P.00-15 - Outlander Forum

P.00-15 - Outlander Forum
00-1
GROUP 00
GENERAL <BODY AND CHASSIS>
CONTENTS
HOW TO USE THIS MANUAL..........00-3
TROUBLESHOOTING GUIDELINES......00-6
HOW TO USE TROUBLESHOOTING/
INSPECTION SERVICE POINTS.......00-6
INITIALIZATION PROCEDURE FOR LEARNING
VALUE IN MFI ENGINE............00-30
ENGINE IDLING LEARNING PROCEDURE
...............................00-31
SERVICING ELECTRICAL SYSTEM. . . .00-32
VEHICLE WASHING................00-33
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS.................00-33
SCAN TOOL (MULTI USE TESTER { M.U.T.III } SUB ASSEMBLY)............00-33
CODING LIST....................00-34
TROUBLESHOOTING CONTENTS........00-6
HOW TO USE THE INSPECTION PROCEDURES
................................00-9
CONNECTOR MEASUREMENT SERVICE POINTS
...............................00-12
CONNECTOR INSPECTION SERVICE POINTS
...............................00-14
HOW TO COPE WITH INTERMITTENT
MALFUNCTIONS...................00-15
HOW TO TREAT PAST TROUBLE......00-17
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE...........................00-18
TOWING AND HOISTING............00-42
VEHICLE IDENTIFICATION.........00-18
LUBRICATION AND MAINTENANCE....00-49
VEHICLE IDENTIFICATION CODE PLATE
...............................00-20
RECOMMENDED LUBRICANTS AND LUBRICANT
CAPACITIES TABLE...............00-51
PRECAUTIONS BEFORE SERVICE.....00-26
SCHEDULED MAINTENANCE TABLE....00-53
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
...............................00-26
HOW TO PERFORM VEHICLE IDENTIFICATION
NUMBER (VIN) WRITING...........00-26
MAINTENANCE SERVICE............00-56
GENERAL DATA AND SPECIFICATIONS
...............................00-46
TIGHTENING TORQUE..............00-48
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER TUBE
CAP) (CHECK FOR LEAKS).........00-56
Continued on next page
00-2
2. FUEL HOSES (CHECK CONDITION)
...............................00-56
3. AIR CLEANER ELEMENT (REPLACE)
...............................00-56
4. EVAPORATIVE EMISSION SYSTEM
(EXCEPT EVAPORATIVE EMISSION
CANISTER) (CHECK FOR CLOGGING)
...............................00-57
5. SPARK PLUGS (REPLACE).......00-57
6. INTAKE AND EXHAUST VALVE CLEARANCE
<INTAKE SIDE ONLY> (INSPECT AND
ADJUST)........................00-57
7. TIMING BELT (REPLACE).......00-58
8. DRIVE BELT (FOR GENERATOR, WATER
PUMP, POWER STEERING OIL PUMP) (CHECK
CONDITION).....................00-58
9. EXHAUST SYSTEM (CONNECTIONS
PORTION OF MUFFLER, MUFFLER PIPES AND
CONVERTER HEAT SHIELDS) (CHECK AND
SERVICE AS REQUIRED)...........00-61
10. ENGINE OIL (CHANGE)........00-62
11. ENGINE OIL FILTER (REPLACE)
...............................00-63
12. TRANSMISSION FLUID.........00-64
13. TRANSFER OIL...............00-67
14. ENGINE COOLANT (CHANGE). . . .00-67
15. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT).........00-69
16. DISC BRAKE PADS (INSPECT FOR WEAR)
...............................00-69
17. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS)........00-69
18. BALL JOINT AND STEERING LINKAGE
SEALS (INSPECT FOR GREASE LEAKS AND
DAMAGE)........................00-69
19. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE).......00-70
20. SUSPENSION SYSTEM (INSPECT FOR
LOOSENESS AND DAMAGE)..........00-70
21. REAR AXLE OIL (CHECK OIL LEVEL)
...............................00-70
22. TIRES (ROTATE).............00-71
23. AIR FILTER (REPLACE).......00-71
MAIN SEALANT AND ADHESIVE TABLE
...............................00-71
GENERAL <BODY AND CHASSIS>
00-3
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
M10001000001USA0000010001
MAINTENANCE, REPAIR AND SERVICING
EXPLANATIONS
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
⦆If a DANGER is not followed, the result is severe
bodily harm or even death.
⦆If a WARNING is not followed, the result could be
bodily injury.
⦆If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
ON-VEHICLE SERVICE
The "ON-VEHICLE SERVICE" section has
procedures for performing inspections and
adjustments of particularly important components.
These procedures are done with regard to
maintenance and servicing, but other inspections
(looseness, play, cracking, damage, etc.) must also
be performed.
TIGHTENING TORQUE INDICATION
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless otherwise
specified, each service procedure covers all models.
Procedures covering specific models are identified by
the model codes, or similar designation (engine type,
transaxle type, etc.). A description of these
designations is covered in this manual under
"VEHICLE IDENTIFICATION."
SERVICE PROCEDURES
The service steps are arranged in numerical order.
Attention to be paid in performing vehicle service are
described in detail in SERVICE POINTS.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
whether or not a part or adjustment is correct.
LIMIT
Shows the maximum or minimum value for judging
whether or not a part or adjustment is acceptable.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
The tightening torque indicates a median and its
tolerance by a unit of N·m (in-lb) or N·m (ft-lb). For
fasteners with no assigned torque value, refer to P.
00-48.
SPECIAL TOOL NOTE
Only MMC special tool part numbers are called out in
the repair sections of this manual. Please refer to the
special tool cross-reference chart located at the
beginning of each group, for the special tool number
that is available in your market.
ABBREVIATIONS
The following abbreviations are used in this manual
for classification of model types:
NOTE:
⦆A/T: Automatic transaxle, or models equipped with
automatic transaxle.
⦆MFI: Multiport fuel injection, or engines equipped
with multiport fuel injection.
⦆FWD: 2-wheel drive vehicles.
⦆AWD: 4-wheel drive vehicles.
⦆A/C: Air conditioning.
⦆3.0L Engine: 2.998 liter 6B31 engine, or a model
equipped with such an engine.
⦆PCM: Powertrain control module
⦆SWS: Simplified wiring system
⦆Keyless Operation System (KOS): Free-hand
Advanced Security Transmitter (F.A.S.T.-key)
GENERAL <BODY AND CHASSIS>
00-4
HOW TO USE THIS MANUAL
EXPLANATION OF MANUAL CONTENTS
Denotes tightening torque.
If there is no indication of
tightening torque, refer to
tightening torque.
Indicates the
section title.
Indicates the
group title.
Indicates the
group number.
Indicates the page number.
Indicates procedures to be performed before the work in that section is started, and
procedures to be performed after the work
in that section is finished.
Mark N denotes non-reusable part.
Component diagram
A diagram of the component parts is provided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
Repair kit or parts sets are shown.
(Only very frequently used parts are shown.)
Brake caliper kit
Pad set
Shim kit
Seal and boot kit
Maintenance and servicing procedures
The numbers provided within the diagram indicate the
sequence for maintenance and servicing procedures.
Removal steps :
The part designation number corresponds to
the number in the illustration to indicate removal
steps.
Disassembly steps :
The part designation number corresponds to
the number in the illustration to indicate disassembly steps.
Installation steps :
Specified in case installation is impossible in
reverse order of removal steps. Omitted if
installation is possible in reverse order of
removal steps.
Assembly steps :
Specified in case installation is impossible in
reverse order of removal steps. Omitted if
assembly is possible in reverse order of
disassembly steps.
ZC6012870000
GENERAL <BODY AND CHASSIS>
00-5
HOW TO USE THIS MANUAL
Classifications of major maintenance / service points
When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.).
These are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or assembly.
Operating procedures,
cautions, etc. on removal,
installation, disassembly and
assembly are described
The title of the page
(following the page on which
the diagram of component
parts is presented) indicating
the locations of lubrication and
sealing procedures.
Grease: repair kit grease
Indicates (by symbols) where
lubrication is necessary.
Symbols for lubrication, sealants and adhesives
Symbols are used to show the locations for lubrication
and for application of sealants and adhesives.
These symbols are included in the diagram of
component parts or on the page following the
component parts page. The symbols do not always
have accompanying text to support that symbol.
Grease
(Multi-purpose grease unless there is a
brand or type specified)
Sealant or adhesive
Brake fluid or automatic transmission fluid
Engine oil, gear oil or air conditioning
compressor oil
Adhesive tape or butyl rubber tape
ZC6012880000
GENERAL <BODY AND CHASSIS>
00-6
TROUBLESHOOTING GUIDELINES
TROUBLESHOOTING GUIDELINES
M10001000088USA0000010001
VERIFY THE COMPLAINT
⦆Make sure the customer's complaint and the service
writer's work order description are understood
before starting work.
⦆Make sure the correct operation of the system is
understood. Read the service manual description to
verify normal system operation.
⦆Operate the system to see the symptoms. Look for
other symptoms that were not reported by the
customer, or on the work order, that may be related
to the problem.
DETERMINE POSSIBLE CAUSES
Compare the confirmed symptoms to the diagnostic
symptom indexes to find the right diagnosis
procedure.
If the confirmed symptoms cannot be found on any
symptom index, determine other possible causes.
⦆Analyze the system diagrams and list all possible
causes for the problem symptoms.
⦆Rank all these possible causes in order of
probability, based on how much of the system they
cover, how likely they are to be the cause, and how
easy they will be to check. Be sure to take
experience into account. Consider the causes of
similar problems seen in the past. The list of causes
should be ranked in order from general to specific,
from most-likely to least-likely, and from easy-tocheck to hard-to-check.
is to make step-by-step checks of the suspected
system components, junctions, and links in logical
order.
Use the diagnostic procedures in the service manual
whenever possible. Follow these procedures carefully
to avoid missing an important step in the diagnosis
sequence. It might be the skipped step that leads to
the solution of the problem.
If the service manual doesn't have step-by-step
procedures to help diagnose the problem, make a
series of checks based on the ranked list of probable
causes. Troubleshooting checks should be made in
the order that the list of causes was ranked:
⦆general to specific
⦆most-likely to least-likely
⦆easy-to-check to hard-to-check
REPAIR THE PROBLEM
When the step-by-step troubleshooting checks find a
fault, perform the proper repairs. Make sure to fix the
root cause of the problem, not just the symptom. Just
fixing the symptom, without fixing the root cause, will
cause the symptom to eventually return.
VERIFY THE REPAIR
After repairs are made, recheck the operation of the
system to confirm that the problem is eliminated. Be
sure to check the system thoroughly. Sometimes new
problems are revealed after repairs have been made.
FIND THE PROBLEM
After the symptoms have been confirmed, and
probable causes have been identified, the next step
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
TROUBLESHOOTING CONTENTS
M10001000133USA0000010001
The SRS-ECU adopts the rollover specification
that the curtain airbag and seat belt pre-tensioner
operate at the occurrence of rollover. Therefore,
do not tilt the vehicle to the right and left with the
IG ON or tilt the SRS-ECU to the right and left with
the IG ON and the harness installed.
During diagnosis, a diagnostic trouble code
associated with other system may be set when the
GENERAL <BODY AND CHASSIS>
00-7
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
ignition switch is turned "ON" with connector(s)
disconnected. On completion, confirm all
systems for diagnostic trouble code(s). If
diagnostic trouble code(s) are set, erase them all.
Since the radiator fan rotates during CAN bus line
diagnostics, make sure that no one is servicing
the engine compartment before diagnosing the
CAN bus line. Since the CAN communication
stops when diagnosing the CAN bus line, the
ETACS-ECU detects the time-out of the engine
control module, and activates the radiator fan to
prevent overheating as fail-safe.
Troubleshooting of electronic control systems for
which scan tool MB991958 can be used follows the
basic outline described below. Even in systems for
which scan tool MB991958 cannot be used, some of
these systems still follow this outline.
1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic
flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is
required, the details of such differences or additions
will also be listed.
Diagnostic method
Gathering information
from the customer.
Coding data check* 6
Does not reoccur
Reoccurs
Check trouble symptom.
CAN bus diagnosis* 1
NG
CAN bus diagnosis chart* 2
OK
Read the diagnosis code.
No diagnosis
code or
communication
with scan tool
MB991958 not
possible
Diagnosis code
displayed.
(Current trouble)* 3
Diagnosis code
displayed.
(Past trouble)* 3
How to treat past
trouble* 4
Diagnosis code
displayed.
(Current trouble)* 3
After taking note of the
malfunction code, erase the
diagnosis code memory.
Recheck trouble symptom.
Read the diagnosis codes.
Diagnosis code
displayed.
Refer to the INSPECTION CHA RT
FOR T ROUBLE SYMP TOMS
(Refer to applica ble g roup) .
Refer to the INSPECTION CHA RT
FOR DI AGNOSIS CODES
(Refer to applica ble g roup) .
Read the diagnosis code.
Diagnosis code
displayed.
(Past trouble)* 3
No diagnosis
code.
How to treat past
trouble* 4
No diagnosis
code.
INTERMITTENT MALFUNCTIONS * 5
ZC604018 0000
⦆*1: For how to diagnose CAN bus lines, refer to
GROUP 54D P.54D-10.
⦆*2: For the CAN bus diagnosis chart, refer to
GROUP 54D P.54D-17.
00-8
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
⦆*3: When scan tool MB991958 detects a diagnostic
trouble code, its display informs users whether a
mechanical problem currently exists or whether it
existed before. The message for the former state
identifies it as an "Active" and the message for the
latter identifies it as a "Stored".
⦆*4: For how to treat past trouble, refer to P.
00-17.
⦆*5: For how to cope with intermittent malfunctions,
refer to P.00-15.
⦆*6: For coding data, refer to P.00-34.
