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GENERAL

1. m Timing chain side AK401050AB 14 In accordance with the procedure shown in figure tighten the bolt of the cylinder head cover to 9 0 1 0 N m 15 Install the ignition coils AT CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION M6020200900493 EN 1 Check entire circumference and length of hoses using a mirror as required 2 Check that hoses installed in grommets pass through the centre of the grommets 3 Check all clamps for tightness and connections for leakage A8 CHECK ENGINE COOLANT LEVEL IN RESERVOIR M6020201000482 AC700017AB n CaN Condenser tank 701810 Check that the coolant level is between the FULL and LOW lines when the engine is at the normal operating temperature A9 CHANGE ENGINE COOLANT M6020201100627 1 Stop the engine after it is fully warmed up 2 Add detergent to the engine coolant in order to flush the cooling system and start the engine AC305655 3 Loosen the drain plug remove the radiator and drain the coolant 4 Feed fresh water into the cooling system through the filler port of the radiator in order to wash the cooling system and then tighten the drain plug 5 Drain the coolant from the radiator condenser tank 6 Install th
2. o o o 0 AC305635 AB 2 Automatic transmission 1 Make sure shift indicator lines up properly in all ranges 2 Depress the accelerator completely to check that the manual kickdown is operating correctly PRE DELIVERY INSPECTION 1 15 ROAD TEST 3 Stop the vehicle on a steep incline 31 VIBRATION AND RATTLES Put the automatic transmission in P position 100090090002 and slowly release the service brakes to see it 1 Locate squeaks rattles and unusual vibrations P position lock holds If it does not hold the 2 Verify that no noise occurs from the engine transmission requires further service transmission axle and body 29 BRAKES 32 ELECTRICAL EQUIPMENT M6010800300027 M6010800600028 1 Service Brake Put the vehicle in gear and apply the brakes while the vehicle is in motion Be sure brake operation is smooth and positive 2 Parking Brake 1 Stop the vehicle on a steep incline With the service brakes firmly applied place the transmission in N position and set the parking brakes 2 Slowly release the service brakes to see if the Set parking brakes will hold 1 Radio 30 STEERING CONTROL Tune the radio to a local broadcasting station and M6010800400024 check the following O 1 Operate the volume tone balance and fader controls etc 2 Pull out the pushbuttons dial another station and set each pushbuttons 3 Operate the AM FM switch 2 Tape player Ins
3. Dy NOTE For vehicles with aluminium wheels attach the camber caster kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment MB991004 Tighten the special tool to the same torque 160 16 as the driveshaft nut NOTE The camber and the caster are pre adjusted at factory and not adjustable 160 16 REAR WHEEL ALIGNMENT 1 Before the wheel alignment measurement adjust the rear suspension wheel and tires in good condition 2 Park the vehicle on a level surface to measure the wheel alignment TOE IN Standard value 3 2 mm If toe in is not within the standard value adjust by fol lowing procedures AC508335AB 1 Turn the toe adjusting bolt the mounting bolt inside the body on the control link to adjust Left wheel Turning clockwise toe in Right wheel Turning clockwise toe in NOTE The scale has gradations of approximately 2 6 mm single side toe angle equivalent to 16 CAMBER Standard value Standard and sporty High ground clearance suspension suspension 0 55 0230 0 35 030 NOTE The Difference between right left wheels must be less than 30 AC305848 AC NOTE For vehicles with aluminium wheels attach the camber caster kingpin gauge by using a compen sator NOTE The camber is pre adjusted at factory and is not adjustable PERIODIC INSPECTION AND MAINTENANC
4. and the clearance C between the clutch pedal and the pedal stopper when the clutch is disengaged are within the standard value Standard value B lt 4A9 LHD gt 99 105 mm lt 4A9 RHD gt 71 5 76 mm lt BWC LHD gt 110 116 mm lt BWC RHD gt 79 5 84 mm Standard value C lt LHD gt 15 mm or more lt RHD gt 11 mm or more 4 When the clutch pedal height and the clearance between the clutch pedal and pedal stopper when the clutch is disengaged are not within the standard value the air may be intruded into the hydraulic system or either the clutch master cylinder or the concentric slave cylinder may be faulty In this case perform air bleeding or check the clutch master cylinder or the concentric slave cylinder and replace it if necessary C2 CHECK PARKING BRAKE LEVER STROKE AND PLAY M6020400200539 Pull the parking brake lever with a force of approx 196 N and count the number of notches Standard value 3 5 notches If the parking brake lever stroke is out of the standard range adjust as described below 1 Remove the floor console assembly 2 Loosen the adjusting nut to the end of the cable rod in order to allow slack in the cables AC202320 AB 3 Remove the rear brake disc adjusting hole plug Then insert a flat tipped screwdriver to turn the adjuster to the arrow direction to expand the shoe until the parking brake shoe makes contact and the disc can no longer be tu
5. crankshaft clockwise one turn or more Auto tensioner 7 0 C Indicator mark W Fo N gt lt lt 1 Make sure that the indicator mark is within the area marked with A in the illustration 2 If the mark is out of the area replace the drive belt NOTE The drive belt tension check is not neces sary as auto tensioner is adopted A2 CHECK INTAKE AIR HOSE FOR DAMAGE vehicles with turbocharger M6020200500279 AC305652 AB 1 Inspect the intake air hoses for cracks or damage A3 REPLACE ENGINE TIMING BELT except vehicles with timing chain M6020200600339 For information concerning the replacement proce dures refer to the Workshop Manual PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A4 CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM BREATHER HOSE M6020200700422 Vice Ce 1 Inspect the breather hose for cracks or damage 2 Clean the inside of the breather hose if neces sary 3 Inspect the ventilation filter for clogging VENTILATION HOSE 1 Check entire circumference and length of hoses using a mirror as required 2 Check all clamps for tightness and the connec tions for leakage 3 Hoses should be replaced immediately if there is any evidence of deterioration or damage POSITIVE CRANKCASE VENTILATION SYSTEM CHECK PCV valve th Grin CANCE cee Vent
6. follow the procedure given below 7 613309 1 Remove the hose shown in the illustration which allows the A T fluid to flow from the A T fluid cooler built into the radiator to the transmission PERIODIC INSPECTION AND MAINTENANCE 2 29 OPERATIONS AFTER ENGINE IS WARMED UP N CAUTION The engine should be stopped within one minute of it being started If the A T fluid has all been dis charged before this stop the engine at that point 2 Start the engine and discharge the A T fluid Driving conditions N range idling Discharge amount Approx 3 5 L aoe AC302068AD 3 Remove the drain plug at the bottom of the transmission case to drain out the remaining A T fluid Discharge amount Approx 2 0 L 4 Install the drain plug with a gasket in between and tighten it to the specified torque Tightening torque 32 2 N m A CAUTION Stop pouring in the A T fluid once 5 5 L has been poured in 5 Pour in new A T fluid through the oil filler tube Amount to add Approx 5 5 L 6 Repeat the operation in step 2 7 Pour in new A T fluid through the oil filler tube Amount to add Approx 3 5 NOTE Carry out steps 2 and 7 so that at least 8 0 L has been discharged from the cooler hose After this discharge a small quantity of A T fluid and check for contamination If the A T fluid is contam inated repeat steps 6 and 7 7 AC613309 AB 8 Connect the ho
7. or the technician might be injured therefore be sure to use the spe TUBES AND OTHER RUBBER PARTS cial tool whenever doing any work for which the use of one is specified PARTS TO BE REPLACED M6001000500027 AC305595 Be careful to avoid spilling any petrol oil etc because if it adheres to any tubes or other rubber parts they might be adversely affected AC305594 If any of the following parts are removed they must LUBRICANTS be replaced with new parts Oil seals Gaskets except rocker cover gasket Packings O rings Lock washers Split pins Self locking nuts M6001000800028 AC305596 In accordance with the instructions in this manual apply the specified lubricants in the specified loca tions during assembly and installation 0 4 GENERAL PRECAUTIONS BEFORE SERVICE BRAKE FLUID e Be careful to avoid spilling any brake fluid because if it adheres to the vehicle body the paint coat might be discoloured SERVICING THE ELECTRICAL SYSTEM M6001001000081 M6001000900025 gt AC305285 CAUTION Before connecting or disconnecting the negative cable be sure to turn off the ignition switch and the lighting switch If this is not done there is the possibility of semiconductor parts being damaged Before replacing a component related to the electri cal system and before undertaking any repair proce
8. A 168 0 mm Limit A 169 0 mm D6 CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION M6020500600415 Fuel vapour canister Fuel delivery pipe Fuel tank assembly AC613482AB 1 Check entire circumference and length of hoses 2 Check all clamps for tightness and connections and pipes for leakage 2 28 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP OPERATIONS AFTER ENGINE IS WARMED UP E1 CHECK FLUID LEVEL IN AUTOMATIC TRANSMISSION 1 Drive the vehicle until the A T fluid temperature M6020600100387 reaches the normal temperature 70 80 C NOTE Measure A T fluid temperature using M U T III Fluid level mm 3040 60 80 Fluid temperature AC700133AC NOTE Check the oil level referring to the charac teristics chart shown if it takes some time to reach the normal operation temperature of A T fluid 70 80 C Park the vehicle on a level surface Move the selector lever to all positions to fully charge the torque converter and the fluid lines with A T fluid and then move the selector lever to the P position Pull out the oil level gauge and wipe off the A T fluid and dirt Then insert the oil level gauge again and pull it to check the condition of the A T fluid NOTE If the A T fluid has a burnt smell or if it has become very contaminated or dirty it means that the A T fluid has become contaminated by minute particles form
9. AND 2 22 E2 CHANGE AUTOMATIC REPLACE AIR PURIFIER FILTER 2 23 TRANSMISSION FLUID 2 28 CHANGE ENGINE OIL 2 30 OPERATIONS OUTSIDE 4 REPLACE ENGINE OIL FILTER 2 31 THE VEHICLE 2 23 E5 CHECK ENGINE IDLING SPEED 2 32 D1 CHECK UNEVEN TYRE WEAR 225 CHECK CO CONCENTRATION 2 33 D2 CHECK FRONT AND REAR WHEEL BEARINGS FOR 225 OTHERS oLa LaL LuaLua 2 34 CHECK BRAKE HOSES AND F1 CHECK BODY CONDITION PIPES FORLEAKAGE 2 25 FOR DAMAGE 2 34 D4 CHECK BRAKE PADS AND F2 ROAD TEST 2 34 DISCS FOR 2 26 D5 CHECK BRAKE SHOE LININGS AND DISCS FOR WEAR 2 26 D6 CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION 2 27 PERIODIC INSPECTION AND MAINTENANCE 2 3 PERIODIC INSPECTION AND MAINTENANCE SCHEDULE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE M6020100100661 For items which indicate both distance and time in months the inspection should be made at whichever distance or time comes first Maintenance item Maintenance Maintenance interval operation OPERATIONS INSIDE THE ENGINE COMPARTMENT V belt for cracks fraying wear and Inspection Every 15 000 km or every 12 mont
