Mitsubishi Pajero 2001 Chassis Workshop Manual (Vol 1 & 2) PDF

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Mitsubishi Pajero 2001 Chassis Workshop Manual (Vol 1 & 2) – PDF DOWNLOAD

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Mitsubishi Pajero 2001 Chassis Workshop Manual (Vol 1 & 2) – PDF DOWNLOAD

Language : English
Pages : 1523
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Mitsubishi Pajero 2001 Chassis Workshop Manual (Vol 1 & 2) – PDF DOWNLOAD

GENERAL 4
HOW TO USE THIS MANUAL 5
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS 5
DEFINITION OF TERMS 5
INDICATION OF TIGHTENING TORQUE 5
MODEL INDICATIONS 6
EXPLANATION OF MANUAL CONTENTS 7
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINT 9
TROUBLESHOOTING CONTENTS 9
DIAGNOSIS FUNCTION 10
HOW TO USE THIS INSPECTION PROCEDURES 13
CONNECTOR MEASUREMENT SERVICE POINT 14
CONNECTOR INSPECTION 15
INSPECTION SERVICE POINTS FOR A BLOWN FUSE 16
POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS 16
TREATMENT BEFORE/AFTER FORDING A STREAM 17
INSPECTION AND SERVICE BEFORE FORDING A STREAM 17
INSPECTION AND SERVICE AFTER FORDING A STREAM 18
VEHICLE IDENTIFICATION 19
VEHICLE INFORMATION CODE PLATE 19
MODELS 19
MODEL CODE 21
CHASSIS NUMBER 22
ENGINE MODEL NUMBER 23
THEFT PROTECTION <R H D > 24
MAJOR SPECIFICATIONS 26
PRECAUTIONS BEFORE SERVICE 32
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 36
SUPPORT LOCATIONS FOR LIFTING AND JACKING 40
SUPPORT POSITIONS FOR A GARAGE JACK 40
SUPPORT POSITIONS FOR AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT 41
STANDARD PART/TIGHTENING-TORQUE TABLE 42
ENGINE <6G7> 44
GENERAL INFORMATION 45
SERVICE SPECIFICATIONS 45
SEALANT 46
SPECIAL TOOLS 46
ON-VEHICLE SERVICE 48
DRIVE BELT TENSION CHECK AND ADJUSTMENT 48
AUTO-TENSIONER CHECK 48
IGNITION TIMING CHECK 48
IDLE SPEED CHECK 49
IDLE MIXTURE CHECK 50
COMPRESSION PRESSURE CHECK 51
INTAKE MANIFOLD VACUUM CHECK 52
LASH ADJUSTER CHECK 52
OIL PAN AND OIL SCREEN 55
TIMING BELT 57
CRANKSHAFT OIL SEAL 65
CAMSHAFT OIL SEAL 67
CYLINDER HEAD GASKET 69
ENGINE ASSEMBLY 72
ENGINE <4D5> 75
GENERAL INFORMATION 76
SERVICE SPECIFICATIONS 77
SEALANTS 77
SPECIAL TOOLS 78
ON-VEHICLE SERVICE 79
DRIVE BELT TENSION CHECK AND ADJUSTMENT 79
AUTO-TENSIONER CHECK 81
VALVE CLEARANCE CHECK AND ADJUSTMENT 82
INJECTION TIMING CHECK AND ADJUSTMENT 83
IDLE SPEED CHECK AND ADJUSTMENT 86
IDLE-UP MECHANISM CHECK AND ADJUSTMENT-FOR A/C 86
COMPRESSION PRESSURE CHECK 87
TIMING BELT TENSION ADJUSTMENT 88
TIMING BELT B TENSION ADJUSTMENT 89
OIL PAN AND OIL SCREEN 91
TIMING BELT AND TIMING BELT B 93
CRANKSHAFT OIL SEAL 99
CAMSHAFT AND CAMSHAFT OIL SEAL 101
CYLINDER HEAD GASKET 104
ENGINE ASSEMBLY 108
ENGINE <4M4> 111
GENERAL INFORMATION 112
SERVICE SPECIFICATIONS 112
SEALANTS AND ADHESIVES 113
SPECIAL TOOLS 113
ON-VEHICLE SERVICE 115
DRIVE BELT TENSION CHECK AND ADJUSTMENT 115
VALVE CLEARANCE CHECK AND ADJUSTMENT 118
INJECTION TIMING CHECK AND ADJUSTMENT 119
IDLE SPEED CHECK 122
COMPRESSION PRESSURE CHECK 122
OIL PAN 124
REMOVAL AND INSTALLATION 124
VACUUM PUMP 126