2. SYSTEM OPERATION AND SYMPTOM
VERIFICATION TESTS
If verification of the symptom(s) is difficult, procedures
for checking operation and verifying symptoms are
shown.
3. DIAGNOSTIC FUNCTION
The following trouble code diagnosis are shown.
⦆How to read diagnostic trouble codes
⦆How to erase diagnostic trouble codes
⦆Input inspection service points
4. DIAGNOSTIC TROUBLE CODE CHART
If the scan tool displays a diagnostic trouble code, find
the applicable inspection procedure according to this
chart.
5. SYMPTOM CHART
If there are symptoms, even though the scan tools
show that no DTCs are set, inspection procedures for
each symptom will be found by using this chart.
6. DIAGNOSTIC TROUBLE CODE
PROCEDURES
Indicates the inspection procedures corresponding to
each diagnostic trouble code. (Refer to P.00-9).
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptom listed in the Symptom Chart. (Refer
to P.00-9).
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have
been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspection
items, and standard values have been provided in this
chart as reference information.
TERMINAL VOLTAGE CHECKS
1.Connect a needle-nosed wire probe to a voltmeter
probe.
Short-circuiting the positive (+) probe between a
connector terminal and ground could damage the
vehicle wiring, the sensor, the ECU, or all three.
Use care to prevent this!
2.Insert the needle-nosed wire probe into each of the
ECU connector terminals from the wire side, and
measure the voltage while referring to the check
chart.
NOTE: Measure voltage with the ECU connectors
connected.You may find it convenient to pull out
the ECU to make it easier to reach the connector
terminals.Checks don't have to be carried out in
the order given in the chart.
3.If voltage readings differ from normal condition
values, check related sensors, actuators, and
wiring. Replace or repair as needed.
4.After repair or replacement, recheck with the
voltmeter to confirm that the repair has corrected
the problem.
TERMINAL RESISTANCE AND CONTINUITY
CHECKS
1.Turn the ignition switch to the "LOCK" (OFF)
position.
2.Disconnect the ECU connector.
If resistance and continuity checks are performed
on the wrong terminals, damage to the vehicle
wiring, sensors, ECU, and/or ohmmeter may
occur. Use care to prevent this!
3.Measure the resistance and check for continuity
between the terminals of the ECU harness-side
connector while referring to the check chart.
NOTE: Checks don't have to be carried out in
the order given in the chart.
4.If the ohmmeter shows any deviation from the
Normal Condition value, check the corresponding
sensor, actuator and related electrical wiring, then
repair or replace.
5.After repair or replacement, recheck with the
ohmmeter to confirm that the repair has corrected
the problem.
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
10. INSPECTION PROCEDURES USING
AN OSCILLOSCOPE
00-9
oscilloscope, these are listed.
When there are inspection procedures using an
HOW TO USE THE INSPECTION PROCEDURES
M10001000135USA0000010001
The causes of many of the problems occurring in
electric circuitry are generally the connectors,
components, the ECU, and the harnesses between
connectors, in that order. These inspection
procedures follow this order. They first try to discover
a problem with a connector or a defective component.
GENERAL <BODY AND CHASSIS>
00-10
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
(1) Relevant circuit(s) of the component which
the DTC indicates are described.
(2) For connector color, refer to GROUP 80A,
How to read configuration diagrams.
Connector : B-4 8
Inta ke air
tempe rature
sensor
(3) Shows the location of the connector(s) from
the circuit(s) above.
B-48(B)
(4) Explains about the operation principle of the
component or its relevant parts in that circuit.
ZC6012890000
GENERAL <BODY AND CHASSIS>
00-11
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
(5) Explains about technical details.
(6) Describes the conditions for that DTC
being set (stored).
(7) Describes possible
cause(s)for that DTC.
(8) Start of the diagnosis procedure
for that DTC.
(M. U.T.-III Sub Assem bly)
(9) Identifies the special tool(s)
necessary for diagnosing that DTC.
Data link
connector
(10) Provides the inspection procedure
for that DTC step by step.
ZC6012900000
HARNESS INSPECTION
Check for an open or short circuit in the harness
between the terminals which were faulty according to
the connector measurements. Carry out this
inspection while referring to GROUP 00E, Harness
Connector Inspection P.00E-2. Here, "Check
harness between power supply and terminal xx" also
includes checking for blown fuse. For inspection
service points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse P.
00-18."
MEASURES TO TAKE AFTER REPLACING
THE ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection
procedure from the beginning.
00-12
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
CONNECTOR MEASUREMENT SERVICE POINTS
M10001000136USA0000010001
Turn the ignition switch to the "LOCK" (OFF) position when
connecting and disconnecting the connectors. Turn the ignition
switch to "ON" when measuring, unless there are instructions to
the contrary.
IF INSPECTING WITH THE CONNECTOR
CONNECTED WATERPROOF CONNECTORS
Special tool
Be sure to use special tool. Never insert a test probe from the
harness side, as this will reduce the waterproof performance and
result in corrosion.
ZC5018920000
IF INSPECTING WITH THE CONNECTOR
CONNECTED ORDINARY (NON-WATERPROOF)
CONNECTORS
Required Special Tool:
⦆MB992006: Extra Fine Probe
Inspect by inserting a test probe from the harness side. If the
connector is too small to insert a test probe (e.g. control unit
connector), do not insert it forcibly. Use special tool MB992006
(extra fine probe).
MB992006
ZC5018930000
IF INSPECTING WITH THE CONNECTOR
DISCONNECTED
MB991219
ZC5019070000
When Inspecting a Female Pin
⦆From front side of the connector
Required Special Tool:
MB991219: Inspection Harness (Included in MB991223,
Harness Set)
The inspection harness for connector pin contact
pressure should be used. The test probe should never be
forcibly inserted, as it may cause a defective contact.
⦆From back side of the connector (SRS-ECU harness side
connector)
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-13
Since the SRS-ECU harness connector is plated to
improve conductivity, observe the warning below when
checking this connector.
SRS-ECU harness
connector
ZC5019080000
Insert the backprobing tool into the connector from
the harness side, and connect the tester to the
backprobing tool. If any tool other than the
backprobing tool is used, it may cause damage to the
harness and other components. Furthermore,
measurement should not be carried out by touching
the backprobing tool directly against the terminals
from the front of the connector. The terminals are
plated to increase their conductivity, so that if they
are touched directly by the backprobing tool, the
plating may break, which will decrease reliability.
When Inspecting a Male Pin
At this time, be careful not to short the connector pins
with the test probes. Doing so may damage the circuits
inside the ECU.
Touch the pin directly with the test probe.
ZC5019090000
00-14
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
CONNECTOR INSPECTION SERVICE POINTS
M10001000137USA0000010001
VISUAL INSPECTION
⦆
Connector disconnected or
improperly connected
Stretched or broken wires
Harness wire breakage
at terminal section
Low contact
pressure
Good
Bad
ZC501910 0000
Connector is disconnected or improperly connected
⦆Connector pins are pulled out
⦆Stretched an broken wires at terminal section
⦆Low contact pressure between male and female terminals
⦆Low connection pressure due to rusted terminals or foreign
matter lodged in terminals
GENERAL <BODY AND CHASSIS>
00-15
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
CONNECTOR PIN INSPECTION
If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be perfect even
when the connector body is connected, because the pins may
pull out of the back side of the connector. Therefore, gently pull
the wires one by one to make sure that no pins pull out of the
connector.
ZC5019110000
CONNECTOR ENGAGEMENT INSPECTION
MB991219
Required Special Tool:
MB991219: Inspection Harness (contained in MB991223 Test
Harness)
Use special tool, MB991219 to inspect the engagement of the
male pins and female pins. [Pin drawing force: 1 N (0.2 pound)
or more]
ZC501916 0000
HOW TO COPE WITH INTERMITTENT
MALFUNCTIONS
M10001000139USA0000010000
Most intermittent malfunctions occur under certain conditions. If
those conditions can be identified, the cause will be easier to
find.
TO COPE WITH INTERMITTENT MALFUNCTION;
1. ASK THE CUSTOMER ABOUT THE MALFUNCTION
Ask what it feels like, what it sounds like, etc. Then ask about
driving conditions, weather, frequency of occurrence, and so on.
2. DETERMINE THE CONDITIONS FROM THE CUSTOMER'S
RESPONSES
Typically, almost all intermittent malfunctions occur from
conditions like vibration, temperature and/or moisture change,
poor connections. From the customer's responses, it should be
reasoned which condition is most likely.
00-16
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
3. USE SIMULATION TEST
Use the simulation tests below to attempt to duplicate the
customer's complaint. Determine the most likely circuit(s) and
perform the simulation tests on the connectors and parts of that
circuit(s). Be sure to use the inspection procedures provided for
diagnostic trouble codes and trouble symptoms.
For temperature and/or moisture condition related intermittent
malfunctions, try to change the conditions of the suspected
circuit components, then use the simulation tests below.
4. VERIFY THE INTERMITTENT MALFUNCTION IS
ELIMINATED
Repair the malfunctioning part and try to duplicate the condition
(s) again to verify the intermittent malfunction has been
eliminated.
SIMULATION TESTS
NOTE: In case of difficulty in finding the cause of the
intermittent malfunction, the data recorder function in the
scan tool is effective.
GENERAL <BODY AND CHASSIS>
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-17
For these simulation tests, shake, then gently bend, pull, and
twist the wiring of each of these examples to duplicate the
intermittent malfunction.
⦆Shake the connector up-and-down, and right-and-left.
⦆Shake the wiring harness up-and-down, and right-and-left.
Especially, check the splice points of wiring harnesses
carefully. Refer to GROUP 00E, Harness Connector
Inspection P.00E-2.
⦆Shake the part or sensor.
ZC5019170000
HOW TO TREAT PAST TROUBLE
M10001000141USA0000010000
Since the trouble may still be present even the status
is "Stored", set the vehicle to the diagnostic trouble
code detection condition and check that the status
changes to "Active". If the status does not change
from "Stored", carry out the following procedure.
1.Establish from the customer whether a fuse or
connector has been replaced or disconnected.
2.If yes, erase the diagnostic trouble code, and then
check that no diagnostic code is reset. If no
diagnostic trouble code is reset, the diagnosis is
complete.
3.If no, follow the applicable Diagnostic Trouble Code
Chart. Then check the wiring harness and
connector, and refer to "How to Cope with
Intermittent Malfunction P.00-15."
GENERAL <BODY AND CHASSIS>
00-18
VEHICLE IDENTIFICATION
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
M10001000138USA0000010000
Remove the blown fuse and measure the resistance between
the load side of the blown fuse and the ground. Close the
switches of all circuits which are connected to this fuse. If the
resistance is almost 0 Ω at this time, there is a short somewhere
between these switches and the load. If the resistance is not 0
Ω, there is no short at the present time, but a momentary short
has probably caused the fuse to blow.
The main causes of a short circuit are the following.
⦆Harness being clamped by the vehicle body
⦆Damage to the outer casing of the harness due to wear or heat
⦆Water getting into the connector or circuitry
⦆Human error (mistakenly shorting a circuit, etc.)
Battery
Fuse
Load
switch
Short-circuit
occurrence
section
Load
ZC5019200000
VEHICLE IDENTIFICATION
M10001000004USA0000010000
VEHICLES IDENTIFICATION NUMBER LOCATION
The vehicle identification number (VIN) is located on a plate
attached to the left top side of the instrument panel.
ZC6012650000
GENERAL <BODY AND CHASSIS>
00-19
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION CODE CHART PLATE
All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
No. Item
Content
J A 4MS 3 1 X 1 7 U 0 0 0 0 0 1
12
1
Country
J: Japan
2
Make
A: Mitsubishi
3
Vehicle type
4: Multi-purpose vehicle
4
Others
GROSS VEHICLE WEIGHT
RATING/BRAKE SYSTEM
M: 5001-6000 lbs/HYDRAULIC
5
Line
S: OUTLANDER FWD
1 2 3 4 5 6 7 8 9 10 11
ZC6009480000
T: OUTLANDER AWD
6
Price class
3: Medium
4: High
7
Body
1: 5-door wagon
8
Engine
X: 3.0L (6B31) MIVEC
9
Check digits*
0, 1, 2, 3, -----------9, X
10
Model year
7: 2007 year
11
Plant
U: Mizushima
12
Serial number
000001 to 999999
NOTE: *: Check digit means a single number, or letter X,
used to verify the accuracy of transcription of vehicle
identification number.
VEHICLE IDENTIFICATION NUMBER LIST
VEHICLES FOR USA (FOR FEDERAL EMISSION REGULATION)
VIN (except sequence number) Brand
Engine
displacement
JA4MS31X_7U
JA4MS41X_7U
MITSUBISHI
OUTLANDER
3.0L
Model code
CW6WXLSYL2M
CW6WXLHYL2M
CW6WXLXYL2M
JA4MT31X_7U
CW6WXLSYZL2M
JA4MT41X_7U
CW6WXLHYZL2M
CW6WXLXYZL2M
(FOR CALIFORNIA EMISSION REGULATION)
VIN (except sequence number) Brand
JA4MS31X_7U
JA4MS41X_7U
MITSUBISHI
OUTLANDER
Engine
displacement
Model code
3.0L
CW6WXLSYL7M
CW6WXLHYL7M
CW6WXLXYL7M
GENERAL <BODY AND CHASSIS>
00-20
VEHICLE IDENTIFICATION CODE PLATE
VIN (except sequence number) Brand
Engine
displacement
Model code
JA4MT31X_7U
CW6WXLSYZL7M
JA4MT41X_7U
CW6WXLHYZL7M
CW6WXLXYZL7M
VEHICLES FOR PUERTO RICO
VIN (except sequence number) Brand
JA4MS31X_7U
MITSUBISHI
OUTLANDER
Engine
displacement
Model code
3.0L
CW6WXLSYL2M
CW6WXLMYL2M
JA4MS41X_7U
CW6WXLXYL2M
JA4MT31X_7U
CW6WXLSYZL2M
VEHICLES FOR CANADA
VIN (except sequence number) Brand
JA4MS31X_7U
MITSUBISHI
OUTLANDER
JA4MS41X_7U
Engine
displacement
Model code
3.0L
CW6WXLSYL3M
CW6WXLXYL3M
JA4MT31X_7U
CW6WXLSYZL3M
JA4MT41X_7U
CW6WXLXYZL3M
VEHICLE IDENTIFICATION CODE PLATE
M10001000054USA0000010000
The vehicle information code plate is riveted to the face of the
passenger’s door sill.