10. CHECK ENGINE COOLANT LEVEL IN RESERVOIR A9 CHANGE ENGINE COOLANT A10 CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE A11 REPLACE AIR CLEANER ELEMENT A12 CHECK FLUID LEVEL IN BRAKE RESERVOIR AND CLUTCH RESERVOIR for hydraulic type clutch GROUP 2 PERIODIC INSPECTION AND MAINTENANCE CONTENTS 2 8 2 8 2 8 2 9 2 41 2 11 2 41 2 14 2 14 2 14 A13 CHANGE BRAKE FLUID A14 CHECK BATTERY ELECTROLYTE OPERATIONS UNDER THE B1 CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS B2 CHECK SUSPENSION ARM BALL JOINTS FOR PLAY AND DUST COVERS FOR DAMAGE B3 CHECK DRIVESHAFT BOOTS FOR DAMAGE B4 CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS including seals and boots B5 CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION B6 CHANGE GEAR OIL IN MANUAL 5 551 B7 CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE AND CHECK PIPE 2 19 2 19 2 19 2 20 2 20 2 20 Continued next page 2 2 C C OPERATIONS INSIDE THE VEHICLE 2 21 OPERATIONS AFTER ENGINE IS C1 CHECK BRAKE PEDAL AND WARMEDUP 2 28 CLUTCH PEDAL FOR FREE PLAY 2 21 E1 CHECK FLUID LEVEL IN C2 CHECK PARKING BRAKE LEVER AUTOMATIC TRANSMISSION 2 28 STROKE
11. PRE DELIVERY INSPECTION Inspection methods are described following the TABLE OF PRE DELIVERY INSPECTION NOTE The spaces for model C Chassis number E engine number aggregate distance travelled in kilometres miles date of inspection name of person conducting the inspection and body colour must be completed without fail NOTE The spaces for place of inspection and name of owner should be completed as required PRE DELIVERY INSPECTION NOTES CONCERNING ENTRIES TABLE OF PRE DELIVERY INSPECTION 0010037 retightening Needs replenishment of repair replenishment of lubricant water etc INSPECTION PROCEDURE First Step 1 Connection of the dark current connector Body 2 Wrap film 3 LZIExterior 4 LZIOperation of door locking systems and door hinges 5 Operation of door mirrors windows and sunroof Under Hood 6 Engine oil level 7 Brake master cylinder fluid level 8 Clutch master cylinder fluid level 9 LZIWasher fluid level 10 Battery condition and connections 11 Power steering fluid level 12 Co Electrical wiring Under Vehicle 13 LITyre and spare tyre pressures 14 Suspension system 15 Steering linkage and split pins 16 Under body Before Road Test 17 Seat adjusters and seat back latches 18 Choke system and inhibitor switch 19 idle control knob 20 instrument panel controls 21 Meters gauges warning lamps and indication lamps 22 LZAir conditioning heater and
12. dures involving the electrical system be sure to first disconnect the negative cable from the battery in order to avoid damage caused by short circuiting ACX00880A APPLICATION OF ANTI CORROSION AGENTS AND UNDERCOATS M6001001100022 If oil or grease gets onto the oxygen sensor it will cause a drop in the performance of the sensor Cover the oxygen sensor with a protective cover when applying anti corrosion agents and undercoats PRE INSPECTION CONDITION M6001001200041 Pre inspection condition refers to the condition that the vehicle must be in before proper engine inspec tion can be carried out If you see the words Set the vehicle to the pre inspection condition In this man ual it means to set the vehicle to the following condi tion e Engine coolant temperature 80 to 90 e Lamps electric cooling fan and all accessories OFF Neutral A T P range VEHICLE WASHING M6001001300082 Approximately AC300832AC If high pressure car washing equipment or steam car washing equipment is used to wash the vehicle be sure to note the following information in order to avoid damage to plastic components etc e Spray nozzle distance Approximately 40 cm or more e Spray pressure 3 900 kPa or less e Spray temperature 82 C or less e Time of concentrated spray to one point within 30 sec GENERAL 0 5 PRECAUTIONS BEFORE SERVICE MULTI USE TESTER SUB ASSEMBLY M60
13. in the painted surface Cracks may be either shallow or deep Dirt in paintwork Rough surface resulting from foreign material in the paint or from dust deposited on wet paint during painting or storage Filed or ground traces Deep scratches in sheet metal surface resulting from improper use of buffer or sander are not completely covered and are visible through paint coating Orange peel The painted surface has the appearance of an orange peel Peeling The paint flakes off partly or over a wide area The peeling may be minor medium or major Pin holes Tiny holes in the painted surface Runs A visible trickle of dried paint on the surface Either undercoat or top coat Scratches Scratches on the painted surface Shrink The painted surface shrinks causing wrinkles Smears Spots of soot or other material deposited on the painted surface Including stains and water spots Spray mist The painted surface includes fine particles of other paint Uneven lustre The lustre of the painted surface is not uniform Uneven metallic dispersion The metallic dispersion of the painted surface is not uniform Visibly incomplete topcoating A part of the undercoating visible 1 6 PRE DELIVERY INSPECTION FIRST STEP FIRST STEP 1 CONNECTION OF DARK CURRENT Press down the storage connector CONNECTOR CONNECTING PROCEDURE M601
14. installed 1 Lower arm Upper arm 2 Stabilizer bar 3 Strut assembly REMOVE FRONT SPRING RESTRAINTS N CAUTION It is very important that these restraints must be removed during predelivery inspection Failure to do so could cause ride and handling com plaints Spring ib ue restraints 3 8 SSO AC305605 With the vehicle correctly positioned on the sub frame contact points and the suspension fully extended remove the rubber restraints from the front springs 15 STEERING LINKAGE AND SPLIT PINS M6010600300023 AC305604 1 Steering linkage retaining nuts and split pins Check visually and by feel that the steering linkage retaining nuts are correctly tightened and the split pins are correctly installed 2 Tie rods and relay rod Check that the tie rods and relay rod of the steering linkage are not bent and that the tie rod end lock nuts are securely tightened 3 Steering components 1 Check that each of the steering components is tightened 2 Check the tie rod end nuts and split pins for proper installation 3 Check the condition of bellows type dust seals 4 Split pins Check the front axle nuts and rear wheel spindle nuts for split pins 16 UNDER BODY M6010600400020 Check under body and under body coating for dam age 1 12 PRE DELIVERY INSPECTION BEFORE ROAD TEST BEFORE ROAD TEST 17 SEAT ADJUSTERS AND SEATBACK LATCHES M601070010
15. mm If numeric values have not been entered new tool set them according to the belt specifications as shown below Once you set them you do not have to set them again The settings remain undeleted even after battery replacement NOTE This operation is to temporarily set the preset data such as the belt specifications because if the measurement is taken without input of the belt specifications conversion to tension value N cannot be made resulting in judgment of error Setting procedure 1 Press down the MASS button till the belt mass select display appears 2 Press the UP or DOWN button to select 01 1 5GT 0 9 and press the MEASURE button to decide it Check to ensure that M 000 9 g m is displayed 3 Press the WIDTH button to change to the belt width input display 4 Press number keys 0 1 0 and 0 sequentially and press the SELECT button to apply them Check to ensure that W 010 0 mm R appears on the display 5 Press the SPAN button to change to the span length input display 6 Press number keys 0 1 0 and 0 sequentially and press the SELECT button to apply them Check to ensure that S 0100 mm appears on the display 4 Press Hz button twice to change the display to the frequency display Hz PERIODIC INSPECTION AND MAINTENANCE 2 7 OPERATIONS INSIDE THE ENGINE COMPARTMENT CAUTION The temperature of the surface of the belt should be as close as pos
16. not wipe the lubricant from the battery posts and cable clamps 11 POWER STEERING FLUID LEVEL M6010500600072 AC305616 1 Check that the fluid level is between MAX and MIN 2 If the fluid is added start the engine and turn the steering wheel from stop to stop several times to expel air from the system Specified gear oil Automatic transmission fluid DEXRON Ill or DEXRON II 12 ELECTRICAL WIRING M6010500700024 AC305617 Each electrical wiring harness and connector 1 Check each harness to be correctly routed and securely clipped 2 Confirm that all connections are tight lgnition cable Be sure that all ignition cables are firmly attached to the spark plugs distributor cap or crank angle sensor and ignition coil UNDER VEHICLE 13 TYRE AND SPARE TYRE PRESSURES M6010600100041 AC305618 1 2 Tyre specification Check the correct tyre specification Tyre pressures Adjust each tyre pressure NOTE Recommended pressure is shown on the tyre pressure label Valve stem extensions Verify that the valve stem extensions are installed where necessary Install the wheel covers wheel rings and hub caps PRE DELIVERY INSPECTION 1 11 UNDER VEHICLE 14 SUSPENSION SYSTEM M6010600200082 AC305609 Check to be sure that each installation bolt and nut is tightened If split pins are used make sure that they are properly
17. of tyre tread 1 2 mm Bellows clip LP Tie rod Lock nut CD 612558 AC 1 Adjust the toe in by undoing the bellows clip and lock nut and turning the left and right tie rod turnbuckles by the same amount in opposite directions NOTE The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle 2 Install the bellows clip and tighten the lock nut to the specified torque Tightening torque 52 2 N m 3 Confirm that the toe in is at the standard value AC306798 4 Use a turning radius gauge to check that the steering angle is at the standard value Standard value Item Specification 40 50 1 30 33 50 Inner wheels Outer wheels for reference 2 24 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE CAMBER CASTER AND KINGPIN INCLINATION Standard value Standard and sporty suspension High ground clearance suspension Camber 0 05 0930 0 10 0930 Caster 2 40 0930 2 30 0 30 Kingpin 13 30 1930 1310 1930 inclination NOTE The Difference between right and left wheels must be less than 30 N CAUTION To prevent the wheel bearing from damage never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened
18. the engine oil filler cap 3 Remove the engine room under cover extension 4 Remove the engine oil pan drain plug to drain engine oil o 5 Install a new drain plug gasket so that it faces in the direction shown in the illustration and then tighten the drain plug to the specified torque Tightening torque 39 5 N m 40 30 20 10 0 10 20 30 40 50 C j SAE 20W 40 20W 50 SAE 15W 40 15W 50 SAE 10W 40 10W 50 SAE 0W 30 5W 30 AC311073 6 Refill with specified quantity of engine oil Specified Engine Oil e ACEA classification A1 B1 A3 B3 A3 B4 or A5 B5 e API classification SG or higher Total quantity Includes volume inside engine oil filter 4 2 L NOTE SAE 0W 30 5W 30 and 5W 40 engine oils can only be used if they meet ACEA A3 B3 A3 B4 or A5 B5 and API SG or higher specifica tions 7 Install the engine oil filler cap 8 Check engine oil level PERIODIC INSPECTION AND MAINTENANCE 2 31 OPERATIONS AFTER ENGINE IS WARMED UP lt BWC gt 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C A CAUTION Use care as engine oil could be hot 2 Remove the engine oil filler cap 3 Remove the engine room under cover extension AC700118 AB 4 Remove the engine oil pan drain plug to drain engine oil 5 Tighten the engine oil pan drain plug to the specified torque Tightening
19. torque 30 N m 6 Refill with specified quantity of engine oil Specified Engine Oil lt Vehicles without DPF gt VW 50501 50601 50700 lt Vehicles with DPF gt VW 50700 Total quantity Includes volume inside engine oil filter 4 0 L 7 Install the engine oil filler cap 8 Check engine oil level E4 REPLACE ENGINE OIL FILTER M6020600400496 lt 4 9 gt 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C N CAUTION Use care as oil could be hot 2 Remove the engine oil filler cap 3 Remove the engine room under cover extension 4 Remove the drain plug to drain oil MB991396 or commercially available tool AC103249 AD 5 Use the respective tool in the following table to remove the engine oil filter Number Special tool MR984204 Commercially available tool MD360935 Oil filter wrench MB991396 or equivalent 6 Clean the filter bracket side mounting surface O ring AC103250AD 7 Apply a small amount of engine oil to the O ring of the new oil filter 8 Once the O ring of the oil filter is touching the flange use the respective tool in the following table to tighten to the specified torque Number Special tool Tightening torque MR984204 Commercially available tool Approximately 3 4 turn 11 1 N m MD360935 filter wrench MB991396 or equivalent Approximately 1 t
20. 0082 AC305622 Check the operation of the various parts of the seats 1 Mechanical adjusters of the seats 2 Operation of the latch for tilting the seatbacks forward and backward 18 INHIBITOR SWITCH M6010701100029 On models with an automatic transmission be sure the engine starts in both P and position and does not start in other positions 19 IDLE CONTROL KNOB M6010700300020 Verify that the diesel engine revolution increases when the idle control knob is pulled out 20 INSTRUMENT PANEL CONTROLS M6010700400083 Check the operation of the following 1 Horn Headlamps Exterior and interior lamps Instrument panel lamps Instrument brightness control 21 METERS GAUGES WARNING LAMPS AND INDICATION LAMPS M6010700500024 Sole pa AC305624 1 Check the meters and gauges are functioning properly 2 Check each indicator lamp and warning lamp functions properly 22 AIR CONDITIONER HEATER AND DEFROSTER SYSTEM M6010700600021 Check the systems for proper operation AC305625 1 Air conditioner 1 Operate the air conditioner system 2 Operate the air conditioner light 3 Operate the control lever in all ranges 4 Operate the blower motor switch in all ranges AC305626 2 Heater and defroster 1 After the engine has warmed up turn on the heater 2 Operate the blower motor switch in all
21. 01001900169 Refer to the M U T II OPERATING INSTRUC TIONS for instructions on handling the M U T III A CAUTION Turn the ignition switch to the LOCK OFF posi tion before connecting or disconnecting the M U T III MB991827 _acs05420AB Connect the M U T III to the diagnosis connector as shown in the illustration IN ORDER TO PREVENT VEHICLES FROM FIRE M6001001500064 Improper installation of electrical or fuel related parts could cause a fire In order to retain the high quality and safety of the vehicle it is important that any accessories that may be fitted or modifica tions repairs that may be carried out which involve the electrical or fuel systems must be carried out in accordance with MMC s information Instructions ENGINE OILS HEALTH WARNING Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitis In addi tion used engine oil contains potentially harmful con taminants which may cause skin cancer Adequate means of skin protection and washing facilities must be provided M6001001600061 RECOMMENDED PRECAUTIONS The most effective precaution is to adapt working practices which prevent as far as practicable the risk of skin contact with mineral oils for example by using enclosed systems for handling used engine oil and by degreasing components wher
22. 0300100233 Storage connector AC700018AB BODY 2 WRAP FILM To protect the exterior finish of vehicles prior to 6010400100100 dealer delivery a protective coating is used The coating is a thin white resin film It is applied to all painted exterior horizontal surfaces of the vehicle and is held in place with a tacky adhesive backing AC305606 PRE DELIVERY INSPECTION BODY Peel off slowly from corners keeping parallel to the body When gt body temperature is high lower it to 50 C or less by sprinkling water so that adhesive may not remain on the body REMOVAL PROCEDURE Wrap film removal Water washing Wipe off by kerosene or white gasoline etc If itis considerably visible use polishing compound Cleaning of border Disposal of removed film Burning is appropriate AC306352 AB Wrapping work Process Operation Content Continuous peeling of film The film is peeled off Water rinse Sand and dust are removed from the vehicle body and it is dried thoroughly Parts where the film is to be reapplied are checked There should be no leftover adhesive swelling or discoloration of the paint film or other defects Treatment of parts where film is to be reapplied Reapplication Treat the defect
23. 4 Fill with specified until the level comes to the lower portion of filler plug hole Specified transmission oil DiaQueen NEW MULTI GEAR OIL SAE 75W 80 API GL 3 Quantity lt 5 gt 1 9L lt 6 gt 2 0 L Tighten the filler plug to the specified torque Tightening torque lt F5MGA gt 43 3 N m lt F6MBA gt 32 2 N m B7 CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE AND CHECK PIPE INSTALLATION M6020301200375 1 Confirm that the exhaust pipe does not interfere with any body components 2 Check the exhaust pipe for damage by stones etc 3 Start the engine and check for gas leaks from the exhaust pipe connections PERIODIC INSPECTION AND MAINTENANCE 2 21 OPERATIONS INSIDE THE VEHICLE OPERATIONS INSIDE THE VEHICLE C1 CHECK BRAKE PEDAL AND CLUTCH PEDAL FOR FREE PLAY BRAKE PEDAL FREE PLAY M6020400100479 1 With the engine stopped depress the brake pedal 2 or 3 times to release the vacuum in the brake booster Then press the brake pedal with your finger and check if the pedal stroke until the pedal becomes heavy play is within the standard value Standard value B 3 8 mm 2 When the brake pedal play is not within the standard value check the brake pedal to clevis pin looseness clevis pin to booster operating rod looseness brake pedal height and stop lamp switch position and adjust or replace as necessary CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL 1 Turn up the
24. 537 2 Remove the floor inspection lid LH Fuel tank pump and gauge assembly connector ___ 3 Disconnect the connector of fuel tank pump and gauge assembly connector 4 Release the fuel pressure in the fuel line Flat tipped screwdriver Retainer Fuel tank pump and gauge assembly Fuel main pipe AC506884AG 5 Insert a flat tip screwdriver wide and 1mm thick into the retainer of the fuel main pipe Flat tipped screwdriver t Fuel tank pump and gauge assembly Fuel main pipe AC506885 AF 6 Turn the flat tipped screwdriver by about 90 degrees to push up the retainer and disconnect the fuel main pipe from the fuel tank pump and gauge assembly 7 Remove the mounting nuts of fuel tank pump and gauge assembly A CAUTION Pay attention not to damage the fuel gauge unit and float of the fuel tank pump and gauge assem bly when removing the fuel tank pump and gauge assembly from the fuel tank 8 Remove the fuel tank pump and gauge assembly from service hole FUEL PUMP MODULE Fuel flange and filter assembly Fuel tank gauge gasket AC702053AB 9 Replace the fuel flange and filter assembly and fuel tank pump and gauge gasket with a new one N CAUTION e Pay attention not to damage the fuel gauge unit and the float of the fuel tank pump and gauge assembly when installing it t
25. Another operator closes the master cylinder outlets with his fingers In this condition release the brake pedal Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with brake fluid 14 CHECK BATTERY ELECTROLYTE LEVEL A CAUTION e If the battery fluid is below the LOWER LEVEL the battery could explode in using e If the battery fluid is over the UPPER LEVEL leakage could result A 6020201700533 Thermometer Hydrometer Battery fluid AC504567AB 1 Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks 2 Use a hydrometer and thermometer to check the specific gravity of the battery fluid Standard value 1 220 1 290 electrolyte temperature 20 C 3 The specific gravity of the battery fluid varies with the temperature so use the following formula to calculate the specific gravity for 20 Use the calculated value to determine whether or not the specific gravity is satisfactory D20 t 20 x 0 0007 Dt D20 Specific gravity converted to a value for electrolyte temperature of 20 C t Electrolyte temperature at the time of meas urement Dt Actual specific gravity 2 16 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A15 REPLACE FUEL FILTER 4A9 1 Remove the rear seat cushion assembly TA AS ta Floor inspection lid LH us J AC612784AB M6020201900
26. E 2 25 OPERATIONS OUTSIDE THE VEHICLE D2 CHECK FRONT AND REAR WHEEL Rear BEARINGS FOR PLAY 1 Remove the caliper assembly and suspend the MBGEORUDAUOTOR caliper assembly with a wire and remove the Front brake disc 1 Remove the caliper assembly brake disc and retain it with a wire and the like to prevent from falling AC511300AC 2 Check the bearing s axial play Place a dial gauge against the hub surface then move the hub in the axial direction and check whether or not there is AC102438 2 Set a dial gauge as shown in the figure Move the axial play hub in the axial direction and measure the axial Limit 0 05 mm 3 Replace the rear hub assembly if an adjustment Limit 0 05 mm cannot be made to within the limit D3 CHECK BRAKE HOSES AND PIPES FOR LEAKAGE M6020500300403 Brake booster Rear disc brake Front disc brake AC700421AB 1 Check entire circumference and length of hoses 2 Check all clamps for tightness and connections and pipes for leakage 2 26 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS OUTSIDE THE VEHICLE D4 CHECK BRAKE PADS AND DISCS FOR WEAR M6020500400499 AC102396AF 1 Check the brake pad thickness through the caliper body check port Standard value 10 0 mm Limit 2 0 mm 2 When the thickness is less than the limit always replace the pads at an axle set 00668 3 Using micrometer measure