TIMING CHAIN 127
CRANKSHAFT OIL SEAL 131
CAMSHAFT 133
CYLINDER HEAD GASKET 137
ENGINE ASSEMBLY 143
ENGINE LUBRICATION 146
GENERAL INFORMATION 147
SERVICE SPECIFICATIONS 148
SEALANT 148
LUBRICANTS 148
SPECIAL TOOLS 148
ON-VEHICLE SERVICE 149
ENGINE OIL CHECK 149
ENGINE OIL REPLACEMENT 149
OIL FILTER REPLACEMENT 150
OIL PRESSURE CHECK 151
ENGINE OIL COOLER 154
GASOLINE DIRECT INJECTION (GDI) 159
GENERALINFORMATION 160
SERVICE SPECIFICATIONS 164
SEALANT 164
SPECIAL TOOLS 164
TROUBLESHOOTING <M/T> 166
TROUBLESHOOTING <A/T> 283
ON-VEHICLE SERVICE 376
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE FUEL PRESSURE) 376
FUEL PUMP OPERATION (LOW PRESSURE) CHECK 377
THROTLE BODY (THROTTLE VALVE AREA) CLEANING 377
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT 377
ACCELERATOR PEDAL POSITION SENSOR ADJUSTMENT 378
FUEL PRESSURE TEST 379
FUEL LEAK CHECK 382
COMPONENT LOCATION 383
ENGINE CONTROL RELAY, FUEL PUMP RELAY, INJECTOR DRIVER CONTROL RELAY AND THROTTLE VALVE CONTROL SERVO RELAY CONTINUITY CHECK 384
INTAKE AIR TEMPERATURE SENSOR CHECK 384
ENGINE COOLANT TEMPERATURE SENSOR CHECK 384
THROTTLE POSITION SENSOR CHECK 385
ACCELERATOR PEDAL POSITION SENSOR CHECK 386
ACCELERATOR PEDAL POSITION SWITCH CHECK 387
OXYGEN SENSOR CHECK 387
INJECTOR CHECK 389
THROTTLE VALVE CONTROL SERVO CHECK 389
CLUTCH SWITCH CHECK 390
PURGE CONTROL SOLENOID VALVE CHECK 390
EGR VALVE CHECK 390
INJECTOR 391
FUEL PUMP (HIGH PRESSURE) 396
THROTTLE BODY 399
INJECTOR DRIVER 402
ENGINE-ECU <M/T>, ENGINE-A/T-ECU <A/T>, THROTTLE VALVE CONTROLLER 403
DIESEL FUEL <4D5> 404
GENERAL INFORMATION 405
SERVICE SPECIFICATIONS 405
SPECIAL TOOL 405
ON-VEHICLE SERVICE 405
FUEL INJECTION TIMING CHECK AND ADJUSTMENT 405
ENGINE IDLE SPEED CHECK AND ADJUSTMENT 405
EVACUATION OF WATER FROM FUEL FILTER 405
EVACUATION OF AIR FROM FUEL LINE 406
FUEL FILTER CARTRIDGE REPLACEMENT 406
FUEL INJECTION PUMP CHECK 406
BOOST COMPENSATOR CHECK 407
INJECTION NOZZLE CHECK AND ADJUSTMENT 407
INJECTION NOZZLE 409
INJECTION PUMP 413
DIESEL FUEL <4M4> 415
GENERAL INFORMATION 416
SERVICE SPECIFICATIONS 417
SEALANT 417
SPECIAL TOOLS 418
TROUBLESHOOTING 419
ON-VEHICLE SERVICE 456
INJECTION TIMING CHECK AND ADJUSTMENT 456
IDLE SPEED CHECK AND ADJUSTMENT 456
ACCELERATOR PEDAL POSITION SENSOR (APS) ADJUSTMENT 456
CONTROL RELAY CONTINUITY CHECK 457
ACCELERATOR PEDAL POSITION SENSOR (APS) CHECK 457
IDLE SWITCH CHECK 457
BOOST AIR TEMPERATURE SENSOR (INTAKE AIR TEMPERATURE SENSOR) CHECK 458
ENGINE COOLANT TEMPERATURE SENSOR CHECK 458
EVACUATION OF WATER FROM FUEL FILTER 459
FUEL FILTER CARTRIDGE REPLACEMENT 459
FUEL INJECTION PUMP CHECK 460
INTAKE AIR RESTRICTION EQUIPMENT CHECK 462
INJECTION NOZZLE CHECK AND ADJUSTMENT 463
INJECTION NOZZLE 464
INJECTION PUMP 470
ENGINE-ECU 473
FUEL SUPPLY 474
GENERAL INFORMATION 475
FUEL TANK <6G7> 475
FUEL TANK <4D5, 4M4> 481
FUEL FILTER 486
ENGINE COOLING 489
GENERAL INFORMATION 490
SERVICE SPECIFICATIONS 490
LUBRICANT 490
SEALANT 490
ON-VEHICLE SERVICE 491
ENGINE COOLANT LEAK CHECKING 491
RADIATOR CAP VALVE OPENING PRESSURE CHECK 491