The plate shows model code, engine model, transaxle model
and body color code.
1
2
3
4
5
6
7
ZC6012860000
GENERAL <BODY AND CHASSIS>
00-21
VEHICLE IDENTIFICATION CODE PLATE
No.
Item
Content
1
MODEL
CW6WXLS CW6WX: Vehicle model
YL2M
LSYL2M: Model series
2
ENGINE
6B31
Engine model
3
EXT
G44B
Exterior code
4
TRANS
AXLE
F6AJA
Transaxle model
5
COLOR
G44
Body color code
6
INT
11E
Interior code
7
OPT
Z06
Equipment code
For monotone color vehicles, the body color code shall be
indicated.
TIRE AND LOADING INFORMATION PLACARD
The tire and loading information placard is located on the inside
sill of the driver’s door.
ZC6012630000
VEHICLE SAFETY CERTIFICATION LABEL
The vehicle safety certification label is attached to the face of the
driver’s door sill.
This label indicates the month and year of manufacture, Gross
Vehicle Weight Rating (GVWR), front and rear Gross Axle
Weight Rating (GAWR), and Vehicle Identification Number
(VIN).
ZC6012640000
GENERAL <BODY AND CHASSIS>
00-22
VEHICLE IDENTIFICATION CODE PLATE
ENGINE MODEL STAMPING
The engine model is stamped on the cylinder block.
These engine model numbers are as shown as follows.
Engine model
Engine displacement
6B31
3.0L
The engine serial number is stamped near the engine model
number.
ZC601575 0001
THEFT PROTECTION
When replacing a part that has the theft protection plate,
label or stamp on it, be sure that the part has either A or B
shown in the figure. It is illegal if both A and B are attached,
or neither A nor B is attached.
In order to protect against theft, a Vehicle Identification Number
(VIN) is attached as a plate or label to the following major parts
of the engine and transaxle, as well as main outer panels:
Engine cylinder block, Transaxle housing, Front end
crossmember, Front fender, Front floor crossmember front,
Doors, liftgate, Hood
In addition, a theft-protection label is attached to replacement
parts for the body outer panel main components, and the same
data is stamped into replacement parts for the engine and the
transaxle.
Theft protection label
For original parts
<Main outer panels>
<Engine, transaxle>
For replacement parts
ZC602692 0000
Cautions regarding panel repairs:
⦆When repainting original parts, do so after first masking
the theft-protection label. After painting, be sure to peel
off the masking tape.
⦆The theft-protection label for replacement parts is
covered by masking tape, so such parts can be painted
as is. The masking tape should be removed after painting
is finished.
⦆The theft-protection label should not be removed from
original parts or replacement parts.
GENERAL <BODY AND CHASSIS>
00-23
VEHICLE IDENTIFICATION CODE PLATE
LOCATIONS
D
C
A
B
H
E
G
F
I
ZC6009470000
Label area (x: for original equipment parts, y: for replacement parts)
Automatic transaxle
Engine
x
y
y
x
ZC601875 0001
ZC601574 0001
GENERAL <BODY AND CHASSIS>
00-24
VEHICLE IDENTIFICATION CODE PLATE
Label area (x: for original equipment parts, y: for replacement parts)
View A (Front end crossmember)
View B (Front fender)
Section a - a
x
b
a
x
a
Section b - b
b
y
ZC5018710000
Right side only
View C (Front floor crossmember front)
The illustration indicates left outer side.
Right side is symmetrically opposite.
ZC5018700000
View D (Side outer panel)
x
x
Right side only
ZC501873 0000
(Front door)
Right side only
ZC501872 0000
(Rear door)
View J
View K
x
x
K
J
c
d
Section d - d
Section c - c
c
The illustration indicates left outer side.
Right side is symmetrically opposite.
d
y
ZC501874 0000
The illustration indicates left outer side.
Right side is symmetrically opposite.
y
ZC501875 0000
GENERAL <BODY AND CHASSIS>
00-25
VEHICLE IDENTIFICATION CODE PLATE
Label area (x: for original equipment parts, y: for replacement parts)
View F (Side outer panel)
View E (Hood)
x
y
x
ZC5018710001
View G (Side outer panel)
The illustration indicates left outer side.
Right side is symmetrically opposite.
ZC501877 0000
View H (Liftgate upper)
Section e - e
e
y
e
y
The illustration indicates left outer side.
Right side is symmetrically opposite.
ZC501877 0001
View I (Liftgate lower)
x
y
ZC501876 0001
x
ZC5018760000
00-26
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
M10001000116USA0000010000
1.Items to review when servicing SRS:
(1)Be sure to read GROUP 52B, Supplemental
Restraint System (SRS). For safe operation,
please follow the directions and heed all
warnings.
(2)Wait at least 60 seconds after disconnecting the
battery cable before doing any further work. The
SRS system is designed to retain enough
voltage to deploy the air bag even after the
battery has been disconnected. Serious injury
may result from unintended air bag deployment
if work is done on the SRS system immediately
after the battery cable is disconnected.
(3)Warning labels must be heeded when servicing
or handling SRS components. Warning labels
can be found in the following locations.
⦆Air bag module (driver’s and passenger’s)
⦆Clock spring
⦆SRS-ECU
⦆Sunvisor
⦆Seat belt with pre-tensioner (driver’s seat and
passenger’s seat)
⦆Side-airbag module (driver’s seat and
passenger’s seat)
⦆Curtain air bag module (right side and left
side)
⦆Lap pre-tensioner (driver’s side)
⦆Glove box
(4)Always use the designated special tools and test
equipment.
(5)Store components removed from the SRS in a
clean and dry place. The air bag module should
be stored on a flat surface and placed so that the
pad surface is facing upward.
(6)Never attempt to disassemble or repair the SRS
components (SRS-ECU, air bag module and
clock spring). If there is a defect, replace the
defective part.
(7)Whenever you finish servicing the SRS, check
the SRS warning light operation to make sure
that the system functions properly.
(8)Be sure to deploy the air bag before disposing
of the air bag module or disposing of a vehicle
equipped with an air bag (Refer to GROUP 52B,
Air Bag Module and Seat Belt Pre-tensioner
Disposal Procedures P.52B-352).
2.Observe the following when carrying out operations
on places where SRS components are installed,
including operations not directly related to the SRS
air bag.
(1)When removing or installing parts, do not allow
any impact or shock to occur to the SRS
components.
(2)If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module, clock
spring, the front impact sensor, the side impact
sensor, and the seat belt pre-tensioner.
⦆SRS-ECU, air bag module, clock spring, front
impact sensor, the side impact sensor: 93 °C
(200 °F) or more
⦆Seat belt pre-tensioner: 90 °C (194 °F) or
more
HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER (VIN) WRITING
M10001000114USA0000010000
The F.A.S.T-Key (Free-hand Advanced Security
Transmitter) is described as the Keyless
Operation System (KOS) in this manual.
Follow the procedure below to register the VIN of the
Wireless Control Module (WCM) and the Keyless
Operation System (KOS).
The VIN is stored in the engine control module (ECM),
WCM, and the KOS-ECU. If the VIN is improperly
erased, the engine warning light or the keyless
operation system warning indicator illuminate, and the
diagnostic trouble code is displayed. When the ECM,
WCM, and the KOS-ECU are replaced, follow the
procedure below to write the VIN.
GENERAL <BODY AND CHASSIS>
00-27
PRECAUTIONS BEFORE SERVICE
Screen frow of M.U.T. - III
KOS/IMMO/Keyless/TPMS
KOS/IMMO/Keyless/TPMS
VIN Registration
VIN Registration
Confirmation
VIN Registration
completed
Result of VIN
Registration
ZC6037920000
WRITING PROCEDURE
Required Special Tools:
⦆MB991958: Scan Tool (M.U.T.-III Sub Assembly)
⦆MB991824: V.C.I.
⦆MB991827: M.U.T.-III USB Cable
⦆MB991910: M.U.T.-III Main Harness A
Check that diagnostic trouble code P0603 "EEPROM fail" is
not set. When diagnostic trouble code P0603 "EEPROM fail"
is set, the ECM cannot store the key code even if the key
code is registered. If this diagnostic trouble code is set,
troubleshoot the ECM and repair. Then register the key code
to the ECM.
Check that diagnostic trouble code P0630 "VIN not
programmed" is not set. When diagnostic trouble code
P0630 "VIN not programmed" is set, the VIN is not written
to the ECM. After VIN is written in ECM, the Key Code
Registration is executed.
GENERAL <BODY AND CHASSIS>
00-28
PRECAUTIONS BEFORE SERVICE
ZC501967
AC404789
Data link
connector
Connect scan tool MB991958 to the 16-pin data link connector
as follows.
NOTE: For details on how to use scan tool MB991958, refer
to the "M.U.T.-III Owner's Manual."
1.Ensure that the ignition switch is at the "LOCK" (OFF) position.
2.Start up the personal computer.
3.Connect special tool MB991827 to special tool MB991824 and
the personal computer.
4.Connect special tool MB991910 to the special tool MB991824.
5.Connect special tool MB991910 to the data link connector of
the vehicle.
6.Turn the special tool MB991824 power switch to the "ON"
position.
MB991910
MB991824
NOTE: When the special tool MB991824 is energized, the
special tool MB991824 indicator light will be illuminated
in a green color.
7.Start the "M.U.T.-III system" on the personal computer and
turn the ignition switch to the "ON" position.
MB991827
ZC5019680000
System Select
System List
1
Model Yea r
MPI/GDI/Diesel
2
Up to 2005 MY
From to 2006 M
Y
KOS/IMMOBI/ Keyless/TPM S
3
AT/CVT/A-M
4
ABS/ASC/ASTC
5
SAS
6
Multi Select 4WD
7
SRS Airbag
8
A/C
9
E TAC S
10
Vehicle In fo rmatio n
Model Name
OUTLANDER
Model Yea r
2007
Model Code
T
OPC
8.Select "KOS/IMMO/Keyless/TPMS" button from the "System
Select" screen. Then, select the applicable option code item
and push the OK button.
9.Select "Special Function" on the next screen.
Loading Option Setup
Option Name
With Option
Meter
Select Model Year and System
OK button
ZC6037850000
10.Select "ENG Key Code Reg." from the "Special Function"
screen.
Vehicles for KOS
System Select
K OS/IMMO/
K e yless/TPM
S
Special Function
Key (Barcode No) &
Key & KOS Key Reg .
Stee ring lo ck unit Reg .
Tire Pressure Sensor ID Che
KOS Key Reg .
Tire Pressure Sensor ID Regist
Comm . Tes t
ck
Tire Pressure Sensor Che
ENG Key Code Reg .
ratio n
ck
Please select function.
ZC6037860000
Vehicles for WCM
System Select
K OS/IMMO/
K e yless/TPM
S
Special Function
Key Regist ratio n
Additional ke y regist ratio n
ENG Key Code Reg .
Keyless ID Reg .
Tire Pressure Sensor ID Che
ck
Tire Pressure Sensor Che
Key Regist ration (Barcode N o.)
Tire Pressure Sensor ID Regist
ratio n
ck
Please select function.
ZC6037870000
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
K OS/IMMO/
K e yless/TPM
00-29
11.Push the OK button after "ENG Key Code Reg." is displayed.
12.Push the OK button after "Completed." is displayed.
13.Turn off scan tool MB991958.
14.Turn the ignition switch to the "LOCK" (OFF) position and
then disconnect scan tool MB991958.
S
OK button
ZC6037880000
VIN WRITING STEPS FOR WCM AND KOS-ECU
ZC501967
AC404789
Data link
connector
Check that diagnostic trouble code B2416 "ECU internal
error" is not set. When diagnostic trouble code B2416 "ECU
internal error" is set, the WCM and the KOS-ECU cannot
store the VIN even if the VIN is written. If this diagnostic
trouble code is set, troubleshoot the WCM or the KOS-ECU
and repair. Then write the VIN to the WCM or the KOS-ECU.
Connect scan tool MB991958 to the 16-pin data link connector
as follows.
NOTE: For details on how to use scan tool MB991958, refer
to the "M.U.T.-III Owner's Manual."
1.Ensure that the ignition switch is at the "LOCK" (OFF) position.
2.Start up the personal computer.
3.Connect special tool MB991827 to special tool MB991824 and
the personal computer.
4.Connect special tool MB991910 to the special tool MB991824.
5.Connect special tool MB991910 to the data link connector of
the vehicle.
6.Turn the special tool MB991824 power switch to the "ON"
position.
MB991910
MB991824
NOTE: When the special tool MB991824 is energized, the
special tool MB991824 indicator light will be illuminated
in a green color.
7.Start the "M.U.T.-III system" on the personal computer and
turn the ignition switch to the "ON" position.
MB991827
ZC5019680000
System Select
System List
1
2
Up to 2005 MY
From to 2006 M
Y
KOS/IMMOBI/ Keyless/TPM S
3
AT/CVT/A-M
4
ABS/ASC/ASTC
5
SAS
6
Multi Select 4WD
7
SRS Airbag
8
A/C
9
E TAC S
10
Model Yea r
MPI/GDI/Diesel
T
Vehicle In fo rmatio n
Model Name
OUTLANDER
Model Yea r
2007
Model Code
OPC
Loading Option Setup
Option Name
With Option
Meter
Select Model Year and System
OK button
ZC6037850000
8.Select "KOS/IMMO/Keyless/TPMS" button from the "System
Select" screen. Then, select the applicable option code item
and push the OK button.
