Mitsubishi Pajero 2001 Chassis Workshop Manual – PDF DOWNLOAD

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Mitsubishi Pajero 2001 Chassis Workshop Manual – PDF DOWNLOAD

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Mitsubishi Pajero 2001 Chassis Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 1527
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Mitsubishi Pajero 2001 Chassis Workshop Manual – PDF DOWNLOAD

FOREWORD 2
WARNING! 3
GENERAL [00] 4
HOW TO USE THIS MANUAL 5
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE 9
TREATMENT BEFORE/AFTER FORDING A STREAM 17
VEHICLE IDENTIFICATION 19
MAJOR SPECIFICATIONS 26
PRECAUTIONS BEFORE SERVICE 32
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 36
SUPPORT LOCATIONS FOR LIFTING AND JACKING 40
STANDARD PART/TIGHTENING-TORQUE TABLE 42
ENGINE [11] 44
ENGINE <6G7> [11A] 45
GENERAL INFORMATION 46
SERVICE SPECIFICATIONS 46
SEALANT 47
SPECIAL TOOLS 47
ON-VEHICLE SERVICE 49
OIL PAN AND OIL SCREEN 56
TIMING BELT 58
CRANKSHAFT OIL SEAL 66
CAMSHAFT OIL SEAL 68
CYLINDER HEAD GASKET 70
ENGINE ASSEMBLY 73
ENGINE <4D5> [11B] 76
GENERAL INFORMATION 77
SERVICE SPECIFICATIONS 78
SEALANTS 78
SPECIAL TOOLS 79
ON-VEHICLE SERVICE 80
OIL PAN AND OIL SCREEN 92
TIMING BELT AND TIMING BELT B 94
CRANKSHAFT OIL SEAL 100
CAMSHAFT AND CAMSHAFT OIL SEAL 102
CYLINDER HEAD GASKET 105
ENGINE ASSEMBLY 109
ENGINE <4M4> [11C] 112
GENERAL INFORMATION 113
SERVICE SPECIFICATIONS 113
SEALANTS AND ADHESIVES 114
SPECIAL TOOLS 114
ON-VEHICLE SERVICE 116
OIL PAN 125
VACUUM PUMP 127
TIMING CHAIN 128
CRANKSHAFT OIL SEAL 132
CAMSHAFT 134
CYLINDER HEAD GASKET 138
ENGINE ASSEMBLY 144
ENGINE LUBRICATION [12] 148
GENERAL INFORMATION 149
SERVICE SPECIFICATIONS 150
SEALANT 150
LUBRICANTS 150
SPECIAL TOOLS 150
ON-VEHICLE SERVICE 151
ENGINE OIL COOLER 156
FUEL [13] 160
GASOLINE DIRECT INJECTION (GDI) [13A] 161
GENERAL INFORMATION 162
SERVICE SPECIFICATIONS 166
SEALANT 166
SPECIAL TOOLS 166
TROUBLESHOOTING <M/T> 168
TROUBLESHOOTING <A/T> 285
ON-VEHICLE SERVICE 378
INJECTOR 393
FUEL PUMP (HIGH PRESSURE) 398
THROTTLE BODY 401
INJECTOR DRIVER 404
ENGINE-ECU<M/T>, ENGINE-A/T-ECU<A/T>, THROTTLE VALVE 405
DIESEL FUEL <4D5> [13B] 406
GENERAL INFORMATION 407
SERVICE SPECIFICATIONS 407
SPECIAL TOOL 407
ON-VEHICLE SERVICE 407
INJECTION NOZZLE 411
INJECTION PUMP 415
DIESEL FUEL <4M4> [13C] 418