ENGINE COOLANT REPLACEMENT 491
CONCENTRATION MEASUREMENT 493
COOLING FAN 494
THERMOSTAT 496
WATER PUMP 499
WATER HOSE AND WATER PIPE 503
RADIATOR 508
INTAKE AND EXHAUST 511
SERVICE SPECIFICATIONS 512
SEALANT 512
SPECIAL TOOL 512
ON-VEHICLE SERVICE 512
INTAKE MANIFOLD VACUUM CHECK <6G7> 512
TURBOCHARGER SUPERCHARGING CHECK <4D5> 512
WASTE GATE ACTUATOR CHECK <4D5> 513
WASTE GATE ACTUATOR CHECK <4M4> 513
AIR CLEANER 514
INTERCOOLER <4D5, 4M4> 515
INTAKE MANIFOLD <6G7> 516
INTAKE MANIFOLD AND THROTTLE BODY <4M4> 518
EXHAUST MANIFOLD <6G7> 521
INTAKE AND EXHAUST MANIFOLD, TURBOCHARGER <4D5> 522
TURBOCHARGER AND EXHAUST MANIFOLD <4M4> 524
TURBOCHARGER <4D5> 526
TURBOCHARGER <4M4> 529
EXHAUST PIPE AND MAIN MUFFLER <6G7> 531
EXHAUST PIPE AND MAIN MUFFLER <4D5> 533
EXHAUST PIPE AND MAIN MUFFLER <4M4> 535
ENGINE ELECTRICAL 537
CHARGING SYSTEM 538
GENERAL INFORMATION 538
OPERATION 538
SYSTEM DIAGRAM 538
SERVICE SPECIFICATIONS 539
SPECIAL TOOL 540
ON-VEHICLE SERVICE 541
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST 541
OUTPUT CURRENT TEST 542
REGULATED VOLTAGE TEST 544
WAVEFORM CHECK USING AN ANALYZER 547
ALTERNATOR 549
STARTING SYSTEM 559
GENERAL INFORMATION 559
SERVICE SPECIFICATIONS 560
STARTER MOTOR 560
IGNITION SYSTEM 573
GENERAL INFORMATION 573
SERVICE SPECIFICATIONS 574
SPECIAL TOOL 574
ON-VEHICLE SERVICE 574
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK 574
SPARK PLUG CHECK AND CLEANING 575
IGNITION FAILURE SENSOR SHECK 576
CAMSHAFT POSITION SENSOR CHECK 576
IGNITION COIL <6G7> 577
CRANK ANGLE SENSOR <6G7> 578
CAMSHAFT POSITION SENSOR <6G7> 578
DETONATION SENSOR <6G7> 579
GLOW SYSTEM 580
GENERAL INFORMATION 580
SERVICE SPECIFICATIONS 581
ON-VEHICLE SERVICE 581
SELF-REGULATING GLOW SYSTEM CHECK 581
GLOW & EGR-CONTROL UNIT CHECK 584
ENGINE-ECU CHECK 585
GLOW PLUG RELAY CHECK 586
GLOW PLUG CHECK 587
ENGINE COOLANT TEMPERATURE SENSOR CHECK 587
GLOW PLUG 588
ENGINE AND EMISSION CONTROL 589
ENGINE CONTROL SYSTEM 591
GENERAL INFORMATION 591
SERVICE SPECIFICATIONS 591
ON-VEHICLE SERVICE 591
ACCELERATOR CABLE CHECK AND ADJUSTMENT <4D5> 591
ACCELERATOR CABLE AND PEDAL 592
AUTO-CRUISE CONTROL SYSTEM 595
GENERAL INFORMATION 595
SPECIAL TOOLS 596
TROUBLESHOOTING 597
ON-VEHICLE SERVICE 615
AUTO-CRUISE CONTROL MAIN SWITCH CHECK 615
AUTO-CRUISE CONTROL SWITCH CHECK 616
AUTO-CRUISE CONTROL COMPONENT CHECK 617
AUTO-CRUISE CONTROL SWITCH 618
EMISSION CONTROL SYSTEM <6G7> 619
GENERAL INFORMATION 619
EMISSION CONTROL DEVICE REFERENCE TABLE 619
SERVICE SPECIFICATIONS 620
SPECIAL TOOLS 620
VACUUM HOSE 620
VACUUM HOSE PIPING DIAGRAM 620
VACUUM CIRCUIT DIAGRAM 621
VACUUM HOSE CHECK 621
VACUUM HOSE INSTALLATION 621
CRANKCASE EMISSION CONTROL SYSTEM 622
GENERAL INFORMATION 622
SYSTEM DIAGRAM 622
COMPONENT LOCATION 622
POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 623
PCV VALVE CHECK 623
EVAPORATIVE EMISSION CONTROL SYSTEM 624
GENERAL INFORMATION 624
SYSTEM DIAGRAM 624
COMPONENT LOCATION 624
PURGE CONTROL SYSTEM CHECK 625
PURGE PORT VACUUM CHECK 625
PURGE CONTROL SOLENOID VALVE CHECK 626