27. HOW TO USE THIS MANUAL PRECAUTIONS BEFORE SERVICE PROTECTING THE VEHICLE DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS REMOVAL AND DISASSEMBLY SPECIAL 5 PARTS TO BE REPLACED TUBES AND OTHER RUBBER PARTS GROUP 0 GENERAL CONTENTS 0 2 LUBRICANTS BRAKE FLUID te t 0 2 SERVICING THE ELECTRICAL SYSTEM 0 2 APPLICATION OF ANTI CORROSION AGENTS AND UNDERCOATS 0 2 PRE INSPECTION CONDITION 0 2 VEHICLE 0 3 MULTI USE TESTER M U T III 0 3 SUB 5 0 3 IN ORDER TO PREVENT VEHICLES ns FROM FIRE ENGINE 6 0 1 0 3 0 3 0 4 0 4 0 4 0 4 0 5 0 5 0 2 GENERAL HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL M6000000100026 This manual contains Pre delivery inspection and Group 0 and 1 have the contents for all vehicle mod Periodic inspection and maintenance els and Group 2 has contents for the relevant vehi cle models PRECAUTIONS BEFORE SERVICE PROTECTING THE VEHICLE REMOVAL AND DISASSEMBLY M6001000100029 M6001000300023 ac AC305590 AC305591 If there is a likelihood of damaging interior or exterior When checking a malfunction find the cause of the parts during service operations protect them with problem
28. If it is determined that removal and or dis suitable covers such as seat covers fender covers assembly is necessary perform the work by following etc the procedures contained in this manual DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS M6001000200026 AC305592 If punch marks or mating marks are made to avoid error in assembly and facilitate the assembly work AC305283 be sure to make them in locations which will have no detrimental effect on performance and or appear If the service work is to be done by two or more ance If an area having many parts similar parts mechanics working together all the mechanics and or parts which are symmetrical right and left is involved should take safety into consideration while disassembled be sure to arrange the parts so that they work they do not become mixed during the assembly proc ess 1 Arrange the parts removed in the proper order 2 Determine which parts are to be reused and which are to be replaced 3 If bolts nuts etc are to be replaced be sure to use only the exact size specified GENERAL 0 3 PRECAUTIONS BEFORE SERVICE SPECIAL TOOLS PARTS M6001000400031 M6001000600024 MITSUBISHI MOTORS KE GENUINE PARTS AC305593 AC305284 If other tools are substituted for the special tools to When replacing parts use MITSUBISHI genuine do service of repair work there is the danger that parts vehicle parts might be damaged
29. MPI system Refer to WORKSHOP MANUAL GROUP 13 Troubleshooting 9 Remove the timing light 10 Turn the ignition switch to LOCK OFF position and then disconnect the M U T III PERIODIC INSPECTION AND MAINTENANCE 2 33 OPERATIONS AFTER ENGINE IS WARMED UP lt BWC gt 1 Set the vehicle to the pre inspection condition MB991827 505420 2 Turn the ignition switch to LOOK OFF position and connect the diagnosis connector to the M U T III 3 Start the engine and let it run at idle 4 Check the idle speed Select item No 2 and take a reading of the idle speed Standard value 830 50 r min 5 If the idle speed is not within the standard value inspect the diesel system E6 CHECK CO CONCENTRATION M6020601000242 1 Before inspection set the vehicle to the pre inspection condition 2 Turn the ignition switch to LOCK OFF position eseli MB991827 AC608435AC 3 Connect the M U T III to the diagnosis connector Set a timing light to the power supply line terminal No 1 of the ignition coil No 1 NOTE The power supply line is looped and also longer than the other ones Start the engine and let it run at idle Check that ignition timing is at the standard value Standard value approximately 10 BTDC Run the engine at 2 500 r min for 2 minute
30. ON AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT OPERATIONS INSIDE THE ENGINE COMPARTMENT A1 CHECK V BELT FOR CRACKS FRAYING WEAR AND ADJUST ITS TENSION V BELT CONDITION Check the whole rounds of the V belt for cracks fray ing and wear M6020200100527 V BELT TENSION ALTERNATOR AND OTHERS BELT TEN SION CHECK AND ADJUSTMENT lt 4A9 gt Check the alternator and others belt tension in the following procedure Standard value Item When checked 140 171 When adjusted 148 164 When replaced 198 221 Vibration 392 588 9 5 12 2 441 539 784 980 10 2 11 5 6 3 7 6 Tension N Deflection mm Reference When the vibration frequency is measured Special tool MB992080 is used Recommendation NOTE The vibration frequency measuring method is recommended for check and adjustment of the alter nator and others belt tension Belt tension meter set MB992080 MB992082 AC507219AB 1 Connect the Special tool microphone assembly MB992082 to the Special tool belt tension meter MB992081 of the Special tool belt tension meter set MB992080 2 Press the POWER button to turn on the power supply 3 Press number key 1 Check to ensure that No 01 appears on the upper left of the display and that the following numeric values are displayed for individual items M W and S M 000 9 g m W 010 0 mm R S 0100
31. P 2 Periodic Inspection and Maintenance 39 ENGINE TRANSMISSION STEERING GEAR BOX AND DIFFERENTIAL FOR LEAKS M6010900700055 Check the engine transmission steering gear box and differential for oil leaks 40 FRONT AND REAR DIFFERENTIAL OIL LEVELS 1 Remove the filler plug 2 Check the oil level If the oil level is at or slightly below the filler hole it is in satisfactory condition M6010900800234 TYPE2 Gear oil AC305646AC Type 1 only Remove the filler plug and check the gear oil level Check that gear oil level is not 8 mm below the bottom of filler plug hole 3 If the level is low replenish the front and or rear differential with fresh oil by using a lubricator NOTE For the specified oil refer to GROUP 2 Periodic Inspection and Maintenance 41 HOSES FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE M6010901000145 AC305647 1 Check all hoses fluid lines and connections for leaks 2 Check all hoses and fluid lines for proper routing away from sharp edges and moving components 1 18 PRE DELIVERY INSPECTION FINAL STEPS FINAL STEPS 42 HEADLAMP AIMING M6011000100116 Screen Headlamp 2 Level surface AC305648 AB Check condition for headlamp aiming NOTE For headlamp aiming procedures refer to the Workshop Manual for that model 43 EQUIPMENT M6011000200050 Check the installation of the various equi
32. PERATIONS OUTSIDE THE VEHICLE D1 uneven tyre wear Inspection Every 30 000 km or every 2 years D2 front and rear wheel bearings for play Inspection Every 60 000 km or every 4 years D3 Check brake hoses and pipes for leakage Inspection Every 30 000 km or every 2 years 04 Check brake pads and discs for wear Inspection Normal Every 15 000 km or every 12 usage months Severe 7 500 km or every 6 usage months D5 Check brake shoe linings and discs for wear Inspection Normal Every 30 000 km or every 2 usage years Severe Every 15 000 km or every 12 usage months D6 Check fuel hoses and pipes for leakage or Inspection Every 30 000 km or every 2 years deterioration OPERATIONS AFTER ENGINE IS WARMED UP fluid level in automatic transmission Inspection Every 15 000 km or every 12 months E2 automatic transmission fluid Change Normal Every 90 000 km or every 6 usage years Severe usage Every 45 000 km or every 3 years PERIODIC INSPECTION AND MAINTENANCE 2 5 PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation E3 Change engine oil ACEA classification Change Normal Every 15 000 km or every 12 lt 4A9 gt For service A1 B1 usage months A3 B3 A3 B4 or A5 B5 Severe Every 7 500 km API classification For usage service SG or higher Change engine o
33. R THE VEHICLE B1 CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS M6020300100386 FRONT SUSPENSION Deterioration and sagging e 717 Bends and SSS damage Ss Noise and A B oil leakage LIOS Be NS 6 EB Cracks bends and dents REAR SUSPENSION Noise and oil leakage Bends and damage Cracks bends and dents AC702021AB PERIODIC INSPECTION AND MAINTENANCE 2 19 OPERATIONS UNDER THE VEHICLE B2 CHECK SUSPENSION ARM BALL JOINTS FOR PLAY AND DUST COVERS FOR DAMAGE LOWER ARM BALL JOINT AXIAL PLAY CHECK M6020300200394 Lower arm AC507631AB Raise the vehicle Move the lower arm up and down with your hands to check for an excessive play in the axial direction of the ball joint If there is an excessive play replace the lower arm assembly DUST COVERS FOR DAMAGE 1 2 Using your fingers press the dust cover to check for a crack or damage If it dust cover has any crack or damage replace the lower arm assembly NOTE If the dust cover has a crack or damage the ball joint could be damaged B3 CHECK DRIVESHAFT BOOTS FOR DAMAGE M6020300400387 4 AC305661 Check the driveshaft boots for damage B4 CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS including seals and boots M6020300500395 AC305662 Move the steering wheel bit by bit to the le
34. RK TERMS 1 5 PRESSURES 1 10 14 SUSPENSION SYSTEM 144 FIRST STEP 1 6 15 STEERING LINKAGE AND SPLIT PINS 4 11 1 CONNECTION OF DARK CURRENT 16 UNDER BODY 1 11 CONNECTOR 1 6 BEFORE ROAD TEST 1 12 BODY uu 1 6 17 SEAT ADJUSTERS AND 2 WRAP FILM 1 6 SEATBACK LATCHES 4 12 3 1 8 18 INHIBITOR SWITCH 1 12 4 OPERATION OF DOOR LOCKING 19 IDLE CONTROL KNOB 1 12 SYSTEMS AND DOOR HINGES 1 8 20 INSTRUMENT PANEL CONTROLS 1 12 5 OPERATION OF DOOR MIRRORS 21 METERS GAUGES WARNING WINDOWS AND SUNROOF 1 8 LAMPS AND INDICATION LAMPS 1 12 22 AIR CONDITIONER HEATER UNDER HOOD 1 9 AND DEFROSTER SYSTEM 1 12 6 ENGINE OILLEVEL 1 9 23 WIPERS AND WASHERS 1 13 7 BRAKE MASTER CYLINDER FLUID 24 OPERATION OF SERVICE BRAKES LEVEL resi en kie irc 1 9 AND PARKING BRAKES 1 13 8 CLUTCH MASTER CYLINDER 25 CLUTCH OPERATION 1 13 FLUIDLEVEL 1 9 26 OPERATION OF SEAT BELTS 9 WASHER FLUID LEVEL 1 9 SHOULDER BELTS AND RETRACTORS 1 14 10 BATTERY CONDITION AND 5 1 10 Continued on next page 11 POWER STEERING FLUID LE
35. VEL 1 10 12 ELECTRICAL WIRING 1 10 1 2 ROAD 1 14 37 MANUAL TRANSMISSION AND 57 ENGINE PERFORMANCE ARD TRANSFER 4WD OIL LEVEL 1 16 EXHAUST 8 1 14 38 AUTOMATIC TRANSMISSION 28 TRANSMISSION IN ALL RANGES 22 1 14 FLUID LEVEL mom of 3 9 1 17 39 ENGINE TRANSMISSION 29 1 15 4 0 D re ns DIFFERENTIAL FOR LEAKS 147 31 VIBRATION AND RATTLES 1 18 A0 EBORTAND REAR DIFFERENTIAL 32 ELECTRICAL EQUIPMENT 1 15 OIE LEVELE 1 17 41 HOSES FLUID LINES AND AFTER ROAD TEST 1 16 CONNECTIONS LOCATED UNDER 33 IDLESPEED ia VEHICLE 147 34 IGNITION DES ia 35 RADIATOR COOLANT LEVEL 1 16 18 36 HOSES FLUID LINES AND 42 HEADLAMP 1 18 CONNECTIONS LOCATED UNDER 43 1 18 1 16 44 EXTERIOR AND INTERIOR 1 18 45 OWNER INSTRUCTIONS 1 18 PRE DELIVERY INSPECTION 1 3 NOTES CONCERNING ENTRIES NOTES CONCERNING ENTRIES This section describes the details and the inspection methods employed for the pre delivery inspection of vehicles The inspection should be conducted according to the sequence described in the TABLE OF
