed wire probe to a voltmeter sensor, actuator and related electrical wiring, then
probe. repair or replace.
CAUTION 5. After repair or replacement, recheck with the
Short-circuiting the positive (+) probe between a ohmmeter to confirm that the repair has corrected
connector terminal and ground could damage the problem.
the vehicle wiring, the sensor, the ECU, or all .

three. Use care to prevent this! 10. INSPECTION PROCEDURES USING AN


OSCILLOSCOPE
2. Insert the needle-nosed wire probe into each of
When there are inspection procedures using an
the ECU connector terminals from the wire side,
oscilloscope, these are listed here.
and measure the voltage while referring to the
check chart.
HOW TO USE THE INSPECTION
PROCEDURES
The causes of many of problems occurring in electric
circuitry are generally the connectors, components,
the ECU and the harnesses between connectors, in
that order. These inspection procedures follow this
order. They first try to discover a problem with a con-
nector or a defective component.

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00-8 GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

(1) Relevant circuit(s) of the component which


the DTC indicates are described.

(2) For connector color, refer to GROUP 80A,


How to read configuration diagrams.

(3) Shows the location of the connector(s) from


the circuit(s) above.

B-48(B) (4) Explains about the operation principle of the


component or its relevant parts in that circuit.

ACX00861AH

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GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-9

(5) Explains about technical details. (6) Describes the conditions for that DTC
being set (stored).

(7) Describes possible


cause(s)for that DTC.

(8) Start of the diagnosis procedure


for that DTC.

Vehicle Communication Interface (MUT-III)


MUT-III USB Cable (9) Identifies the special tool(s)
MUT-III Main Harness necessary for diagnosing that DTC.

MB991911

MB991824

MB991827 AC306409AF

(10) Provides the inspection procedure


for that DTC step by step.

AC308626 AB
. .

HARNESS INSPECTION MEASURES TO TAKE AFTER REPLACING THE


Check for an open or short circuit in the harness ECU
between the terminals which were faulty according to If the trouble symptoms have not disappeared even
the connector measurements. Carry out this inspec- after replacing the ECU, repeat the inspection proce-
tion while referring to GROUP 00E, Harness Con- dure from the beginning.
nector Inspection. Here, "Check harness between
power supply and terminal xx" also includes check-
ing for blown fuse. For inspection service points
when there is a blown fuse, refer to "Inspection Ser-
vice Points for a Blown Fuse."

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00-10 GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR MEASUREMENT SERVICE POINTS


Turn the ignition switch to "OFF" when connecting and discon-
necting the connectors. Turn the ignition switch to "ON" when
measuring if there are no instructions to the contrary.
.

IF INSPECTING WITH THE CONNECTOR CONNECTED


(WITH CIRCUIT IN A CONDITION OF CONTINUITY)
<Waterproof Connectors>
Be sure to use special tool. Never insert a test probe from the
SPECIAL TOOL
harness side, as this so will reduce the waterproof performance
and result in corrosion.

ACX00863AE

IF INSPECTING WITH THE CONNECTOR CONNECTED


(WITH CIRCUIT IN A CONDITION OF CONTINUITY)
<Ordinary (non-waterproof) Connectors>
Check by inserting the test probe from the harness side. Note
that if the connector (control unit, etc.) is too small to permit
insertion of the test probe, it should not be forced; use the
backprobing tool for this purpose.

CONNECTOR
AC001606AB

IF INSPECTING WITH THE CONNECTOR DISCONNECTED


<When Inspecting a Female Pin>
From front side of the connector
Required Special Tool:
MB991219: Inspection Harness (contained in MB991223 Test
Harness)
The inspection harness for connector pin contact pressure
should be used. The test probe should never be forcibly
inserted, as it may cause a defective contact.

MB991219

ACX00865 AB

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GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-11
From back side of the connector (SRS-ECU harness side con-
SRS-ECU HARNESS
CONNECTOR
nector)
Since the SRS-ECU harness connector is plated to improve
conductivity, observe the warning below when checking this
connector.
WARNING
Insert the backprobing tool into connector from har-
ness side, and connect the tester to the backprobing
tool. If any tool other than the backprobing tool is
AC001607AB
used, it may cause damage to the harness and other
components. Furthermore, measurement should not
be carried out by touching the backprobing tool
directly against the terminals from the front of the
connector. The terminals are plated to increase their
conductivity, so that if they are touched directly by
the backprobing tool, the plating may break, which
will decrease reliability.
.

IF INSPECTING WITH THE CONNECTOR DISCONNECTED


<When Inspecting a Male Pin>
CAUTION
At this time, be careful not to short the connector pins with
the test probes. To do so may damage the circuits inside
the ECU.
Touch the pin directly with the test bar.

ACX00867 AB

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00-12 GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR INSPECTION SERVICE POINTS


.

VISUAL INSPECTION
• Connector is disconnected or improperly connected
CONNECTOR DISCONNECTED OR • Connector pins are pulled out
IMPROPERLY CONNECTED
• Due to harness tension at terminal section
• Low contact pressure between male and female terminals
• Low connection pressure due to rusted terminals or foreign
matter lodged in terminals

DEFECTIVE CONNECTOR CONTACT

HARNESS WIRE BREAKAGE


AT TERMINAL SECTION

LOW CONTACT
PRESSURE
GOOD
BAD

ACX00868 AB

CONNECTOR PIN INSPECTION


If the connector pin stopper is damaged, the terminal connec-
tions (male and female pins) will not be perfect even when the
connector body is connected, because the pins may pull out of
the back side of the connector. Therefore, gently pull the wires
one by one to make sure that no pins pull out of the connector.

ACX00869AB

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GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-13
CONNECTOR ENGAGEMENT INSPECTION
Required Special Tool:
• MB991219: Inspection Harness (contained in MB991223
Test Harness)
Use special tool, MB991219, to inspect the engagement of the
male pins and female pins. [Pin drawing force: 1 N (0.2 pound)
or more]
MB991219

ACX00870 AB

HOW TO COPE WITH INTERMITTENT 3. Use simulation test


MALFUNCTIONS • In the cases of vibration or poor connections, use
the simulation tests below to attempt to duplicate
Most intermittent malfunctions occur under certain
the customer's complaint. Determine the most
conditions. If those conditions can be identified, the
likely circuit(s) and perform the simulation tests
cause will be easier to find.
.
on the connectors and parts of that circuit(s). Be
TO COPE WITH INTERMITTENT MALFUNCTION; sure to use the inspection procedures provided
for diagnostic trouble codes and trouble symp-
1. Ask the customer about the malfunction
toms.
• Ask what it feels like, what it sounds like, etc.
• For temperature and/or moisture conditions
Then ask about driving conditions, weather, fre-
related intermittent malfunctions try to change the
quency of occurrence, and so on.
conditions of the suspected circuit components,
2. Determine the conditions from the customer's then use the simulation tests below.
responses
4. Verify the intermittent malfunction is elimi-
• Typically, almost all intermittent malfunctions
nated
occur from conditions like vibration, temperature
• Repair the malfunctioning part and try to dupli-
and/or moisture change, poor connections. From
cate the condition(s) again to verify the intermit-
the customer's responses, it should be reasoned
tent malfunction has been eliminated.
which condition is influenced.
.

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00-14 GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

SIMULATION TESTS
NOTE: In case of difficulty in finding the cause of the intermit-
tent malfunction, the data recorder function in the scan tool is
effective.
For these simulation tests, shake, then gently bend, pull, and
twist the wiring of each of these examples to duplicate the inter-
mittent malfunction.
• Shake the connector up-and-down, and right-and-left.
• Shake the wiring harness up-and-down, and right-and-left.
Especially, check the splice points of wiring harnesses care-
fully. Refer to GROUP 00E, HARNESS CONNECTOR
INSPECTION P.00E-2.
• Vibrate the part or sensor.

ACX00871 AB

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GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION
00-15
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the blown fuse and measure the resistance between
the load side of the blown fuse and the ground. Set the
switches of all circuits which are connected to this fuse to a
condition of continuity. If the resistance is almost 0 Ω at this
time, there is a short somewhere between these switches and
BATTERY the load. If the resistance is not 0 Ω, there is no short at the
present time, but a momentary short has probably caused the
fuse to blow.
The main causes of a short circuit are the following.
• Harness being clamped by the vehicle body
FUSE • Damage to the outer casing of the harness due to wear or
heat
SHORT-
CIRCUIT • Water getting into the connector or circuitry
LOAD OCCURRENCE • Human error (mistakenly shorting a circuit, etc.)
SWITCH SECTION

LOAD

ACX00872 AB

VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION
M1001000400638

VEHICLE IDENTIFICATION NUMBER LOCATION


The vehicle identification number (VIN) is located on a plate
attached to the left top side of the instrument panel.

ACX00873 AB

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00-16 GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION CODE CHART PLATE


All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
NO. ITEM CONTENT
1 Country J; Japan
JA4NW51 S14J 000001
2 Make A; Mitsubishi
12
3 Vehicle type 4; Multi-purpose vehicle
1 2 3 4 5 6 7 8 9 10 11 4 Others GROSS VEHICLE WEIGHT
ACX00874 AF RATING/BRAKE SYSTEM
M; 5001-6000lbs/HYDRAULIC
5 Line W; MONTERO
6 Price class 2; Low
3; Medium
5; Premium
7 Body 1; 5-Door wagon
8 Engine S; 3.8L
9 Check digits* 0, 1, 2, 3, -----------9, X
10 Model year 4; 2004 year
11 Plant J; Pajero Manufacturing Co., Ltd.
12 Serial number 000001 to 999999

NOTE: *: Check digit means a single number or letter X used to


verify the accuracy of transcription of vehicle identification num-
ber.