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 627
GENERAL INFORMATION 627
OPERATION 627
SYSTEM DIAGRAM 627
COMPONENT LOCATION 627
EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK 628
EGR VALVE (STEPPER MOTOR) CHECK 628
EGR VALVE 630
CANISTER 631
CATALYTIC CONVERTER 632
GENERAL INFORMATION 632
EMISSION CONTROL SYSTEM <4D5> 633
GENERAL INFORMATION 633
SERVICE SPECIFICATIONS 633
SEALANT 633
SPECIAL TOOL 633
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 634
GENERAL INFORMATION 634
SYSTEM DIAGRAM 634
COMPONENT LOCATION 634
FUNCTION CHECK 635
EGR SOLENOID VALVE OPERATION CHECK 635
EGR SOLENOID VALVE RESISTANCE CHECK 636
LEVER POSITION SENSOR (LPS) ADJUSTMENT 636
ENGINE SPEED SENSOR CHECK 637
ENGINE COOLANT TEMPERATURE SENSOR CHECK 637
CHECK AT THE GLOW & EGR CONTROL UNIT 639
EMISSION CONTROL SYSTEM <4M4-VEHICLES WITH EGR> 640
GENERAL INFORMATION 640
SERVICE SPECIFICATIONS 640
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 641
GENERAL INFORMATION 641
SYSTEM DIAGRAM 641
COMPONENT LOCATION 641
FUNCTION CHECK 642
EGR SOLENOID VALVE OPERATION CHECK 642
EGR SOLENOID VALVE RESISTANCE CHECK 643
ACCELERATOR PEDAL POSITION SENSOR (APS), ENGINE COOLANT TEMPERATURE SENSOR, INTAKE AIR TEMPERATURE SENSOR, FUEL TEMPERATURE S 643
CHECK AT ENGINE-ECU 643
CATALYTIC CONVERTER 643
GENERAL INFORMATION 643
CLUTCH 644
GENERAL INFORMATION 645
SERVICE SPECIFICATIONS 645
LUBRICANTS 645
ON-VEHICLE SERVICE 645
CLUTCH PEDAL INSPECTION AND ADJUSTMENT 645
CLUTCH PEDAL POSITION SWITCH CONTINUITY CHECK 646
BLEEDING 646
CLUTCH PEDAL 647
CLUTCH CONTROL 648
CLUTCH MASTER CYLINDER 651
MANUAL TRANSMISSION 652
GENERAL INFORMATION 653
LUBRICANTS 653
SEALANTS 653
SPECIAL TOOLS 653
TROUBLESHOOTING <SS4 II> 654
ON-VEHICLE SERVICE 657
TRANSMISSION OIL CHECK 657
OIL REPLACEMENT 657
4WD DETECTION SWITCH CONTINUITY CHECK <V5MT1> 658
HIGH/LOW DETECTION SWITCH CONTINUITY CHECK <V5MT1> 658
TRANSMISSION CONTROL <V5MT1> 659
TRANSMISSION CONTROL <V5MT3> 660
TRANSMISSION ASSEMBLY 661
4WD INDICATOR-ECU/TRANSFER-ECU 668
AUTOMATIC TRANSMISSION 670
SERVICE SPECIFICATIONS 671
LUBRICANTS 671
SPECIAL TOOLS 671
TROUBLESHOOTING 672
<A/T> 672
<SS4 II> 739
TROUBLESHOOTING <SHIFT LOCK AND KEY INTERLOCK MECHANISM> 761
ON-VEHICLE SERVICE 763
BASIC ADJUSTMENT PROCEDURES 763
TRANSFER OIL CHECK 768
TRANSFER OIL CHANGE 768
LOCATION OF CONTROL COMPONENTS 770
CONTROL COMPONENT CHECKS 771
TORQUE CONVERTER STALL TEST 774
FLUID PRESSURE TEST 775
HYDRAULITIC CIRCUIT 779
LINE PRESSURE ADJUSTMENT 780
SELECTOR LEVEL OPERATION CHECK 780
TRANSFER SHIFT LEVER OPERATION CHECK 783
TRANSMISSION CONTROL CABLE ADJUSTMENT 783
TRANSFER-ECU CHECK 784
POSITION INDICATOR LAMP CHECK 784
TRANSMISSION CONTROL 785
A/T-ECU 798
TRANSFER-ECU 799
PROPELLER SHAFT 811
GENERAL INFORMATION 812
SERVICE SPECIFICATIONS 812
LUBRICANT 812
SPECIAL TOOLS 812
PROPELLER SHAFT 812
FRONT AXLE 820
GENERAL INFORMATION 821
SERVICE SPECIFICATIONS 823
LUBRICANTS 823
SEALANTS 824
SPECIAL TOOLS 824
ON-VEHICLE SERVICE 829
WHEEL BEARING BACKLASH CHECK 829
FRONT AXLE TOTAL BACKLASH CHECK 829