36. and drain the coolant 4 Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area Cylinder block drain plug LA Gasket AC403641AB 5 Replace the gasket and tighten the cylinder block drain plug to the specified torque Tightening torque 27 3 N m 6 Securely tighten the drain plug of the radiator 7 Reinstall the radiator condenser tank CAUTION Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of an improper anti freeze can cause corrosion of the aluminium compo nents d RID A 2 S MES CEAN P 08991871 3232 Gu uS T Se M LL 2279 25 2 q AC609929AB PERIODIC INSPECTION AND MAINTENANCE 2 13 OPERATIONS INSIDE THE ENGINE COMPARTMENT 8 By referring to the section on coolant select an appropriate concentration for safe operating temperature within the range of 30 to 6096 Use special tool LLC changer MB991871 to refill the engine coolant up to the top of the radiator port A convenient mixture is a 5096 water and 50 antifreeze solution freezing point 31 C Recommended antifreeze DIA QUEEN SUPER LONG LIFE COOLANT or equivalent Quantity 6 0 L NOTE For how to use special tool MB991871 refer to its manufacturer s instructions 9 Tighten the radiator cap securely 10 Re
37. bushings metal or worn parts In such a case the transmission needs to be over hauled and the A T fluid cooler line needs to be flushed out HOT AC700134 5 Check that the A T fluid level is between the HOT marks on the oil level gauge If the A T fluid level is too low add more A T fluid until the level reaches between the HOT marks Automatic transmission fluid DIA QUEEN ATF SP Ill NOTE If the A T fluid level is too low the oil pump draws air into the system along with the A T fluid and air bubbles will thus from in the fluid circuit This will cause a drop in fluid pressure and cause the shift points to change and the clutches and brakes to slip If the A T fluid level is too high the gear will churn the A T fluid and cause bubbles to develop which can then cause the same prob lems as when the A T fluid is too low In either case the air bubbles can cause overheating and oxidation of the A T fluid and also prevent the valves clutches and brakes from operating nor mally In addition if bubbles develop in the A T fluid the A T fluid can overflow from the transmis sion vent holes and be mistaken for leaks 6 Securely re insert the oil level gauge E2 CHANGE AUTOMATIC TRANSMISSION FLUID M6020600200469 Specifications DIA QUEEN ATF SP III F4A4A CHANGE PROCEDURE In you have an A T fluid changer use the A T fluid changer to flush the A T fluid If you do not have an A T fluid changer
38. defroster systems 23 Wipers and washers 24 Operation of service brakes and parking brakes 25 LZIClutch operation 26 LLIOperation of seat belts shoulder belts and retractors Road Test 27 ZI Engine performance and exhaust gas 28 LEI Transmission in all ranges 29 LZIBrakes 30 Steering control 31 Vibration and rattles 32 LI Electrical equipment After Road Test 33 speed 34 LLlllgnition timing 35 LI Radiator coolant level 36 LZIHoses fluid lines and connections located under hood 37 Manual transmission and transfer 4WD oil level 38 Automatic transmission fluid level 39 Engine transmission steering gear box and differential for leaks 40 Front and rear differential oil levels 41 L1 Hoses fluid lines and connections located under vehicle Final Steps 42 Headlamp aiming 43 LI Equipment 44 LLIExterior and interior 45 LLIOwner instructions AC401525 PRE DELIVERY INSPECTION PAINTWORK TERMS 1 5 PAINTWORK TERMS Definition M6010200100098 Remark A raised bubble in the paint from the base or the undercoat caused by abnormal moisture The bubble may contain either water or air Change in tone The colour tone of the painted surface is not uniform Including wrong colour discoloration and decolouration Contact mark A mark on the painted surface as a result of contact by hands or clothing at the time of paint application Crack A crack
39. disc thickness at eight positions approximately 45 apart and 10 mm in from the outer edge of the disc Standard value Front 26 0 mm Rear 10 0 mm Limit Front 24 4 mm Rear 8 4 mm NOTE Thickness variation at least 8 positions should not be more than 0 015 mm 4 If the disk thickness is less than the limits replace it with a new one BRAKE DISC RUN OUT CHECK 1 Remove the brake assembly and then hold it with wire 2 Temporarily install the disc with the hub nut 00669 3 Place a dial gauge approximately 5 mm from the outer circumference of the brake disc and measure the run out of the disc Limit Front 0 06 mm Rear 0 08 mm D5 CHECK BRAKE SHOE LININGS AND DISCS FOR WEAR BRAKE LINING THICKNESS CHECK 1 Remove the brake disc M6020500500407 ACX00708AE 2 Measure the thickness of the brake lining at the place worn the most Standard value A 2 8 mm Limit A 1 0 mm 3 Replace the shoe and lining assembly as an axle set if brake lining thickness is less than the limit PERIODIC INSPECTION AND MAINTENANCE 2 27 OPERATIONS OUTSIDE THE VEHICLE BRAKE DISC INSIDE DIAMETER CHECK 3 Replace the brake disc when the inside diameter 1 Remove the brake disc exceeds the limit value or the brake disc is worn unevenly ACX00709AD 2 Measure the inside diameter of the brake disc at two or more locations Standard value
40. e pedal to floorboard clearance when the with approximately 500 a N force clutch is just disengaged AC305628 AB 1 Service brakes 1 Check the clearance between the brake pedal and the floor board when the brake pedal is depressed AC305631 3 Verify correct clutch pedal free play NOTE For inspection and adjustment of the clutch pedal refer to GROUP 2 Periodic Inspec tion and Maintenance 1 14 PRE DELIVERY INSPECTION 26 OPERATION OF SEAT BELTS SHOULDER BELTS AND RETRACTORS M6010701000022 AC305632 ROAD TEST 1 Verify that the seat belt warning lamp operates properly 2 Check all seat belts and harnesses to assure that they connect and hold properly 3 Lean forward to check that the shoulder harnesses allow movement 4 Check the condition of the belts and anchors 5 Check for proper seat belt retraction ROAD TEST 27 ENGINE PERFORMANCE AND EXHAUST GAS M6010800100023 AC305633 1 Engine performance Check the engine for proper performance and accelerator pedal for smooth operation 2 Exhaust system 1 Check the exhaust system components for gas leaks 2 Verify that no black smoking is emitted from the end of the exhaust pipe diesel powered vehicles 28 TRANSMISSION IN ALL RANGES M6010800200020 AC305634 1 Manual transmission Check the transmission in all forward ranges and in reverse Button po
41. e practicable before handling them Other precautions e Avoid prolonged and repeated contact with oils particularly used engine oils Wear protective clothing including impervious gloves where practicable Avoid contaminating clothes particularly under pants with oil Do not put oily rags in pockets the use of overalls without pockets will avoid this Do not wear heavily soiled clothing and oil impregnated foot wear Overalls must be cleaned regularly and kept separately from per sonal clothing e Where there is a risk of eye contact eye protec tion should be worn for example chemical gog gles or face shields in addition an eye wash facility should be provided Obtain first aid treatment immediately for open cuts and wounds Wash regularly with soap and water to ensure all oil is removed especially before meals skin cleansers and nail brushes will help After clean ing the application of preparations containing lanolin to replace the natural skin oils is advised Do not use petrol kerosine diesel fuel gas oil thinners or solvents for cleaning skin e Use barrier creams applying them before each work period to help the removal of oil from the skin after work e f skin disorders develop obtain medical advice without delay NOTES 1 1 GROUP 1 PRE DELIVERY INSPECTION CONTENTS NOTES CONCERNING ENTRIES 1 3 UNDER VEHICLE 1 10 13 TYRE AND SPARE TYRE PAINTWO
42. e radiator condenser tank 2 12 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT N CAUTION Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of an improper anti freeze can cause the corrosion of the aluminium com ponents 7 Depending upon conditions of operation determine the amount of long life coolant antifreeze or antirust to be added to the coolant Recommended antifreeze 4A9 DIA QUEEN SUPER LONG LIFE COOLANT or equivalent lt BWC gt BASF Glysantin Alu Protect Premium G30 8 Fill the cooling system with soft water through the filler port and add long life coolant if necessary 9 Fill the radiator condenser tank with coolant 10 Install the radiator cap and the radiator condenser tank cap A CAUTION When removing the radiator cap be careful to blow out steam and boiling water 11 Recheck the engine coolant level after a road test REMOVAL OF ENGINE COOLANT FROM THE CYLINDER BLOCK DRAIN PLUG 4A9 1 Drain the water from the radiator heater core and engine after unplugging the radiator drain plug and removing the radiator cap N Cylinder block drain plug Drive shaft 2 assembly WA 613431 2 Drain the water in the water jacket by unplugging the drain plug of the cylinder block 3 Remove the radiator condenser tank
43. ed brake fluid DOT3 or DOT4 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A CAUTION Use the specified brake fluid Avoid using a mix ture of the specified brake fluid and other fluid If brake fluid is exposed to the air it will absorb moisture as water is absorbed from the atmos phere the boiling point of the brake fluid will decrease and the braking performance will be seriously impaired For this reason use a hermet ically sealed 1 L or 0 5 L brake fluid container Firmly close the cap of the brake fluid container after use 3 When fresh fluid has come to flow out from the vinyl tube tighten the bleeder screw NOTE This change from existing to fresh fluid can be judged by change in colour of fluid that flows out LH drive vehicles m Front of vehicle pj 3 AC607427 AE RH drive vehicles 2 3 b Front of vehicle L SS 4 1 AC607428AD 4 Repeat above steps for other bleeder screws MASTER CYLINDER BLEEDING When removed the master cylinder assembly bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier When no brake fluid is in the master cylinder 1 Fill the brake fluid reservoir with brake fluid 2 Depress and hold the brake pedal 2 15 AC700199AB 3