VEHICLE IDENTIFICATION NUMBER LIST


.

<VEHICLES FOR USA>


VIN (EXCEPT SEQUENCE BRAND ENGINE MODEL CODE
NUMBER) DISPLACEMENT
JA4MW31S_4J MITSUBISHI 3.8L V77WLYHVL2M
JA4MW51S_4J MONTERO V77WLYXVL2M
JA4MW21S_4J V77WLYDVL2M
.

<VEHICLES FOR PUERTO RICO>


VIN (EXCEPT SEQUENCE BRAND ENGINE MODEL CODE
NUMBER) DISPLACEMENT
JA4MW31S_4J MITSUBISHI 3.8L V77WLYHVCL2M
MONTERO
.

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GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION
00-17
<VEHICLES FOR CANADA>
VIN (EXCEPT SEQUENCE BRAND ENGINE MODEL CODE
NUMBER) DISPLACEMENT
JA4MW31S_4J MITSUBISHI 3.8L V77WLYHVL3M
JA4MW51S_4J MONTERO V77WLYXVL3M

VEHICLE INFORMATION CODE PLATE


M1001005400451
The vehicle information code plate is riveted onto the cowl top
outer panel in the engine compartment.
The plate shows model code, engine model, transmission
model and body color code.
NO. ITEM CONTENT
1 MODEL V77WLYXV V77W; Vehicle model
L2M
LYXVL2M; Model series
2 ENGINE 6G75 Engine model
3 EXT A69D Exterior code
4 TRANSAXL V5A51 V5A51; Transmission model
E 4300
4300; Rear differential
reduction
5 COLOR, A69 21T A69; Body color code
INT OPT Z08
21T; Interior code
ACX01697 Z08; Equipment code

For monotone color vehicles, the body color code shall be indi-
cated. For two-tone vehicles, each color code only shall be indi-
cated in series.
CHASSIS NUMBER
.

STAMPING LOCATION
The chassis number is stamped on the center of the dash
panel.
.

CHASSIS NUMBER CODE CHART


CHASSIS CONTENT
NUMBER
CODE
V77W3J000001 V77W; V77W; MONTERO
AC203793AB Vehicle line
3J000001; Refer to 10th thru 17th digits of
VIN plate

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00-18 GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION

VEHICLE SAFETY CERTIFICATION LABEL


The vehicle safety certification label is attached to the face of
the left door sill.
This label indicates the month and year of manufacture, Gross
Vehicle Weight Rating (GVWR), front and rear Gross Axle
Weight Rating (GAWR), and Vehicle Identification Number
(VIN).

AC203794AB

ENGINE MODEL STAMPING


The engine model is stamped on the cylinder block.
These engine model numbers are as shown as follows.
ENGINE MODEL ENGINE DISPLACEMENT
6G75 3.8L

The engine serial number is stamped near the engine model


number.

AC203954 AB

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GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION
00-19
THEFT PROTECTION
In order to protect against theft, a Vehicle Identification Number
THEFT PROTECTION PLATE (VIN PLATE) (VIN) is attached as a plate or label to the following major parts
of the engine and transmission, as well as main outer panels:
FOR ENGINE Engine cylinder block, Transmission housing. Fender, Doors,
Liftgate, Quarter panel, Hood, Bumpers
In addition, a theft-protection label is attached to replacement
parts for the body outer panel main components, and the same
data are stamped into replacement parts for the engine and the
transmission.
FOR TRANSMISSION
CAUTION
Cautions regarding panel repairs:
1. When repainting original parts, do so after first masking
the theft-protection label. After painting, be sure to peel
off the masking tape.
2. The theft-protection label for replacement parts is cov-
ered by masking tape, so such parts can be painted as
THEFT PROTECTION LABEL is. The masking tape should be removed after painting
FOR MAIN OUTER PANELS is finished.
3. The theft-protection label should not be removed from
original parts or replacement parts.
[FOR ORIGINAL PARTS]

[FOR REPLACEMENT PARTS]

ACX00878 AB

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00-20 GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION

LOCATIONS
TARGET AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS)

ENGINE AUTOMATIC TRANSMISSION

A B
A

ENGINE UNDERSIDE

ACX01547 AB ACX01191AC

FENDER QUARTER PANEL

A
B

The illustration indicates left outer side. The illustration indicates left outer side.
Right side is symmetrically opposite. Right side is symmetrically opposite.
ACX01192 AB ACX01193 AB

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GENERAL <BODY AND CHASSIS>
VEHICLE IDENTIFICATION
00-21
TARGET AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS)

FRONT DOOR REAR DOOR

The illustration indicates right outer side. B


Left side is symmetrically opposite. The illustration indicates right outer side.
ACX01194 AB Left side is symmetrically opposite. ACX01195 AB

HOOD BACK DOOR

A B

B
ACX01196 AB ACX01197 AB

FRONT BUMPER REAR BUMPER

A B

AC203796AB
AC203795AB

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00-22 GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE

PRECAUTIONS BEFORE SERVICE


M1001000500486

SUPPLEMENTAL RESTRAINT SYSTEM (5) Store components removed from the SRS in a
(SRS) clean and dry place. The air bag module
should be stored on a flat surface and placed
1. Items to follow when servicing SRS
so that the pad surface is facing upward.
(1) Be sure to read GROUP 52B, Supplemental
(6) Never attempt to disassemble or repair the
Restraint System (SRS). For safe operation,
SRS components (SRS-ECU, air bag module,
please follow the directions and heed all
clock spring and seat belt pre-tensioner). If
warnings.
there is a defect, replace the defective part.
(2) Wait at least 60 seconds after disconnecting
(7) Whenever you finish servicing the SRS, check
the battery cable before doing any further
the SRS warning light operation to make sure
work. The SRS system is designed to retain
that the system functions properly.
enough voltage to deploy the air bag even
after the battery has been disconnected. (8) Be sure to deploy the air bag before disposing
Serious injury may result from unintended air of the air bag module or disposing of a vehicle
bag deployment if work is done on the SRS equipped with an air bag. (Refer to GROUP
system immediately after the battery cable is 52B, Air Bag Module Disposal Procedures
disconnected. P.52B-234.)
(3) Warning labels must be heeded when 2. Observe the following when carrying out
servicing or handling SRS components. operations on places where SRS components are
Warning labels can be found in the following installed, including operations not directly related
locations. to the SRS air bag.
• Hood (1) When removing or installing parts, do not allow
• Front impact sensor, side impact sensor any impact or shock to the SRS components.
• Sun visor (2) If heat damage may occur during paint work,
• Glove box remove the SRS components. After
• SRS-ECU re-installing them, check the SRS warning light
• Steering wheel operation to make sure that the system
• Air bag module, side−airbag modules functions properly.
• Clock spring • • SRS-ECU, air bag module, clock spring: 93°C
• Steering gear box (200°F) or more
• Seat belt pre-tensioner • • Seat belt pre-tensioner: 90°C (194°F) or more
(4) Always use the designated special tools and
test equipment.

SERVICING ELECTRICAL SYSTEM


WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
1. Note the following before proceeding with working on the
electrical system.
Never perform unauthorized modifications to any electrical
device or wiring. Such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result in
a fire in the vehicle.

ACX00880AB

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GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
00-23
CAUTION
• Before connecting or disconnecting the negative bat-
tery cable, be sure to turn off the ignition switch and
the lights. (If this is not done, there is the possibility of
semiconductor parts being damaged.)
• After completion of the work steps (when the negative
battery terminal is connected), warm up the engine and
allow it to idle for approximately 10 minutes under the
conditions described below in order to stabilize engine
control conditions, and then check to be sure that the
idling is satisfactory.
2. When servicing the electrical system, disconnect the
negative cable terminal from the battery.
Engine coolant temperature: 85 − 95°C (185 − 203°F)
Lights and all accessories: OFF
Transmission: N or P position
Steering wheel: straight-forward position

VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
APPROXIMATELY spray nozzle at a distance of at least approximately 40cm (16
40 cm (16 in) inches) from any plastic parts and all opening parts (doors, lug-
gage compartment, etc.).

ACX00881AB

APPLYING ANTI-CORROSION AGENT OR OTHER


UNDERCOAT AGENTS
Be careful not to adhere oil or grease to the heated oxygen
sensor. If adhered, the sensor may malfunction. Protect the
heated oxygen sensor with a cover before applying anti-corro-
sion agent, etc.

SCAN TOOL (MUT-III Sub Assembly)


CAUTION
Turn the ignition switch to the "LOCK" (OFF) position
before disconnecting or connecting the scan tool.
NOTE: MUT-III Trigger Harness is not necessary when pushing
V.C.I. ENTER key.

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00-24 GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE

VEHICLE COMMUNICATION MUT-III USB CABLE MUT-III MAIN HARNESS A


INTERFACE (V.C.I.)

DO NOT USE

MB991824 MB991827 MB991910

MUT-III MAIN HARNESS B MUT-III MAIN HARNESS C MUT-III MEASUREMENT ADAPTER

DO NOT USE

MB991911 MB991914 MB991825

MUT-III TRIGGER HARNESS

MB991826 AC2010881AC

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GENERAL <BODY AND CHASSIS>
TREATMENT BEFORE/AFTER DRIVING THROUGH WATER
00-25
TREATMENT BEFORE/AFTER DRIVING THROUGH WATER
M1001000600074

INSPECTION AND SERVICE BEFORE • Inspect the dust boot and breather hose for
DRIVING THROUGH WATER cracks or damage, and replace them if cracks or
damage are found.
Vehicles which are driven through water, or which
may possibly be driven through water, should be
subjected to the following inspections and mainte-
nance procedures in advance.