FRONT AXLE GEAR OIL LEVEL CHECK 830
DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT 830
SOLENOID VALVE OPERATION CHECK 831
HUB AND KNUCKLE ASSEMBLY 832
DRIVE SHAFT 835
INNER SHAFT, HOUSING TUBE 843
FREEWHEEL CLUTCH ASSEMBLY, DIFFERENTIAL CARRIER 847
FREEWHEEL CLUTCH ASSEMBLY 850
DIFFERENTIAL CARRIER 853
SOLENOID VALVE, VACUUM PIPE, VACUUM TANK 868
FRONT DIFFERENTIAL MOUNT 870
REAR AXLE 872
GENERAL INFORMATION 873
SERVICE SPECIFICATIONS 874
LUBRICANTS 875
SEALANTS 875
SPECIAL TOOLS 876
ON-VEHICLE SERVICE 879
REAR AXLE TOTAL BACKLASH CHECK 879
GEAR OIL LEVEL CHECK 879
WHEEL BEARING AXIAL PLAY CHECK 879
REAR DIFFERENTIAL LOCK DETECTION SWITCH CHECK 880
REAR DIFFERENTIAL LOCK SYSTEM AIR LEAKAGE CHECK 880
REAR HUB ASSEMBLY 881
KNUCKLE 884
DRIVE SHAFT 885
REAR DIFFERENTIAL LOCK 891
DIFFERENTIAL CARRIER 894
WHEEL AND TYRE 911
GENERAL INFORMATION 912
SERVICE SPECIFICATIONS 912
TROUBLESHOOTING 913
ON-VEHICLE SERVICE 917
TYRE INFLATION PRESSURE CHECK 917
TYPE WEAR CHECK 917
WHEEL RUNOUT CHECK 917
WHEEL AND TYRE 917
POWER PLANT MOUNT 918
GENERAL INFORMATION 919
SPECIAL TOOLS 920
ENGINE MOUNTING 921
TRANSMISSION MOUNTING 923
№1 CROSSMEMBER 924
FRONT SUSPENSION 927
GENERAL INFORMATION 928
SERVICE SPECIFICATIONS 929
SPECIAL TOOLS 929
ON-VEHICLE SERVICE 930
WHEEL ALIGNMENT CHECK AND ADJUSTMENT 930
BALL JOINT DUST COVER CHECK 932
UPEER ARM ASSEMBLY 933
SHOCK ABSORBER ASSEMBLY 936
LOWER ARM ASSEMBLY 939
STABILIZER BAR 942
REAR SUSPENSION 944
GENERAL INFORMATION 945
SERVICE SPECIFICATIONS 946
SPECIAL TOOLS 946
ON-VEHICLE SERVICE 947
WHEEL ALIGNMENT CHECK AND ADJUSTMENT 0
BALL JOINT DUST COVER CHECK 948
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
BASIC BRAKE SYSTEM 961
GENERAL INFORMATION 962
SERVICE SPECIFICATIONS 964
LUBRICANTS 965
SPECIALTOOLS 965
TROUBLESHOOTIN <Vehicles with ABS> 966
ON-VEHICLE SERVICE 978
BRAKE PEDAL CHECK AND ADJUSTMENT 978
HYDRAULITIC BRAKE BOOSTER (HBB) OPERATION CHECK <VEHICLES WITH ABS> 979
HBB CHECK <VEHICLES WITH ABS> 982
HBB MOTOR RELAY CONTINUITY CHECK <VEHICLES WITH ABS> 983
BRAKE BOOSTER OPERATING TEST <VEHICLES WITH ABS> 983
CHECK VALVE OPERATION CHECK <VEHICLES WITHOUT ABS> 984
LOAD SENSING SPRING LENGTH CHECK AND ADJUSTMENT <VEHICLES WITHOUT ABS> 984
LOAD SENSING PROPORTIONING VALVE FUNCTION TEST <VEHICLES WITHOUT ABS> 985
BLEEDING <VEHICLES WITH ABS> 986
BLEEDING <VEHICLES WITHOUT ABS> 988
BRAKE FLUID LEVEL SENSOR CHECK 989
BRAKE BOOSTER VACUUM SWITCH CHECK <Vehicles with 4D5 engine> 989
DISC BRAKE PAD CHECK AND REPLACEMENT 990
DISC BRAKE ROTOR CHECK 991
BRAKE DISC THICKNESS CHECK 991
BRAKE DISC RUN-OUT CHECK AND CORRECTION 992
BRAKE PEDAL 993
HYDRAULITIC BRAKE BOOSTER (HBB) <Vehicles with ABS> 995
HBB BUZZER <Vehicles with ABS> 999
MASTER CYLINDER AND BRAKE BOOSTER <Vehicles without ABS> 1000
MASTER CYLINDER 1002
FRONT DISC BRAKE 1003
REAR DISC BRAKE 1008
LOAD SENSING PROPORTIONING VALVE <Vehicles without ABS> 1013
ANTI-SKI9D BRAKING SYSTEM (ABS) <4WD> 1014
GENERAL INFORMATION 1015
SERVICE SPECIFICATIONS 1017
SPECIAL TOOLS 1017
TROUBLESHOOTING 1017
ON-VEHICLE SERVICE 1040
WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT 1040
ABS VALVE RELAY CONTINUITY CHECK 1041
HYDRAULITIC BRAKE BOOSTER (HBB) – HYDRAULITIC UNIT CHECK 1042
SOLENOID VALVE CHECK 1043
WHEN THE BATTERY IS FLAT 1044
ABS-ECU 1045
WHEEL SPEED SENSOR 1046
G SENSOR 1049
PARKING BRAKES 1050
GENERAL INFORMATION 1051
SERVICE SPECIFICATIONS 1051
LUBRICANTS 1051
SEALANT 1052
ON-VEHICLE SERVICE 1052
PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1052
PARKING BRAKE SWITCH CHECK 1053
LINING RUNNING-IN 1053
PARKING BRAKE LEVER 1054
PARKING BRAKE CABLE 1055
PARKING BRAKE DRUM 1056
STEERING 1058
GENERAL INFORMATION 1059
SERVICE SPECIFICATIONS 1062
LUBRICANTS 1062
SEALANT AND ADHESIVE 1062
SPECIAL TOOLS 1063
ON-VEHICLE SERVICE 1065
STEERING WHEEL FREE PLAY CHECK 1065
STEERING ANGLE CHECK 1065
TIE ROD END BALL JOINT STARTING TORQUE CHECK 1065
STATIONARY STEERING EFFORT CHECK 1066
STEERING WHEEL RETURNABILITY CHECK 1066
OIL PUMP BELT TENSION CHECK <6G7, 4D5> 1066
POWER STEERING FLUID LEVEL CHECK 1067
POWER STEERING FLUID REPLACEMENT 1067
POWER STEERING SYSTEM BLEEDING 1067
OIL PUMP PRESSURE TEST 1068
POWER STEERING OIL PRESSURE SWITCH CHECK <6G7, 4M4> 1069
BALL JOINT DUST COVER CHECK 1069
STEERING WHEEL AND SHAFT 1070
POWER STEERING GEAR BOX AND LINKAGE 1073
POWER STEERING OIL PUMP 1087
POWER STEERING OIL HOSES 1092
BODY 1099
HOOD 1101
FENDER 1103
FUEL FILLER DOOR 1104
WINDOW GLASS 1106
ADHESIVE 1106
SPECIAL TOOL 1106
WINDOW REPAIR 1106
WINDSHIELD 1108
QUARTER WINDOW GLASS 1112
BACK DOOR GLASS 1114
DOORS 1116
SERVICE SPECIFICATIONS 1116
SEALANT 1116
SPECIAL TOOLS 1116
TROUBLESHOOTING 1117
ON-VEHICLE SERVICE 1117
DOOR FIT ADJUSTMENT 1117
DOOR WINDOW GLASS ADJUSTMENT 1117
DEFECTIVE POWER WINDOW ADJUSTMENT AND REPLACEMENT 1118
POWER WINDOW SAFETY MECHANISM CHECK 1118
DOOR OUTSIDE HANDLE PLAY CHECK 1119
POWER WINDOW OPERATION CURRENT CHECK 1119
CIRCUIT BREAKER (INKORPORATED IN THE POWER WINDOW MOTOR) CHECK 1119
DOOR INSIDE HANDLE PLAY CHECK AND ADJUSTMENT 1119
DOOR ASSEMBLY 1120
DOOR TRIM AND WATERPROOF FILM 1122
DOOR GLASS AND REGULATOR 1128
DOOR HANDLE AND LATCH 1131
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP 1134
BACK DOOR 1137
SERVICE SPECIFICATION 1137
SEALANT 1137
SPECIAL TOOL 1137
TROUBLESHOOTING 1137
ON-VEHICLE SERVICE 1138
BACK DOOR FIT ADJUSTMENT 1138
BACK DOOR HANDLE PLAY CHECK 1138
BACK DOOR ASSEMBLY 1139
BACK DOOR TRIM AND WATERPROOF FILM 1141
BACK DOOR HANDLE AND LATCH 1142
KEYLESS ENTRY SYSTEM 1143
TROUBLESHOOTING 1143
ON-VEHICLE SERVICE 1143
HOW TO REPLACE A BATTERY OF THE TRANSMITTER 1143
ENCRYPTED CODE REGISTRATION METHOD 1143
KEYLESS ENTRY SYSTEM 1144
SUNROOF 1145
SERVICE SPECIFICATION 1145
TROUBLESHOOTING 1145
ON-VEHICLE SERVICE 1145
WATER TEST 1145
SUNROOF FIT ADJUSTMENT 1145
SUNROOF 1146
EXTERIOR 1153
FRONT BUMPER 1155
ADHESIVE 1155
SPECIAL TOOL 1155
FRONT BUMPER 1156
REAR BAMPER 1160
ROOF RAIL 1163
MOULDING 1163
ADHESIVE 1163
SPECIAL TOOL 1163
MOULDING 1164
GARNISH 1168
ADHESIVE 1168
GARNISH 1169
MUDGUARD 1171
ADHESIVE 1171
MUDGUARD 1171
REAR DEFLECTOR 1173
SPECIAL TOOL 1173
