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P.00-6 - Pajero 4x4 Off

1. 00 45 16 BRAKE HOSES CHECK FOR DETERIORATION RECOMMENDED LUBRICANTS AND 5 00 46 LUBRICANT CAPACITIES TABLE 00 31 Continued on next page SCHEDULED MAINTENANCE TABLE 00 34 00 2 17 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND 00 46 18 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE 00 46 19 FRONT AXLE AND REAR AXLE CONVENTIONAL DIFFERENTIAL INSPECT OIL LEVEL 00 47 20 PROPELLER SHAFT JOINTS LUBRICATE WITH GREASE sien alist 00 47 21 EXHAUST SYSTEM CONNECTION PORTION OF MUFFLER PIPINGS AND CONVERTER HEAT SHIELDS CHECK AND SERVICE AS REQUIRED 00 47 22 SRS MAINTENANCE SRS COMPONENT CHECK DAMAGE FUNCTION CONNECTION TO WIRING HARNESS 00 48 23 TIRES ROTATE 00 54 MAIN SEALANT AND ADHESIVE GENERAL lt BODY AND CHASSIS gt 00 3 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL MAINTENANCE REPAIR AND SERVICING EXPLANATIONS This manual provides explanations etc concerning procedures for the inspection maintenance repair and servicing of the subject model Unless otherwise specified each service procedure covers all models Procedures covering specific models are identified by the model codes or similar designation engine type transmission type
2. VEHICLE SAFETY CERTIFICATION LABEL SU The vehicle safety certification label is attached to the face of the left door sill gt This label indicates the month year of manufacture Gross Vehicle Weight Rating GVWR front and rear Gross Axle CI Weight Rating GAWR and Vehicle Identification Number NS VIN om AC203794AB TSB Revision 203954 THEFT PROTECTION PLATE VIN PLATE FOR ENGINE 6 Co MITSUBISHI MITSUBISHI ia MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI FOR TRANSMISSION BISHI MITSUBISHI MITSUBISHI MITSUBIS HI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MI ISHI MITSUBISHI i ra E 5 MITSUBISHI MITSUBISHI ISHI MITSUBISHI MITSUBISHI MITSUBISI THEFT PROTECTION LABEL FOR MAIN OUTER PANELS FOR ORIGINAL PARTS ITSUBISAT MITSUBR BISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUB ITSU MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISH MITSUBISH IBISHI MITSUBISHI FOR REPLACEMENT PARTS R X DOT 00878 GENERAL lt BODY AND CHASSIS gt VEHICLE IDENTIFICATION 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 mo
3. Mating marks alignment e After turning the clock spring fully clockwise turn it approxi mately 3 4 5 turns counterclockwise until the mating marks are aligned 9 Install the steering column covers steering wheel and air bag module 10 Check the steering wheel for noise binding or difficult operation A 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 senger 11 Check the steering wheel for excessive free play TSB Revision 00 52 AIR MODULE DEPLOYMENT SECTION GENERAL lt BODY AND CHASSIS gt ACX00590 AC MAINTENANCE SERVICE REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION Refer to GROUP 52B Air Bag Module and Clock Spring 52 33 Front Seatback Assembly with Side airbag Module A WARNING If any improper part is found during the following inspection replace the front seatback assembly with a new one e 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 52Ba 48 e 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 C
4. 00 50 CENTER PILLAR NN GENERAL BODY AND CHASSIS zi 0 7 IMPACT SENSOR ACXO00591AC SRS ECU ACX00587AB MAINTENANCE SERVICE Side Impact Sensors A WARNING e If the side impact sensor is not installed securely and correctly the side airbag may not operate nor mally e If a dent crack deformation or rust is detected replace with a new sensor 1 Check the side impact sensor for dents cracks or deformation The side impact sensors are located inside the center pillars LH RH 2 Check the connector for damage and terminal for deformation 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 LH is symmetrical to this SRS Air Bag Control Unit SRS ECU A 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 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 52Ba 31 Air Bag Module Steering Wheel and Clock Spring A WARNING
5. 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 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 4 EVAPORATIVE EMISSION SYSTEM CHECK FOR LEAKS AND CLOGGING EXCEPT EVAPORATIVE EMISSION CANISTER 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 A 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 performa
6. 515 3 V77WLYXVL2M lt VEHICLES FOR CANADA gt VIN EXCEPT SEQUENCE BRAND ENGINE MODEL CODE NUMBER DISPLACEMENT 1 4 315 3 MITSUBISHI 3 8L V77WLYHVL3M JA4NW51S 3J MONTERO V77WLYXVL3M TSB Revision GENERAL lt BODY AND CHASSIS gt 00 1 7 VEHICLE IDENTIFICATION VEHICLE INFORMATION CODE PLATE M1001005400280 The vehicle information code plate is riveted onto the cowl top 4M MITSUBISHI outer panel in the engine compartment The plate shows model code engine model transmission model and body color code NO ITEMS CONTENTS 1 MODEL V77WLYXV V77W Vehicle model EAM LYXVL2M Model series 2 ENGINE 6G75 Engine model EXT A69D Exterior code 4 TRANSAXL V5A51 V5A51 Transmission model E 500 4300 Rear differential reduction 5 COLOR A69 21T A69 Body color code STET 208 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 1 74 panel CHASSIS NUMBER CODE CHART CHASSIS CONTENTS NUMBER CODE ARK e 1 V77W3J000001 V77W V77W MONTERO AC203793AB Vehicle line 3J000001 Refer to 10th thru 17th digits of VIN plate
7. Overall width mm in Wheelbase mm in Tread front mm Tread rear mm Overhang front mm Overhang rear mm in mm in Angle of approach degrees Angle of departure degrees Vehicle weight kg Ib Curb weight Gross vehicle weight rating Gross axle weight rating front Gross axle weight rating rear Seating capacity Engine Model No Piston displacement Transmission Model No Type Fuel system Overall height unladen mm in V77WLYHVL2M 3M V77WLYXVL2M 3M 4 795 188 7 4 795 188 7 2 11 875 73 8 1 875 73 8 1 885 74 2 1 885 74 2 2 780 109 4 2 780 109 4 5 1 560 61 4 1 560 61 4 1 560 61 4 1 560 61 4 710 28 0 710 28 0 Minimum running ground clearance Fuel supply system Electronic controlled multiport fuel injection 8 1 305 51 4 1 305 51 4 g 235 9 3 235 9 3 42 2 140 4 718 2 170 4 784 21606085 feres 1 200 2 646 1 200 2 646 1 650 3 638 1 650 3 638 6G75 6G75 V5A51 V5A51 5 speed automatic 5 speed automatic TSB Revision GENERAL lt BODY AND CHASSIS gt 00 29 TIGHTENING TORQUE TIGHTENING TORQUE Each torque value in the table is a standard value for 1 If toothed washers are inserted M1001001100146 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
8. GASKET 4 BRAKE DISC Required Special Tool 990520 Disc Brake Piston Expander INSTALLATION SERVICE POINT gt gt lt lt DISC BRAKE ASSEMBLY INSTALLATION 1 To check the brake drag force after mounting the pad measure the hub torque in the advancing direction using a spring balance with the pad is removed A CAUTION Do not allow any oil grease or other contamination to contact the friction surfaces of the pads and brake discs 2 After re installing the caliper support to the knuckle install the pad clips and the pads to the caliper support LUBRICATION AND SEALING POINTS TSB Revision reusable part Denotes tightening torque If there is no indication of tightening torque refer to tightening torque Repair kit or set parts are shown Only very frequently used parts are shown Operating procedures cautions etc On removal installation disassembly and assembly are described The title of the page following the page on which the diagram of component parts is presented indicating the locations of lubrication and sealing procedures Indicates by symbols where lubrication is necessary ACX00860 AC 00 6 GENERAL lt BODY AND CHASSIS gt TROUBLESHOOTING GUIDELINES TROUBLESHOOTING GUIDELINES VERIFY THE COMPLAINT e Make sure the customer s complaint and the ser vice writer s work order descript