ACX00850AB

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00-26 GENERAL <BODY AND CHASSIS>
TREATMENT BEFORE/AFTER DRIVING THROUGH WATER

INSPECTION AND SERVICE AFTER • Check for water, mud, sand, etc. in the rear brake
DRIVING THROUGH WATER drum, starter motor, brake pipe and fuel pipe.
• Check for water in the fluid or oil inside the front
After fording a stream, check the following points. If
differential, rear differential, transmission and
abnormal condition is evident, clean, replace or lubri-
transfer.
cate.
• Check all boots and breather hoses for cracks
and damage.

TRANSFER

FILLER PLUG

FRONT DIFFERENTIAL REAR DIFFERENTIAL

FILLER PLUG FILLER PLUG

ACX00851 AB

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GENERAL <BODY AND CHASSIS>
TOWING AND HOISTING
00-27
TOWING AND HOISTING
M1001000800142

WRECKER TOWING RECOMMENDATION


.

FRONT TOWING PICKUP


CAUTION
• Do not tow this vehicle with a wrecker using sling-type
SLING TYPE equipment to prevent the bumper from deformation. If
this vehicle is towed, use wheel lift or flat bed equip-
NO
ment.
• Make sure that the transmission remains in the "N"
position.
• For the four-wheel-drive vehicle, move the transfer shift
lever to "2H" position
WHEEL LIFT TYPE The vehicle may be towed on its rear wheels for extended dis-
tances provided the parking brake is released. It is recom-
mended that vehicles be towed using the front pickup
whenever possible.

FLAT BED TYPE

ACX00883 AB

REAR TOWING PICKUP


CAUTION
• This vehicle cannot be towed by a wrecker using
SLING TYPE sling-type equipment to prevent the lower arm from
deformation.If this vehicle is towed, use a wheel lift or
NO
flat bed equipment.
• Do not use the steering column lock to secure the front
wheel for towing.
• For the four-wheel-drive vehicle, move the transfer shift
lever to "2H" position.
WHEEL LIFT TYPE • If these limits cannot be met, the front wheels must be
placed on a tow dolly.
Automatic transmission vehicle may be towed on the front
wheels at speeds not to exceed 50 km/h (30 mph) for distances
not to exceed 30 km (18 miles).
.

TOWING WHEN KEYS ARE NOT AVAILABLE


FLAT BED TYPE When a locked vehicle must be towed and keys are not avail-
able, the vehicle may be lifted and towed from the front, pro-
vided the parking brake is released. If not released, the rear
wheels should be placed on a tow dolly.

ACX00884 AB

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00-28 GENERAL <BODY AND CHASSIS>
TOWING AND HOISTING

HOISTING
.

EMERGENCY JACKING
FRONT
Place a jack under one of the jacking points shown in the illus-
tration.

JACKING
POINTS

REAR

JACKING
POINTS

AB
ACX01548

FLOOR JACK
CAUTION
• A floor jack must never be used on any part of the
underbody.
• Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
A regular floor jack may be used under the front crossmember
FRONT
or rear frame.

REAR

ACX01698 AB

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GENERAL <BODY AND CHASSIS>
TOWING AND HOISTING
00-29
POST TYPE
CAUTION
When service procedures require removal of the rear sus-
pension, the fuel tank or the spare tire, place additional
weight on the rear end of the vehicle or anchor the vehicle
to a hoist to prevent center of gravity changes.
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations shown in the illustration.
Conventional hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side
frame.

BOLTS SIDE SILL REAR END

ATTACHMENT ATTACHMENT

ACX01699 AB

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00-30 GENERAL <BODY AND CHASSIS>
GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS


M1001000900484

10 11
9

5 7 4 8 6
2 1
AC204542

ITEM V77WLYHVL2M/3M V77WLYXVL2M/3M V77WLYDVL2M V77WLYHVCL2M

Vehicle dimensions
Overall length mm (in) 1 4,830 (190.2) 4,830 (190.2) 4,830 (190.2) 4,830 (190.2)
Overall width mm (in) 2 1,895 (74.6) 1,895 (74.6) 1,885 (74.2) 1,885 (74.2)
Overall height (unladen) 3 1,885 (74.2) 1,885 (74.2) 1,855 (73.0) 1,855 (73.0)
mm (in)
Wheelbase mm (in) 4 2,780 (109.4) 2,780 (109.4) 2,780 (109.4) 2,780 (109.4)
Tread − front mm (in) 5 1,560 (61.4) 1,560 (61.4) 1,560 (61.4) 1,560 (61.4)
Tread − rear mm (in) 6 1,560 (61.4) 1,560 (61.4) 1,560 (61.4) 1,560 (61.4)
Overhang − front mm (in) 7 710 (28.0) 710 (28.0) 710 (28.0) 710 (28.0)
Overhang − rear mm (in) 8 1,305 (51.4) 1,305 (51.4) 1,305 (51.4) 1,305 (51.4)
Minimum running ground 9 235 (9.3) 235 (9.3) 235 (9.3) 235 (9.3)
clearance mm (in)
Angle of approach degrees 10 39° 39° 39° 39°
Angle of departure degrees 11 24° 24° 24° 24°
Vehicle weight kg (lb)
Curb weight 2,145 (4,729) 2,170 2,080 (4,586) 2,090 (4,608)
(4,784)<2M>,
2,175
(4,795)<3M>
Gross vehicle weight rating 2,720 (5,997) 2,720 (5,997) 2,720 (5,997) 2,720 (5,997)
Gross axle weight rating - front 1,200 (2,646) 1,200 (2,646) 1,200 (2,646) 1,200 (2,646)
Gross axle weight rating - rear 1,650 (3,638) 1,650 (3,638) 1,650 (3,638) 1,650 (3,638)
Seating capacity 7 7 5 5
Engine
Model No. 6G75 6G75 6G75 6G75
Piston displacement 3.8L 3.8L 3.8L 3.8L
Transmission
Model No. V5A51 V5A51 V5A51 V5A51

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GENERAL <BODY AND CHASSIS>
TIGHTENING TORQUE
00-31
ITEM V77WLYHVL2M/3M V77WLYXVL2M/3M V77WLYDVL2M V77WLYHVCL2M

Type 5-speed 5-speed 5-speed 5-speed


automatic automatic automatic automatic
Fuel system
Fuel supply system Electronic-controlled multiport fuel injection

TIGHTENING TORQUE
M1001001100146
Each torque value in the table is a standard value for 1. If toothed washers are inserted.
tightening under the following conditions. 2. If plastic parts are fastened.
1. Bolts, nuts and washers are all made of steel and 3. If bolts are tightened to plastic or die-cast
plated with zinc. inserted nuts.
2. The threads and bearing surface of bolts and 4. If self-tapping screws or self-locking nuts are
nuts are all in dry condition. used
The values in the table are not applicable:
Standard bolt and nut tightening torque
THREAD SIZE STANDARD TIGHTENING TORQUE
NOMINAL BOLT PITCH HEAD MARK "4" HEAD MARK "7" HEAD MARK "8"
DIAMETER (mm)
(mm)
M5 0.8 2.5±0.5 N⋅m (23±4 in-lb) 5.0±1.0 N⋅m (44±9 in-lb) 6.0±1.0 N⋅m (53±9 in-lb)
M6 1.0 5.0±1.0 N⋅m (44±9 in-lb) 9.0±2.0 N⋅m (79±18 10±2 N⋅m (89±17 in-lb)
in-lb)
M8 1.25 12±2 N⋅m (107±17 in-lb) 22±4 N⋅m (16±3 ft-lb) 25±4 N⋅m (18±3 ft-lb)
M10 1.25 24±4 N⋅m (18±3 ft-lb) 44±10 N⋅m (33±7 ft-lb) 53±7 N⋅m (39±5 ft-lb)
M12 1.25 41±8 N⋅m (30±6 ft-lb) 83±12 N⋅m (61±9 ft-lb) 98±12 N⋅m (72±9 ft-lb)
M14 1.5 73±12 N⋅m (54±9 ft-lb) 140±20 N⋅m (104±14 155±25 N⋅m (115±18
ft-lb) ft-lb)
M16 1.5 110±20 N⋅m (81±15 ft-lb) 210±30 N⋅m (155±22 235±35 N⋅m (174±25
ft-lb) ft-lb)
M18 1.5 165±25 N⋅m (122±18 300±40 N⋅m (222±29 340±50 N⋅m (251±37
ft-lb) ft-lb) ft-lb)
M20 1.5 225±35 N⋅m (166±26 410±60 N⋅m (303±44 480±70 N⋅m (354±52
ft-lb) ft-lb) ft-lb)
M22 1.5 300±40 N⋅m (222±29 555±85 N⋅m (410±62 645±95 N⋅m (476±70
ft-lb) ft-lb) ft-lb)
M24 1.5 395±55 N⋅m (292±40 735±105 N⋅m (543±77 855±125 N⋅m (631±92
ft-lb) ft-lb) ft-lb)