REAR DEFLECTOR 1173
SIDE STEP 1174
SIDE STEP 1174
WINDSHIELD WIPER AND WASHER 1175
SERVICE SPECIFICATIONS 1175
TROUBLESHOOTING 1175
WINDSHIELD WIPER AND WASHER 1176
REAR WIPER AND WASHER 1180
REFERENCE VALUE 1180
TROUBLESHOOTING 1180
REAR WIPER AND WASHER 1180
HEADLAMP WASHER 1183
TROUBLESHOOTING 1183
HEADLAMP WASHER 1183
WIPER DEICER 1184
SPECIAL TOOL 1184
WIPER DEICER 1185
MARKS 1187
MARKS 1187
OUTSIDE DOOR MIRROR 1188
SPECIAL TOOL 1188
TROUBLESHOOTING 1188
OUTSIDE DOOR MIRROR 1189
INTERIOR 1193
SERVICE SPECIFICATIONS 1194
SPECIAL TOOL 1194
INSTRUMENT PANEL <L H DRIVE VEHICLES> 1195
INSTRUMENT PANEL <R H DRIVE VEHICLES> 1199
FLOOR CONSOLE 1203
TRIMS 1204
SUNVISOR HOLDER 1208
FRONT SEAT 1209
REAR/SECOND SEAT 1216
THRID SEAT 1226
FRONT SEAT BELT 1229
REAR SEAT BELT <SHORT WHEELBASE> 1231
SECOND/THRID SEAT BELT <LONG WHEELBASE> 1232
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1233
GENERAL INFORMATION 1234
SRS SERVICE PRECAUTIONS 1235
SPECIAL TOOLS 1237
TEST EQUIPMENT 1238
TROUBLESHOOTING 1239
POST-COLLISION DIAGNOSTIS 1255
INDIVIDUAL COMPONENT SERVICE 1258
WARNING/CAUTION LABELS 1259
FRONT IMPACT SENSORS 1260
SRS AIR BAG CONTROL UNIT (SRS-ECU) 1262
AIR BAG MODULES AND CLOCK SPRING 1264
SIDE IMPACT SENSOR 1273
AIR BAG MODULE DISPOSAL PROCEDURES 1275
UNDEPLOYED AIR BAG MODULES 1275
DEPLOYED AIR BAG MODULES DISPOSAL PROCEDURES 1284
CHASSIS ELECTRICAL 1286
BATTERY 1288
SERVICE SPECIFICATIONS 1288
ON-VEHICLE SERVICE 1288
ELECTROLYTE LEVEL AND SPECIFIC GRAVITY CHECK 1288
CHARGING 1289
BATTERY TEST 1289
IGNITION SWITCH AND IMMOBILIZER <EXCEPT FOR 4D56> 1290
SPECIAL TOOLS 1290
TROUBLESHOOTING 1290
IGNITION SWITCH AND IMMOBILIZER-ECU 1295
IGNITION SWITCH AND IMMOBILIZER <4D56> 1298
SPECIAL TOOLS 1298
TROUBLESHOOTING 1298
IGNITION SWITCH AND IMMOBILIZER-ECU 1303
COMBINATION METER 1307
SERVICE SPECIFICATIONS 1307
SEALANTS 1308
SPECIAL TOOLS 1308
TROUBLESHOOTING 1308
ON-VEHICLE SERVICE 1314
SPEEDOMETER CHECK 1314
TACHOMETER CHECK 1314
FUEL GAUGE UNIT CHECK 1315
ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK 1316
COMBINATION METER 1317
HEADLAMP ASSEMBLY 1320
SERVICE SPECIFICATIONS 1320
SPECIAL TOOLS 1320
TROUBLESHOOTING 1320
ON-VEHICLE SERVICE 1320
HEADLAMP AIMING ADJUSTMENT 1320
LUMINANCE MEASUREMENT 1322
HEADLAMP BULB REPLACEMENT 1323
HEADLAMP ASSEMBLY 1324
FOG LAMP 1325
SERVICE SPECIFICATIONS 1325
SPECIAL TOOLS 1325
TROUBLESHOOTING 1325
ON-VEHICLE SERVICE 1325
FOG LAMP AIMING CHECK 1325
FOG LAMPS 1328
SIDE TURN-SIGNAL LAMPS 1329
SPECIAL TOOL 1329
SIDE TURN-SIGNAL LAMPS 1330
ROOM LAMP 1330
TROUBLESHOOTING 1330
ON-VEHICLE SERVICE 1330
ROOM LAMP DELAY-OFF TIME ADJUSTMENT PROCEDURE 1330
REAR COMBINATION LAMPS 1331
SPECIAL TOOLS 1331
TROUBLESHOOTING 1331
REAR COMBINATION LAMPS 1331
HIGH-MOUNTED STOP LAMP 1332
COLUMN SWITCH 1332
SPECIAL TOOL 1332
HAZARD WARNING LAMP SWITCH 1334
SPECIAL TOOL 1334
HAZARD WARNING LAMP SWITCH 1334
HORN 1335
CIGARETTE LIGHTER 1335
ACCESSORY SOCKET 1335
RHEOSTAT 1336
CLOCK OR CENTER DISPLAY 1337
TROUBLESHOOTING 1337
CLOCK OR CENTER DISPLAY 1351
RADIO/TAPE PLAYER 1352