9. WARNING and CAUTION are as follows f a DANGER is not followed the result is severe bodily harm or even death If a WARNING is not followed the result could be bodily injury e f a CAUTION is not followed the result could be damage to the vehicle vehicle components or service equipment TIGHTENING TORQUE INDICATION The tightening torque indicates a median and its tol erance by a unit of N m in Ib or N m ft lb For fas teners with no assigned torque value refer to P 00 29 SPECIAL TOOL NOTE Only MMC special tool part numbers are called out in the repair sections of this manual Please refer to the special tool cross reference chart which is located in the service manual at the beginning of each group for a cross reference from the MMC special tool number to the special tool number that is available in your market MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types 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 6675 engine or a model equipped with such an engine TSB Revision 00 4 GENERAL lt BODY AND CHASSIS gt HOW TO USE THIS MANUAL EXPLANATION OF MANUAL CONTENTS Maintenance and servicing procedures The numbers provided wi
10. n the cases of vibration or poor connections use the simulation tests below to attempt to duplicate the customer s complaint Determine the most likely circuit s and perform the simulation tests 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 toms e For temperature and or moisture conditions related intermittent malfunctions try to change the conditions of the suspected circuit components 2 Determine the conditions from the customer s then use the simulation tests below responses e Typically almost all intermittent malfunctions occur from conditions like vibration temperature and or moisture change poor connections From the customer s responses it should be reasoned which condition is influenced Most intermittent malfunctions occur under certain conditions If those conditions can be identified the cause will be easier to find 1 Ask the customer about the malfunction e Ask what it feels like what it sounds like etc Then ask about driving conditions weather fre quency of occurrence and so on 4 Verify the intermittent malfunction is elimi nated e Repair the malfunctioning part and try to dupli cate the condition s again to verify the intermit tent malfunction has been eliminated TSB Revision 00 14 GENERAL lt BODY AND CHASSIS gt HOW TO USE TROUBLESHOO
11. 17 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003500281 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 18 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003600277 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 TSB Revision GENERAL lt BODY AND CHASSIS gt 00 47 MAINTENANCE SERVICE 19 FRONT AXLE AND REAR AXLE CONVENTIONAL DIFFERENTIAL INSPECT OIL LEVEL M1001007100100 Remove the filler plug and inspect the oil level at the bottom of the filler hole If the oil level is slightly below the filler hole the condition is satisfactory FRONT DIFFERENTIAL 20 PROPELLER SHAFT JOINTS LUBRICATE WITH GREASE Lubricate the propeller shaft joints with grease The propeller shaft joints should be repacked with multipurpose grease M1001007300063 01798 21 EXHAUST SYSTEM CONNECTION PORTION OF MUFFLER PIPINGS AND CONVERTER HEAT SHIELDS C
12. 18 Drive shaft boots Inspect for grease leaks and X damage every 12 months or 19 Front axle Without Inspect oil level at X X and rear axle LSD 20 Propeller shaft joints Lubricate with grease every 2 X years or 21 Exhaust system Check and service as required X connection portion of every 2 years or muffler piping and converter heat shields 22 SRS air bag Inspect the SRS system at 10 years 23 Rotate every 12 months or Every 12 000 km 7 500 miles NOTE 3 If the mileage is less than 12 000 km 7 500 miles 1 For California Massachusetts Vermont and each year the oil filter should be replaced at Maine this maintenance is recommended but not every oil change required 4 Change fluid under severe usage conditions only 72 Not required if belt was previously changed TSB Revision GENERAL lt BODY AND CHASSIS gt 00 36 MAINTENANCE SERVICE SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS Maintenance should be carried out according to the following table NO MAINTENANCE SERVICE KILOMETERS IN 24 48 72 96 120 144 168 SEVERE INTERVALS THOUSANDS USAGE MILEAGE IN 15 75 105 CONDITIONS THOUSANDS 3 Air cleaner Replace at X IX X X X IX X jAandE element 5 Sparkplugs Replaceat RR X X 9 Engine oil Change every 3 months or Every 4 800 km 3 000 miles B C D and G 10 oil filter Replace every 6 months or Every 9 600
13. Inspection Ser vice Points for a Blown Fuse Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points NO Go to Step 2 ACX00862 AH MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU repeat the inspection proce dure from the beginning TSB Revision 00 10 GENERAL lt BODY AND CHASSIS gt HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR MB991219 ACX00865 AB 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 Required Special Tool MD998459 Test Harness Waterproof Connectors Be sure to use special tool MD998459 Never insert a test probe from the harness side as this so will reduce the water proof performance and result in corrosion 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 IF INSPECTING WITH THE CONNECTOR DISCONNECTED lt When Inspecting a Female Pin gt From front side of the connector Required Specia
14. Intake air temperature sensor failed Open or shorted intake air temperature sensor circuit or loose connector PCM failed 8 Start of the diagnosis procedure for that DTC 9 Identifies the special tool s necessary for diagnosing that DTC STEP 1 Using scan tool MB991502 check data list item 13 Intake Air Temperature Sensor amp CAUTION To prevent damage to scan tool MB991502 always turn the ignition switch to LOCK OFF position before connecting or disconnecting scan tool MB991502 1 Connect scan tool MB991502 to the data link connector 2 Turn the ignition switch to ON position 3 Set scan tool MB991502 to the data reading mode for item 13 Intake Air Temperature Sensor e The intake air temperature and temperature shown with the scan tool should approximately match 4 Turn the ignition switch to LOCK OFF position Q Is the sensor operating properly YES It can be assumed that this malfunction is intermittent 10 Provides the inspection procedure for that DTC step by step HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements Carry out this inspec tion while referring to GROUP OOE Harness Con 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
15. Revision GENERAL lt BODY AND CHASSIS gt RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE Gasohol A mixture of 10 ethanol grain alcohol and 90 unleaded gasoline may be used in your vehicle If driveability problems are experienced as a result of using gasohol it is recommended that the vehicle be operated on gasoline Methanol Do not use gasolines containing meth anol wood alcohol Using this type of alcohol can result in vehicle performance deterioration and dam age critical parts in the fuel system components Fuel system damage and performance problems resulting from the use of gasolines containing methanol may not be covered by the new vehicle warranty 00 31 GASOLINES CONTAINING METHY TERTIARY BUTYL ETHER MTBE Unleaded gasoline containing 1596 or less MTBE may be used in your vehicle Fuel containing MTBE over 1596 in volume may cause reduced engine per formance and produce vapor lock or hard starting MATERIALS ADDED TO FUEL Indiscriminate use of fuel system cleaning agents should be avoided Many of these materials intended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS M1001001300300 PART Engine oil CD EC Automatic transmission Transfer Front axle Rear axle Power st