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00-32 GENERAL <BODY AND CHASSIS>
LUBRICATION AND MAINTENANCE

Flange bolt and nut tightening torque


THREAD SIZE STANDARD TIGHTENING TORQUE
NOMINAL BOLT PITCH HEAD MARK "4" HEAD MARK "7" HEAD MARK "8"
DIAMETER (mm)
(mm)
M6 1.0 5.0±1.0 N⋅m (44±9 in-lb) 10±2 N⋅m (89±17 in-lb) 12±2 N⋅m (107±17 in-lb)
M8 1.25 13±2 N⋅m (111±22 in-lb) 24±4 N⋅m (18±3 ft-lb) 27±5 N⋅m (20±4 ft-lb)
M10 1.25 26±4 N⋅m (19±3 ft-lb) 49±9 N⋅m (36±7 ft-lb) 58±7 N⋅m (43±5 ft-lb)
M10 1.5 24±4 N⋅m (18±3 ft-lb) 45±8 N⋅m (33±6 ft-lb) 55±10 N⋅m (41±7 ft-lb)
M12 1.25 46±8 N⋅m (34±6 ft-lb) 95±15 N⋅m (70±11 ft-lb) 105±15 N⋅m (78±11 ft-lb)
M12 1.75 43±8 N⋅m (32±6 ft-lb) 83±12 N⋅m (61±9 ft-lb) 98±12 N⋅m (72±9 ft-lb)

LUBRICATION AND MAINTENANCE


M1001001200369
Maintenance and lubrication service recommenda- 2. Operation of Vehicle
tions have been compiled to provide maximum pro- (1) Short-trip operation at freezing temperature
tection for the vehicle owner's investment against all (engine not thoroughly warmed up)
reasonable types of driving conditions. Since these (2) More than 50% operation in heavy city traffic
conditions vary with the individual vehicle owner's during hot weather greater than 32°C(90°F)
driving habits, the area in which the vehicle is oper-
(3) Extensive idling
ated and the type of driving to which the vehicle is
(4) Driving in sandy areas
subjected, it is necessary to prescribe lubrication and
maintenance service on a time frequency as well as (5) Driving in salty areas
mileage interval basis. (6) Driving in dusty conditions
Oils, lubricants and greases are classified and (7) Driving off-road
graded according to standards recommended by the
Society of Automotive Engineers (SAE), the Ameri- ENGINE OIL
can Petroleum Institute (API) and the National Lubri- CAUTION
cating Grease Institute (NLGI). Test results submitted to EPA have shown that
laboratory animals develop skin cancer after pro-
MAINTENANCE SCHEDULES longed contact with used engine oil. Accordingly,
Information for service maintenance is provided in the potential exists for humans to develop a
the "SCHEDULED MAINTENANCE TABLE." Three number of skin disorders, including cancer, from
schedules are provided; one for "Required Mainte- such exposure to used engine oil. Therefore,
nance." one for "General Maintenance" and one for when changing engine oil, be careful not to touch
"Severe Usage Service." it as much as possible. Protective clothing and
The item numbers in "SCHEDULED MAINTENANCE gloves, that cannot be penetrated by oil, should
TABLE" correspond to the section numbers in be worn. The skin should be thoroughly washed
"MAINTENANCE SERVICE." with soap and water, or use waterless hand
cleaner, to remove any used engine oil. Do not
SEVERE SERVICE use gasoline, thinners, or solvents.
Vehicles operating under severe service conditions Either of the following engine oils should be used:
will require more frequent service. 1. Engine oil displaying ILSAC certification mark.
Component service information is included in appro- 2. Engine oil conforming to the API classification SL,
priate units for vehicles operating under one or more SL/CF.
of the following conditions: For further details, refer to "LUBRICANTS SELEC-
1. Trailer towing or police, taxi or commercial type TION."
operation.

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GENERAL <BODY AND CHASSIS>
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
00-33
LUBRICANTS AND GREASES Using fuels containing alcohol is not recommended
Semi-solid lubricants bear the NLGI designation and unless the nature of the blend can be determined as
are further classified as grades 0, 1, 2, 3, etc. being satisfactory.
Whenever "Chassis Lubricant" is specified, Multipur- Gasohol: A mixture of 10% ethanol (grain alcohol)
pose Grease, NLGI grade Number 2, should be and 90% unleaded gasoline may be used in your
used. vehicle. If driveability problems are experienced as a
result of using gasohol, it is recommended that the
FUEL USAGE STATEMENT vehicle be operated on gasoline.
Methanol: Do not use gasolines containing meth-
CAUTION anol (wood alcohol). Using this type of alcohol can
Using leaded gasoline in your car will damage result in vehicle performance deterioration and dam-
the catalytic converters and heated oxygen sen- age critical parts in the fuel system components. Fuel
sors, and affect the warranty coverage validity. system damage and performance problems resulting
This vehicle must use unleaded gasoline only. from the use of gasolines containing methanol may
Premium fuel is recommended. not be covered by the new vehicle warranty.
This vehicle has a fuel filler tube which is especially
designed to accept only the smaller-diameter .

GASOLINES CONTAINING METHY TERTIARY


unleaded gasoline dispensing nozzle.
BUTYL ETHER (MTBE)
Your car is designed to operate on premium grade
Unleaded gasoline containing 15% or less MTBE
unleaded gasoline having a minimum octane rating
may be used in your vehicle. (Fuel containing MTBE
of 91 [(MON + RON)/2], or 95 RON. If premium
over 15% in volume may cause reduced engine per-
grade unleaded gasoline is not available, unleaded
formance and produce vapor lock or hard starting.
gasoline having an octane rating of 87 [(MON +
RON)/2], or 91 RON may be used. However, the per-
formance level may be reduced.
MATERIALS ADDED TO FUEL
MON: Motor Octane Number Indiscriminate use of fuel system cleaning agents
RON: Research Octane Number should be avoided. Many of these materials intended
.
for gum and varnish removal may contain highly
GASOLINES CONTAINING ALCOHOL active solvents or similar ingredients that can be
Some gasolines sold at service stations contain alco- harmful to gasket and diaphragm materials used in
hol although they may not be so identified. fuel system component parts.

RECOMMENDED LUBRICANTS AND LUBRICANT


CAPACITIES TABLE
M1001001300429

RECOMMENDED LUBRICANTS
PART SPECIFICATION REMARK
Engine oil Engine oil displaying ILSAC For further details, refer to
certification mark or conforming to "LUBRICANTS SELECTION"
the API classification SL, SL/CF section.
Automatic transmission MITSUBISHI genuine ATF SP-III -
Transfer API classification GL-4 SAE grade number: SAE 75W-90
or 75W/85W
Front axle, Rear axle API classification GL-5 or higher For further details, refer to
"Lubricants Selection" section.

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00-34 GENERAL <BODY AND CHASSIS>
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE

PART SPECIFICATION REMARK


Power steering GENUINE MITSUBISHI POWER -
STEERING FLUID
Brakes Conforming to DOT 3 or DOT 4
Engine coolant MITSUBISHI genuine coolant or -
an equivalent
Door hinges, back door hinges Engine oil -

LUBRICANT CAPACITY TABLE


DESCRIPTION SPECIFICATION
3
Engine oil dm (qt) Oil pan (excluding oil filter) 4.3 (4.5)

Engine oil dm3 (qt) Oil filter 0.3 (0.32)

Engine oil dm3 (qt) Oil cooler 0.3 (0.32)

Engine coolant dm3 (qt) 9.0 (9.5)

Automatic transmission dm3 (qt) 9.3 (9.8)

Transfer dm3 (qt) 2.8 (3.0)


Differential Front axle dm3 (qt) 1.2 (1.3)

Rear axle dm3 (qt) 1.6 (1.7)

Power steering dm3 (qt) 1.0 (1.1)

Fuel tank dm3 (gal) 90 (23.8)

LUBRICANT SELECTION
.

ENGINE OIL
CAUTION
Never use nondetergent or straight mineral oil.
Oil Identification Symbol
ILSAC CERTIFICATION MARK Use only engine oils displaying the ILSAC certification mark
("STARBURST" SYMBOL) ("Starburst" symbol) on the container.

ACX00394AI

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GENERAL <BODY AND CHASSIS>
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
00-35
If these oils are not available, an API classification SL, SL/CF
API SERVICE SYMBOL
can be used.

AC309404AB

Oil Viscosity
The SAE grade number indicates the viscosity of the oil. A
proper SAE grade number should be selected according to
-20 0 20 40 60 80 100 120 F ambient temperature.

-30 -20 -10 0 10 20 30 40 50


-18 38
C
SAE 10W-30

SAE 5W-20, 5W-30

AC309403AB

FRONT AXLE/REAR AXLE


LUBRICANT API CLASSIFICATION GL-5
OR HIGHER
Expected temperature range Viscosity range
Greater than −23°C (−10°F) SAE 90, SAE 85W-90 or SAE
80W-90
−20°C to −34°C (−10°F to SAE 80W or SAE 80W-90
−30°F)
Less than −34°C (−30°F) SAE 75W

SELECTION OF COOLANT
.

COOLANT
Relationship between Coolant Concentration and Specific Gravity

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00-36 GENERAL <BODY AND CHASSIS>
SCHEDULED MAINTENANCE TABLE

CAUTION
• If the concentration of the coolant is less than 30%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is greater than 60%, both the anti-freeze and engine cool-
ing properties will decrease, affecting the engine adversely. For these reasons, be sure to main-
tain the concentration level within the specified range.
• Do not use a mixture of different brands of anti-freeze.