TROUBLESHOOTING 1352
RADIO AND CD AUTO CHANGER 1365
FRONT SPEAKERS 1366
REAR SPEAKERS 1366
ANTENNA 1367
DEFOGGER 1370
TROUBLESHOOTING <VEHICLE WITH AUTOMATIC AIR CONDITIONER> 1370
ON-VEHICLE SERVICE 1370
PRINTED HEATER CHECK 1370
DEFOGGER RELAY CONTINUITY CHECK 1370
DEFOGGER SWITCH <VEHICLE WITH MANUAL AIR CONDITIONER> 1371
SMART WIRING SYSTEM (SWS) 1372
GENERAL INFORMATION 1373
SPECIAL TOOLS 1378
TROUBLESHOOTING 1379
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING 1379
DIAGNOSTIC FUNCTION 1379
DIAGNOSIS CODE CHART 1380
DIAGNOSIS CODE INSPECTION PROCEDURES 1381
TROUBLE SYMPTOM CHART 1384
INSPECTION PROCEDURE FOR TROUBLE SYMTOMS 1388
CHECK AT ECU TERMINALS 1425
ON-VEHICLE SERVICE 1431
ADJUSTMENT PROCEDURES OF SWS FUNCTION 1431
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL A/C> 1433
SERVICE SPECIFICATIONS 1434
LUBRICANTS 1434
TROUBLESHOOTING <Front heater, Front A/C> 1435
TROUBLESHOOTING <Front Heater, Rear Cooler> 1438
ON-VEHICLE SERVICE 1440
REFRIGERANT LEVEL TEST THROUGH PERFOMANCE TEST 1440
MAGNETIC CLUTCH TEST 1441
RECEIVER DRIER TEST 1441
COMPRESSOR DRIVE BELT ADJUSTMENT 1441
DUAL PRESSURE SWITCH CHECK 1441
CHARGING 1442
PERFORMANCE TEST 1446
FRONT BLOWER RELAY AND REAR BLOWER RELAY CONTINUITY CHECK <Vehicles with rear cooler> 1449
CONTINUITY CHECK OF A/C COMPRESSOR RELAY AND CONDENSER FAN RELAY 1449
PTC HEATER RELAY CONTINUITY CHECK <4M41> 1450
IDLE-UP OPERATION CHECK <Diesel> 1450
VACUUM ACTUATOR CHECK <Diesel-powered Vehicles> 1451
IDLE-UP SOLENOID VALVE CHECK 1452
CLEAN AIR FILTER REPLACEMENT PROCEDURE 1453
FRONT A/C 1454
AIR CONDITIONER CONTROL PANEL ASSEMBLY AND A/C SWITCH REMOVAL AND INSTALLATION 1454
INSTALLATION SERVICE POINTS 1454
HEATER UNIT AND BLOWER ASSEMBLY 1457
BLOWER MOTOR AND RESISTOR 1460
INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR 1461
AUTOMATIC COMPRESSOR-ECU AND AIR THERMO SENSOR ASSEMBLY 1462
REARHEATER AND REAR COOLER 1463
REAR A/C SWITCH, FRONT REAR FAN SWITCH 1463
REAR A/C CONTROL UNIT 1465
REAR HEATER UNIT <Floor console> 1465
REAR HEATER UNIT AND REAR BLOWER ASSEMBLY <QUARTER TRIM> 1468
HEAT SWITCH <4M41> 1471
COMPRESSOR 1472
CONDENSER ASSEMBLY AND CONDENSER FAN 1476
REFRIGERANT LINE 1478
ENGINE COOLANT TEMPERATURE SWITCH <4D56> 1482
IDLE-UP SYSTEM <Diesel-powered Vehicles> 1484
DUCTS 1485
VENTILATION 1487
HEATER, AIR CONDITIONER AND VENTILATION <AUTOMATIC A/C> 1488
SERVICE SPECIFICATIONS 1489
LUBRICANTS 1489
SPECIAL TOOLS 1490
TROUBLESHOOTING <Front A/C> 1490
TROUBLESHOOTING <REAR A/C> 1507
ON-VEHICLE SERVICE 1511
MAGNETIC CLUTCH TEST 1511
IDLE-UP OPERATION CHECK <Petrol> 1512
FRONT A/C 1512
AUTOMATIC A/C CONTROL PANEL ASSEMBLY (A/C-ECU) 1512
BLOWER LINEAR CONTROLLER 1513
AIR MIX DAMPER MOTOR AND AIR OUTLET CHANGEOVER DAMPER MOTOR REMOVAL AND INSTALLATION 1514
HEATER WATER TEMPERATURE SENSOR 1516
PHOTO SENSOR 1517
OUTSIDE AIR TEMPERATURE SENSOR 1517
REAR A/C 1517
ELECTRIC MOTOR FOR THE AIR UOTLET CHANGEOVER DAMPER 1517
REFRIGERANT LINE <PETROL> 1518
COMPRESSOR <petrol> 1520

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S.V 08/24