16. 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 52Ba 33 2 Check the pad cover for dents cracks or deformation TSB Revision GENERAL lt BODY AND CHASSIS gt MAINTENANCE SERVICE DRIVER S INFLATOR INFLATOR CASE CASE PROTECTIVE TUBES ACX01302 AB MATING MARK ACX00602 AB AIR BAG MODULE ACX01319 AB 00 51 3 Check the connector for damage and deformed terminals 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 6 Check the clock spring connectors and protective tube for damage and terminals for deformities 7 Visually check the case for damage A 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 may be severed obstructing normal operation of the 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
17. 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 MARK 4 HEAD MARK 7 HEAD MARK 8 DIAMETER mm mm M5 2 5 0 5 N m 23 4 in Ib 5 0 1 0 4449 in Ib 6 0 1 0 5349 in Ib M6 1 0 5 0 1 0 N m 4449 in Ib 9 0 2 0 N m 79 18 in 10 2 N m 89417 Ib M8 12 2 N m 107 417 indb 22 4 N m 1643 ft lb 2544 18 3 ft lb M10 2444 1843 ft lb 44 10 N m 3347 ft lb 5327 N m 3955 ft lb M12 4148 3046 ft lb 83412 N m 6149 ft lb 98412 N m 7249 ft lb M14 1 5 73 12 N m 5449 ft lb 140 20 N m 104 14 ft 155425 N m 115 18 ft Ib Ib M16 110 20 N m 81415 ft lb 210 30 155422 ft 235135 N m 174425 ft Ib Ib M18 1 5 165 25 N m 122 18 ft 300 40 N m 222429 ft 340 50 N m 251 37 ft Ib Ib Ib M20 1 5 225 35 166 26 ft 410 60 N m 303 44 ft 480 70 354 52 ft Ib Ib Ib M22 1 5 300 40 N m 222 29 ft 555 85 N m 410 62 ft 645 95 N m 476 70 ft Ib Ib Ib M24 1 5 395455 N m 292 40 ft 735 105 543477 855 125 N m 631492 Ib ft Ib ft lb Flange bolt and nut tightening torque THREAD SIZE STANDARD TIGHT
18. drip rail floor side panels Heavy Drip Check Sealer trunk front panel tail gate gray or hinge 3M AAD Part No 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 e Waterproof door film e Fender panel e Splash shield e Mud guard e 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 TSB Revision 00 56 GENERAL lt BODY AND CHASSIS gt MAIN SEALANT AND ADHESIVE TABLE APPLICATION 3M NO LOCTITEG PERMATEXGNO 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 27200 3M AAD Part No 8731 Medium Strength Blue Threadlocker Sealing of various threaded 3M AAD Part 8672 Permatex The Right Stuff parts dust covers Ultrapro High Temp Silicone No 25223 Differential carrier packing Gasket or dust covers and ball joint and 3M AAD Part No 8679 linkage Packing and shims _ black or of steering box sealing of 3M AAD Part No 8678 rack support cover and top black Press In Place cover of steering box Silicone gasket strips housing seal of junc
19. 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 dm 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 Adding volume Approximately 6 0 dm 6 3 quarts A 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 TSB Revision GENERAL lt BODY AND CHASSIS gt MAINTENANCE SERVICE 01184 COLD HOT 000846 FLUID LEVEL mm 20 0 8 DIPSTICK FLUID TEMPERATURE ACX02008AB FILLER PLUG HOLE OIL LEVEL ACX00895AB 00 43 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 11 Che
20. getting into the connector or circuitry e Human error mistakenly shorting a circuit etc VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number VIN is located on a plate attached to the left top side of the instrument panel TSB Revision 00 16 GENERAL lt BODY AND CHASSIS gt VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits The vehicle OK e AIRBAG X 51 S13J 000001 123456 78 91011 number is a code which tells country make vehicle type etc NO ITEMS CONTENTS 1 Country J Japan 2 Make A Mitsubishi 3 Vehicle type 4 Multi purpose vehicle 4 Others GROSS VEHICLE WEIGHT RATING BRAKE SYSTEM 6001 7000lbs HYDRAULIC Line W MONTERO Price class 3 Medium 5 Premium 7 Body 1 5 Door wagon 8 Engine 5 3 8L 9 Check digits 0 1 2 3 9 X 10 Model year 3 2003 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 JAANW31S 3 MITSUBISHI 3 8L V77WLYHVL2M 1 4
21. important step in the diagno sis sequence It might be the skipped step that leads to the solution of the problem If the service manual doesn t have step by step pro cedures to help diagnose the problem come up with a series of checks based on the ranked list of proba ble causes Troubleshooting checks should be made in the order that the list of causes was ranked e general to specific e most likely to least likely e easy to check to hard to check REPAIR THE PROBLEM When the step by step troubleshooting checks find a fault perform the proper repairs Make sure to fix the root cause of the problem not just the symptom Just fixing the symptom without fixing the root cause will cause the symptom to eventually return VERIFY THE REPAIR After repairs are made recheck the operation of the system to confirm that the problem is eliminated 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 Troubleshooting of electronic control systems for which the scan tool can be used follows the basic outline described below Even in systems for which the scan tool cannot be used part of these systems still follow this outline TROUBLESHOOTING CONTENTS 1 STANDARD FLOW OF DIAGNOSTIC TROU BLESHOOTING Troubleshooting strategy are shown M1001000200344 2 SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of
22. km 6 000 miles A B C D and G 12 Change fluid at X X X B G and H transmission fluid IH Weser TR TR E 15 ee for wear every 6 months Every 9 600 6 000 miles A and F pads 23 Rotate every 6 months Every 9 600 km 6 000 miles B C E G and H Severe usage conditions E Driving in sandy areas A Driving in dusty conditions F Driving in salty areas B Trailer towing or police taxi or commercial type More than 50 operation in heavy city traffic or operation at sustained high speeds during hot weather grater C Extensive idling driving in stop and go traffic than 32 C 90 F D Short trip operation at freezing temperatures Driving off road engine not thoroughly warmed up 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 TSB Revision GENERAL lt BODY AND CHASSIS gt 00 37 MAINTENANCE SERVICE 2 FUEL HOSES CHECK CONDITION M1001001700137
23. outer side Right side is symmetrically opposite Right side is symmetrically opposite ACX01192AB ACX01193AB TSB Revision 00 20 GENERAL lt BODY AND CHASSIS gt VEHICLE IDENTIFICATION TARGET AREA A FOR ORIGINAL EQUIPMENT PARTS B FOR REPLACEMENT PARTS FRONT DOOR The illustration indicates right outer side Left side is symmetrically opposite ACX01194AB REAR DOOR Y RY The illustration indicates right outer side Left side is symmetrically opposite Acxo1195AB HOOD ACX01196 AB BACK DOOR ACX01197 AB FRONT BUMPER REAR BUMPER AC203795AB AC203796 AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 21 PRECAUTIONS BEFORE SERVICE PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM SRS 1 Items to follow when servicing SRS 1 Be sure to read GROUP 52B Supplemental Restraint System SRS For safe operation please follow the directions and heed all warnings 2 Wait at least 60 seconds after disconnecting the battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected 3 Warning labels must be heeded when servici
24. position 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 ACX00883AB REAR TOWING PICKUP N CAUTION e This vehicle cannot be towed by a wrecker using sling SLING TYPE type equipment to prevent the lower arm from deforma tion If this vehicle is towed use a wheel lift or flat bed equipment Donot use the steering column lock to secure the front wheel for towing e For the four wheel drive vehicle move the transfer shift lever to 2H position e 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 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 TSB Revision 00 26 GENERAL lt BODY AND CHASSIS gt TOWING AND HOISTING HOISTING EMERGENCY JACKING Place a jack under one of the jacking points shown in the illus tration JACKING POINTS ACX0154AB FLOOR JACK N CAUTION A floor jack must never be used on part of the un