COOLANT TEMPERATURE °C (°F) FREEZING SAFE OPERATING COOLANT


AND SPECIFIC GRAVITY TEMPERATURE TEMPERATURE CONCENTRATION
(SPECIFIC
VOLUME)
10 (50) 20 (68) 30 (86) 40 50 °C (°F) °C (°F) %
(104) (122)
1.054 1.050 1.046 1.042 1.036 −16 (3.2) −11 (12.2) 30
1.063 1.058 1.054 1.049 1.044 −20 (−4) −15 (5) 35
1.071 1.067 1.062 1.057 1.052 −25 (−13) −20 (−4) 40
1.079 1.074 1.069 1.064 1.058 −30 (−22) −25 (−13) 45
1.087 1.082 1.076 1.070 1.064 −36 (−32.8) −31 (−23.8) 50
1.095 1.090 1.084 1.077 1.070 −42 (−44) −37 (−35) 55
1.103 1.098 1.092 1.084 1.076 −50 (−58) −45 (−49) 60

Example
• The safe operating temperature is −15°C (5° F) when the specific gravity is 1.058 at the coolant tempera-
ture of 20° C (68° F)

SCHEDULED MAINTENANCE TABLE


M1001001400448
.

SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE


PERFORMANCE
Inspection and service should be performed any time if a malfunction is observed or suspected.

NO. EMISSION SERVICE KILOMETERS 24 48 72 96 120 144 168 192


CONTROL INTERVALS IN
SYSTEM THOUSANDS
MAINTENANCE MILEAGE IN 15 30 45 60 75 90 105 120
THOUSANDS
MONTHS 12 24 36 48 60 72 84 96
1 Fuel system (tank, Check for leaks X X
pipe line and
connection, and fuel
tank filler tube cap)
2 Fuel hoses Check condition X*3 X X X
3 Air cleaner filter Replace X X X X

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GENERAL <BODY AND CHASSIS>
SCHEDULED MAINTENANCE TABLE
00-37
NO. EMISSION SERVICE KILOMETERS 24 48 72 96 120 144 168 192
CONTROL INTERVALS IN
SYSTEM THOUSANDS
MAINTENANCE MILEAGE IN 15 30 45 60 75 90 105 120
THOUSANDS
MONTHS 12 24 36 48 60 72 84 96
4 Evaporative Check for leaks and clogging X X
emission control
system (except
evaporative
emission canister)
5 Spark plugs Replace X
6 Ignition cables Replace X X
7 Timing belt Replace X*1 X*2 X*4
8 Drive belts (for Check condition X X X X
generator, water
pump, power
steering pump
9 Exhaust system Check and service X*3 X X X
(connection portion
of muffler, muffler
pipes and converter
heat shields)
.

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE


NO. GENERAL SERVICE KILOMETERS 24 48 72 96 120 144 168 192
MAINTENANCE INTERVALS IN
THOUSANDS
MILEAGE IN 15 30 45 60 75 90 105 120
THOUSANDS
MONTHS 12 24 36 48 60 72 84 96
10 Engine oil Change Every 6 months or every 12,000 km (7,500
miles)
11 Engine oil filter Replace Every 6 months or every 12,000 km (7,500
miles)
12 Transmission fluid Check fluid level and condition X X X X X X X X
13 Transfer oil Check oil level and condition X X X X
14 Engine coolant Change X at X X
first
15 Coolant hoses Inspect X X X X
(radiator hose, heater
hose)
16 Disc brake pads, Inspect for wear X X X X X X X X
rotors
17 Brake hoses Check for deterioration or X X X X X X X X
leaks

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00-38 GENERAL <BODY AND CHASSIS>
SCHEDULED MAINTENANCE TABLE

NO. GENERAL SERVICE KILOMETERS 24 48 72 96 120 144 168 192


MAINTENANCE INTERVALS IN
THOUSANDS
MILEAGE IN 15 30 45 60 75 90 105 120
THOUSANDS
MONTHS 12 24 36 48 60 72 84 96
18 Ball joint and steering Inspect for grease leaks and X X X X
linkage seals damage
19 Drive shaft boots Inspect for grease leaks and X X X X X X X X
damage
20 Suspension system Inspect for looseness and X X X X
damage
21 Rear axle oil Check oil level X X X X
22 Propeller shaft joints Lubricate grease X X X X
with grease nipple
23 SRS air bag Inspect system Every 10 years
24 Tires Rotate Every 6 months or every 12,000 km (7,500
miles)
NOTE: .
*1: For California, Massachusetts, Vermont and Maine, this maintenance is recommended but is not required
to maintain the emissions warranty.
*2: This maintenance is not required if previously replaced.
*3: The maintenance is recommended but is not required to maintain the emissions warranty.
*4
: In case of replaced at 96,000km (60,000 miles)/48 months
.

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS


Maintenance should be carried out according to the following table:

NO. MAINTE- SERVICE KILOMETERS 24 48 72 96 120 144 168 192


NANCE INTER- IN
THOUSANDS
ITEM VALS
MILEAGE IN 15 30 45 60 75 90 105 120
THOUSANDS
MONTHS 12 24 36 48 60 72 84 96
3 Air cleaner Replace X X X X X X X X
filter
10 Engine oil Change Every 3 months or every 6,000 km (3,750 miles)
11 Engine oil Replace Every 3 months or every 6,000 km (3,750 miles)
filter
12 Transmission Change X X X X X X X X
fluid (check) (check) (check) (check)
13 Transfer oil Change X X X X
16 Disc brake Inspect for wear Every 6 months or every 12,000 km (7,500 miles)
pads, rotors
20 Suspension Inspect for looseness Every 6 months or every 12,000 km (7,500 miles)
system and damage
24 Tires Rotate Every 3 months or every 6,000 km (3,750 miles)

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-39
Severe usage conditions:
1. Driving on dusty, rough, muddy or salt-spread roads
2. Towing or police, taxi or commercial operation
3. Extensive idling and/or low speed operation
4. Repeated short-trip operation at freezing temperatures (engine not thoroughly warmed up)
5. Extended use of brakes while driving
6. Driving in sandy areas
7. More than 50% operation in heavy city traffic during hot weather above 90°C (32°F)

MAINTENANCE SERVICE
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTIONS, AND FUEL TANK FILLER TUBE
CAP) (Check for leaks)
M1001001600130
1. Check for damage or leakage in the fuel lines and
connections.
2. Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, checking, tears,
cuts, abrasions and excessive swelling indicate deterioration
of the rubber.
3. If the fabric casing of the rubber hose is exposed by cracks
and abrasions in the fuel system, the hoses should be
replaced.

2. FUEL HOSES (CHECK CONDITION)


M1001001700137
Make sure that the hoses do not come in contact with any heat
source or moving component which might cause heat damage
or mechanical wear.

3. AIR CLEANER ELEMENT (Replace)


M1001001800286
The air cleaner element will become dirty during use, reducing
its effect. Replace it with a new one.
.

REPLACEMENT OF AIR CLEANER ELEMENT


1. Loosen the clamp coupling the air intake hose and the air
cleaner housing cover, and separate the air intake hose.
2. Disconnect the volume airflow sensor connector.
3. Disconnect the air cleaner housing cover clips.
4. Remove the air cleaner housing cover and replace the air
ACX01378 AC cleaner element with a new one.
5. Clamp the clips and coupling, and then connect the volume
airflow sensor connector.

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00-40 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

4. EVAPORATIVE EMISSION SYSTEM (CHECK


FOR LEAKS AND CLOGGING) - EXCEPT
EVAPORATIVE EMISSION CANISTER
M1001001900272
If the fuel-vapor vent line is clogged or damaged, the fuel vapor
mixture will escape into the atmosphere causing excessive
emissions. Disconnect the line at both ends, and blow it clean
with compressed air. Remove the fuel tank filler tube cap from
the filler tube and check to see if there is evidence that the
packing makes improper contact to the filler tube.

5. SPARK PLUGS (REPLACE)


M1001002000302

CAUTION
Iridium plugs are used. Use care not to damage the iridium
and platinum tips of the plugs. Do not adjust the spark
plug gap.
1. Spark plugs must spark properly to assure proper engine
performance and reduce exhaust emission level. Therefore,
they should be replaced periodically with new ones.
IRIDIUM
TIP Spark plug type
MAKER IDENTIFICATION NO.
PLATINUM
TIP AKX01327AB NGK IFR6S
DENSO SK20PR-A8

2. The new plugs should be checked for the proper gap.


Spark plug gap: 0.7 − 0.8 mm (0.028 − 0.031 inch)
3. Install the spark plugs and tighten to 25±5 N⋅m (18±4 ft-lb).

6. IGNITION CABLES (REPLACE)


M1001002100064

CAUTION
INCORRECT CORRECT When disconnecting an ignition cable, be sure to hold the
cable boot. If the cable is disconnected by pulling on the
cable alone, an open circuit might result.
The ignition cables should be replaced periodically with new
ones. After replacing, make sure that the ignition cables are
routed properly and fully seated.

AKX00434 AC

7. TIMING BELT (REPLACE)


M1001002300284
Replace the belt with a new one according to the maintenance
schedule on P.00-36 to assure proper engine performance.
For removal and installation procedures, refer to GROUP 11A,
Engine Mechanical − Timing Belt − Removal and Installation
P.11A-36.

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-41
8. DRIVE BELT (FOR GENERATOR AND WATER
PUMP, POWER STEERING PUMP) (CHECK
CONDITION)
M1001002500459
DRIVE BELT TENSION CHECK
Check the drive belt tension by the following procedure.
.