44. ert a cassette tape in the tape player and check as follows AC305636 1 Check the operation of the tape feeder and rewind 1 Check for excessive play or looseness 2 Check the ejection 2 Check the steering wheel centre 3 Check the operation of volume tone balance and fader controls etc 1 16 PRE DELIVERY INSPECTION AFTER ROAD TEST AFTER ROAD TEST 33 IDLE SPEED Check the engine idle speed NOTE For specific idle speed adjustment proce dure refer to GROUP 2 Periodic Inspection and Maintenance 34 IGNITION TIMING M6010900100172 M6010900200179 AC305641 Check the ignition timing Except MPI vehicles with crankshaft mounted crankshaft angle sensor NOTE For the inspection and adjustment of the igni tion timing refer to GROUP 2 Periodic Inspection and Maintenance 35 RADIATOR COOLANT LEVEL M6010900300154 N CAUTION Do not remove the radiator cap while the cooling system is under pressure When removing the radiator cap be careful of steam and boiling water Add coolant only to the reserve tank if it is required AC305642 1 Check that the coolant level in the reserve tank is at or above LOW mark at normal engine operating temperature And check cooling system for leaks 2 Check that the coolant concentration is 3096 to 6095 36 HOSES FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD M6010900400203 CAUTION Remember tha
45. floor carpet under the brake pedal AC505506 AD 2 Start the engine and depress the brake pedal with approximately 500 N and measure clearance between the brake pedal and the floor panel Standard value C 85 mm or more 3 When the clearance is not within the standard value check for air in the brake line and thickness of the disc brake pad and correct or replace as necessary 4 Recover the floor carpet under the brake pedal CLUTCH PEDAL CHECK AND ADJUST MENT NOTE This clutch pedal assembly is unadjustable because of its structure AC601326 AB 1 Measure the clutch pedal looseness A Standard value A 4 mm or less 2 When the clutch pedal looseness is not within the standard value the clutch pedal assembly may be faulty In this case check the clutch pedal assembly and replace it if necessary 2 22 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE VEHICLE lt LHD gt Clutch pedal height Clutch pedal Distance between the clutch pedal and the pedal stopper when the clutch is released Pedal stopper ES SM iS Pedal B stopper Clutch pedal X AC612473AC lt RHD gt Clutch pedal height 2 5 Clutch pedal Pedal stopper B v Distance between the clutch pedal and the pedal stopper when the clutch is released ane Clutch pedal Pedal stopper 612474 Check that the clutch pedal height
46. ft or right and check to be sure that there is no play or looseness in the linkage coupling that the installation is not loose and that the rod or arm is not bent or damaged y NAI TU Sy AC507632AB Check to be sure that the seal and boot of the ball joint are correctly installed in the correct position and that they are not damaged Check tie rod end lock nut for looseness If lock nut is loose adjust toe in and then tighten lock nut to the specified torque Tightening torque 51 2 N m 2 20 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE B5 CHECK GEAR OIL LEVEL IN MANUAL TRANSMISSION M6020300600262 F5MGA Filler plug hole I Filler plug Transmission oil AC702182AD F6MBA Filler plug hole Transmission oil Filler plug AC210553 AE 1 Remove the filler plug 2 Check that the oil level is up to the lower edge of the filler plug hole 3 Check that the oil is not noticeably dirty 4 Tighten the filler plug to the specified torque Tightening torque lt F5MGA gt 43 3 N m lt F6MBA gt 32 2 N m B6 CHANGE GEAR OIL IN MANUAL TRANSMISSION M6020300800329 WANN Sa 1 Remove the filler plug 2 Remove the drain plug and drain the oil 3 Tighten the drain plug to the specified torque Tightening torque lt F5MGA gt 43 3 N m lt F6MBA gt 32 2 Nm
47. hs adjust its tension A2 intake air hose for damage vehicles Inspection Every 30 000 km or every 2 years with turbocharger engine timing belt except vehicles Inspection Every 120 000 km with timing chain A4 operation of crankcase emission Inspection Every 30 000 km or every 2 years control system A5 spark plugs lridium tipped type Replace Every 90 000 km 6 valve clearance except vehicles with Inspection Every 90 000 km auto lash adjuster A7 radiator hoses for damage and proper Inspection Every 30 000 km or every 2 years connection A8 engine coolant level in reservoir Inspection Every 30 000 km or every 2 years A9 engine coolant Change Every 60 000 km or every 4 years A10 Check air cleaner element for clogging and Inspection Normal Every 15 000 km or every 12 damage usage months Severe Every 7 500 km or every 6 usage months A11 Replace air cleaner element Replace Normal Every 45 000 km or every 3 usage years Severe More frequently usage A12 Check fluid level in brake reservoir and clutch Inspection Every 15 000 km or every 12 months reservoir for hydraulic type clutch A13 Change brake fluid Change Every 30 000 km or every 2 years A14 Check battery electrolyte level Inspection Every 15 000 km or every 12 months A15 Replace fuel filter 4A9 engine Replace Every 150 000 km or every 10 years BWC engine Replace Ever
48. il lt Vehicles without Change Every 15 000 km or every 12 months lt BWC gt DPF gt VW 50501 50601 50700 lt Vehicles with DPF gt VW 50700 E4 engine oil filter lt 4A9 gt Replace Normal Every 15 000 km or every 12 usage months Severe Every 7 500 km usage Replace engine oil filter lt BWC gt Replace Every 15 000 km or every 12 months E5 engine idling speed Inspection Every 15 000 km or every 12 months E6 Check CO concentration Inspection Every 15 000 km or every 12 months E7 Check exhaust gas recirculation EGR system Inspection Every 60 000 km or every 4 years OTHERS F1 Check body condition for damage Inspection Every year F2 Road test Inspection Every 15 000 km or every 12 months NOTE Severe usage specifications apply to only vehicles used under severe operating conditions Severe operating conditions include the followings cases Driving in dusty area Driving on rough roads on submerged roads or hilly areas Driving cold zones Engine idling for a long time or short distance travel during cold weather Frequent sudden application of brakes Towing of a trailer Use as a taxi or as a rent a car When more than 50 of driving is in heavy city traffic and the ambient temperature is 32 or more WD When more than 50 of driving is at 120 km h or the ambient temperature is 30 or more 2 6 PERIODIC INSPECTI
49. ilation hose WY AC700014AC 1 Remove the ventilation hose from the PCV Positive crankcase ventilation valve 2 Remove the PCV valve from the rocker cover 3 Reinstall the PCV valve at the ventilation hose 4 Start the engine and run at idle PERIODIC INSPECTION AND MAINTENANCE 2 9 OPERATIONS INSIDE THE ENGINE COMPARTMENT PCV valve AK300021AC 5 Place finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt NOTE At this moment the plunger in the PCV valve moves back and forth 6 If vacuum is not felt clean the PCV valve or replace it 7 Apply a small amount of new engine oil to the O ring on the PCV valve and tighten to the specified torque Tightening torque 2 5 0 4 N m PCV VALVE CHECK PCV valve AK300022AC 1 Insert a thin rod into the PCV valve from the side shown in the illustration rocker cover installation side and move the rod back and forth to check that the plunger moves 2 If the plunger does not move there is clogging in the PCV valve In this case clean or replace the PCV valve A5 REPLACE SPARK PLUGS M6020200800333 After removing old spark plugs install new ones and tighten them at the specified torque A6 CHECK VALVE CLEARANCE except vehicles with auto lash adjuster M6020202400074 VALVE CLEARANCE CHECK AND ADJUSTMENT lt 4A9 gt NOTE Perform the val
50. move the radiator condenser tank cap and add the engine coolant up to the FULL line 11 Turn the A C switch to OFF position to start the engine and warm up until the radiator fan operates NOTE This work is to open the thermostat fully 12 Rev the engine several times and then stop it Check that there are no coolant leaks 13 Remove the radiator cap with the engine cool and then refill the engine coolant up to the top of the radiator port 14 Tighten the radiator cap securely A CAUTION Do not overfill the radiator condenser tank 15 Remove the radiator condenser tank cap and add the engine coolant up to the FULL line lt BWC gt 1 Drain the engine coolant from the radiator heater core and engine after unplugging the radiator plug and removing the radiator condenser tank cap T VON Engine oil cooler f se Engine oil 2 Drain the engine coolant in the water jacket by disconnect the engine oil cooler hose 3 Remove the radiator condenser tank and drain the engine coolant 4 Install the radiator condenser tank 5 Drain the engine coolant then clean the path of the coolant by injecting water from the radiator condenser tank cap area 6 Connect the engine oil cooler hose 7 Securely tighten the drain plug of the radiator N CAUTION Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of a
51. n improper anti freeze can cause corrosion of the aluminium compo nents 8 By referring to the section on engine coolant select an appropriate concentration for safe operating temperature within the range of 50 Use special tool LLC changer MB991871 to refill the engine coolant to the FULL line of the radiator condenser tank A convenient mixture is a 5096 water and 50 antifreeze solution Recommended antifreeze BASF Glysantin Alu Protect Premium G30 Quantity 7 5 L Includes 0 62 L in the con denser tank NOTE For how to use special tool MB991871 refer to its manufacturer s instructions 9 Tighten the radiator condenser tank cap securely 10 Turn the A C switch to OFF position to start the engine and warm up until the radiator fan operates NOTE This work is to open the thermostat fully 11 Rev the engine several times and then stop it Check that there are no engine coolant leaks 12 Remove the radiator condenser tank cap with the engine cool and then refill the engine coolant again to the FULL line of the radiator condenser tank 2 14 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT A10 CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE M6020201200431 1 Check air cleaner element for clogging and damage 2 Clean deposited dust from the element in the following manner 1 Lightly tap the element against the top of a bench 2 Blow comp
52. o the fuel tank e When installing the fuel tank pump and gauge assembly to the fuel tank check that the fuel gauge unit moving area moves smoothly 10 Install the fuel tank pump and gauge assembly to the fuel tank through the service hole and tighten the mounting nuts to the specified torque Tightening torque 2 5 0 4 PERIODIC INSPECTION AND MAINTENANCE 2 17 OPERATIONS INSIDE THE ENGINE COMPARTMENT Retainer LC Fuel main pipe AURURUTRAE 11 Before the installation push up the retainer of the fuel main pipe La Fuel tank pump and gauge assembly Fuel main pipe AC606020 AF 12 Connect the connector of fuel main pipe to the fuel tank securely and push down the retainer of the connector to lock it firmly lt BWC gt e Unclasp the fuel filter bracket clamp 13 After the installation slightly pull the fuel main pipe to check that it is connected securely At this time also check that there is approximately 1 mm play T 1 pues Fuel tank pump and gauge assembly connector ES AC613224AB 14 Connect the fuel tank pump and gauge assembly connector S Wi i Floor inspection lid LH J AC612784AB 15 Install the floor inspection lid LH 16 Install the rear seat cushion assembly i filter 7 AC701879AB 2 18 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS UNDER THE VEHICLE OPERATIONS UNDE