25. the ECU harness side connector while referring to the check chart NOTE Checks dont have to be carried out in the order given in the chart 4 If the ohmmeter shows any deviation from the Normal Condition value check the corresponding sensor actuator and related electrical wiring then repair or replace 5 After repair or replacement recheck with the ohmmeter to confirm that the repair has corrected the problem 10 INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope these are listed here TSB Revision 00 8 GENERAL lt BODY AND CHASSIS gt HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS DTC P0110 Intake Air Temperature Circuit Malfunction INTAKE AIR TEMPERATURE SENSOR INCORPORATED IN VOLUME AIR FLOW SENSOR 1 Relevant circuit s of the component which the DTC indicates are described RED BLUE D 108 MU803781 POWERTRAIN CONTROL MODULE PCM 2 For connector color refer to GROUP 80A CONNECTOR B 48 CU 2 How to read configuration diagrams a INTAKE AIR DE TEMPERATURE 8 Shows the location of the connector s from the circuit s above 4 Explains about the operation principle of the ACX00226 AK component or its relevant parts in that circuit CIRCUIT OPERATION The intake air temperature sensor is a negative e Approximately 5 volts are applied to the intake air temperature coefficient type of resistor When th
26. the symptoms is difficult procedures for checking operation and verifying symptoms are shown 3 DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown e How to read diagnostic trouble codes e How to erase diagnostic trouble codes e Input inspection service points TSB Revision GENERAL lt BODY AND CHASSIS gt 00 7 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 4 DIAGNOSTIC TROUBLE CODE CHART 5 SYMPTOM CHART If there are symptoms even though the results of inspection using the scan tool show that all diagnos tic trouble codes are normal inspection procedures for each symptom will be found by using this chart 6 DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code Refer to 00 7 7 SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart Refer to 00 7 8 SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information 9 CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors inspec tion items and standard values have been provided in this chart as reference information Terminal Voltage Checks 1 Connect a needle nosed wire probe to a voltmeter probe A CAUTION Short circuiting the positive probe between a connector terminal and ground could damage the vehicl
27. 00 1 GROUP 00 GENERAL lt BODY AND CHASSIS gt CONTENTS HOW TO USE THIS MANUAL 00 3 MAINTENANCE SERVICE 00 36 1 FUEL SYSTEM TANK PIPE LINE AND TROUBLESHOOTING GUIDELINES 00 6 CONNECTIONS AND FUEL TANK FILLER TUBE CAP Check for leaks 00 36 HOW TO USE TROUBLESHOOTING 2 FUEL HOSES CHECK CONDITION 00 37 INSPECTION SERVICE POINTS 00 6 3 AIR CLEANER ELEMENT Replace 00 37 4 EVAPORATIVE EMISSION SYSTEM CHECK FOR LEAKS AND CLOGGING EXCEPT EVAPORATIVE 5 5 EMISSION CANISTER MONS 00 37 2 2 5 SPARK PLUGS Replace 00 37 b 6 IGNITION CABLES Replace 00 38 PRECAUTIONS BEFORE SERVICE 7 TIMING BELT REPLACE 00 38 8 DRIVE BELT FOR GENERATOR AND WATER TREATMENT BEFORE AFTER DRIVING CONDITION cce e THROUGH 00 23 9 ENGINE OIL 00 40 10 ENGINE OIL FILTER REPLACE 00 40 TOWING AND HOISTING 00 25 11 AUTOMATIC TRANSMISSION FLUID CHECK 00 41 GENERAL DATA AND 12 AUTOMATIC TRANSMISSION FLUID CHANGE SPECIFICATIONS 00 248__ _ 00 42 13 TRANSFER OIL CHECK OIL LEVEL 00 43 TIGHTENING TORQUE 00 29 14 ENGINE COOLANT CHANGE 00 44 15 DISC BRAKE PADS INSPECT FOR LUBRICATION AND MAINTENANCE 00 30
28. 1 765 kPa 256 psi are high quality filters and are recommended as follows Mitsubishi Oil Filter Part Number MD352626 or equivalent TSB Revision GENERAL lt BODY AND CHASSIS gt 00 41 O RING FLUID LEVEL mm in FLUID TEMPERATURE F ACX02008AB COLD HOT AC000846 ACX00893 MAINTENANCE SERVICE 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 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 Drain the engine oil by removing the oil drain plug Use an oil filter wrench to remove the engine oil filter Clean the contact surface of the filter bracket Lubricate the O ring of the new oil filter with a small amount of new engine oil amp 0 N 11 AUTOMATIC TRANSMI
29. 12 GENERAL lt BODY AND CHASSIS gt HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out 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 CONNECTOR DISCONNECTED OR IMPROPERLY CONNECTED HARNESS WIRE BREAKAGE AT TERMINAL SECTION c 7 LOW CONTACT 8 x sr PRESSURE 6 22 amp ACX00868 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 pull out of the back side of the connector Therefore gently pull the wires gt by to make sure that no pins pull out of the connector ACX00869AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 1 3 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR ENGAGEMENT INSPECTION Required Special Tool e 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 MB991219 armo 7 ACX00870 AB HOW TO COPE WITH INTERMITTENT 3 Use simulation test MALFUNCTIONS e
30. 8 Generator Water Pump Power Steering Pump Drive Belt Tension Check and Adjustment A CAUTION Perform the check after rotating the engine in the normal direction one revolution or more 1 Check that the indicator mark of the auto tensioner is located between the marks shown as A on the tensioner bracket 2 If the mark is located out of the space A replace the drive belt NOTE Since the auto tensioner is used it is not necessary to adjust the tension of the belt INDICATOR MARK ACX00751AB Check of auto tensioner 1 Run the engine at idling speed and then stop it to check CLOCKWISE whether the drive belt is centered on the auto tensioner pulley 2 Insert a1 2 inch breaker bar into the square hole on the drive belt auto tensioner and rotate it clockwise until the tensioner touches the stopper 3 Align hole B with hole A and insert a 5 0 mm 0 20 inch Allen wrench to hold the tensioner Then loosen the drive belt and then remove the drive belt auto tensioner 4 Move the auto tensioner right and left by using a 1 2 inch breaker bar or similar tool to verify that it moves smoothly 5 If some abnormality is found during the above mentioned check 1 and 3 replace the auto tensioner 6 Install the drive belt auto tensioner with Allen wrench inserted ACX01424AB TSB Revision 00 40 p ALLEN WRENCH 2 gt SX ACX01376AB GOOD MAXIMU
31. ATING 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 1112 2 30 146 1042 1438 eea 1022 1 063 1 058 1 054 1 049 1 044 20 4 15 5 35 1 071 1 067 1 062 1057 1 052 25 13 20 4 40 pne 1058 oea 48019 1087 1 082 1076 1070 1 064 36 32 8 31 23 8 5 5 50 1 095 1 090 1 084 1 077 1 070 42 44 37 35 55 60 44 1 103 1 098 1 092 1 084 1 076 50 58 45 49 Example The safe operating temperature is 15 5 F when the specific gravity is 1 058 at the coolant tempera ture of 20 C 68 F TSB Revision 00 34 GENERAL lt BODY AND CHASSIS gt SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE Inspection and service should be performed any time a malfunction is observed or suspected M1001001400307 EMISSION SERVICE KILOMETERS 168 CONTROL SYSTEM INTERVALS IN MAINTENANCE THOUSANDS MILEAGE IN THOUSANDS Fuel system tank Check for leaks every 5 years or X pipe line and connection and fuel tank filler tube cap Check condon everyayearsor X X K Air cleaner element at OXI X system except every 5 years or evaporative emis