9.Select "Coding" on the next screen.
GENERAL <BODY AND CHASSIS>
00-30
PRECAUTIONS BEFORE SERVICE
10.Select "VIN Writing" on "Coding" screen.
System Select
KOS/IMMOBI/ Keyless/TPM S
Coding
VIN W ritin g
Please select function.
ZC6037890000
KOS/IMMOBI/ Keyless/TPM S
Coding
11.Push the OK button after the VIN written in the engine control
module is displayed.
12.Push the OK button after "VIN Writing will start. Are you
sure?" is displayed.
13.Push the OK button after "Completed." is displayed.
VIN W ritin g
VIN W ritin g
VIN (Engine ECU)
00000000000000000
VIN currently w ritten in ECM is displ ayed .
W rite the number displ ayed on the screen in Immobili
zer KOS/EC U.
OK button
Press the OK button to execute.
ZC6037900000
KOS/IMMOBI/ Keyless/TPM S
Coding
Result of VIN W
VIN W ritin g
14.Result of VIN writing is displayed.
15.Resister the other ID code. (Refer to GROUP 42B,
Troubleshooting - ID Code Registration Judgment Table P.
42B-12Vehicles
with
KOS
or
GROUP
42C,
Troubleshooting - ID Code Registration Judgment Table P.
42C-8Vehicles with WCM.)
VIN W ritin g
ritin g
00000000000000000
ZC6037940000
INITIALIZATION PROCEDURE FOR LEARNING
VALUE IN MFI ENGINE
M10001000117USA0000010000
When the following service is performed, initialize the learning
value.
⦆Replacing engine assembly*
⦆Replacing throttle body and at cleaning
⦆Replacing knock sensor
NOTE: *: Initialize A/T-related learning value.
INITIALIZATION PROCEDURE
Required Special Tools:
⦆MB991958: Scan Tool (M.U.T.-III Sub Assembly)
⦆MB991824: V.C.I.
⦆MB991827: M.U.T.-III USB Cable
⦆MB991910: M.U.T.-III Main Harness A
GENERAL <BODY AND CHASSIS>
00-31
PRECAUTIONS BEFORE SERVICE
ZC501967
AC404789
Data link
connector
Connect scan tool MB991958 to the 16-pin data link connector
as follows.
NOTE: For details on how to use scan tool MB991958, refer
to the "M.U.T.-III Owner's Manual."
1.Ensure that the ignition switch is at the "LOCK" (OFF) position.
2.Start up the personal computer.
3.Connect special tool MB991827 to special tool MB991824 and
the personal computer.
4.Connect special tool MB991910 to the special tool MB991824.
5.Connect special tool MB991910 to the data link connector of
the vehicle.
6.Turn the special tool MB991824 power switch to the "ON"
position.
MB991910
MB991824
NOTE: When the special tool MB991824 is energized, the
MB991827
ZC5019680000
special tool MB991824 indicator light will be illuminated
in a green color.
7.Turn the ignition switch to the "ON" position.
8.Select "Special Function" form the menu screen.
9.Select "Learned Value Reset" form the menu screen.
10.Initialize the learning value.
11.After initialization of the learning value, learn the idling in MFI
engine. (Refer to LEARNING PROCEDURE FOR IDLING IN
MFI ENGINE P.00-31).
ENGINE IDLING LEARNING PROCEDURE
M10001000118USA0000010000
PURPOSE
When the ECM is replaced, or when the learned value is
initialized, the idle may not be stabilized. Carry out the learning
method by following the procedures below.
LEARNING PROCEDURE
1.Start the engine and warm to reach 80°C (176°F) or more.
NOTE: When the engine coolant temperature is 80°C (176°
F) or more, the warm-up is not needed if the ignition
switch is in "ON" position once.
2.Turn the ignition switch to "LOCK" (OFF) position.
3.After 10 seconds or more, start the engine again.
4.For 10 minutes, carry out the idling under the condition shown
below and then confirm the engine has the normal idling.
⦆Transaxle: P range
⦆Operation in ignition-related, fan and attachments: Not to be
operated
⦆Engine coolant temperature: 80°C (176°F) or more
NOTE: If the engine stalls while idling, check for a
dirty (on the throttle valve) of the throttle body and
00-32
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
clean if needed. Then perform the service from Procedure
1 again.
INITIALIZATION PROCEDURE FOR THROTTLE
ACTUATOR CONTROL MOTOR
When the battery cable is disconnected and reconnected,
throttle actuator control motor valve (Fully closed position) is
eliminated, so that the throttle valve opening angle control would
not be performed correctly. When the battery cable is
disconnected and reconnected, initialize the throttle actuator
control motor using the following procedure.
1.Turn the ignition switch to the "ON" position and then, place
the ignition switch in "LOCK" (OFF) position.
2.For 10 seconds or more, keep the ignition switch in
"LOCK" (OFF) position.
SERVICING ELECTRICAL SYSTEM
M10001000119USA0000010000
Battery posts, terminals and related accessories contain
lead and lead compounds. WASH HANDS AFTER
HANDLING.
1.Note the following before proceeding with working on the
electrical system.
Never perform unauthorized modifications to any electrical
device or wiring. Such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result in
a fire in the vehicle.
ZC5012600000
⦆Before connecting or disconnecting the negative
battery cable, be sure to turn the ignition switch to the
"LOCK" (OFF) position and turn off the lights (If this is
not done, there is the possibility of semiconductor
parts being damaged).
⦆After completion of the work (and the negative battery
terminals is connected), warm up the engine and allow
it to idle for approximately 10 minutes under the
conditions described below in order to stabilize engine
control conditions, and then check to be sure that the
idle is satisfactory.
⦆Engine coolant temperature: 85 - 95°C (185 - 203°F)
⦆Lights and all accessories: OFF
⦆Transaxle: "P" position
⦆Steering wheel: straight-forward position
2.When servicing the electrical system, disconnect the negative
cable terminal from the battery.
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
00-33
VEHICLE WASHING
M10001000120USA0000010000
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least approximately 40cm (16
inches) from any plastic parts and all opening parts (doors,
luggage compartment, etc.).
Approximately
40 cm (16 in)
ZC501232 0000
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
M10001000110USA0000010000
Be careful not to apply oil or grease to the heated oxygen sensor.
If applied, the sensor may malfunction. Protect the heated
oxygen sensor with a cover before applying anti-corrosion agent,
etc.
SCAN TOOL (MULTI USE TESTER { M.U.T.-III } SUB ASSEMBLY)
M10001000122USA0000010000
Turn the ignition switch to the "LOCK" (OFF)
position before disconnecting or connecting the
scan tool.
NOTE: M.U.T.-III trigger harness is not necessary
when pushing V.C.I. ENTER key.
GENERAL <BODY AND CHASSIS>
00-34
PRECAUTIONS BEFORE SERVICE
Vehicle communication interface (V.C.I)
M.U.T.-lll USB cable
MB991824
M.U.T.-lll main harness B
MB991827
M.U.T.-lll main harness C
M.U.T.-lll main harness A
MB991910
M.U.T.-lll measurement adapter
Do not use
Do not use
MB991911
MB991914
MB991825
M.U.T.-lll trigger harness
MB991826
ZC501929 0000
CODING LIST
M10001000147USA0000010000
Before troubleshooting, check that the coding data written into
the engine control module and ETACS-ECU are normal. If they
are not the same as the initial settings, various functions and
systems will not work correctly.
VARIANT CODING
Required Special Tools:
⦆MB991958: Scan Tool (M.U.T.-III Sub Assembly)
⦆MB991824: Vehicle Communication Interface (V.C.I.)
⦆MB991827: M.U.T.-III USB Cable
⦆MB991910: M.U.T.-III Main Harness A (Vehicles with
CAN communication system)
The items marked with*3are actually installed to a vehicle
but their initial settings are "Not present." This is because
the items do not adapt CAN, and does not indicate abnormal
coding data.
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
00-35
The coding data can be checked by operating scan tool
MB991958.
NOTE: For details on how to use the scan tool MB991958,
refer to the "M.U.T.-III Owner’s manual".
ZC501967
AC404789
Data link
connector
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before
connecting or disconnecting scan tool MB991958.
1.Ensure that the ignition switch is at the "LOCK" (OFF) position.
2.Start up the personal computer.
3.Connect special tool MB991827 to special tool MB991824 and
the personal computer.
4.Connect special tool MB991910 to special tool MB991824.
5.Connect special tool MB991910 to the data link connector.
6.Turn the power switch of special tool MB991824 to the "ON"
position.
MB991910
MB991824
NOTE: When special tool MB991824 is energized, special
MB991827
ZC5019680000
tool MB991824 indicator light will be illuminated in a
green color.
7.Start the "M.U.T.-III system" on the personal computer.
8.Turn the ignition switch to the "ON" position.
9.Select "System select" from the start-up screen.
10.Select "From 2006 MY" under "Model Year". Check that
"Vehicle Information" contents are correct.
11.On the system list screen, select "GasolineENG" to check the
engine control module data, and "ETACS" to check the
ETACS-ECU data.
NOTE:
⦆If "Loading Option Setup" list is shown, click appropriate
box.
⦆When you select "GasolineENG" system, a selection
screen appears asking whether MITSUBISHI. Select a
button that the engine belongs to.
12.Select "Coding."
13.Select "Coding Information."
14.If the displayed coding information is different from the
corresponding initial setting in the list, replace the ECU with
a correctly coded one. For replacement of the engine control
module, refer to GROUP 13Aa, engine control module P.
13Aa-37. For replacement of the ETACS-ECU, refer to
GROUP 54Ad, ETACS P.54Ad-93.
Item name
ENGINE CONTROL MODULE CODING DATA LIST
Initial value
Vehicle Model
OUTLANDER
Model year
(Displays the model year)
Destination
U.S.
Detail Destination
USA (49STATES)
Transmission
6AT
00-36
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
Item name
Initial value
Engine type
S4 MIVEC
Engine power
Normal
Final drive
FWD or AWD
Final gear ratio
6.466
T/M Type
SPORTS MODE
Fuel cut Maximum Speed
210 km/h
Tire circumference
2124mm
IMMOBILIZER
Present
TCM
Present
ABS
Present or Not present
ASC
Present or Not present
Power window Dr
Present
Power window As
Not present
Power window RR
Not present
Power window RL
Not present
Power window RP
Not present
Sunroof
Sunroof not present or Sunroof present
S/W variation
Variation No.1
Item name
ETACS-ECU CODING DATA LIST
Initial value
Vehicle line
OUTLANDER
Model year
(Displays the model year)
Destination
U.S.
Transaxle
6AT
Engine type
S4 MIVEC
Engine power
Normal
Handle side
LHD
Final drive
Front Drive or AWD FF Base
Transfer
FWD or ECC
Tire size
225/55R18 or 215/70R16
Tire circumference
2155mm
Fuel tank
60L
DRL*1
Dimming DRL W/P or Independent DRL/P
Smart entry system
Not present or Type C
TPMS*1
Present
Keyless entry*2
Present
SKIM
Type B
Cruise control
Present
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
Item name
Initial value
Corner sensor
Not present
Head light auto leveling device
Not present
Oil level warning
Not present
Water separate warning
Not present
Speed meter scale
km/h or mph
Idle neutral control
Not present
ENG-CVT unit control
Not present
INVECS control
Not present
Lock-up slip control
Not present
Side air bag
Present
Number of speaker*2
Premium or 6 speakers
Seat material*2
Fabric or Leather
Auto light control
No
Front differential
Open
Rear differential
Undefined
Power window type
Type P4
Sunroof type
Not present or Type S4
WCM
Present
OCM
Present
ORC
Present
A/C
Present
AUDIO*2
Not present or Present
AND*3
Not present or Present
VES*3
Not present
DISP*3
Not present
NAVI*2 *3
Not present
CAMERA*3
Not present
TURNER*3
Not present
PSD_L
Not present
PSD_R
Not present
ETG
Not present
MSMD
Not present
HFM
Not present or Present
ABS
Not present or Present
A.S.C.
Not present or Present
SAS
Not present or Present
AWD
Not present or Present
00-37
00-38
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
Item name
Initial value
TCM
Present
ACTV_STB
Not present
Pre-Crush
Not present
EPS
Not present
ACDAYC
Not present
Power window Dr
Present
Power window As
Not present
Power window RR
Not present
Power window RL
Not present
Power window BK
Not present
Sunroof
Not present or Present
RLS*2
Not present
IG key illumination
W/ getting off
Turn signal bulb
21W+21W+5W
Rear wiper
Enable
Fold mirror
Disabled
Head light
4 beams
Head light washer
Disabled
Front fog light mode
A spec.
Front fog light*2
Not present or Present
Rear fog light*2
Not present/ChgOK
Room light delay timer/door and H/L
Long
Room light by H/L
Full
Gate/Trunk light
Mode-2 (cargo)
Headlight auto cut mode
C-spec
Headlight auto cut
Enable
Door lock system
A-spec (NAS)
Auto door lock/unlock
Disabled
key reminder unlock
B-spec/Dr and As
Horn type*2
Dual horn
Gate/trunk opener mode
Present
Cooling fan
Relay control
Security alarm mode
C-spec (US)
Security alarm function
Present/Chg Ng
Pre-alarm
Present
Multi mode RKE
Disabled
Gate/Trunk
Gate type
Manner switch*2
Not present/ChgNg
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
Item name
Initial value
Remote engine starter*2
Not present/ChgNg
Panic Alarm
Enable
Front wiper
Speed Sensitive
Comfort flasher type
Present/Chg OK
Dome light Center Switch
Not present
Wiper washer check bulb
Present
H/L leveling type
Not present or Com less/static
AFS*1type
Not present
ARS*1type
Not present
Compressor type
Scroll type 90 cc/rev
Temparature type
Celsius or Fahrenheit
Rear view camera
Not present
Nose view camera
Not present
Side view camera
Not present
Average speed
Available
Language status
English
Fuel amount
Liter or US gallon
Fuel consumption scale
L/100km or MPG(US)
Speed gauge tolerance
U.S.