53. pment 1 Floor mats 2 Spare tyre 3 Jack jack handle and tool set 44 EXTERIOR AND INTERIOR M6011000300154 AC613484 Finally check and clean the exterior and interior 1 Wash the vehicle to remove all traces of road grime and other dirt on the vehicle as a result of new vehicle preparations 2 Clean exterior and interior glass surface 3 Remove all protective covers 4 Remove undercoat overspray excess window sealer and excess weatherstrip adhesive 5 Verify that the secondary key can not unlock the glove box and tailgate boot lid if so equipped 6 Remove shipping and inspection stickers 45 OWNER INSTRUCTIONS M6011000400054 1 Verify that the owner s manual and service booklet is in the glove box 2 Place the spare keys in envelope in the glove box before delivery 2 1 PERIODIC INSPECTION AND MAINTENANCE SCHEDULE OPERATIONS INSIDE THE ENGINE A1 CHECK V BELT FOR CRACKS FRAYING WEAR AND ADJUST ITS A2 CHECK INTAKE AIR HOSE FOR DAMAGE vehicles with turbocharger A3 REPLACE ENGINE TIMING BELT except vehicles with timing chain A4 CHECK OPERATION OF CRANKCASE EMISSION CONTROL SYSTEM 5 REPLACE SPARK PLUGS A6 CHECK VALVE CLEARANCE except vehicles with auto lash adjuster A7 CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION A8
54. pump pulley A C compressor pulley um pulley AK305688AB Use a belt tension gauge to check that the belt ten sion is within the standard value NOTE Before inspection remove the oil level gauge guide lt Belt deflection check gt Alternator Approximately pulley 100 N Water pump Deflection Fi A C compressor pulley Crankshaft pulley Apply approx 100 N of force to the middle of the alternator and others belt between the pulleys at the place indicated by the arrow and check that the amount of deflection is within the standard value AC700535AB If not within the standard value adjust the belt ten sion by the following procedure pes Adjusting bolt RIS can fixing nut Nut for alternator 9 G pivot bolt PN 402420 1 Loosen the nut of the alternator pivot bolt 2 Loosen the alternator fixing nut 3 Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values 4 Temporarily tighten the alternator fixing nut Tightening torque 10 5 3 5 2 8 5 Tighten the nut of the alternator pivot bolt Tightening torque 47 0 5 N m 6 Tighten the alternator fixing nut Tightening torque 22 5 2 5 7 Tighten the adjusting bolt Tightening torque 5 0 1 0 N m DRIVE BELT TENSION CHECK lt BWC gt A CAUTION Check the drive belt tension after turning the
55. ranges 3 Move the control to Defrost position From front and side defroster From centre ventilators From side ventilators From under the instrument panel From under the front seat some models only PRE DELIVERY INSPECTION 1 13 BEFORE ROAD TEST 23 WIPERS AND WASHERS M6010700700028 AC305629 AC305627 2 Verify correct brake pedal free play NOTE For inspection and adjustment of the 1 Front wiper and washer service brake refer to GROUP 2 Periodic 1 Check operation of the front wipers in all Inspection and Maintenance ranges 2 Parking brake 2 Check the aim of the front washer stream Check the parking brake drag and lever travel 3 Check the wiper blade stop positions NOTE For inspection and adjustment of the park 4 Verify that the interval between cycles of ing brake refer to GROUP 2 Periodic Inspection wiping is shifted when timer knob is turned to and Maintenance any position 5 Verify that the front wipers function by 25 CLUTCH OPERATION operating the washer switch 6010700900282 2 Rear wiper and washer 1 Check the operation of the rear wiper 2 Check the aim of the rear washer stream 3 Check the wiper blade stop positions 24 OPERATION OF SERVICE BRAKES AND PARKING BRAKES M6010700800274 AC305630AC V E J 1 Check the clutch operation in all driving ranges Depress brake pedal 2 Check th
56. replacing the transmission with a new one if overhauling the existing transmission or if the fluid has deteriorated or is contaminated the fluid cooler line must always be flushed out AC613309 AB 1 Remove the hose shown in the illustration which allows the A T fluid to flow from the A T fluid cooler built into the radiator to the transmission CAUTION The engine should be stopped within one minute of it being started If the A T fluid has all been dis charged before this stop the engine at that point 2 Start the engine and discharge the A T fluid Driving conditions N range idling Discharge amount Approx 3 5 L CAUTION Stop pouring in the A T fluid once 3 5 L has been poured in 3 Pour in new A T fluid through the oil filler tube Amount to add Approx 3 5 L 4 Repeat the operation in step 2 and 3 NOTE Carry out steps 2 and 3 so that at least 8 0 L has been discharged from the cooler hose After this discharge a small quantity of A T fluid and check for contamination If the A T fluid is contam inated repeat steps 2 and 3 5 Carry out the procedure in CHANGE PROCEDURE from step 2 onwards CHANGE ENGINE OIL lt 4A9 gt 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C A CAUTION Use care as engine oil could be hot M6020600300574 2 Remove
57. ressed air from inside the element 3 Wipe off dust on the air cleaner interior 4 Install the air cleaner body A11 REPLACE AIR CLEANER ELEMENT M6020201300483 The air cleaner element will become dirty and loaded with dust during use and the filtering effect will be substantially reduced Replace it with a new one lt 4A9 gt B NS MT OJA 701812 1 Unclasp the air cleaner cover clip 2 Remove the air cleaner element and install a new one 3 Be sure to close the air cleaner cover completely when clamping it A12 CHECK FLUID LEVEL IN BRAKE RESERVOIR AND CLUTCH RESERVOIR for hydraulic type clutch M6020202300107 AC507763 1 Check that the fluid level is between the MAX and MIN mark 2 If itis below the MIN marks replenish with fresh brake fluid up to the MAX mark A13 CHANGE BRAKE FLUID M6020201600547 AC305659 1 Remove the cap of the bleeder screw connect a vinyl tube and place its other end in a receptacle A CAUTION If the reservoir tank completely runs out of fluid during operation air will find way into the brake line Pay attention therefore to the fluid level and replenish as necessary 2 Loosen the bleeder screw and depress the brake pedal supply new brake fluid when the level of the fluid within the reservoir tank decreases Specifi
58. rned Back off the adjuster to the opposite direction by five notches PERIODIC INSPECTION AND MAINTENANCE 2 23 OPERATIONS OUTSIDE THE VEHICLE N CAUTION Be careful that the parking brake lever notch number should be within the standard range If the notch number is too low rear brake dragging can be caused 4 Adjust the parking brake lever stroke to the standard value by turning the adjusting nut After adjustment check that there is no free play between the adjusting nut and the parking brake lever 5 After the parking brake lever stroke is adjusted raise the rear of the vehicle Release the parking brake and turn the rear wheels to confirm that the rear brakes are not dragging C3 REPLACE AIR PURIFIER FILTER M6020400300310 AC613485AB 1 Remove the glove box 2 Remove the air purifier cover and the air purifier assembly 3 Install a new air purifier assembly and install the air purifier cover 4 Install the glove box OPERATIONS OUTSIDE THE VEHICLE D1 CHECK UNEVEN TYRE WEAR M6020500800066 FRONT WHEEL ALIGNMENT Measure wheel alignment with alignment equipment on a level surface The front suspension steering system wheels and tires should be serviced to nor mal condition before measuring wheel alignment TOE IN Standard value At the centre
59. s Set the CO HC tester 2 34 PERIODIC INSPECTION AND MAINTENANCE OTHERS 9 Check the CO contents and the HC contents at idle Standard value CO contents 0 5 or less HC contents 100 ppm or less 10 If there is a deviation from the standard value inspect the MPI system Refer to WORKSHOP MANUAL GROUP 13 Troubleshooting 11 Remove the timing light and CO HC tester 12 Turn the ignition switch to LOCK OFF position and then disconnect the M U T III OTHERS F1 CHECK BODY CONDITION FOR Drive the vehicle and check for conditions DAMAGE 1 Check free play of steering wheel 20700100306 2 Check efficiency of service brakes and parking 1 Check underbody coating for damage brakes system 2 Check body painting for damage 3 Check driveability of engine F2 ROAD TEST 4 Check condition of instruments gauges M6020700200400 indicators exterior lamps heater and ventilators 5 Check abnormal noise of each part 6 Check the tyres for wear and for the correct air pressure AC613484
60. s on the parts where film is to be reapplied If a solvent is used to remove leftover adhesive wipe off the solvent thoroughly 1 Basically the parts where the film is to be applied should be the same as the film that is to be applied 2 Apply the film from the lower portion of the body working upward progressively Apply pressure using a plastic squeegee or similar tool 3 As necessary cut the film at the various parts such as windshield washer nozzles hood and trunk lid CAUTION e Apply the film with the body at a temperature of 10 40 C Workability is good in this temperature range e If the outside surface of the film the side with no adhesive is brought into direct contact with the paint film and left in that state it may result in loss of paint gloss so make sure the film does not get folded under or otherwise make contact with the paint film e Air bubbles and wrinkles do not have a particularly bad influence on the pain film but every effort should be made to prevent air bubbles from being trapped under the film by applying pressure from the centre of the film outward toward the edges during application e To prevent intrusion of rainwater be sure to press down the overlapping portions and cut ends of the film securely 1 8 PRE DELIVERY INSPECTION BODY 3 EXTERIOR M6010400200196 AC613484 1 Visually inspect the entire exterior 1 Paint condition 2 Corro
61. se which was disconnected in step 1 and then securely re insert the oil level gauge 9 Start the engine and let it run at idle for 1 2 minutes 10 Move the selector lever to all positions once and then return it to the N position HOTI AC700134 11 Check that the A T fluid level on the oil level gauge is at the COLD mark If it is not up to this mark add more A T fluid 12 Drive the vehicle until the A T fluid temperature reaches the normal temperature 70 80 C and then re check the A T fluid level NOTE The COLD mark is for reference only the HOT marks should be used as the standard for judgment NOTE A T fluid temperature using M U T III Fluid level mm 10 0 30 Oil level gauge 40 60 80 Fluid temperature AC700132AC NOTE Check the oil level referring to the charac teristics chart shown if it takes some time until reaching the normal operation temperature of A T fluid 70 80 13 When A T fluid is under the specified level top up A T fluid When A T fluid is over the specified level drain the excessive A T fluid from the drain plug to adjust A T fluid level to the specified level 14 Securely insert the oil level gauge into the oil filler tube 2 30 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP AUTOMATIC TRANSMISSION FLUID COOLER LINE FLUSHING N CAUTION If