32. ENING TORQUE NOMINAL BOLT PITCH HEAD MARK 4 HEAD MARK 7 HEAD MARK 8 DIAMETER mm mm M6 5 0 1 0 44 9 in Ib 10 2 N m 89 17 in Ib 12 2 N m 107 17 in Ib 8 1342 N m 111 22 24 4 N m 1823 ft lb 27 5 N m 20 4 ft lb M10 2644 19 3 ft lb 49 9 N m 3647 5847 4325 ft lb M10 24 4 N m 1843 ft lb 4538 N m 3346 ft lb 55410 N m 4147 ft lb M12 4648 N m 3446 ft lb 95 15 Nm 70411 ft lb 105 15 78 11 ft lb M12 1 75 43 8 N m 32 6 ft lb 83412 N m 6149 ft lb 98412 N m 72 9 ft lb TSB Revision 00 30 GENERAL lt BODY AND CHASSIS gt LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE Maintenance and lubrication service recommenda tions have been compiled to provide maximum pro tection for the vehicle owner s investment against all reasonable types of driving conditions Since these conditions vary with the individual vehicle owner s driving habits the area in which the vehicle is oper ated and the type of driving to which the vehicle is subjected it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis Oils lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers SAE the Ameri can Petroleum Institute API and the National Lubri cating Grease Institute NLGI MAINTENANCE SCHEDULES Inform
33. HECK AND SERVICE AS REQUIRED M1001005800114 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 TSB Revision 00 48 GENERAL lt BODY AND CHASSIS gt DATE OF MANUFACTURE CERTIFICATION LABEL MFD BY MITSUBISHI MOTORS CORPORATION 2000 GVWR UE TW JAPAN GAWR TIRES FR RIMS T COLO TIRES m quis S oe i ME SAFETY ABCOEFG VEHICLE Tee ACX00901AB SRS WARNING LIGHT 2 x1000r min 01667 MAINTENANCE SERVICE 22 SRS MAINTENANCE SRS COMPONENT CHECK DAMAGE FUNCTION CONNECTION TO WIRING HARNESS ETC M1001003700274 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 Turn the ignition key to the ON position Does the SRS warning light illuminate for about seven seconds and then remain off for at least five seconds after turning OFF If yes the SRS system is functioning properly If no refer to GROUP 52B Diagnosis P 52Bb 3 TSB Revision GENERAL lt BODY AND CHASSIS gt 00 49 MAINTENANCE SERVICE SRS Component Visual Check DANGER Wait at least 60 seconds after disconnecting the bat TAPE tery cable before doing any furt
34. IS gt MAIN SEALANT AND ADHESIVE TABLE a O E amp ACX00903 AB 23 TIRES ROTATE M1001008900262 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 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 LOCTITEG PERMATEXGNO 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 semicircular packing and 3M AAD Part No 8679 cylinder head Between oil Black 8678 Black Press In pressure switch and engine Place Silicone 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
35. M a ACX00892 AB GENERAL lt BODY AND CHASSIS gt MAINTENANCE SERVICE 7 After the drive belt has been installed remove the Allen wrench while holding the drive belt auto tensioner with a socket wrench drive Then release the drive belt auto tensioner slowly 8 Check for proper tension 9 ENGINE OIL CHANGE Use the specified oil Refer to 00 31 1 After warming up the engine remove the oil filler cap AN WARNING Use care Oil could be hot 2 Remove the drain plug to allow the engine oil to drain 3 Replace the drain plug gasket with a new one and then tighten the drain plug to the specified torque NOTE Install the drain plug gasket so it faces in the direc tion shown in the illustration Tightening torque 39 5 N m 29 3 ft Ib 4 Pour new engine oil in through the oil filler tube M1001002600304 Engine oil capacity 4 3 dm 4 5 quarts excluding oil filter 0 3 dm 0 32 quart oil cooler 0 3 dm 0 32 quart 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 10 OIL FILTER REPLACE M1001002700282 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
36. SSION FLUID CHECK FLUID LEVEL M1001002900275 1 Drive the vehicle until the fluid temperature rises to the normal temperature 70 80 158 176 F If it takes some amount of time until the transmission fluid reaches its normal operating temperature 70 80 C 158 176 F check the transmission fluid level by referring to the diagram at left NOTE The transmission fluid temperature is measured with scan tool MB991502 2 Park the vehicle on a level surface 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 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 br
37. TING 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 e Shake the connector up and down and right and left e Shake the wiring harness up and down and right and left Especially check the splice points of wiring harnesses care fully Refer to GROUP 00 HARNESS CONNECTOR INSPECTION P 00E 2 e Vibrate the part or sensor ACX00871 AB TSB Revision GENERAL lt BODY AND CHASSIS gt VEHICLE IDENTIFICATION BATTERY CIRCUIT 1 OCCURRENCE ACX00872 AB 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 Q at this time there is a short somewhere between these switches and the load If the resistance is not 0 Q 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 e Harness being clamped by the vehicle body e Damage to the outer casing of the harness due to wear or heat e Water
38. akes TSB Revision 00 42 GENERAL lt BODY AND CHASSIS gt ACX01185AB MAINTENANCE SERVICE 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 e When trouble shooting the transmission e When overhauling the transmission e 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 12 AUTOMATIC TRANSMISSION FLUID CHANGE M1001006900136 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 started If the fluid has all drained out before then the
39. ap 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 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 DISC BRAKE PADS INSPECT FOR WEAR M1001003200138 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 N 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 TSB Revision 00 46 GENERAL lt BODY AND CHASSIS gt MAINTENANCE SERVICE 16 BRAKE HOSES CHECK FOR DETERIORATION OR LEAKS M1001003400273 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
40. ation for service maintenance is provided in the SCHEDULED MAINTENANCE TABLE Three schedules are provided one for Required Mainte nance one for General Maintenance and one for Severe Usage Service The item numbers in SCHEDULED MAINTENANCE TABLE correspond to the section numbers in MAINTENANCE SERVICE SEVERE SERVICE Vehicles operating under severe service conditions will require more frequent service Component service information is included in appro priate units for vehicles operating under one or more of the following conditions 1 Trailer towing or police taxi or commercial type operation 2 Operation of Vehicle 1 Short trip operation at freezing temperature engine not thoroughly warmed up 2 More than 50 operation in heavy city traffic during hot weather greater than 32 C 90 F 3 Extensive idling 4 Driving in sandy areas 5 Driving in salty areas 6 Driving in dusty conditions 7 Driving off road M1001001200295 ENGINE OIL A CAUTION Test results submitted to EPA have shown that laboratory animals develop skin cancer after pro longed contact with used engine oil Accordingly the potential exists for humans to develop a number of skin disorders including cancer from such exposure to used engine oil Therefore when changing engine oil be careful not to touch it as much as possible Protective clothing and gloves that cannot be penetrated by oil should be worn The skin should be thoro
41. ck that the fluid level is at the COLD mark on the dipstick If the level is lower than this pour in more fluid 12 Drive the vehicle until the fluid temperature rises to the normal temperature 70 80 158 176 F and then check the fluid level again If it takes some amount of time until the transmission fluid reaches its normal operating temperature 70 80 C 158 176 F check the transmission fluid level by referring to the diagram at left The transmission fluid level must be at the HOT mark NOTE The transmission fluid temperature is measured with scan tool MB991502 The COLD level is for reference only the HOT level should be regarded as the standard level 13 Firmly insert the dipstick into the oil filler tube 13 TRANSFER OIL CHECK OIL LEVEL M1001003000082 Transfer Oil Check 1 2 Remove the filler plug Check that the oil level is up to the lower edge of the filler plug hole Check that the oil is not noticeably dirty and that it has a suitable viscosity Tighten the filler plug to the specified torque Tightening torque 32 2 N m 24 1 ft lb TSB Revision 00 44 GENERAL lt BODY AND CHASSIS gt MAINTENANCE SERVICE TRANSFER OIL CHANGE 1 Remove the filler plug 2 Remove the drain plug and drain oil 3 Tighten the drain plug to the specified torque Tightening torque 32 2 N m 24 1 ft lb 4 Add the oil until the level comes to the lower po