Coolant temp gauge threshold
Normal
Frost warning threshold
U.S.
Distance to empty
Available
Average fuel consumption
Available
Instant fuel consumption
Available
Time traveled
Not available
Distance traveled
Not available
Fuel used
Not available
Trip autoreset IG OFF -> ON
Available
Variable speed alarm
Not available
Rest reminder
Available
Instant speed
Not available
Seat belt reminder type
Type 1
Seat belt reminder flashing
Available
Seat belt reminder indicator
D and P independ
Reverse alarm
Not available
Key reminder
Available
Lighting monitor
Available
GCC speed alarm
Not available
00-39
00-40
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
Item name
Initial value
Condition tone alarm
Available
Rent-a-car mode always IG-OFF
Available
Rent-a-car mode door open IG-OFF
Available
Service reminder schedule table
NAS 10
ACD control display
Not available
TPMS information
220 kPa
Horn chirp by RKE
Present/ChgOK
Rear S/R unlock output
Not present
Trailer turn detection
present
Lever
Not present
AFS
Not present
SATR
Not present or Present
Fuel tank type
Type0 or Type1
KOS auto lock customize
Not present
DRL function
Present/Chg OK
FACU
Not present
S AWC control display
Not available
Diesel particulate filter
Not present
Language mode
Not available or Available
WSS
Not present or Present
Control bit for EEPROM writing
0 or 1
NOTE:
⦆*1: TPMS is an abbreviation of Tire Pressure Monitoring
System, DRL of Daytime Running Light, AFS of Adaptive
Front lighting System, and ARS of Advanced Rear lighting
System. However, the systems are not used for this vehicle.
⦆*2: The setting can be changed by the option coding. Refer to.
⦆*3: The item is actually installed to a vehicle, but its initial
setting is "Not present." This is because the item does not
adapt CAN, and does not indicate abnormal coding data.
OPTION CODING
Required Special Tools:
⦆MB991958: Scan Tool (M.U.T.-III Sub Assembly)
⦆MB991824: Vehicles Communication Interface (V.C.I.)
⦆MB991827: M.U.T.-III USB Cable
⦆MB991910: M.U.T.-III Main Harness A (Vehicles with CAN communication system)
If there is any item indicated by the option coding after
equipment change, set ETACS-ECU so that the option
coding data corresponds with the equipment content.
Functions and systems do not work normally if the setting
does not correspond with the equipment.
GENERAL <BODY AND CHASSIS>
PRECAUTIONS BEFORE SERVICE
The ETACS-ECU option coding data can be checked
or changed by operating scan tool MB991958.
⦆How to check option coding data
1. Connect the scan tool MB991958. Refer to P.
00-34.
2. Turn the ignition switch to the "ON" position.
3. Select "System select" from the start-up
screen.
4. Select "From 2006 MY" under "Model Year".
Check that "Vehicle Information" contents are
correct.
5. Select "ETACS" from "System List", and then
press "OK" button.
00-41
8. Check
the displayed option coding
information.
⦆How to change option coding data
1. Connect the scan tool MB991958. Refer to.
2. Turn the ignition switch to the "ON" position.
3. Select "System select" from the start-up
screen.
4. Select "From 2006 MY" under "Model Year".
Check that "Vehicle Information" contents are
correct.
5. Select "ETACS" from "System List", and then
press "OK" button.
NOTE: If "Loading Option Setup" list is
NOTE: If "Loading Option Setup" list is
shown, click appropriate box.
6. Select "Coding."
7. Select "Option Coding."
8. Change to correct option coding data.
LIST
shown, click appropriate box.
6. Select "Coding."
7. Select "Option Coding Information."
Item name
Auto light control
AUDIO (CAN)
RLS
Number of speaker
Seat material
Front fog light
Rear fog light
Horn type
Manner switch
Remote engine starter
AND
HFM
SATR
Compressor type
DRL function
Wiper washer check bulb
GENERAL <BODY AND CHASSIS>
00-42
TOWING AND HOISTING
TOWING AND HOISTING
M10001000008USA0000010000
WRECKER TOWING RECOMMENDATION
FRONT TOWING PICKUP <FWD>
Sling type
NO
Wheel lift type
YES
Flat bed type
This vehicle cannot be towed by a wrecker using sling-type
equipment; as the bumper may become deformed. If this
vehicle is towed, use wheel lift or flat bed equipment.
The vehicle may be towed on its rear wheels for extended
distances provided the parking brake is released. It is
recommended that vehicles be towed using the front pickup
whenever possible.
YES
ZC5019410000
FRONT TOWING PICKUP <AWD>
Sling type
NO
⦆If only the front wheels or only the rear wheels are lifted
for towing, the bumper will be damaged.
In addition, lifting of the rear wheels causes the transfer
case oil to flow forward, and may result in heat damage
to the rear bushing of the transfer.
⦆The vehicle must not be towed by placing only its front
wheels or only the rear wheels on a rolling dolly. This will
result in deterioration of the viscous coupling causing the
vehicle to jump forward suddenly.
If this vehicle is towed, use flat bed equipment only.
Wheel lift type
NO
Flat bed type
YES
ZC5019410001
GENERAL <BODY AND CHASSIS>
TOWING AND HOISTING
00-43
REAR TOWING PICKUP <FWD>
Sling type
Wheel lift type
Flat bed type
NO
YES
YES
⦆This vehicle cannot be towed by a wrecker using slingtype equipment; doing so may cause the lower arm to
become deformed.
If this vehicle is towed, use a wheel lift or flat bed
equipment.
⦆Do not use the steering column lock to secure the front
wheels for towing.
⦆Make sure the transaxle is in Neutral if vehicle will have
drive wheels on the ground.
⦆If these requirements cannot be met, the front wheels
must be placed on a tow dolly.
Automatic transaxle vehicles may be towed on the front wheels
at speeds not to exceed 50 km/h (30 mph) for distances not to
exceed 30 km (18 miles).
ZC5019420000
TOWING WHEN KEYS ARE NOT AVAILABLE
When a locked vehicle must be towed and keys are not
available, the vehicle may be lifted and towed from the front,
provided the parking brake is released. If not released, the rear
wheels should be placed on a tow dolly.
SAFETY PRECAUTIONS
The following precautions should be taken when towing the
vehicle:
1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO
OR WRAPPING AROUND THE BUMPER.
2. Any loose, protruding, or damaged parts such as hoods,
doors, fenders, trim, etc. should be secured or removed prior
to moving the vehicle.
3. Refrain from going under a vehicle when it is lifted by the
towing equipment, unless the vehicle is adequately
supported by safety stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed when
towing a vehicle.
LIFTING, JACKING SUPPORT LOCATION
FLOOR JACK
⦆Never support any point other than the specified one, or
that point will be deformed.
⦆For lifting, put rubber or similar material between the side
sill and rigid rack, or the side sill area will be damaged.
GENERAL <BODY AND CHASSIS>
00-44
TOWING AND HOISTING
<Front side>
<Rear side>
Spare tire
Center member
Rigid rack
Notch
Notch
Rubber
Rubber
ZC501944 0000
POST TYPE
Special care should be taken when raising the vehicle
on a frame contact type hoist. The hoist must be
equipped with the proper adapters in order to support
the vehicle at the proper locations.
GENERAL <BODY AND CHASSIS>
00-45
TOWING AND HOISTING
When service procedures require removing rear
suspension, fuel tank and spare tire, place additional weight
on the rear end of vehicle, or anchor vehicle to hoist to
prevent tipping when the center of gravity changes.
Notch
Notch
ZC501945 0000
GENERAL <BODY AND CHASSIS>
00-46
GENERAL DATA AND SPECIFICATIONS
GENERAL DATA AND SPECIFICATIONS
M10001000009USA0000010000
<Except vehicles for CANADA>
3
9
7
5
2
4
1
8
6
ZC5019470000
Item
CW6W
XLSYL2M/7M
Vehicle
Overall length
1 4,640 (182.7)
dimension mm Overall width
2 1,800 (70.9)
(in)
Overall
height 3 1,680 (66.1)
(unladen)
<Vehicles
without
roof
rail>
1,720 (67.7)
<Vehicles with
roof rail>
XLHYL2M/7M
XLSYZL2M/7M XLHYZL2M/7M
4,640 (182.7)
4,640 (182.7)
4,640 (182.7)
1,800 (70.9)
1,800 (70.9)
1,800 (70.9)
1,720 (67.7)
1,680 (66.1)
1,720 (67.7)
<Vehicles with <Vehicles
<Vehicles with
roof rail>
without
roof roof rail>
rail>
1,720 (67.7)
<Vehicles with
roof rail>
Wheelbase
4 2,670 (105.1)
2,670 (105.1)
2,670 (105.1)
2,670 (105.1)
Tread-front
5 1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
Tread-rear
6 1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
Overhang-front
7 965 (38.0)
965 (38.0)
965 (38.0)
965 (38.0)
Overhang-rear
8 1,005 (39.6)
1,005 (39.6)
1,005 (39.6)
1,005 (39.6)
215 (8.5)
215 (8.5)
215 (8.5)
1,635 (3,604)
1,680 (3,703)
1,700 (3,747)
2,350 (5,181)
2,350 (5,181)
Ground clearance 9 215 (8.5)
Vehicle weight Curb weight
1,615 (3,560)
kg (lb)
Gross vehicle weight 2,300 (5,071)
rating
Gross axle
rating-front
weight 1,090 (2,403)
Gross axle
rating-rear
weight 1,280 (2,822)
Seating capacity
5
Engine
Model No.
6B31
Piston displacement
3.0 L
Model No.
F6AJA
Type
6-speed automatic
Fuel supply system
Multiport fuel injection
Transaxle
Fuel system
W6AJA
GENERAL <BODY AND CHASSIS>
00-47
GENERAL DATA AND SPECIFICATIONS
Item
CW6W
XLMYL2M
Vehicle
Overall length
1 4,640 (182.7)
dimension mm Overall width
2 1,800 (70.9)
(in)
Overall
height 3 1,680 (66.1)
(unladen)
<Vehicles
without
roof rail>
1,720 (67.7)
<Vehicles with roof
rail>
4,640 (182.7)
4,640 (182.7)
1,800 (70.9)
1,800 (70.9)
1,720 (67.7)
1,680 (66.1)
<Vehicles with roof <Vehicles
without
rail>
roof rail>
1,720 (67.7)
<Vehicles with roof
rail>
4 2,670 (105.1)
2,670 (105.1)
2,670 (105.1)
Tread-front
5 1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
Tread-rear
6 1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
Overhang-front
7 965 (38.0)
965 (38.0)
965 (38.0)
Overhang-rear
8 1,005 (39.6)
1,005 (39.6)
1,005 (39.6)
215 (8.5)
215 (8.5)
1,670 (3,681)
1,735 (3,825)
Vehicle weight Curb weight
1,675 (3,692)
kg (lb)
Gross vehicle weight 2,300 (5,071)
rating
Gross axle
rating-front
weight 1,090 (2,403)
Gross axle
rating-rear
weight 1,280 (2,822)
Seating capacity
7
Engine
Model No.
6B31
Piston displacement
3.0 L
Model No.
F6AJA
Type
6-speed automatic
Fuel supply system
Multiport fuel injection
Fuel system
XLXYZL2M/7M
Wheelbase
Ground clearance 9 215 (8.5)
Transaxle
XLXYL2M/7M
2,350 (5,181)
W6AJA
<Vehicles for CANADA>
3
9
5
2
7
4
1
8
6
ZC5019470000
GENERAL <BODY AND CHASSIS>
00-48
TIGHTENING TORQUE
Item
CW6W
XLSYL3M
Vehicle
Overall length
1 4,640 (182.7)
dimension mm Overall width
2 1,800 (70.9)
(in)
Overall
height 3 1,680 (66.1)
(unladen)
<Vehicles
without
roof
rail>
1,720 (67.7)
<Vehicles with
roof rail>
XLSYZL3M
XLXYL3M
XLXYZL3M
4,640 (182.7)
4,640 (182.7)
4,640 (182.7)
1,800 (70.9)
1,800 (70.9)
1,800 (70.9)
1,720 (67.7)
1,680 (66.1)
1,720 (67.7)
<Vehicles with <Vehicles
<Vehicles with
roof rail>
without
roof roof rail>
rail>
1,720 (67.7)
<Vehicles with
roof rail>
Wheelbase
4 2,670 (105.1)
2,670 (105.1)
2,670 (105.1)
2,670 (105.1)
Tread-front
5 1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
Tread-rear
6 1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
1,540 (60.6)
Overhang-front
7 965 (38.0)
965 (38.0)
965 (38.0)
965 (38.0)
Overhang-rear
8 1,005 (39.6)
1,005 (39.6)
1,005 (39.6)
1,005 (39.6)
215 (8.5)
215 (8.5)
215 (8.5)
1,680 (3,703)
1,670 (3,681)
1,735 (3,825)
2,350 (5,181)
2,300 (5,071)
2,350 (5,181)
Ground clearance 9 215 (8.5)
Vehicle weight Curb weight
1,615 (3,560)
kg (lb)
Gross vehicle weight 2,300 (5,071)
rating
Gross axle
rating-front
weight 1,090 (2,403)
Gross axle
rating-rear
weight 1,100 (2,425)
Seating capacity
5
Engine
Model No.
6B31
Piston displacement
3.0 L
Model No.
F6AJA
Type
6-speed automatic
Fuel supply system
Multiport fuel injection
Transaxle
Fuel system
7
W6AJA
F6AJA
W6AJA
TIGHTENING TORQUE
M10001000011USA0000010000
Each torque value in the table is a standard value for
tightening under the following conditions.