62. sible to normal tem perature Do not let any contaminants such as water or oil get onto the microphone If strong gusts of wind blow against the microphone or if there is loud sources of noise nearby the values measured by the microphone may not correspond to actual values If the microphone is touching the belt while the measurement is being made the values measured by the microphone may not corre spond to actual values Do not take the measurement while the vehi cle s engine is running Alternator pulley MB992080 Microphone 10 15 mm Water pump pulley Crankshaft lt pulley AK603849AC A C compressor pulley Hold the microphone to the middle of the alternator and others belt between the pulleys at the place indicated by the arrow about 10 15 mm away from the rear surface of the belt and so that it is perpendicular to the belt within an angle of 159 Press the MEASURE button Gently tap the middle of the belt between the pulleys the place indicated by the arrow with your finger as shown in the illustration and check that the vibration frequency of the belt is within the standard value NOTE To take the measurement repeatedly fillip the belt again After the completion of the measurement press and hold the POWER button to turn off the power supply When using the tension gauge Alternator Sensi ension gauge Water
63. sion scratches 3 Bent edges dented panels 2 Coated surfaces maintenance Touch up minor paint chips and flaws Refer to paintwork terms 4 OPERATION OF DOOR LOCKING SYSTEMS AND DOOR HINGES M6010400300137 AC210253AB 1 Open each door to check the release mechanism and ease of operation 2 Close the door to check the latch and striker 3 Open the door operate the lock lever and close the door to check the lock 4 Partially close the door to check the open door detent 5 Unlock each door with the key to check lock operation 6 Verify that all doors can be locked by the lock buttons NOTE Adjust and lubricate the door latches strikers and locks as required M Child protection knob NOS bow AC305610 AB 7 Verify that the rear doors can t be opened by the inner door handle when the child protection knob at the end of the door is shifted to the LOCK position with the inside lock plunger raised NOTE Set the lock to the FREE position on child protection of both rear doors For four door models 5 OPERATION OF DOOR MIRRORS WINDOWS AND SUNROOF M6010400400082 AC613484 1 Door mirrors Check that the mirror operate properly 2 Door windows Close all door windows to the fully closed position to check ease of operation 3 Power windows Check that the door windows operate when the respective switches are operated Check that when the lock swi
64. t the air conditioner system is under pressure 1 Check all brake fuel power steering and air conditioner lines and connections verify proper routing check connections for leaks tighten loose connector as required 2 Inspect routing and connections of all vacuum and radiator and heater houses NOTE Keep in mind that an oily residue around an air conditioner connector does not necessarily indicate a leak Oil is used to lubricate fittings dur ing assembly Be sure lines are not twisted or kinked 37 MANUAL TRANSMISSION AND TRANSFER 4WD OIL LEVEL M6010900500211 Transmission oil AC305644 AB 1 Remove the filler plug 2 Check the oil level If the oil level is at or slightly below the filler hole it is in satisfactory condition 3 If the level is low replenish the transmission and transfer case with fresh oil by using a lubricator NOTE For the specified oil refer to GROUP 2 Periodic Inspection and Maintenance PRE DELIVERY INSPECTION 1 17 AFTER ROAD TEST 38 AUTOMATIC TRANSMISSION FLUID LEVEL M6010900600230 ACO005861AD 1 Remove the dipstick and check the fluid level 2 Fluid level is okay if it is in the specified range as illustration at normal engine operating temperature 3 If the level is below the lower notch replenish fluid until the level reaches the upper notch NOTE For the specified automatic transmission fluid refer to GROU
65. tches are depressed the respective door windows can no more be opened or closed PRE DELIVERY INSPECTION 1 9 UNDER HOOD 4 Slide window Close the slide window to the fully closed position to check operation 5 Sunroof Close the sunroof to the fully closed position to check operation UNDER HOOD 6 ENGINE OIL LEVEL M6010500100107 NIW AC305611AB Check that the oil level is between MAX and MIN If it is at or below MIN add the necessary amount of the specified engine oil referring to GROUP 2 Peri odic Inspection and Maintenance 7 BRAKE MASTER CYLINDER FLUID LEVEL M6010500200115 AC702028 Check the fluid level If it is below the MIN mark replenish fresh brake fluid up to the MAX mark Specified Brake Fluid DOT3 or DOT4 8 CLUTCH MASTER CYLINDER FLUID LEVEL M6010500300026 AC305613 Check the fluid level If itis below the MIN mark replenish fresh brake fluid up to the MAX mark Specified Brake Fluid DOT3 or DOT4 9 WASHER FLUID LEVEL M6010500400078 AC305614 Check the fluid level if it is low replenish the washer fluid 1 Windshield washer reservoir 2 Rear window washer reservoir 1 10 PRE DELIVERY INSPECTION UNDER VEHICLE 10 BATTERY CONDITION AND CONNECTIONS M6010500500042 UPPER LEVEL LOWER LEVEL AC305615 Inspect the battery connections Verify that they are tightened NOTE Do
66. thickness of the removed valve tappet 9 Calculate the thickness of the newly installed valve tappet through the following equation A thickness of newly installed valve tappet B thickness of removed valve tappet C measured valve clearance Equation Intake valve A B C 0 22 mm Exhaust valve A C 0 30 mm Top view Under view Identification mark Identification mark AK604588AB NOTE The valve tappet ranges 2 70 3 30 mm and has 31 types per 0 02 mm The thickness below a decimal point is stamped on the reverse side of the valve tappet Example In case of 2 90 mm 90 is stamped 10 Install the valve tappet selected through the procedure 9 and put the camshaft in position 11 After installing the timing chain measure the valve clearance using the procedure 3 to 6 Confirm the clearance is within the standard value 12 Remove any liquid gasket remaining on the cylinder head cover the timing chain case and the cylinder head N CAUTION The timing chain should be installed within 3 minutes of applying liquid gasket Timing chain assembly AC311270AC 13 Apply a 4 mm bead of liquid gasket as illustrated Specified sealant LOCTITE 5971 or exact equivalent PERIODIC INSPECTION AND MAINTENANCE 2 11 OPERATIONS INSIDE THE ENGINE COMPARTMENT 10 wae 1 5 i To 4 fet
67. urn 14 2 Nm 9 Install the drain plug and refill the engine oil 10 Rev the engine a few times and check to be sure that no engine oil leaks from the installation section of the oil filter PERIODIC INSPECTION AND MAINTENANCE OPERATIONS AFTER ENGINE IS WARMED UP 1 Remove the sealing cap 2 Replace the oil filter element E5 CHECK ENGINE IDLING SPEED M6020601300094 4A9 1 Before inspection set the vehicle to the pre inspection condition 2 Turn the ignition switch to LOCK OFF position Diagnosis MB991910 MB991824 NXg 7 991827 AC608435AC 3 Connect the to the diagnosis connector Ne yi e oan No 1 Ignition coil SO f K d 2 N fA gt VA AK604940AB 4 Seta timing light to the power supply line terminal No 1 of the ignition coil No 1 NOTE The power supply line is looped and also longer than the other ones 5 Start the engine and let it run at idle 6 Check that ignition timing is at the standard value Standard value approximately 10 BTDC 7 Check the idle speed Standard value 750 100 r min NOTE The idle speed is controlled automatically by the idle speed control system NOTE When using the M U T III select item No 2 and take a reading of the idle speed 8 If the idle speed is outside the standard value inspect the
68. ve clearance check and adjustment at the engine cold state 1 Remove all ignition coils 2 Remove the cylinder head cover N CAUTION Turn the crankshaft always clockwise Timing mark AK604597AB 3 Turn the crankshaft clockwise and align the timing mark on the exhaust camshaft sprocket against the upper face of the cylinder head as shown in Figure Therefore No 1 cylinder goes to the compression top dead centre Exhaust valve side 1 No 3 Intake valve side AK305589AB 4 Using a thickness gauge measure the valve clearance with the arrow shown in Figure If deviated from the standard value make note for the valve clearance Standard value Intake valve 0 22 0 04 mm Exhaust valve 0 30 0 04 mm 2 10 PERIODIC INSPECTION AND MAINTENANCE OPERATIONS INSIDE THE ENGINE COMPARTMENT Timing mark AK604598AB 5 Turn the crankshaft clockwise 360 degrees and put the timing mark on the exhaust camshaft sprocket in position shown in Figure Therefore No 4 cylinder goes to the compression top dead centre Exhaust valve side No 2 N Intake valve side AK305589AC 6 Check the valve clearance with the arrow shown in Figure In the same procedure as 4 T If the valve clearance is deviated from the standard value remove the camshaft and the valve tappet Wall thickness AK304938 AB 8 Using a micrometer measure the
69. y 30 000 km or every 2 years OPERATIONS UNDER THE VEHICLE B1 Check suspension system for damage and Inspection Every 30 000 km or every 2 years looseness B2 suspension arm ball joints for play and Inspection Every 30 000 km or every 2 years dust covers for damage driveshaft boots for damage Inspection Normal Every 30 000 km or every 2 usage years Severe Every 7 500 km usage 2 4 PERIODIC INSPECTION AND MAINTENANCE PERIODIC INSPECTION AND MAINTENANCE SCHEDULE Maintenance item Maintenance Maintenance interval operation B4 Check steering linkage for damage and loose Inspection Every 30 000 km or every 2 years connections including seals and boots B5 Check gear oil level in manual transmission Inspection Every 15 000 km or every 12 months B6 Change gear oil in manual transmission Change Normal Every 195 000 km or every usage 13 years Severe Every 90 000 km or every 6 usage years B7 Check exhaust pipe connections for gas Inspection Every 30 000 km or every 2 years leakage and check pipe installation OPERATIONS INSIDE THE VEHICLE C1 brake pedal and clutch pedal for free Inspection Every 15 000 km or every 12 months play C2 Check parking brake lever stroke and play Inspection Every 15 000 km or every 12 months Replace air purifier filter Replace Every 15 000 km or every 12 months O

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