GENERAL INFORMATION 419
SERVICE SPECIFICATIONS 420
SEALANT 420
SPECIAL TOOLS 421
TROUBLESHOOTING 422
ON-VEHICLE SERVICE 459
INJECTION NOZZLE 467
INJECTION PUMP 473
ENGINE-ECU 476
FUEL SUPPLY [13D] 478
GENERAL INFORMATION 479
FUEL TANK <6G7> 479
FUEL TANK <4D5, 4M4> 485
FUEL FILTER 490
ENGINE COOLING [14] 494
GENERAL INFORMATION 495
SERVICE SPECIFICATIONS 495
LUBRICANT 495
SEALANT 495
ON-VEHICLE SERVICE 496
COOLING FAN 499
THERMOSTAT 501
WATER PUMP 504
WATER HOSE AND WATER PIPE 508
RADIATOR 513
INTAKE AND EXHAUST [15] 516
SERVICE SPECIFICATIONS 517
SEALANT 517
SPECIAL TOOL 517
ON-VEHICLE SERVICE 517
AIR CLEANER 519
INTERCOOLER <4D5, 4M4> 520
INTAKE MANIFOLD <6G7> 521
INTAKE MANIHOLD AND THROTTLE BODY <4M4> 523
EXHAUST MANIFOLD <6G7> 526
INTAKE AND EXHAUST MANIFOLD, TURBOCHARGER <4D5> 527
TURBOCHARGER AND EXHAUST MANIFOLD <4M4> 529
TURBOCHARGER <4D5> 531
TURBOCHARGER <4M4> 534
EXHAUST PIPE AND MAIN MUFFLER <6G7> 536
EXHAUST PIPE AND MAIN MUFFLER <4D5> 538
EXHAUST PIPE AND MAIN MUFFLER <4M4> 540
ENGINE ELECTRICAL [16] 542
CHARGING SYSTEM 543
GENERAL INFORMATION 543
SERVICE SPECIFICATIONS 544
SPECIAL TOOL 545
ON-VEHICLE SERVICE 546
ALTERNATOR 554
STARTING SYSTEM 564
GENERAL INFORMATION 564
SERVICE SPECIFICATIONS 565
STARTER MOTOR 565
IGNITION SYSTEM 578
GENERAL INFORMATION 578
SERVICE SPECIFICATIONS 579
SPECIAL TOOL 579
ON-VEHICLE SERVICE 579
IGNITION COIL<6G7> 582
CRANK ANGLE SENSOR<6G7> 583
CAMSHAFT POSITION SENSOR <6G7> 583
DETONATION SENSOR <6G7> 584
GLOW SYSTEM 585
GENERAL INFORMATION 585
SERVICE SPECIFICATIONS 586
ON-VEHICLE SERVICE 586
GLOW PLUG 593
ENGINE AND EMISSION CONTROL [17] 594
ENGINE CONTROL SYSTEM 596
GENERAL INFORMATION 596
SERVICE SPECIFICATIONS 596
ON-VEHICLE SERVICE 596
ACCELERATOR CABLE AND PEDAL 597
AUTO-CRUISE CONTROL SYSTEM 600
GENERAL INFORMATION 600
SPECIAL TOOL 601
TROUBLESHOOTING 602
ON-VEHICLE SERVICE 620
AUTO-CRUISE CONTROL SWITCH 623
EMISSION CONTROL SYSTEM <6G7> 624
GENERAL INFORMATION 624
SERVICE SPECIFICATIONS 625
SPECIAL TOOL 625
VACUUM HOSE 625
CRANKCASE EMISSION CONTROL SYSTEM 627
EVAPORATIVE EMISSION CONTROL SYSTEM 629
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 632
EGR VALVE 635
CANISTER 636
CATALYTIC CONVERTER 637
EMISSION CONTROL SYSTEM <4D5> 638
GENERAL INFORMATION 638
SERVICE SPECIFICATIONS 638
SEALANT 638
SPECIAL TOOL 638
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 639