1. Bolts, nuts and washers are all made of steel and
plated with zinc.
2. The threads and bearing surface of bolts and nuts
are all in dry condition.
The values in the table are not applicable:
1. If toothed washers are inserted.
2. If plastic parts are fastened.
3. If bolts are tightened to plastic or die-cast inserted
nuts.
4. If self-tapping screws or self-locking nuts are used.
GENERAL <BODY AND CHASSIS>
00-49
LUBRICATION AND MAINTENANCE
STANDARD BOLT AND NUT TIGHTENING TORQUE
Standard tightening torque
Thread size
Nominal
bolt Pitch
diameter (mm)
(mm)
Head mark "4"
Head mark "7"
Head mark "8"
M5
0.8
2.5 ± 0.5 N·m (23 ± 4 in- 5.0 ± 1.0 N·m (44 ± 9 in- 6.0 ± 1.0 N·m (53 ± 9 inlb)
lb)
lb)
M6
1.0
5.0 ± 1.0 N·m (44 ± 9 in- 8.5 ± 1.5 N·m (76 ± 13 10 ± 2 N·m (89 ± 17 inlb)
in-lb)
lb)
M8
1.25
11 ± 2 N·m (98 ± 17 in- 20 ± 4 N·m (15 ± 3 ft-lb) 24 ± 4 N·m (18 ± 3 ft-lb)
lb)
M10
1.25
23 ± 4 N·m (17 ± 3 ft-lb) 42 ± 8 N·m (31 ± 6 ft-lb) 53 ± 7 N·m (39 ± 5 ft-lb)
M12
1.25
42 ± 8 N·m (31 ± 6 ft-lb) 80 ± 10 N·m (59 ± 7 ft-lb) 93 ± 12 N·m (68 ± 9 ft-lb)
M14
1.5
70 ± 10 N·m (52 ± 7 ft-lb) 130 ± 20 N·m (96 ± 15 ft- 150 ± 20 N·m (111 ± 14
lb)
ft-lb)
M16
1.5
105 ± 15 N·m (78 ± 11 ft- 195 ± 25 N·m (144 ± 18 230 ± 30 N·m (170 ± 22
lb)
ft-lb)
ft-lb)
M18
1.5
150 ± 20 N·m (111 ± 14 290 ± 40 N·m (214 ± 29 335 ± 45 N·m (247 ± 33
ft-lb)
ft-lb)
ft-lb)
M20
1.5
210 ± 30 N·m (155 ± 22 400 ± 60 N·m (295 ± 44 465 ± 65 N·m (343 ± 48
ft-lb)
ft-lb)
ft-lb)
M22
1.5
290 ± 40 N·m (214 ± 29 540 ± 80 N·m (398 ± 59 630 ± 90 N·m (465 ± 66
ft-lb)
ft-lb)
ft-lb)
M24
1.5
375 ± 55 N·m (277 ± 40 705 ± 105 N·m (520 ± 77 820 ± 120 N·m (605 ± 88
ft-lb)
ft-lb)
ft-lb)
FLANGE BOLT AND NUT TIGHTENING TORQUE
Standard tightening torque
Thread size
Nominal
bolt Pitch
diameter (mm)
(mm)
Head mark "4"
Head mark "7"
Head mark "8"
M6
1.0
5.0 ± 1.0 N·m (44 ± 9 in- 10 ± 2 N·m (89 ± 17 in- 12 ± 2 N·m (107 ± 17 inlb)
lb)
lb)
M8
1.25
13 ± 2 N·m (111 ± 22 in- 24 ± 4 N·m (18 ± 3 ft-lb) 28 ± 5 N·m (20 ± 4 ft-lb)
lb)
M10
1.25
26 ± 5 N·m (19 ± 4 ft-lb) 50 ± 5 N·m (37 ± 4 ft-lb) 58 ± 7 N·m (43 ± 5 ft-lb)
M10
1.5
25 ± 4 N·m (18 ± 3 ft-lb) 46 ± 8 N·m (34 ± 6 ft-lb) 55 ± 5 N·m (41 ± 3 ft-lb)
M12
1.25
47 ± 9 N·m (35 ± 6 ft-lb) 93 ± 12 N·m (68 ± 9 ft- 105 ± 15 N·m (78 ± 11
lb)
ft-lb)
M12
1.75
43 ± 8 N·m (32 ± 6 ft-lb) 83 ± 12 N·m (61 ± 9 ft- 98 ± 12 N·m (72 ± 9 ftlb)
lb)
LUBRICATION AND MAINTENANCE
M10001000012USA0000010000
Maintenance
and
lubrication
service
recommendations have been compiled to provide
maximum protection for the vehicle owner's
investment against all reasonable types of driving
00-50
GENERAL <BODY AND CHASSIS>
LUBRICATION AND MAINTENANCE
conditions. Since these conditions vary with the
individual vehicle owner's driving habits, the area in
which the vehicle is operated and the type of driving
to which the vehicle is subjected, it is necessary to
prescribe lubrication and maintenance service on a
time frequency as well as mileage interval basis.
Oils, lubricants and greases are classified and graded
according to standards recommended by the Society
of Automotive Engineers (SAE), the American
Petroleum Institute (API) and the National Lubricating
Grease Institute (NLGI).
thoroughly washed with soap and water, or use
waterless hand cleaner, to remove any used
engine oil. Do not use gasoline, thinners, or
solvents.
Either of the following engine oils should be used:
Engine oils displaying ILSAC certification symbol or
conforming to the API classification SL, SL/CF.
For further details, refer to "RECOMMENDED
LUBRICANTS AND LUBRICANT CAPACITIES
TABLE - LUBRICANT SELECTION P.00-51."
MAINTENANCE SCHEDULES
Semi-solid lubricants bear the NLGI designation and
are further classified as grades 0, 1, 2, 3, etc.
Whenever "Chassis Lubricant" is specified,
Multipurpose Grease, NLGI grade Number 2, should
be used.
Information for service maintenance is provided in the
"SCHEDULED MAINTENANCE TABLE." Three
schedules are provided; one for "Required
Maintenance." one for "General Maintenance" and
one for "Severe Usage Service."
The item numbers in "SCHEDULED MAINTENANCE
TABLE" correspond to the section numbers in
"MAINTENANCE SERVICE."
SEVERE SERVICE
Vehicles operating under severe service conditions
will require more frequent service.
Component service information is included for
vehicles operating under one or more of the following
conditions:
1.Trailer towing or police, taxi or commercial type
operation.
2.Operation of Vehicle
(1)Short-trip operation at freezing temperature
(engine not thoroughly warmed up)
(2)More than 50% operation in heavy city traffic
during hot weather above 32°C (90°F)
(3)Extensive idling
(4)Driving in sandy areas
(5)Driving in salty areas
(6)Driving in dusty conditions
(7)Driving off-road
ENGINE OIL
Test results submitted to EPA have shown that
laboratory animals develop skin cancer after
prolonged contact with used engine oil.
Accordingly, the potential exists for humans to
develop a number of skin disorders, including
cancer, from such exposure to used engine oil.
Therefore, when changing engine oil, be careful
not to touch it as much as possible. Protective
clothing and gloves, that cannot be penetrated by
oil, should be worn. The skin should be
LUBRICANTS AND GREASES
FUEL USAGE STATEMENT
Using leaded gasoline in this car will damage the
catalytic converters and heated oxygen sensors,
and affect the warranty coverage validity.
This vehicle must use unleaded gasoline only.
This vehicle has a fuel filler tube which is especially
designed to accept only the smaller-diameter
unleaded gasoline dispensing nozzle.
The 2.4L model is designed to operate on unleaded
gasoline having a minimum octane rating of 87 [(MON
+ RON)/2], or 91 RON.
NOTE:
⦆MON: Motor Octane Number
⦆RON: Research Octane Number
GASOLINE CONTAINING ALCOHOL
Some gasoline sold at service stations contain alcohol
although they may not be so identified.
Using fuels containing alcohol is not recommended
unless the nature of the blend can be determined as
being satisfactory.
Gasohol: A mixture of 10% ethanol (grain alcohol) and
90% unleaded gasoline may be used in your vehicle.
If driveability problems are experienced as a result of
using gasohol, it is recommended that the vehicle be
operated on gasoline.
Methanol:Do not use gasoline containing
methanol (wood alcohol).Using this type of alcohol
can result in vehicle performance deterioration and
damage critical parts in the fuel system components.
Fuel system damage and performance problems
resulting from the use of gasoline containing methanol
may not be covered by the new vehicle warranty.
GENERAL <BODY AND CHASSIS>
00-51
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
GASOLINE CONTAINING METHYL TERTIARY
BUTYL ETHER (MTBE)
Unleaded gasoline containing 15% or less MTBE may
be used in your vehicle. (Fuel containing MTBE over
15% in volume may cause reduced engine
performance and produce vapor lock or hard starting.
for gum and varnish removal may contain highly
active solvents or similar ingredients that can be
harmful to gasket and diaphragm materials used in
fuel system component parts.
MATERIALS ADDED TO FUEL
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
M10001000013USA0000010000
RECOMMENDED LUBRICANTS
Lubricant
Specifications
Remarks
Engine oil
Engine oils displaying ILSAC For further details, refer to
certification symbol ("Starburst" "LUBRICANTS
SELECTION"
symbol) or conforming to the API section.
classification SM or higher
Transmission fluid
DIA QUEEN J2
Transfer oil
Hypoid gear oil API classification GL-5 or higher
Rear differential gear oil
Hypoid gear oil API classification GL-5 or higher
⦆Above -23°C(-10°F): SAE90,
85W-90, 80W-90
⦆From -34°C to -23°C(-30°F to
-10°F): SAE80W, 80W-90
⦆Below -34°C(-30°F): SAE75W
Power steering fluid
Genuine
Mitsubishi
Steering Fluid
Brakes fluid
Conforming to Brake fluid DOT 3 or DOT 4
Engine coolant
Long Life Antifreeze Coolant or an equivalent
Door hinges, back door hinges
Engine oil
-
Power -
-
LUBRICANT CAPACITY TABLE
Description
Engine oil dm3(qt)
Specification
Oil pan (excluding oil filter)
4.0 (4.2)
Oil filter
0.3 (0.32)
Engine coolant dm3(qt)
7.0 (7.4)
Transmission fluid dm3(qt)
8.4 (8.9)
Transfer oil dm3(qt)
0.53 (0.56)
Rear differential gear oil dm3(qt)
0.5 (0.53)
Power steering fluid dm3(qt)
1.0 (1.06)
GENERAL <BODY AND CHASSIS>
00-52
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
Description
Specification
Fuel tank dm3(gal)
60 (15.9)
LUBRICANT SELECTION
ENGINE OIL
ILSAC certification symbol
("Starburst" symbol)
Never use nondetergent or straight mineral oil.
Use only engine oils displaying the ILSAC certification symbol
("Starburst" symbol) on the container.
ZC6011140000
If these oils are not available, an API classification SM or higher
can be used.
API service symbol
RVICE
SM
AP
I
SE
SAE
5W-20
ZC604408 AA00
OIL VISCOSITY
The SAE grade number indicates the viscosity of the oil. A proper
SAE grade number should be selected according to ambient
temperature.
NOTE: SAE 5W-20 engine oil is strongly recommended for
optimum fuel economy and cold starting. If the ambient
temperature is not within the usable temperature range of
SAE 5W-20 shown in the above illustration, use SAE 10W-30
engine oil.
ZC601066 AA00
SELECTION OF COOLANT
COOLANT
Relationship between Coolant Concentration and
Specific Gravity
⦆If the concentration of the coolant is below 30%,
the anti-corrosion property will be adversely
GENERAL <BODY AND CHASSIS>
00-53
SCHEDULED MAINTENANCE TABLE
affected. In addition, if the concentration is
above 60%, both the anti-freeze and engine
cooling properties will decrease, affecting the
engine adversely. For these reasons, be sure to
Coolant temperature °C
specific gravity
(°F)
maintain the concentration level within the
specified range.
⦆Do not use a mixture of different brands of antifreeze.
and Freezing
temperature
Safe
operating Coolant
temperature
concentration
(specific volume)
10 (50) 20 (68) 30 (86) 40
(104)
50
(122)
°C (°F)
°C (°F)
%
1.054
1.050
1.046
1.042
1.036
-16 (3)
-11 (12)
30
1.063
1.058
1.054
1.049
1.044
-20 (-4)
-15 (5)
35
1.071
1.067
1.062
1.057
1.052
-25 (-13)
-20 (-4)
40
1.079
1.074
1.069
1.064
1.058
-30 (-22)
-25 (-13)
45
1.087
1.082
1.076
1.070
1.064
-36 (-33)
-31 (-24)
50
1.095
1.090
1.084
1.077
1.070
-42 (-44)
-37 (-35)
55
1.103
1.098
1.092
1.084
1.076
-50 (-58)
-45 (-49)
60
Example
The safe operating temperature is -15°C (5° F) when
the specific gravity is 1.058 at the coolant temperature
of 20°C (68°F)
SCHEDULED MAINTENANCE TABLE
M10001000014USA0000010000
SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE
PERFORMANCE
Inspection and service should be performed any time
if a malfunction is observed or suspected.
No.
Emission
control Service
system maintenance intervals
Kilometers
in
thousands
24
48
72
96
120
144
168
192
Mileage in 15
thousands
30
45
60
75
90
105
120
Months
24
36
48
60
72
84
96
12
1
Fuel system (tank, Check for leaks
pipe
line
and
connection, and fuel
tank filler tube cap)
2
Fuel hoses and pipes
Check condition
X*
X
X
X
3
Air cleaner element
Replace
X
X
X
X
4
Evaporative emission Check for
control system (except clogging
evaporative emission
canister)
leaks
X
and
X
X
X
GENERAL <BODY AND CHASSIS>
00-54
No.