42. d mainte nance procedures in advance 1 i 6 E 1 E VIA X 2A sae 00 ACX00850AB TSB Revision 00 24 GENERAL lt BODY AND CHASSIS gt TREATMENT BEFORE AFTER DRIVING THROUGH WATER INSPECTION AND SERVICE AFTER e Check for water mud sand etc in the rear brake DRIVING THROUGH WATER drum starter motor brake pipe and fuel pipe f e Check for water in the fluid or oil inside the front Ee OTA a ee eie opal poni If differential rear differential transmission and abnormal condition is evident clean replace or lubri icu cele e Check all boots and breather hoses for cracks and damage eque ERE m mE ESE i FRONT DIFFERENTIAL j REAR DIFFERENTIAL ACX00851 AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 25 TOWING AND HOISTING TOWING AND HOISTING WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP A 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 ment e Make sure that the transmission remains in the N position e For the four wheel drive vehicle move the transfer shift lever to 2H
43. del number THEFT PROTECTION In order to protect against theft a Vehicle Identification Number VIN is attached as a plate or label to the following major parts of the engine and transmission as well as main outer panels 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 A 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 is The masking tape should be removed after painting is finished 3 The theft protection label should not be removed from original parts or replacement parts TSB Revision GENERAL lt BODY AND CHASSIS gt 00 1 9 VEHICLE IDENTIFICATION LOCATIONS TARGET AREA A FOR ORIGINAL EQUIPMENT PARTS B FOR REPLACEMENT PARTS ENGINE AUTOMATIC TRANSMISSION lt V4A51 V5A51 gt ENGINE UNDERSIDE ACX01547AB 01191 FENDER QUARTER PANEL The illustration indicates left outer side The illustration indicates left
44. derbody Donot 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 or rear frame ACX01698 AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 27 TOWING AND HOISTING POST TYPE N 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 SIDE SILL REAR END BOLTS 5 JE ER ATTACHMENT ATTACHMENT Bf ul is ee ACX01699 AB TSB Revision 00 28 GENERAL lt BODY AND CHASSIS gt GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS M1001000900309 i PA AC204542 ITEM Vehicle dimensions Overall length mm in
45. e temperature sensor output terminal terminal 6 intake air temperature rises the resistance from the PCM terminal 64 via the resistor in the decreases PCM The ground terminal terminal 5 is The intake air temperature sensor output voltage grounded with or PCM terminal 57 increases when the resistance increases and decreases when the resistance decreases ACX00861AH TSB Revision GENERAL lt BODY AND CHASSIS gt 00 9 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 5 Explains about technical details TECHNICAL DESCRIPTION The intake air temperature sensor conyefts the intake air temperature to a voltag The PCM checks whether thigVoltage is within specified range DTC SET CONDITIONS Check Conditions Two seconds or more have passed since the engine was started Judgement Criteria e Intake air temperature sensor output voltage has continued to be 4 6 volts or higher corresponding to an air intake temperature of 45 C 49 F or lower for 2 seconds DIAGNOSIS Required Special Tool MB991502 Scan Tool MUT II e ntake air temperature sensor output voltage ha continued to be 0 2 volt or lower correspopaifig to an air intake temperature of 125 C higher for 2 seconds 6 Describes the conditions for that DTC being set stored 7 Describes possible cause s for that DTC TROUBLESHOOTING HINTS The most likely causes for this code to be set are e
46. e wiring the sensor the ECU or all three Use care to prevent this 2 Insert the needle nosed wire probe into each of the ECU connector terminals from the wire side 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 NOTE Measure voltage with the ECU connectors connected You may find it convenient to pull out the ECU to make it easier to reach the connector terminals Checks don t have to be carried out in the order given in the chart 3 If voltage readings differ from normal condition values check related sensors actuators and wiring then replace or repair 4 After repair or replacement recheck with the voltmeter to confirm that the repair has corrected the problem Terminal Resistance and Continuity Checks 1 Turn the ignition switch to the LOCK OFF position 2 Disconnect the ECU connector A CAUTION If resistance and continuity checks are per formed on the wrong terminals damage to the vehicle wiring sensors ECU and or ohmmeter may occur Use care to prevent this 3 Measure the resistance and check for continuity between the terminals of
47. eering Brakes Engine coolant Door hinges back door hinges Engine oil SPECIFICATION Engine oil displaying ILSAC certification mark or conforming the API classification SJ EC or SJ section MITSUBISHI genuine ATF SP III API classification GL 4 SAE grade number SAE 75W 90 or 75W 85W API classification GL 5 or higher For further details refer to Lubricants Selection section GENUINE MITSUBISHI POWER STEERING FLUID Conforming to DOT 3 or DOT 4 MITSUBISHI genuine coolantor an equivalent REMARK For further details refer to LUBRICANTS SELECTION LUBRICANT CAPACITY TABLE DESCRIPTION Engine oil dm qt Engine oil dm qt Oil filter Engine oil dm qt Engine coolant dm qt Automatic transmission dm qt Transfer dm qt Oil pan excluding oil filter 4 3 4 5 SPECIFICATION 0 32 0 32 0 3 0 3 9 5 9 8 9 0 9 3 2 8 3 0 TSB Revision 00 32 GENERAL lt BODY AND CHASSIS gt RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE SPECIFICATION 1 2 1 3 1 6 1 7 1 0 1 1 DESCRIPTION Differential Front axle dm qt Rear axle dm qt Power steering dm qt Fuel tank dm gal 90 23 8 LUBRICANT SELECTION ENGINE OIL A CAUTION Never use nondetergent or straight mineral oil Cil Identification Symbol Use only engine oils displaying the ILSAC certificati
48. etc A description of these designations is covered in this manual under VEHI CLE IDENTIFICATION ON VEHICLE SERVICE ON VEHICLE SERVICE are procedures for per forming inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing but other inspec tions for looseness play cracking damage etc must also be performed SERVICE PROCEDURES The service steps are arranged in numerical order Attention must to be paid in performing vehicle ser vice are described in detail in SERVICE POINTS DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength It is a value established outside the range of standard value M1001000100381 REFERENCE VALUE Indicates the adjustment value prior to starting the work presented in order to facilitate assembly and adjustment procedures and so they can be com pleted in a shorter time DANGER WARNING AND CAUTION DANGER WARNING and CAUTION call special attention to a necessary action or to an action that must be avoided The differences among DANGER