CHECK AT THE GLOW & EGR CONTROL UNIT 644
EMISSION CONTROL SYSTEM <4M4-VEHICLES WITH 645
GENERAL INFORMATION 645
SERVICE SPECIFICATIONS 645
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 646
CATALYTIC CONVERTER 648
CLUTCH [21] 650
GENERAL INFORMATION 651
SERVICE SPECIFICATIONS 651
LUBRICANTS 651
ON-VEHICLE SERVICE 651
CLUTCH PEDAL 653
CLUTCH CONTROL 654
MANUAL TRANSMISSION [22] 658
GENERAL INFORMATION 659
LUBRICANTS 659
SEALANTS 659
SPECIAL TOOL 659
TROUBLESHOOTING <SS4 II> 660
ON-VEHICLE SERVICE 663
TRANSMISSION CONTROL <V5MT1> 665
TRANSMISSION CONTROL <V5MT3> 666
TRANSMISSION ASSEMBLY 667
4WD INDICATOR-ECU/TRANSFER-ECU 674
AUTOMATIC TRANSMISSION [23] 676
SERVICE SPECIFICATIONS 677
LUBRICANTS 677
SPECIAL TOOLS 677
TROUBLESHOOTING <A/T> 678
TROUBLESHOOTING <SS4 II> 745
TROUBLESHOOTING <SHIFT LOCK AND KEY INTERLOCK 767
ON-VEHICLE SERVICE 769
TRANSMISSION CONTROL 791
SHIFT LOCK AND KEY INTERLOCK MECHANISMS 795
TRANSMISSION ASSEMBLY 797
TRANSMISSION OIL COOLER 802
A/T-ECU 804
TRANSFER-ECU 805
PROPELLER SHAFT [25] 806
GENERAL INFORMATION 807
SERVICE SPECIFICATIONS 807
LUBRICANT 807
SPECIAL TOOL 807
PROPELLER SHAFT 807
FRONT AXLE [26] 816
GENERAL INFORMATION 817
SERVICE SPECIFICATIONS 819
LUBRICANTS 819
SEALANTS 820
SPECIAL TOOLS 820
ON-VEHICLE SERVICE 825
HUB AND KNUCKLE ASSEMBLY 828
DRIVE SHAFT 831
INNER SHAFT, HOUSING TUBE 839
FREEWHEEL CLUTCH ASSEMBLY, DIFFERENTIAL CARRIER 843
FREEWHEEL CLUTCH ASSEMBLY 846
DIFFERENTIAL CARRIER 849
SOLENOID VALVE, VACUUM PIPE, VACUUM TANK 864
FRONT DIFFERENTIAL MOUNT 866
REAR AXLE [27] 868
GENERAL INFORMATION 869
SERVICE SPECIFICATIONS 870
LUBRICANTS 871
SEALANTS 871
SPECIAL TOOLS 872
ON-VEHICLE SERVICE 875
REAR HUB ASSEMBLY 877
KNUCKLE 880
DRIVE SHAFT 881
REAR DIFFERENTIAL LOCK 887
DIFFERENTIAL CARRIER 890
WHEEL AND TYRE [31] 908
GENERAL INFORMATION 909
SERVICE SPECIFICATIONS 909
TROUBLESHOOTING 910
ON-VEHICLE SERVICE 914
WHEEL AND TYRE 914
POWER PLANT [32] 916
GENERAL INFORMATION 917
SPECIAL TOOLS 918
ENGINE MOUNTING 919
TRANSMISSION MOUNTING 921
No 1 CROSSMEMBER 922
FRONT SUSPENSION [33A] 926
GENERAL INFORMATION 927
SERVICE SPECIFICATIONS 928
SPECIAL TOOLS 928
ON-VEHICLE SERVICE 929
UPPER ARM ASSEMBLY 932
SHOCK ABSORBER ASSEMBLY 935
LOWER ARM ASSEMBLY 938
STABILIZER BAR 941
REAR SUSPENSION [34] 944
GENERAL INFORMATION 945
SERVICE SPECIFICATIONS 946
SPECIAL TOOLS 946