SCHEDULED MAINTENANCE TABLE
Emission
control Service
system maintenance intervals
Iridiumtipped type
Kilometers
in
thousands
24
48
72
96
120
144
168
192
Mileage in 15
thousands
30
45
60
75
90
105
120
Months
12
24
36
48
60
72
84
96
Replace
Every 84 months or every 168,000 km (105,000
miles)
5
Spark plugs
6
Intake valve clearance Inspect and adjust
X
X
X
X
If valve noise increases, adjust valve clearance
7
Timing belt
Replace
Every 168,000 km (105,000 miles)
8
Drive belts (for the Check condition
generator, water pump
and power steering
pump)
X
X
X
X
9
Exhaust
system Check and service
(connection portion of
muffler, muffler pipes
and converter heat
shields)
X*
X
X
X
GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE
No. General
Service
Kilometers in 24 48 72 96
maintenance
intervals
thousands
Mileage
thousands
120 144 168 192
in 15
30
45
60
75
90
105 120
12
24
36
48
60
72
84
Months
96
10
Engine oil
Change
Every 6 months or every 12,000 km (7,500
miles)
11
Engine oil filter
Replace
Every 6 months or every 12,000 km (7,500
miles)
13
Transfer oil
Check oil level and condition
X
X
X
X
Change
X
Change
X at
first
X
X
X
X
X
14
Engine coolant
15
Coolant
hoses Inspect
(radiator hose, heater
hose)
16
Disc brake
rotors
17
Brake hoses
18
Ball joint and steering Inspect for grease leaks and
linkage seals
damage
pads, Inspect for wear
X
X
Every 12 months or every 24,000 km (15,000
miles)
Check for deterioration or leaks Every 12 months or every 24,000 km (15,000
miles)
X
X
X
X
GENERAL <BODY AND CHASSIS>
00-55
SCHEDULED MAINTENANCE TABLE
No.
General
maintenance
Service
intervals
Kilometers
thousands
in 24
48
72
96
120 144 168 192
Mileage
thousands
in 15
30
45
60
75
90
105 120
12
24
36
48
60
72
84
Months
96
19
Drive shaft boots
Inspect for grease leaks and Every 12 months or every 24,000 km (15,000
damage
miles)
20
Suspension system
Inspect for
damage
21
Rear axle oil
Check oil level
22
Tires
Rotate
Every 12,000 km (7,500 miles)
23
Air filter
Replace
Every 18 months or every 24,000 km (15,000
miles)
looseness
and
X
X
X
X
X
X
X
X
NOTE: *: This maintenance is recommended but is
not required to maintain the emissions warranty.
SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS
Maintenance should be carried out according to the
following table:
No.
Maintenance
item
Service
intervals
Kilometers
thousands
in 24
48
72
96
120
144
168
192
Mileage
thousands
in 15
30
45
60
75
90
105
120
12
24
36
48
60
72
84
96
Months
3
Air
cleaner Replace
element
Every 12 months or every 24,000 km (15,000 miles)
10
Engine oil
Change
Every 3 months or every 6,000 km (3,750 miles)
11
Engine oil filter
Replace
Every 3 months or every 6,000 km (3,750 miles)
12
Transmission
fluid
Change
X
X
chec
k
16
Disc
brake Inspect for wear
pads, rotors
17
Brake hoses
19
Drive
boots
20
Suspension
system
Inspect for
damage
23
Air filter
Inspect for clogging
Every 3 months or every 6,000 km (3,750 miles)
Replace
NOTE: inspect and replace alternately
X
X
chec
k
X
chec
k
X
X
X
chec
k
Every 6 months or every 12,000 km (7,500 miles)
Check for deterioration or leaks Every 12 months or 24,000 km (15,000 miles)
shaft Inspect for grease leaks and Every 12 months or 24,000 km (15,000 miles)
damage
Severe usage conditions:
looseness
and Every 6 month or 12,000 km (7,500 miles)
GENERAL <BODY AND CHASSIS>
00-56
MAINTENANCE SERVICE
1. Driving on dusty, rough, muddy or salt-spread
roads
2. Towing or police, taxi or commercial operation
3. Extensive idling and/or low speed operation
4. Repeated short-trip operation at freezing
temperatures (engine not thoroughly warmed up)
5. Extended use of brakes while driving
6. Driving in sandy areas
7. More than 50% operation in heavy city traffic
during hot weather above 32°C (90°F)
MAINTENANCE SERVICE
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER TUBE
CAP) (CHECK FOR LEAKS)
M10001000016USA0000010000
Check for damage or leakage in the fuel lines and connections.
Fuel main pipe
Fuel high-pressure tube
ZC6033310000
2. FUEL HOSES (CHECK CONDITION)
M10001000017USA0000010000
1.Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, tears, cuts,
abrasions and excessive swelling indicate deterioration of the
rubber.
2.If the fabric casing of the rubber hose is exposed by cracks
and abrasions in the fuel system, the hoses should be
replaced.
3. AIR CLEANER ELEMENT (REPLACE)
M10001000018USA0000010000
The air cleaner element will become dirty during use, reducing
its effectiveness. Replace it with a new one.
Replacement of air cleaner element:
1. Unclasp the air cleaner housing.
2. Remove the air cleaner element and install a new one.
3. When clamping the air cleaner housing in place, be sure that
the cover is completely closed.
ZC6038320000
GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-57
4. EVAPORATIVE EMISSION SYSTEM (EXCEPT
EVAPORATIVE EMISSION CANISTER) (CHECK
FOR CLOGGING)
M10001000019USA0000010000
If the fuel-vapor vent line is clogged or damaged, fuel vapor will
escape into the atmosphere causing excessive emissions.
Disconnect the line at both ends, and blow it clean with
compressed air. Remove the fuel tank filler tube cap from the
filler tube and check to see if there is evidence that the seal
makes improper contact to the filler tube.
5. SPARK PLUGS (REPLACE)
M10001000020USA0000010001
Iridium plugs are used. Use care not to damage the iridium
tips of the plugs. Do not adjust the spark plug gap.
1.Spark plugs must spark properly to assure proper engine
performance and reduce exhaust emission level. Therefore,
they should be replaced periodically with new ones.
Spark plug type
MAKER
Iridium tip
Platinum tip
ZK600368AA00
NGK
2.The new plugs should be checked for the proper gap.
Spark plug gap: 0.7 - 0.8 mm (0.028 - 0.031 inch)
3.Install the spark plugs and tighten to 25 ± 5 N·m (18 ± 4 ft-lb).
6. INTAKE AND EXHAUST VALVE CLEARANCE
<INTAKE SIDE ONLY> (INSPECT AND ADJUST)
M10001000129USA0000010000
1.Before checks, check that the engine oil, starter and battery
are normal. Also, set the vehicle in the following condition:
⦆Engine coolant temperature: 80 - 95°C (176 - 203°F)
⦆Lights and all accessories: OFF
⦆Transaxle: P range
NOTE: On vehicles for Canada, the headlight, taillight,
etc. remain lit even when the lighting switch is in "OFF"
position but this is no problem for checks and adjustment.
2.Remove all of the ignition coils.
3.Remove the rocker cover.
4.Turn the crankshaft clockwise until the notch on the pulley is
lined up with the "T" mark on the timing indicator.
GENERAL <BODY AND CHASSIS>
00-58
MAINTENANCE SERVICE
Right bank
No. 1
No. 3
No. 2
No. 5
No. 4
No. 6
5.Move the rocker arms on the No.1 and No.4 cylinders up and
down by hand to determine which cylinder has its piston at the
top dead center on the compression stroke.
If both intake and exhaust valve rocker arms have a valve lash,
the piston in the cylinder corresponding to these rocker arms
is at the top dead center on the compression stroke.
6.Valve clearance inspection and adjustment can be performed
on rocker arms indicated by white arrow mark when the No.1
cylinder piston is at the top dead center on the compression
stroke, and on rocker arms indicated by black arrow mark
when the No.4 cylinder piston is at the top dead center on the
compression stroke.
7.Measure the valve clearance for intake side.
If the valve clearance is not as specified, loosen the rocker
arm lock nut and adjust the clearance using a thickness gauge
while turning the adjusting screw.
Standard value (hot engine): 0.20 mm (0.008 inch)
NOTE: Valve clearance check and adjustment is
Left bank
ZK600324 0000
unnecessary for exhaust side due to auto lash adjuster
installed.
8.While holding the adjusting screw with a screwdriver to
prevent it from turning, tighten the lock nut to the specified
torque.
Tightening torque: 9 ± 1 N·m (80 ± 9 in-lb)
9.Turn the crankshaft 360 degrees to line up the notch on the
crankshaft pulley with the "T" mark on the timing indicator.
10.Repeat steps (7) and (8) on other valves for clearance
adjustment.
11.Install the rocker cover.
12.Install the ignition coils.
7. TIMING BELT (REPLACE)
M10001000023USA0000010001
Replace the belt with a new one according to the maintenance
schedule P.00-53to assure proper engine performance.
For removal and installation procedures, refer to GROUP 11A,
Engine Mechanical - Timing Belt - Removal and Installation P.
11A-49.
8. DRIVE BELT (FOR GENERATOR, WATER PUMP,
POWER STEERING OIL PUMP) (CHECK
CONDITION)
M10001000025USA0000010001
Power steering oil pump drive belt tension check
When using special tool MB992080: recommendation
Required Special Tools:
⦆MB992080: Belt tension meter set
GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-59
⦆MB992081: Belt tension meter
⦆MB992082: Microphone assembly
NOTE: The vibration frequency measuring method is
recommended for check and adjustment of the drive belt
tension.
1.Connect the special tool MB992082 to the special tool
MB992081 of the Special tool MB992080.
2.Press the "POWER" button to turn on the power supply.
3.Press the numeral key of "1" and check that "No.1" appears
on the upper left of the display.
Belt tension meter set (MB992080)
MB992081
NOTE: This operation is to temporarily set the preset
MB992082
ZC5012270000
10 − 15 mm
(0.4 − 0.59 in)
15˚
MB992080
15˚
Power steering
oil pump pulley
Tap lightly
with a finger
ZC6004500000
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 judgement of error.
4.Press "Hz" button twice to change the display to the frequency
display (Hz).
⦆The temperature of the surface of the belt should be as
close to normal temperature as possible.
⦆Do not allow any contaminants such as water or oil to get
onto the microphone.
⦆If strong gusts of wind blow against the microphone or if
there are any 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 correspond to actual values.
⦆Do not take the measurement while the vehicle's engine
is running.
5.Hold special tool MB992080 to the middle of the drive belt
between the pulleys (at the place indicated by arrow),
approximately 10 - 15 mm (0.4 - 0.59 inch) away from the rear
surface of the belt so that it is perpendicular to the belt (within
an angle of ± 15 degree).
6.Press the "MEASURE" button.
7.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 measure that the vibration frequency of the
belt is within the standard value.
Standard value: 128 - 165 Hz
When using scan tool MB991958: recommendation
Required Special Tools:
⦆MB991958: Scan Tool (M.U.T.-III Sub Assembly)
⦆MB991824: Vehicle Communication Interface (V.C.I.)
⦆MB991910: M.U.T.-III Main Harness A
GENERAL <BODY AND CHASSIS>
00-60
MAINTENANCE SERVICE
⦆MB991668: Belt Tension Meter Set
NOTE: The vibration frequency measuring method is
recommended for check and adjustment of the drive belt
tension.
To prevent damage to special tool MB991824, always turn
the ignition switch to the "LOCK" (OFF) position before
connecting or disconnecting special tool MB991824.
1.Connect special tool MB991668 to special tool MB991824.
2.Connect special tool MB991910 to special tool MB991824.
3.Connect scan tool MB991910 to the data link connector.
4.Turn the ignition switch to the "ON" position and select "Belt
Tension" from the menu special tool MB991824 screen.
10 − 20 mm
(0.4 − 0.8 in)
15˚
15˚
MB991668
Power steering
oil pump pulley
Tap lightly
with a finger
ZC6004510000
Tension gauge
Power steering
oil pump pulley
ZC6004520000
⦆The temperature of the surface of the belt should be as
close to normal temperature as possible.
⦆Do not allow any contaminants such as water or oil to get
onto the microphone.
⦆If strong gusts of wind blow against the microphone or if
there are any 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 correspond to actual values.
⦆Do not take the measurement while the vehicle's engine
is running.
5.Hold special tool MB991668 to the middle of the drive belt
between the pulleys (at the place indicated by the arrow),
about 10 - 20 mm (0.4 - 0.8 inch) away from the rear surface
of the belt and so that it is perpendicular to the belt (within an
angle of ± 15 degree angle).
6.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.
Standard value: 128 - 165 Hz
WHEN USING A TENSION GAUGE
Use a belt tension gauge to check that the belt tension is within
the standard value.
Standard value: 294 - 490 N (66 - 110 lb)
GENERAL <BODY AND CHASSIS>
00-61
MAINTENANCE SERVICE
Approximately
100 N (22 lb)
Belt deflection check
Apply approximately 100 N (22 lb) of force to the middle of the
drive belt between the pulleys (at the place indicated by the
arrow) and check that the amount of deflection is within the
standard value.
Standard value: 11.9 - 15.6 mm (0.47 - 0.61 in)
Power steering
oil pump pulley
ZC6004530000
Power steering drive belt tension adjustment
Adjusting bolt
Lock nut
ZC6003070000
If the tension or deflection is outside the standard value, adjust
by the following procedure.
1.Loosen the tensioner pulley lock nut.
2.Adjust the belt tension to the standard value by turning the
adjusting bolt. The tension will increase when turning the
adjusting bolt clockwise, and decrease when turning
counterclockwise.