<When using scan tool MB991958>


Required Special Tools:
• MB991668: Belt Tension Meter Set
• MB991958: Scan Tool (MUT-III Sub Assembly)
• MB991824: Vehicle Communication Interface (V.C.I.)
• MB991911: MUT-III Main Harness B
CAUTION
To prevent damage to scan tool MB991824, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991824.
1. Connect special tool MB991668 to scan tool MB991824.
2. Connect scan tool MB991910 to scan tool MB991824.
DATA LINK
CONNECTOR 3. Connect scan tool MB991910 to the data link connector.
4. Turn the ignition switch to the "ON" position and select "Belt
Tension" from the menu scan tool MB991824 screen.
CAUTION
• The temperature of the surface of the belt should be as
close as possible to underhood temperature.
• Do not let any contaminants such as water or oil get
MB991668 onto the microphone.
• If strong gusts of wind blow against the microphone or
if there are any loud sources of noise nearby, the val-
ues measured by the microphone may not correspond
to actual values.
MB991910 • If the microphone is touching the belt while the mea-
surement is being made, the values measured by the
microphone may not correspond to actual values.
MB991824
• Do not take the measurement while the vehicle's engine
AC309175AB
AC309175 is running.
IDLER PULLEY 5. Hold special tool MB991668 (microphone) to the middle of
the drive belt between the pulleys (at the place indicated by
MB991668
(MICROPHONE) the arrow), about 10 − 20 mm (0.4 − 0.8 inch) away from the
15˚ rear surface of the belt and so that it is perpendicular to the
TAP LIGHTLY belt (within an angle of ± 15 degree angle).
15˚ WITH A FINGER
6. Gently tap the middle of the belt between the pulleys (the
GENERATOR
place indicated by the arrow) with your finger as shown in
PULLEY the illustration, and check that the vibration frequency of the
10 – 20mm belt is within the standard value.
(0.4 – 0.8in) AC302702AC Standard value: 88 − 121 Hz
.

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00-42 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

<When using the tension gauge>


IDLER PULLEY
Use a belt tension gauge to check that the belt tension is within
the standard value.
Standard value: 197 − 371 N (44 − 83 lb)
TENSION
GAUGE

GENERATOR
PULLEY

AC302703AC
AC302703

9. EXHAUST SYSTEM (CONNECTION PORTION


OF MUFFLER, PIPINGS AND CONVERTER HEAT
SHIELDS) (CHECK AND SERVICE AS REQUIRED)
M1001005800318
1. Check for holes and gas leaks due to damage, corrosion,
etc.
2. Check the joints and connections for looseness and gas
leaks.
3. Check the hanger rubber and brackets for damage.

10. ENGINE OIL (CHANGE)


M1001002600382
Use the specified oil. (Refer to P.00-33.)
1. After warming up the engine, remove the oil filler cap.
WARNING
Use care. Oil could be hot.
2. Remove the drain plug to allow the engine oil to drain.
DRAIN PLUG
3. Replace the drain plug gasket with a new one, and then
GASKET tighten the drain plug to the specified torque.
NOTE: Install the drain plug gasket so it faces in the direc-
OIL PAN SIDE tion shown in the illustration.
Tightening torque: 39 ± 5 N⋅m (29 ± 3 ft-lb)
4. Pour new engine oil in through the oil filler tube.
Engine oil capacity: 4.3 dm3 (4.5 quarts) [excluding oil
39 ± 5 N·m
29 ± 3 ft-lb filter 0.3 dm3 (0.32 quart), oil cooler 0.3 dm3 (0.32
ACX01795AB quart)]
5. Start the engine and run it at idle for a few minutes.
6. Stop the engine and check to ensure that the engine oil level
is within the level range indicated on the dip stick.
GOOD

MAXIMUM MINIMUM

ACX00892AB

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-43
11. ENGINE OIL FILTER (REPLACE)
M1001002700367
The quality of replacement filters varies considerably. Only high
quality filters should be used to assure most efficient service.
Genuine oil filters require that the filter is capable of withstand-
ing a pressure of 1,765 kPa (256 psi) are high quality filters and
are recommended as follows:
Mitsubishi Oil Filter Part Number: MD352626 or equiv-
alent
.

ENGINE OIL FILTER SELECTION


This vehicle is equipped with a full-flow, throw-away oil filter.
The same type of filter is recommended as a replacement filter
for this vehicle. It is possible, particularly in cold weather, that
this vehicle may develop high oil pressure for a short duration.
Make sure that any replacement filter used on this vehicle is a
high-quality filter. The filter can withstand a pressure of 1,765
kPa (256 psi) [manufacturer's specifications] to avoid the filter
and engine damage. The following is a high-quality filter and is
strongly recommended for use on this vehicle: Mitsubishi
O-RING ACX00893 AB Engine Oil Filter Part number MD352626.
Any replacement oil filter should be installed in accordance with
the oil filter manufacturer's installation instructions.
1. Remove the under cover.
2. Drain the engine oil by removing the oil drain plug.
3. Use an oil filter wrench to remove the engine oil filter.
4. Clean the contact surface of the filter bracket.
5. Lubricate the O-ring of the new oil filter with a small amount
of new engine oil.

12. TRANSMISSION FLUID


M1001002900350

Checking transmission fluid level


FLUID LEVEL [mm (in)] 1. Drive the vehicle until the fluid temperature rises to the
20 (0.8) DIPSTICK normal temperature [70 − 80°C (158 − 176°F)].
10 (0.4) If it takes some amount of time until the transmission fluid
0 (0) reaches its normal operating temperature [70 − 80°C (158 −
–10 (–0.4) 176°F)], check the transmission fluid level by referring to the
–20 (–0.8) diagram at left.
–30 (–1.2) NOTE: The transmission fluid temperature is measured with
–40 (–1.6)
80
scan tool MB991502.
40 60
(104) (140) (176) 2. Park the vehicle on a level surface.
FLUID TEMPERATURE [˚C (˚F)] ACX02008AB
3. Move the selector lever through all positions to fill the torque
converter and the hydraulic circuits with fluid, and then move
the selector lever to the "N" position.
4. After wiping off any dirt from around the dipstick, remove the
dipstick and check the condition of the fluid.
NOTE: If the fluid smells as if it is burnt, it means that the
fluid has been contaminated by fine particles from the bush-
ings and friction materials, a transmission overhaul and
flashing the cooler line flushing may be necessary.

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00-44 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

5. Check that the fluid level is at the "HOT" mark on the


dipstick. If the fluid level is lower than this, pour in more
MITSUBISHI GENUINE ATF SP-III or equivalent until the
level reaches the "HOT" mark.
NOTE: If the fluid level is too low, the oil pump will draw in
air along with the fluid, which will cause bubbles to form.
This will in turn cause the hydraulic pressure to drop, which
will result in late shifting and slipping of the clutches and
brakes.
AC000846AB If the fluid level is too high, the gear makes bubbles in trans-
mission fluid. Same phenomena will occur when the trans-
mission fluid volume is little.
In either case, air bubbles can interfere with normal valve,
clutch, and brake operation. Foaming can cause fluid to
escape from the transmission vent, in which case it may be
mistaken for a leak.
6. Securely insert the dipstick.
NOTE: The fluid and filter should always be replaced when:
.
• When trouble shooting the transmission
• When overhauling the transmission
• When the oil is noticeably dirty or burnt (vehicle was
driven under severe conditions)
Further more, the oil filters are special filters which are only
to be used for the automatic transmission.

Change transmission fluid


If you have a fluid changer, replace the fluid by the following
procedure.
1. Disconnect the hose shown in the illustration which
connects the transmission and the oil cooler (inside the
radiator). Place a container under the hose to collect the
transmission fluid.
2. Start the engine and let the fluid drain out.
Running conditions: "N" range with engine idling
CAUTION
The engine should be stopped within one minute after it is
ACX01184 AB
started. If the fluid has all drained out before then, the
engine should be stopped at that point.
3. Remove the drain plug from the bottom of the transmission
case to drain the fluid.
Discharge volume: Approximately 2.0 dm3 (2.1 quarts)
4. Install the drain plug with a new gasket, and tighten it to the
specified torque.
Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)
5. Pour new transmission fluid in through the oil filler tube.

ACX01185AB
Adding volume: Approximately 6.0 dm3 (6.3 quarts)

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-45
CAUTION
Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in Step 2. (to pump out the rest of the
contaminated fluid)
7. Pour the transmission fluid in through the oil filler tube.
NOTE: Check the fluid for contamination or burnt smell. If
fluid is still contaminated or burnt, repeat Steps 7 and 8
before proceeding to Step 8.
8. Reconnect the hose which was disconnected in step 1
above, and firmly replace the dipstick.
9. Start the engine and run it at idle for 1 − 2 minutes.
10. Move the selector lever through all positions, and then
move it to the "N" position.

ACX01184 AB

11.Check that the fluid level is at the "COLD" mark on the


dipstick. If the level is lower than this, pour in more fluid.

AC000846AB

FLUID LEVEL [mm (in)] 12.Drive the vehicle until the fluid temperature rises to the
20 (0.8) DIPSTICK normal temperature [70 − 80°C (158 − 176°F)], and then
10 (0.4) check the fluid level again. If it takes some amount of time
0 (0) until the transmission fluid reaches its normal operating
–10 (–0.4) temperature [70 − 80°C (158 − 176°F)], check the
–20 (–0.8) transmission fluid level by referring to the diagram at left.
–30 (–1.2)
The transmission fluid level must be at the "HOT" mark.
–40 (–1.6) NOTE: The transmission fluid temperature is measured with
40 60 80
(104) (140) (176) scan tool MB991502. The "COLD" level is for reference
FLUID TEMPERATURE [˚C (˚F)] ACX02008AB only; the "HOT" level should be regarded as the standard
level.
13. Firmly insert the dipstick into the oil filler tube.