ON-VEHICLE SERVICE 947
UPPER ARM ASSEMBLY 949
SHOCK ABSORBER/COIL SPRING/LOWER ARM ASSEMBLY 952
STABILIZER BAR 954
TOE CONTROL ARM ASSEMBLY/TOE CONTROL TOWER BAR 956
TRAILING ARM ASSEMBLY 959
SERVICE BRAKES [35] 960
BASIC BRAKE SYSTEM [35A] 961
GENERAL INFORMATION 962
SERVICE SPECIFICATIONS 964
LUBRICANTS 965
SPECIAL TOOLS 965
TROUBLESHOOTING <Vehicles with ABS> 966
ON-VEHICLE SERVICE 978
BRAKE PEDAL 993
HYDRAULIC BRAKE BOOSTER (HBB) <Vehicles with ABS> 995
HBB BUZZER <Vehicles with ABS> 999
MASTER CYLINDER AND BRAKE BOOSTER 1000
FRONT DISC BRAKE 1003
REAR DISC BRAKE 1008
LOAD SENSING PROPORTIONING VALVE <Vehicles without ABS> 1013
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> [35B] 1014
GENERAL INFORMATION 1015
SERVICE SPECIFICATIONS 1017
LUBRICANT 961
SEALANTS 961
SPECIAL TOOLS 1017
TROUBLESHOOTING 1017
ON-VEHICLE SERVICE 1040
BRAKE PEDAL 961
HYDRAULIC BRAKE BOOSTER (HBB) 961
HBB BUZZER 961
FRONT DISC BRAKE 961
REAR DISC BRAKE 961
ABS-ECU 1045
WHEEL SPEED SENSOR 1046
G SENSOR 1049
PARKING BRAKES [36] 1050
GENERAL INFORMATION 1051
SERVICE SPECIFICATIONS 1051
LUBRICANTS 1051
SEALANT 1052
ON-VEHICLE SERVICE 1052
PARKING BRAKE LEVER 1054
PARKING BRAKE CABLE 1055
PARKING BRAKE DRUM 1056
STEERING [37A] 1058
GENERAL INFORMATION 1059
SERVICE SPECIFICATIONS 1062
LUBRICANTS 1062
SEALANT AND ADHESIVE 1062
SPECIAL TOOLS 1063
ON-VEHICLE SERVICE 1065
STEERING WHEEL AND SHAFT 1070
POWER STEERING GEAR BOX AND LINKAGE 1073
POWER STEERING OIL PUMP 1087
POWER STEERING OIL HOSES 1092
BODY [42] 1100
HOOD 1102
FENDER 1104
FUEL FILLER DOOR 1105
WINDOW GLASS 1107
ADHESIVE 1107
SPECIAL TOOL 1107
WINDOW REPAIR 1107
WINDSHIELD 1109
QUARTER WINDOW GLASS 1113
BACK DOOR GLASS 1115
DOORS 1117
SERVICE SPECIFICATIONS 1117
SEALANT 1117
SPECIAL TOOLS 1117
TROUBLESHOOTING 1118
ON-VEHICLE SERVICE 1118
DOOR ASSEMBLY 1121
DOOR TRIM AND WATERPROOF FILM 1123
DOOR GLASS AND REGULATOR 1129
DOOR HANDLE AND LATCH 1132
WINDOW GLASS RUNCHANNEL AND DOOR OPENING 1135
BACK DOOR 1138
SERVICE SPECIFICATION 1138
SEALANT 1138
SPECIAL TOOL 1138
TROUBLESHOOTING 1138
ON-VEHICLE SERVICE 1139
BACK DOOR ASSEMBLY 1140
BACK DOOR TRIM AND WATERPROOF FILM 1142
BACK DOOR HANDLE AND LATCH 1143
KEYLESS ENTRY SYSTEM 1144
TROUBLESHOOTING 1144
ON-VEHICLE SERVICE 1144
KEYLESS ENTRY SYSTEM 1145
SUNROOF 1146
SERVICE SPECIFICATION 1146
TROUBLESHOOTING 1146
ON-VEHICLE SERVICE 1146