49. heck the air bag module deployment section for dents or deformation 2 Check the connector for damage check the terminals for deformation and check the harness for binding Seat belt with pre tensioner A WARNING e If the seat belt pre tensioner is not installed securely and correctly the seat belt pre tensioner may not operate normally e 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 TSB Revision GENERAL lt BODY AND CHASSIS gt 00 53 MAINTENANCE SERVICE WIRING HARNESS INSTRUMENT WIRING HARNESS SIDE AIRBAG WIRING HARNESS P SS es FRONT WIRING FLOOR WIRING HARNESS HARNESS SEAT BELT WITH PRE TENSIONER AC205493AB 1 Check the connector for poor connection A 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 52Ba 18 TSB Revision 00 54 GENERAL lt BODY AND CHASS
50. her work The SRS e SATIRE 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 A 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 52 7 3 Disconnect a connector from the SRS ECU Front Impact Sensors 1 Check that the arrows on the sensors face toward the front of the vehicle The SRS may not activate if a front impact sensor is N 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 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 52Ba 18 and GROUP 52B Front Impact Sensor P 52Ba 27 ACX01318 AB TSB Revision
51. ies 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 16in inches from any plastic parts and all opening parts doors lug Cd FE 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 II A CAUTION 7 SCAN TOOL MUTI Turn the ignition switch to the LOCK OFF position before disconnecting or connecting the scan tool To operate the scan tool refer to MUT II MUT II Reference Manual ROM PACK A ACX00882 AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 23 TREATMENT BEFORE AETER DRIVING THROUGH WATER TREATMENT BEFORE AFTER DRIVING THROUGH WATER M1001000600074 INSPECTION AND SERVICE BEFORE e Inspect the dust boot and breather hose for DRIVING THROUGH WATER cracks or damage and replace them if cracks or Vehicles which are driven through water or which damage are found may possibly be driven through water should be subjected to the following inspections an
52. ion are under stood before starting work e Make sure the correct operation of the system is understood Read the service manual description to verify any aspect of normal system operation Operate the system to see the symptoms Look for other symptoms that were not reported by the customer or on the work order that may be related to the problem DETERMINE POSSIBLE CAUSES Compare the confirmed symptoms to the diagnostic symptom indexes to get to the right diagnosis proce dure If the confirmed symptoms can not be found on any symptom index determine other possible causes e Analyze the system diagrams and list all possible causes for the problem symptoms e Rank all these possible causes in order of proba bility based on how much of the system they cover how likely they are to be the cause and how easy they will be to check Be sure to take experience into account Consider the causes of similar problems seen in the past The list of causes should be ranked in order from general to specific from most likely to least likely and from easy to check to hard to check M1001008800157 FIND THE PROBLEM After the symptoms have been confirmed and prob able causes have been identified the next step is to make step by step checks of the suspected system components junctions and links in logical order Use the diagnostic procedures in the service manual whenever possible Follow these procedures care fully to avoid missing an
53. joint engine coolant temperature gauge unit large size and engine Between oil pan and engine 3M AAD Part No Permatex Ultra Gray block 3M AAD Part No 599 No 82194 3M AAD Part No 3M AAD Part No WEATHER Between tempered glass 3M AAD Part No 8509 STRIPPING body flanges and Auto Bedding and Glazing FOR GLASS weatherstrip Compound or 3M AAD Part No 8633 Windo weld Resealant WEATHER Between laminated glass and 3M AAD Part No 8633 STRIPPING weatherstrip FOR GLASS TSB Revision GENERAL lt BODY AND CHASSIS gt 00 55 MAIN SEALANT AND ADHESIVE TABLE APPLICATION 3M NO LOCTITE 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 Weatherstrip Adhesive 3M AAD Part No 8008 No 82 81850 black Super Weatherstrip Adhesive or 3M AAD Part No 8011 Black Weatherstrip Adhesive Sealing of various grommets 3M AAD Part 8509 and packing 3M AAD Part No 8678 Adhesion of headliners and 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
54. l 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 From back side of the connector SRS ECU harness side con nector TSB Revision SRS ECU HARNESS CONNECTOR GENERAL lt BODY AND CHASSIS gt 00 1 1 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 001607 00867 Since the SRS ECU harness connector is plated to improve conductivity observe the warning below when checking this connector A 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 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 When Inspecting a Male Pin N 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 TSB Revision 00
55. mproper anti freeze can cause the corrosion of the aluminum components 7 lt Refilling engine coolant without the special tool 1 Loosen the air bleed bolt RADIATOR CAP DRAIN PLUG 23 LOOSEN ACX00896 AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 45 AIR BL ML AM 1421 Nm L _120 13 1 B 21203 ACX00898 AB MAINTENANCE SERVICE 2 By referring to the section on coolant select an appropriate concentration for safe operating temperature within the range of 30 to 60 Refill the system with a high quality ethylene glycol antifreeze at the selected 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 hole and then tighten the air bleed bolt 8 lt When special tool MB991871 is used gt By referring to the section on coolant select an appropriate concentration for safe operating temperature within the range of 30 to 60 Use special tool 991871 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 coolant or an equivalent Quantity 9 0 dm 9 5 quarts 9 Reinstall the radiator c
56. nce and reduce exhaust emission level Therefore they should be replaced periodically with new ones M1001002000238 IRIDIUM TIP Spark plug type MAKER IDENTIFICATION NO PLATINUM T AKX01327AB NGK IFR6S DENSO SK20PR A8 TSB Revision 00 38 GENERAL lt BODY AND CHASSIS gt PLUG GAP GAUGE Measure DIRECTION AKX00433 AB INCORRECT CORRECT AKX00434 AC MAINTENANCE SERVICE 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 A CAUTION When disconnecting an ignition cable be sure to hold the cable boot If the cable is disconnected by pulling on the cable 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 M1001002100020 T TIMING BELT REPLACE M1001002300024 Replace the belt with a new one according to the maintenance schedule on P 00 34 to assure proper engine performance For removal and installation procedures refer to GROUP 11A Timing Belt P 11A 33 TSB Revision GENERAL lt BODY AND CHASSIS gt 00 39 MAINTENANCE SERVICE 8 DRIVE BELT FOR GENERATOR AND WATER PUMP POWER STEERING PUMP CHECK CONDITION M100100250031
57. ng or handling SRS components Warning labels can be found in the following locations e Hood e Front impact sensor side impact sensor e Sun visor e Glove box e SRS ECU e Steering wheel e Air bag module side airbag modules Clock spring e Steering gear box e Seat belt pre tensioner 4 Always use the designated special tools and test equipment M1001000500312 5 Store components removed from the SRS ina clean and dry place The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward 6 Never attempt to disassemble or repair the SRS components SRS ECU air bag module clock spring and seat belt pre tensioner If there is a defect replace the defective part 7 Whenever you finish servicing the SRS check the SRS warning light operation to make sure that the system functions properly 8 Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag Refer to GROUP 52B Air Bag Module Disposal Procedures P 52Ba 48 Observe the following when carrying out operations on places where SRS components are installed including operations not directly related to the SRS air bag 1 When removing or installing parts do not allow any impact or shock to the SRS components 2 If heat damage may occur during paint work remove the SRS components After re installing them check the SRS warning light operati