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00-46 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

13. TRANSFER OIL


M1001003000134

Checking transfer oil level


1. Remove the filler plug.
2. Check that the oil level is up to the lower edge of the filler
FILLER plug hole.
PLUG HOLE 3. Check that the oil is not noticeably dirty, and that it has a
suitable viscosity.
4. Tighten the filler plug to the specified torque.
OIL LEVEL Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)

ACX00895AB

Changing transfer oil


1. Remove the filler plug.
2. Remove the drain plug and drain oil.
3. Tighten the drain plug to the specified torque.
OIL DRAIN
PLUG OIL FILLER Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)
PLUG
4. Add the oil until the level comes to the lower portion of the
filler plug hole.
Specified oil: Hypoid gear oil SAE 75W-90 or
75W-85W conforming to API classification GL-4
ACX01200 AB Quantity: 2.8 dm3 (3.0 quarts)
5. Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 N⋅m (24 ± 1 ft-lb)

14. ENGINE COOLANT (CHANGE)


M1001003100379
Required Special Tools:
• MB991871: LLC changer
Check the cooling system parts such as the radiator, heater
and oil cooler hoses, thermostat and their connections for leak-
age and damage.
.

Changing Coolant
1. Set the temperature control knob to the "HOT" position.

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-47
WARNING
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
2. Remove the radiator cap, radiator drain plug and engine
RADIATOR CAP
drain plug to drain the coolant.
3. Remove the reserve tank and drain the coolant.
4. After completely draining the coolant, reinstall the drain
DRAIN PLUG plugs and flush the engine and radiator using a radiator
cleaning fluid.
5. After the flushing is completed, completely drain the
cleaning fluid and install the radiator and engine drain plugs.
6. Assemble the reservoir tank.
LOOSEN ACX00896 AB
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 aluminum components.
7. <Refilling engine coolant without the special tool>
(1) Loosen the air bleed bolt.
(2) By referring to the section on coolant, select an
appropriate concentration for safe operating temperature
AIR BLEED BOLT
within the range of 30 to 60%. Refill the system with a
14±1 N·m high quality ethylene glycol antifreeze at the selected
120±13 in-lb
concentration. A convenient mixture is a 50% water and
50% antifreeze solution [freezing point: −31°C (−32.8°F)].
Pour in coolant until it overflows from the air bleed bolt
CAUTION LABEL hole, and then tighten the air bleed bolt.

AC203797AB

8. <When special tool MB991871 is used>


AIR HOSE By referring to the section on coolant, select an appropriate
MB991871 concentration for safe operating temperature within the
range of 30 to 60 %. Use special tool MB991871 to refill the
coolant. A convenient mixture is a 50 % water and 50 %
antifreeze solution [freezing point: −31°C (−32.8 °F)].
NOTE: For how to use special tool MB991871, refer to its
manufacturer’s instructions.
Recommended antifreeze: Long life antifreeze cool-
AC204032AB
ant or an equivalent
Quantity: 9.0 dm3 (9.5 quarts)
9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the thermostat
opens.
11.After repeatedly revving the engine up to 3,000 r/min several
times, then stop the engine.

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00-48 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

12.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 reserve tank.
13.Add coolant to the reserve tank between the "FULL" and
"LOW" mark if necessary.

15. COOLANT HOSES (RADIATOR HOSE,


HEATER HOSE) (INSPECT)
M1001009700045
Inspect the surface of radiator hoses and heater hoses for heat
and mechanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indicate deterio-
ration of the rubber.

16. DISC BRAKE PADS (INSPECT FOR WEAR)


M1001003200310
Check for fluid contamination and wear. Replace the complete
set of pads if defective.
Thickness of lining
Minimum limit: 2.0 mm (0.08 inch)
CAUTION
The pads for the right and left wheels should be replaced
at the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.
ACX00898AB

17. BRAKE HOSES (CHECK FOR


DETERIORATION OR LEAKS)
M1001003400336
Inspection of brake hoses and tubing should be included in all
brake service operations.
The hoses should be checked for:
1. Incorrect length, severe surface cracking, pulling, scuffing or
worn spots. (If the fabric casing of the hoses is exposed by
cracks or abrasion in the rubber hose cover, the hoses
should be replaced. Eventual deterioration of the hose and
possible bursting failure may occur.)
2. Incorrect installation, twisting or interference with wheel, tire
or chassis.

18. BALL JOINT AND STEERING LINKAGE


SEALS (INSPECT FOR GREASE LEAKS AND
DAMAGE)
M1001003500344
1. These components, which are permanently lubricated at the
factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
contamination.
2. Inspect the dust cover and boots for proper sealing, leakage
and damage, and replace them if defective.

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-49
19. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE)
M1001003600330
1. These components, which are permanently lubricated at the
factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
contamination.
2. Inspect the dust cover and boots for proper sealing, leakage
and damage. Replace them if defective.

20. SUSPENSION SYSTEM (INSPECT FOR


LOOSENESS AND DAMAGE)
M1001009600060
Visually inspect the front/rear suspension components for dete-
rioration and damage. Re-tighten the front/rear suspension
components retaining bolts to specified torque.

21. REAR AXLE OIL (CHECK OIL LEVEL)


M1001007500078

Rear differential Oil Check


Check that gear oil level is not 5 mm (0.2 inch) below the bot-
tom of filler plug hole.
GEAR OIL
Specified gear oil: Hypoid gear oil API classification
GL-5 or higher
Above −23°C(−10°F): SAE90, 85W-90, 80W-90
UPPER From −34°C to −23°C(−30°F to −10°F): SAE80W,
LIMIT
80W-90
LOWER Below −34°C(−30°F): SAE75W
LIMIT 5 mm
(0.2 in)
ACX01083AB

22. PROPELLER SHAFT JOINTS WITH GREASE


NIPPLE (LUBRICATE WITH GREASE)
M1001007300104
Lubricate the propeller shaft joints with grease.
The propeller shaft joints should be repacked with multipurpose
grease.

ACX01798

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00-50 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

23. SRS AIR BAG (INSPECT FOR SRS SYSTEM)


M1001003700348
The SRS must be inspected by an authorized dealer 10 years
after the car manufacture date shown on the certification label
located on the left center sill.
.

SRS Warning Light Check

DATE OF
MANUFACTURE
CERTIFICATION LABEL
2000

ACX00901AB

Turn the ignition key to the "ON" position. Does the "SRS"
SRS WARNING LIGHT
AT
TEMP
warning light illuminate for about seven seconds, and then
SRS
remain off for at least five seconds after turning OFF? If yes,
the SRS system is functioning properly. If no, refer to GROUP
6 7 52B, Diagnosis P.52B-22.
5 8
P
4 R .

3
N
D SRS Component Visual Check
5
2 4
3
1 2
x1000r/min
1 ACX01667AB
DANGER
Wait at least 60 seconds after disconnecting the bat-
TAPE tery cable before doing any further work. The SRS
BATTERY
system is designed to retain enough voltage to
deploy the air bag for a short time even after the bat-
tery has been disconnected, so serious injury may
result from unintended air bag deployment if work is
done on the SRS system immediately after the battery
cable is disconnected.
BATTERY CABLE
ACX00902 AB
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
1. Turn the ignition switch to the "LOCK" (OFF) position,
disconnect the negative battery cable and tape the terminal.
2. Remove the floor console assembly. (Refer to GROUP 52A,
Floor Console P.52A-7.)
3. Disconnect a connector from the SRS-ECU.
.

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-51
Front Impact Sensors
1. Check that the arrows on the sensors face toward the front
of the vehicle.
FRONT IMPACT SENSORS
WARNING
The SRS may not activate if a front impact sensor is
not installed properly, which could result in serious
injury or death to the vehicle's driver and passenger.
2. Check the radiator support panel and front impact sensor for
deformation or rust.
3. Check the front impact sensor wiring harness for
ACX01318 AB
binding;check the connector for damage; and check the
terminals for deformation.
Replace the sensor and/or wiring harness if they fail the
visual check. (Refer to GROUP 52B, SRS Service
Precautions P.52B-18 and GROUP 52B, Front Impact
Sensor P.52B-211.)
.

Side Impact Sensors


WARNING
• If the side impact sensor is not installed securely
and correctly, the side-airbag may not operate nor-
mally.
• If a dent, crack, deformation or rust is detected,
replace with a new sensor.
1. Check the side impact sensor for dents, cracks or
CENTER deformation. The side impact sensors are located inside the
PILLAR
SIDE center pillars (LH/RH).
IMPACT 2. Check the connector for damage, and terminal for
SENSOR deformation.
FORWARD
3. Check that there is no bending or corrosion in the center
pillars (LH/RH).
NOTE: The illustration at left shows the right side impact sen-
sor (RH). The position of the side impact sensor (
ACX00591AC LH) is symmetrical to this.
.

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00-52 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

SRS Air Bag Control Unit (SRS-ECU)


WARNING
The SRS may not activate if the SRS-ECU (with
built-in safing G-sensor and analog G-sensor) is not
installed properly, which could result in serious injury
or death to the vehicle's driver and passenger.
1. Check the SRS-ECU case and brackets for dents, cracks,
SRS-ECU deformation or rust.
2. Check the connector for damage, and check the terminals
for deformation or rust.
Replace the SRS-ECU if it fails the visual check. (Refer to
GROUP 52B, SRS Air bag Control Unit P.52B-215.)
.