SUNROOF 1147
EXTERIOR [51] 1154
FRONT BUMPER 1156
ADHESIVE 1156
SPECIAL TOOL 1156
FRONT BUMPER 1157
REAR BUMPER 1161
ROOF RAIL 1164
MOULDING 1164
ADHESIVE 1164
SPECIAL TOOL 1164
MOULDING 1165
GARNISH 1169
ADHESIVE 1169
GARNISH 1170
MUDGUARD 1172
ADHESIVE 1172
MUDGUARD 1172
REAR DEFLECTOR 1174
SPECIAL TOOL 1174
REAR DEFLECTOR 1174
SIDE STEP 1175
SIDE STEP 1175
WINDSHIELD WIPER AND WASHER 1176
SERVICE SPECIFICATIONS 1176
TROUBLESHOOTING 1176
WINDSHIELD WIPER AND WASHER 1177
REAR WIPER AND WASHER 1181
REFERENCE VALUE 1181
TROUBLESHOOTING 1181
REAR WIPER AND WASHER 1181
HEADLAMP WASHER 1184
TROUBLESHOOTING 1184
HEADLAMP WASHER 1184
WIPER DEICER 1185
SPECIAL TOOL 1185
WIPER DEICER 1186
MARKS 1188
MARKS 1188
OUTSIDE DOOR MIRROR 1189
SPECIAL TOOL 1189
TROUBLESHOOTING 1189
OUTSIDE DOOR MIRROR 1190
INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) [52] 1194
INTERIOR [52A] 1195
SERVICE SPECIFICATIONS 1196
SPECIAL TOOL 1196
INSTRUMENT PANEL <L H DRIVE VEHICLES> 1197
INSTRUMENT PANEL <R H DRIVE VEHICLES> 1201
FLOOR CONSOLE 1205
TRIMS 1206
SUNVISOR HOLDER 1210
FRONT SEAT 1211
REAR/SECOND SEAT 1218
THIRD SEAT 1228
FRONT SEAT BELT 1231
REAR SEAT BELT<SHORT WHEELBASE> 1233
SECOND/THIRD SEAT BELT<LONG WHEELBASE> 1234
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) [52B] 1236
GENERAL INFORMATION 1237
SRS SERVICE PRECAUTIONS 1238
SPECIAL TOOLS 1240
TEST EQUIPMENT 1241
TROUBLESHOOTING 1242
SRS MAINTENANCE 1254
POST-COLLISION DIAGNOSIS 1258
INDIVIDUAL COMPONENT SERVICE 1261
WARNING/CAUTION LABELS 1262
FRONT IMPACT SENSORS 1263
SRS AIR BAG CONTROL UNIT (SRS-ECU) 1265
AIR BAG MODULES AND CLOCK SPRING 1267
SIDE IMPACT SENSOR 1276
AIR BAG MODULE DISPOSAL PROCEDURES 1278
CHASSIS ELECTRICAL [54] 1288
CHASSIS ELECTRICAL [54A] 1289
BATTERY 1291
SERVICE SPECIFICATIONS 1291
ON-VEHICLE SERVICE 1291
IGNITION SWITCH AND IMMOBILIZER<EXCEPT FOR 4D56> 1293
SPECIAL TOOLS 1293
TROUBLESHOOTING 1293
IGNITION SWITCH AND IMMOBILIZER-ECU 1298
IGNITION SWITCH AND IMMOBILIZER<4D56> 1301
SPECIAL TOOLS 1301
TROUBLESHOOTING 1301
IGNITION SWITCH AND IMMOBILIZER-ECU 1306
COMBINATION METER 1310
SERVICE SPECIFICATIONS 1310
SEALANTS 1311
SPECIAL TOOLS 1311
TROUBLESHOOTING 1311
ON-VEHICLE SERVICE 1317
COMBINATION METER 1320
HEADLAMP ASSEMBLY 1323
SERVICE SPECIFICATIONS 1323
SPECIAL TOOLS 1323
TROUBLESHOOTING 1323
ON-VEHICLE SERVICE 1323