58. on mark Starburst symbol on the container ILSAC certification mark Starburst symbol ACX00885 AC If these oils are not available an API classification SJ EC or SJ CD EC can be used ACX00886 AB Oil Viscosity The SAE grade number indicates the viscosity of the oil A proper SAE grade number should be selected according to ambient temperature 1 SAE 5W 30 PREFERRED ACX00887AB TSB Revision GENERAL lt BODY AND CHASSIS gt 00 33 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE 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 to 34 C 10 F 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 A CAUTION e 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 e Do not use a mixture of different brands of anti freeze COOLANT TEMPERATURE F FREEZING SAFE OPER
59. on to make sure that the system functions properly e SRS ECU air bag module clock spring 93 200 or more e Seat belt pre tensioner 90 194 F or more SERVICING ELECTRICAL SYSTEM AN 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 TSB Revision 00 22 GENERAL lt BODY AND CHASSIS gt PRECAUTIONS BEFORE SERVICE A CAUTION e 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 e 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 accessor
60. re essential points for removal or disassembly gt gt A lt lt Indicates that there are essential points for installation assembly Symbols for lubrication sealants and adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is pro vided by using symbols in the diagram of component parts or on the page following the component parts page and explained Grease Multipurpose grease unless there is a brand or type specified Sealant or adhesive Brake fluid or automatic transmission fluid Engine oil gear oil or air conditioning com pressor oil Adhesive tape or butyl rubber tape ACX00859 AC TSB Revision GENERAL lt BODY AND CHASSIS gt HOW TO USE THIS MANUAL Indicates the group number Indicates the section title Indicates the group title BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION Post installation Operation e Brake Fluid Supplying Air Bleeding Refer to Ld Pre removal Operation Brake Fluid Draining 113 9 Nem 7 00 5 Indicates the page number Mark denotes non BRAKE CALIPER KIT PAD SET SHIM KIT AND BOOT KIT REMOVAL STEPS REMOVAL STEPS continued 1 BRAKE HOSE CONNECTION gt gt lt lt 3 DISC BRAKE ASSEMBLY 2
61. rtion of the filler plug hole Specified oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classification GL 4 Quantity 2 8 dm 3 0 quarts 5 Tighten the filler plug to the specified torque Tightening torque 32 2 N m 24 1 ft lb OIL DRAIN PLUG 01200 AB 14 ENGINE COOLANT CHANGE M1001003100283 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 A CAUTION 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 little to let the pres sure escape through the vinyl tube After relieving the steam pressure remove the cap by slowly turning it coun terclockwise 2 Remove the radiator cap radiator drain plug and engine drain plug to drain the coolant 3 Remove the reserve tank and drain the coolant 4 After completely draining the coolant reinstall the drain 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 A CAUTION Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of an i
62. sion Spark plugs Replace a Ignition cables Replace every 5 years or Evaporative emission Check for leaks and clogging X canister GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE NO GENERAL SERVICE KILOMETERS 24 48 72 96 120 144 168 MAINTENANCE INTERVALS THOUSANDS MILEAGE IN 75 105 THOUSANDS 7 Timing belt Replace at x1 150006 km 100 000 mis 8 Drive belt for generator Check condition at water pump power 2180100 pump 9 Change oil every 12 months Every 12 000 km 7 500 miles 10 Engine oil filter oil filter Engine oil filter Replace every 12 Replace every 12 months or X 11 Automatic transmission Check fluid level every 12 fluid months or 12 Automatic transmission Change fluid at fluid 4 13 Transfer oil Check oil level TSB Revision GENERAL lt BODY AND CHASSIS gt 00 35 SCHEDULED MAINTENANCE TABLE NO GENERAL SERVICE KILOMETERS 24 48 72 96 120 144 168 MAINTENANCE INTERVALS THOUSANDS MILEAGE IN THOUSANDS LLL X 14 Engine coolant Change at first 4 years or after that Every 2 years or 15 Disc brake pads Inspect for wear every 12 X months or 16 Brake hoses Check for deterioration or leaks X X X X X every 12 months or 17 Ball joint and steering Inspect for grease leaks and X linkage seals damage every 2 years or
63. thin the diagram indicate the sequence for maintenance and servicing procedures e Removal steps The part designation number corresponds to the number in the illustration to indicate remov al steps Disassembly steps The part designation number corresponds to the number in the illustration to indicate disas sembly steps Indicates procedures to be performed be fore the work in that section is started and procedures to be performed after the work in that section is finished Component diagram A diagram of the component parts is pro vided near the front of each section in order to give the reader a better understanding of the installed condition of component parts Installation steps Specified when installation is impossible in reverse order of removal steps omitted if installation is possible in reverse order of re moval steps e Assembly steps Specified when assembly is impossible in reverse order of disassembly steps Omitted if assembly is possible in reverse order of disas sembly steps Classifications of major maintenance service points When there are major points relative to maintenance and servicing procedures Such as essential maintenance and service points maintenance and service standard values information regarding the use of special tools etc These are arranged together as major maintenance and service points and explained in detail A Indicates that there a
64. tion face 3M AAD Part No 8661 or of knuckle arm flange 3M AAD Part No 8663 Super Silicone 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 Threadlocker 27100 or AGENT Connecting of tilt steering 3M AAD Part No 8731 27200 bolt Fan pulley gear Sealing Medium Strength of small gaps and flange Threadlocker 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 TSB Revision
65. ughly washed with soap and water or use waterless hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents Either of the following engine oils should be used 1 Engine oil displaying ILSAC certification mark 2 Engine oil conforming to the API classification SJ EC or SJ CD EC For further details refer to LUBRICANTS SELEC TION LUBRICANTS AND GREASES Semi solid lubricants bear the NLGI designation and are further classified as grades 0 1 2 3 etc Whenever Chassis Lubricant is specified Multipur pose Grease NLGI grade Number 2 should be used FUEL USAGE STATEMENT CAUTION Using leaded gasoline in your car will damage the catalytic converters and heated oxygen sen sors and affect the warranty coverage validity This vehicle must use unleaded gasoline only Premium fuel is recommended This vehicle has a fuel filler tube which is especially designed to accept only the smaller diameter unleaded gasoline dispensing nozzle Your car is designed to operate on unleaded gaso line having a minimum octane rating of 87 MON RON 2 or 91 RON MON Motor Octane Number RON Research Octane Number GASOLINES CONTAINING ALCOHOL Some gasolines sold at service stations contain alco hol although they may not be so identified Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory TSB

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