Air Bag Module, Steering Wheel and Clock Spring


ACX00587AB
WARNING
The removed air bag module should be stored in a
clean, dry place with the pad cover face up.
1. Remove the air bag module, steering wheel and clock
spring. (Refer to GROUP 52B, Air Bag Module and Clock
Spring P.52B-217.)
2. Check the pad cover for dents, cracks or deformation.
DRIVER'S INFLATOR 3. Check the connector for damage and deformed terminals,
SIDE CASE and check the harness for binding.
4. Check the air bag inflator case for dents, cracks or
deformation.
5. Check the harness (built into the steering wheel) and
connectors for damage, and check the terminals for
deformation.

CONNECTOR

PASSENGER'S
SIDE
CONNECTOR

INFLATOR
CASE ACX00589 AB

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-53
6. Check the clock spring connectors and protective tube for
CASE damage, and terminals for deformities.
7. Visually check the case for damage.
WARNING
If the clock spring's mating mark is not properly
aligned, the steering wheel may not completely rotate
during a turn, or the flat cable within the clock spring
PROTECTIVE may be severed, obstructing normal operation of the
TUBES
ACX01302 AB
SRS and possibly leading to serious injury to the
vehicle's driver and passenger.
8. Align the mating marks of the clock spring, and after turning
the front wheels to the straight-ahead position, install the
clock spring to the column switch.
Mating marks alignment
• After turning the clock spring fully clockwise, turn it approxi-
mately 3 4/5 turns counterclockwise until the mating marks
are aligned.
MATING MARK

ACX00602 AB

9. Install the steering column covers, steering wheel and air


bag module.
10.Check the steering wheel for noise, binding or difficult
AIR BAG operation.
MODULE
DANGER
The SRS may not activate if any of the above compo-
nents are not installed properly, which could result in
serious injury or death to the vehicle's driver and pas-
ACX01319 AB senger.
11.Check the steering wheel for excessive free play.
REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS
THAT INSPECTION. (Refer to GROUP 52B, Air Bag Module
and Clock Spring P.52B-217.)
.

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00-54 GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE

Front Seatback Assembly with Side-airbag Module


WARNING
• If any improper part is found during the following
inspection, replace the front seatback assembly
with a new one.
• Dispose of the old one according to the specified
procedure. (Refer to GROUP 52B, Air Bag Module
and Seat Belt Pre-Tensioner Disposal Procedures
P.52B-234.)
• Never attempt to measure the circuit resistance of
the air bag module (squib) even if you are using
the specified tester. If the circuit resistance is mea-
sured with a tester, accidental air bag deployment
will result in serious personal injury.
1. Check the air bag module deployment section for dents or
AIR BAG MODULE deformation.
DEPLOYMENT
SECTION 2. Check the connector for damage; check the terminals for
deformation; and check the harness for binding.
.

Seat belt with pre-tensioner


WARNING
• If the seat belt pre-tensioner is not installed
ACX00590 AC
securely and correctly, the seat belt pre-tensioner
may not operate normally.
• If a dent, crack, deformation or rust is detected,
replace with a new seat belt 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.
.

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GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-55
WIRING HARNESS

INSTRUMENT WIRING
HARNESS

SIDE - AIRBAG
WIRING HARNESS

FRONT WIRING FLOOR WIRING


HARNESS HARNESS

SEAT BELT WITH


PRE-TENSIONER

AC205493AB
1. Check the connector for poor connection.
DANGER
The SRS system may not operate if SRS harnesses or
connectors are damaged or improperly connected,
which could result in serious injury or death to the
vehicle's driver and passenger.
2. Check the harness for binding; check the connectors for
damage; and check the terminals for deformation.
REPLACE ANY CONNECTORS OR HARNESS THAT FAIL
THE VISUAL INSPECTION. (Refer to GROUP 52B, SRS
Service Precautions P.52B-18.)

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00-56 GENERAL <BODY AND CHASSIS>
MAIN SEALANT AND ADHESIVE TABLE

24. TIRES (ROTATE)


M1001008900325
Rotate tires regularly to equalize tire wear and help extend tire
life. Recommended tire rotation is every 12,000 km (7,500
miles) under normal driving conditions and every 9,600 km
(6,000 miles) in severe driving conditions.
Timing for the rotation may vary according to vehicle condition,
road surface conditions, and individual driver's habits.
When rotating tires, check for uneven wear, damage, and
wheel alignment. Abnormal wear is usually caused by incorrect
tire pressure, improper wheel alignment, out-of balance
ACX00903 AB wheels, or severe braking.
The first rotation is the most important to achieve more uniform
wear for all tires on the vehicle.

MAIN SEALANT AND ADHESIVE TABLE


M1001003800152

APPLICATION 3M NO. LOCTITE/


PERMATEXNO.
ENGINE AND Between rocker cover and 3M AAD Part No. 8660 Permatex Ultra Black
DRIVETRAIN camshaft bearing cap. Ultrapro High Temp. Silicone 598, No.82180
Between rocker cover, Gasket or 3M AAD Part No.
semicircular packing and 8679 Black/8678 Black
cylinder head. Between oil Press-In-Place Silicone
pressure switch and engine. gasket strips
Between engine coolant 3M AAD Part No. 8731 Loctite242 Blue Service
temperature switch, engine Medium Strength Blue Tool Removable 24200
coolant temperature sensor, Threadlocker
thermo valve, thermo switch,
joint, engine coolant
temperature gauge unit
(large-size) and engine
Between oil pan and engine 3M AAD Part No. 8672, Permatex Ultra Gray
block 3M AAD Part No. 8704 or 599, No.82194
3M AAD Part No. 8679/
3M AAD Part No. 8678
WEATHERSTRI Between tempered glass, 3M AAD Part No. 8509 -
PPING FOR body flanges, and Auto Bedding and Glazing
GLASS weatherstrip Compound or 3M AAD Part
No. 8633 Windo-weld
Resealant
WEATHERSTRI Between laminated glass and 3M AAD Part No. 8633 -
PPING FOR weatherstrip
GLASS

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GENERAL <BODY AND CHASSIS>
MAIN SEALANT AND ADHESIVE TABLE
00-57
APPLICATION 3M NO. LOCTITE/
PERMATEXNO.
INTERIORS Adhesive of vinyl chloride 3M AAD Part No. 8088 Permatex Vinyl Repair
cloth General Trim Adhesive or Kit No.81786
3M AAD Part No. 8064
Vinyl Trim Adhesive
Adhesion of door 3M AAD Part No. 8001 Permatex Super Black
weatherstrip (yellow) or 3M AAD Part Weatherstrip Adhesive
No. 8008 (black) Super No.82, 81850
Weatherstrip Adhesive or
3M AAD Part No. 8011
Black Weatherstrip Adhesive
Sealing of various grommets 3M AAD Part No. 8509 or -
and packing 3M AAD Part No. 8678
Adhesion of headliners and 3M AAD Part No. 8088 Permatex Spray
various interior decorative General Trim Adhesive or Adhesive No.82019
materials 3M AAD Part No. 8090
Super Trim Adhesive
BODY Sealing of sheet metal joints, 3M AAD Part No. 8531 -
SEALANTS drip rail, floor, side panels, Heavy Drip-Check Sealer
trunk, front panel, tail gate (gray) or 3M AAD Part No.
hinge 8302 Ultrapro Autobody
Sealant (clear) or 3M AAD
Part No. 8361 Urethane A/B
Sealant (gray or white)
Miscellaneous body sealants 3M AAD Part No. 8633 -
(original mounted Windo-weld Resealant
w/adhesive tape)
• Waterproof door film
• Fender panel
• Splash shield
• Mud guard
• Rear combination lamp
Fuel Tank and Pad 3M AAD Part No. 8088 Permatex Spray
General Trim Adhesive or Adhesive No.82019
3M AAD Part No. 8090
Super Trim Adhesive

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00-58 GENERAL <BODY AND CHASSIS>
MAIN SEALANT AND ADHESIVE TABLE

APPLICATION 3M NO. LOCTITE/


PERMATEXNO.
CHASSIS Sealant of various flange 3M AAD Part No. 8730 Loctite272 High Strength
SEALANT faces and threaded parts. High Strength Red and High Temperature
Packing of fuel gauge unit Threadlock or 3M AAD Part 27200
No. 8731 Medium Strength
Blue Threadlocker
Sealing of various threaded 3M AAD Part No. 8672 Permatex The Right Stuff
parts, dust covers. Ultrapro High Temp. Silicone No.25223
Differential carrier packing, Gasket or 3M AAD Part No.
dust covers and ball joint and 8679 (black) or 3M AAD
linkage. Packing and shims Part No. 8678 (black)
of steering box, sealing of Press-In-Place Silicone
rack support cover and top gasket strips 3M AAD Part
cover of steering box No. 8661 or 3M AAD Part
housing, seal of junction face No. 8663 Super Silicone
of knuckle arm flange sealant
Seal of brake shoe hold down 3M AAD Part No. 8633 -
pin and wheel cylinder of Windo-weld Resealant
drum brakes
QUICK FIX - 3M AAD Part No. 8155 LoctiteQuicktite Super
ADHESIVE Quick Fix Adhesive Glue 21309
ANAEROBIC Fixing of various threads, 3M AAD Part No. 8730 Loctite271,
STRONG bolts, screws. Fixing of High Strength Threadlocker High-Strength
SEALING differential drive gear bolt, or 3M AAD Part No. 8731 Threadlocker 27100 or
AGENT Connecting of tilt steering Medium Strength 27200
bolt. Fan, pulley, gear Sealing Threadlocker
of small gaps and flange
faces
UNDER - 3M AAD Part No. 8883 Permatex Heavy-Duty
COATING Rubberized Undercoating Undercoating 81833
AGENT Aerosol or 3M AAD Part
No. 8864 Body Schutz
Undercoating (qt)

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