HEADLAMP ASSEMBLY 1327
FOG LAMPS 1328
SERVICE SPECIFICATIONS 1328
SPECIAL TOOLS 1328
TROUBLESHOOTING 1328
ON-VEHICLE SERVICE 1328
FOG LAMPS 1331
SIDE TURN-SIGNAL LAMPS 1332
SPECIAL TOOL 1332
SIDE TURN-SIGNAL LAMPS 1333
ROOM LAMP 1333
TROUBLESHOOTING 1333
ON-VEHICLE SERVICE 1333
REAR COMBINATION LAMPS 1334
SPECIAL TOOLS 1334
TROUBLESHOOTING 1334
REAR COMBINATION LAMPS 1334
HIGH-MOUNTED STOP LAMP 1335
COLUMN SWITCH 1335
SPECIAL TOOL 1335
COLUMN SWITCH 1335
HAZARD WARNING LAMP SWITCH 1337
SPECIAL TOOL 1337
HAZARD WARNING LAMP SWITCH 1337
HORN 1338
CIGARETTE LIGHTER 1338
ACCESSORY SOCKET 1338
RHEOSTAT 1339
CLOCK OR CENTER DISPLAY 1340
TROUBLESHOOTING 1340
CLOCK OR CENTER DISPLAY 1354
RADIO/TAPE PLAYER 1355
TROUBLESHOOTING 1355
RADIO AND CD AUTO CHANGER 1368
FRONT SPEAKERS 1369
REAR SPEAKERS 1369
ANTENNA 1370
DEFOGGER 1373
TROUBLESHOOTING <VEHICLE WITH AUTOMATIC AIR CONDITIONER> 1373
ON-VEHICLE SERVICE 1373
DEFOGGER SWITCH <VEHICLE WITH MANUAL AIR CONDITIONER> 1374
SMART WIRING SYSTEM (SWS) 1376
RADIATOR (RADIATOR FAN MOTOR) 0
AUTOMATIC TRANSMISSION 0
ANTI-LOCK BRAKE SYSTEM (ABS) 54
DOOR HANDLE LATCH (DOOR LOCK) 0
DOOR GLASS-REGULATOR (POWER WINDOWS) 0
KEYLESS ENTRY SYSTEM 0
WINDSHIELD WIPER/WASHER 0
REAR WIPER/WASHER 0
SRS AIRBAG 42
HEATER 0
AIR CONDITIONER 0
SMART WIRING SYSTEM (SWS) [54B] 1376
GENERAL INFORMATION 1377
SPECIAL TOOLS 1382
TROUBLESHOOTING 1383
ON-VEHICLE SERVICE 1435
HEATER, AIR CONDITIONER AND VENTILATION [55] 1436
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL A/C> [55A] 1437
SERVICE SPECIFICATIONS 1438
LUBRICANTS 1438
TROUBLESHOOTING <Front heater, Front A/C> 1439
TROUBLESHOOTING <Rear Heater, Rear Cooler> 1442
ON-VEHICLE SERVICE 1444
FRONT A/C 1458
REAR HEATER AND REAR COOLER 1467
HEAT SWITCH <4M41> 1475
COMPRESSOR 1476
CONDENSER ASSEMBLY AND CONDENSER FAN 1480
REFRIGERANT LINE 1482
ENGINE COOLANT TEMPERATURE SWITCH<4D56> 1486
IDLE-UP SYSTEM <Diesel-powered Vehicles> 1488
DUCTS 1489
VENTILATION 1491
HEATER, AIR CONDITIONER AND VENTILATION <AUTOMATIC A/C>[55B] 1492
SERVICE SPECIFICATIONS 1493
LUBRICANTS 1493
SPECIAL TOOLS 1494
TROUBLESHOOTING <FRONT A/C> 1494
TROUBLESHOOTING <REAR A/C> 1511
ON-VEHICLE SERVICE 1515
FRONT A/C 1516
PHOTO SENSOR 1521
OUTSIDE AIR TEMPERATURE 1521
REAR A/C 1521
REFRIGERANT LINE <PETROL> 1522
COMPRESSOR <petrol> 1524

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