Standard value:
Item
When adjusted When replaced
Vibration
frequency Hz
138 - 157
165- 196
Tension N (lb)
343 - 441
(77 - 99)
490 - 686
(110 - 154)
Deflection
12.7 - 14.6
(Reference) mm (0.50 - 0.57)
(in)
9.2 - 11.9
(0.36 - 0.47)
3.Tighten the lock nut to the specified torque.
Tightening torque: 47 ± 11 N·m (35 ± 8 ft-lb)
Check after turning the crankshaft one or more rotations
clockwise.
4.Check the belt deflection amount and tension, and readjust if
necessary.
5.When the belt tension is adjusted by measuring the belt
deflection, adjust it with a tool for vibration frequency
measurement or tension measurement afterward.
9. EXHAUST SYSTEM (CONNECTIONS PORTION
OF MUFFLER, MUFFLER PIPES AND CONVERTER
GENERAL <BODY AND CHASSIS>
00-62
MAINTENANCE SERVICE
HEAT SHIELDS) (CHECK AND SERVICE AS
REQUIRED)
M10001000058USA0000010000
1.Check for holes and exhaust gas leaks due to damage,
corrosion, etc.
2.Check the joints and connections for looseness and exhaust
gas leaks.
3.Check the rubber hangers and brackets for damage.
ZC6038990000
10. ENGINE OIL (CHANGE)
M10001000026USA0000010000
1.Start the engine and allow it to warm up until the temperature
of the coolant reaches 80 - 90°C (176 - 194°F).
Use care as oil could be hot.
2.Remove the engine oil filler cap.
3.Remove the drain plug to drain oil.
4.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 (29 ± 3 ft-lb)
Drain plug gasket
Engine
oil pan side
ZC601065AA00
5.Refill the specified quantity of oil.
Specified Engine Oil: Engine oils displaying ILSAC
certification symbol ("Starburst" symbol) or
conforming to the API classification SL, SL/CF or
higher
Total quantity: 4.3 dm3(4.5 quarts)
NOTE: SAE 5W-20 engine oil is strongly recommended for
ZC601066 AA00
optimum fuel economy and cold starting. If the ambient
temperature is not within the usable temperature range of
SAE 5W-30 shown in the above illustration, use SAE 10W-30
engine oil.
6.Install the engine oil filler cap.
GENERAL <BODY AND CHASSIS>
00-63
MAINTENANCE SERVICE
7.Pull out the oil dipstick, clean off the engine oil on the oil
dipstick, and then reinsert the oil dipstick.
8.Pull out the oil dipstick, and check the engine oil level is within
the marks on one side of the oil dipstick (engine cover side).
Oil dipstick (engine cover side)
Good
NOTE:
Maximum
Minimum
ZC604409 AA00
⦆Check might be difficult shortly after the engine stopping or
the engine oil replacement.
⦆If difficult, take some time (approx. 30 sec.) and try again.
⦆Information label indicating the engine oil check process on
the rocker cover.
9.Check that the engine oil is not excessively dirty, that there is
no coolant or gasoline mixed in, and that it is sufficiently thick
and slippery.
10.Start the engine and run it at idle for a few minutes.
11.Check the level range indicated on the dipstick.
11. ENGINE OIL FILTER (REPLACE)
M10001000027USA0000010000
The quality of replacement filters varies considerably. Only high
quality filters should be used to assure most efficient service.
Genuine oil filters require that the filter is capable of withstanding
a pressure of 1,765 kPa (256 psi) are high quality filters and are
recommended as follows:
Mitsubishi Oil Filter Part Number: MD332687,
MD365876, MD360935 or equivalent
Engine Oil Filter Selection
This vehicle is equipped with a full-flow, throw-away oil filter.
The same type of filter is recommended as a replacement filter
for this vehicle. It is possible, particularly in cold weather, that
this vehicle may develop high oil pressure for a short duration.
Make sure that any replacement filter used on this vehicle is a
high-quality filter. The filter must withstand a pressure of 1,765
kPa (256 psi) [manufacturer's specifications] to avoid filter and
ultimately engine damage. The following is a high-quality filter
and is strongly recommended for use on this vehicle: Mitsubishi
Engine Oil Filter Part number MD332687, MD365876 and
MD360935.
Any replacement oil filter should be installed in accordance with
the oil filter manufacturer's installation instructions.
Oil Filter Replacement
1.Start the engine and allow it to warm up until the temperature
of the coolant reaches 80 - 90°C (176 - 194°F)
Use care as oil could be hot.
2.Remove the engine oil filler cap.
3.Remove the drain plug to drain oil.
GENERAL <BODY AND CHASSIS>
00-64
MAINTENANCE SERVICE
4.Use the respective tool in the following table to remove the
engine oil filter.
Number
Special tool
MB991828,
MB991396
or equivalent
ZC6010810000
MD332687 or MD365876
Oil filter wrench (MB991828)
or equivalent
MD360935
Oil filter wrench (MB991396)
or equivalent
5.Clean the filter bracket side mounting surface and ensure the
old O-ring has been removed.
6.Apply a small amount of engine oil to the O-ring of the new oil
filter.
7.Screw on the oil filter by hand until it touches the surface of
the flange and then tighten it with an oil filter wrench.
Number
Special tool
Tightening torque
MD332687 or MB991828 or Approximately 3/4 turn [16 ±
MD365876
equivalent
4 N·m (12 ± 3 ft-lb)]
O-ring
ZC601082 0001
MD360935
MB991396 or Approximately one turn [14 ±
equivalent
2 N·m (124 ± 18 in-lb)]
8.Install the drain plug and refill engine oil (Refer to P.12-4).
9.Rev the engine a few times, and check to be sure that no
engine oil leaks at the oil filter.
12. TRANSMISSION FLUID
M10001000029USA0000010000
Check fluid level and condition
1.Drive the vehicle until the transmission fluid temperature rises
to the normal operating temperature [70 - 80°C (158 - 176°F)].
FLUID LEVEL [mm (in)]
20 (0.8)
NOTE: The transmission fluid temperature is measured
0 (0)
HOT
10 (0.4)
with scan tool MB991958.
NOTE: If it takes some amount of time until the
– 10 (– 0.4)
DIPSTICK
– 20 (– 0.8)
40
60
80
(104)
(176)
(140)
FLUID TEMPERATURE [°C (°F)] ZC602774AA00
transmission fluid reaches its normal operating
temperature [70 - 80°C (158 - 176°F)], check the
transmission fluid level by referring to the left
diagram.
2.Park the vehicle on a level surface.
3.Move the selector lever through all positions to fill the torque
converter and the hydraulic circuits with fluid, and then move
the selector lever to the "N" position.
4.After wiping off any dirt around the dipstick, remove the
dipstick and check the condition of the transmission fluid.
NOTE: If the transmission fluid smells as if it is burnt,
it means that the transmission fluid has been
contaminated by fine particles from the bushings and
friction materials. Transaxle overhaul and cooler line
flushing may be necessary.
GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-65
5.Check transmission fluid level is at the "HOT" mark on the
dipstick. If the transmission fluid level is less than this, add DIA
QUEEN J2 until the level reaches the "HOT" mark.
<Top side view>
<Back side view>
ZC6027800000
NOTE: If the transmission fluid level is too low, the oil
pump will draw in air along with the transmission fluid,
which will form bubbles. If the transmission fluid level
is too high, rotating components inside the transaxle
will churn the fluid and air into a foamy liquid. Both
conditions (level too low or too high) will cause the
hydraulic pressure to drop, which will result in late
shifting and slipping of the clutches and brakes.
NOTE: In either case, air bubbles can interfere with
normal valve, clutch, and brake operation. Also, foaming
can cause transmission fluid to escape from the transaxle
vent where it may be mistaken for a leak.
6.Securely insert the dipstick.
NOTE: The transmission fluid should always be replaced
under the following conditions:
⦆When troubleshooting the transaxle.
⦆When overhauling the transaxle.
⦆When the transmission fluid is noticeably dirty or burnt
(driving under severe conditions).
Change transmission fluid
If you have a transmission fluid changer, use this changer to
replace the transmission fluid. If you do not have a transmission
fluid changer, replace the transmission fluid by the following
procedure.
1.Disconnect the hose shown in the illustration which connects
the transaxle and the oil cooler (inside the radiator). Place a
container under the hose to collect the fluid.
Transmission fluid cooler
ZC6022350000
Drive shaft
The engine should be stopped within one minute after it is
started. If all the transmission fluid has drained out before
then, the engine should be stopped at that point.
2.Start the engine and let the transmission fluid drain out.
(Running conditions: "N" range with engine idling)
Approximately 3.5 dm3(3.7 quarts) of transmission
fluid should be removed.
3.Remove the drain plug from the bottom of the transaxle case
to drain the transmission fluid.
Approximately 2.0 dm3(2.1 quarts) of transmission
fluid should be removed.
4.Install the drain plug with a new gasket, and tighten it to the
specified torque.
ZC6013090000
GENERAL <BODY AND CHASSIS>
00-66
MAINTENANCE SERVICE
Tightening torque: 32 ± 2 N·m (23 ± 2 ft-lb)
Stop pouring if the full volume of transmission fluid cannot
be added.
5.Add new transmission fluid (DIA QUEEN J2) through the oil
filter tube.
Approximately 5.5 dm3(5.8 quarts) of transmission
fluid should be added.
6.Repeat the procedure in Step 2. (to pump out the rest of the
contaminated transmission fluid)
7.Add new transmission fluid (DIA QUEEN J2) through the oil
filter tube.
Approximately 3.5 dm3(3.7 quarts) of transmission
fluid should be added.
NOTE: Check for contamination or a burnt odor. If the
transmission fluid is still contaminated or burnt, repeat
Steps 6 and 7 before proceeding to Step 8.
8.Reconnect the hose which was disconnected in step 1 above,
and firmly insert the dipstick.
9.Start the engine and run it at idle for one to two minutes.
10.Move the selector lever through all positions, and then move
it to the "N" position.
Transmission fluid cooler
ZC6022350000
11.Check that the transmission fluid level is at the "COLD" mark
on the dipstick. If the level is less than this, add transmission
fluid.
<Top side view>
<Back side view>
ZC6027800001
FLUID LEVEL [mm (in)]
20 (0.8)
0 (0)
HOT
10 (0.4)
– 10 (– 0.4)
DIPSTICK
– 20 (– 0.8)
40
60
80
(104)
(176)
(140)
FLUID TEMPERATURE [°C (°F)] ZC602774AA00
12.Drive the vehicle until the transmission fluid temperature
rises to the normal operating temperature [70 - 80°C (158 176°F)], and then check the transmission fluid level again.
The transmission fluid level must be at the "HOT" mark.
NOTE: The transmission fluid temperature is measured
with scan tool MB991958.
NOTE: The "COLD" level is for reference only; the "HOT"
level should be regarded as the standard level.
NOTE: If it takes some amount of time until the
transmission fluid reaches its normal operating
temperature [70 - 80°C (158 - 176°F)], check the
GENERAL <BODY AND CHASSIS>
MAINTENANCE SERVICE
00-67
transmission fluid level by referring to the left
diagram.
13.If the transmission fluid is less than the specified level, add
transmission fluid.
If the transmission fluid is greater than the specified level,
drain the excess fluid through the drain plug to adjust the
transmission fluid to the specified level.
14.Firmly insert the dipstick into the oil filler tube.
13. TRANSFER OIL
M10001000030USA0000010000
Checking transfer oil level
Filler plug hole
Transfer oil
1.Remove the oil filler plug.
2.Check that the oil level is just below the lower edge of the oil
filler plug hole.
3.Check that the oil is not excessively foul and has moderate
viscosity.
4.Install the oil filler plug and tighten to the specified torque.
Tightening torque: 32 ± 2 N·m (23 ± 2 ft-lb)
Filler plug
ZC5016410000
Change transfer oil
Filler plug
Drain plug
Front exhaust pipe
ZC6022200000
1.Remove the oil drain plug to drain the transfer oil.
2.Install the oil drain plug and tighten to the specified torque.
Tightening torque: 32 ± 2 N·m (23 ± 2 ft-lb)
3.Remove the oil filler plug and fill the transfer oil up to the lower
edge of the oil filler plug hole.
Brand name: Hypoid gear oil API classification
GL-5 SAE 90
Filling amount: 0.53 dm3(0.56 quarts)
4.Install the oil filler plug and tighten to the specified torque.
Tightening torque: 32 ± 2 N·m (23 ± 2 ft-lb)
14. ENGINE COOLANT (CHANGE)
M10001000031USA0000010000
Check the cooling system parts such as the radiator, heater and
oil cooler hoses, thermostat and their connections for leakage
and damage.
GENERAL <BODY AND CHASSIS>
00-68
MAINTENANCE SERVICE
Change Coolant
Water feed
hose B
Front roll stopper
When removing the radiator cap, use care to avoid contact
with hot coolant or steam. Place a shop towel over the cap
and turn the cap counterclockwise a little to let the pressure
escape through the vinyl tube. After relieving the steam
pressure, remove the cap by slowly turning it
counterclockwise.
1.Remove the radiator cap and drain plug to drain the coolant.
2.Remove the water feed hose B, and drain the coolant in the
water jacket.
3.Remove the radiator condenser tank assembly 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.
5.Install the water feed hose B.
6.Securely tighten the radiator drain plug.
7.Assemble the radiator condenser tank assembly.
ZC602730AA00
MB991871
Air hose
ZC602532 AA00
⦆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
aluminum components.
⦆Vehicles for California emission regulation: If the coolant
contact the PremAir® direct ozone reduction (DOR)
radiator, wash it with water at once.
8.By referring to the section on coolant, select an appropriate
concentration for safe operating temperature within the range
of 30 to 60 %. Use special tool MB991871 to refill the coolant.
A convenient mixture is a 50 % water and 50 % antifreeze
solution [freezing point: -31°C (-24 °F)].
Recommended antifreeze: Long Life Antifreeze
Coolant or an equivalent
Quantity:
9.5 dm3(10.0 quarts)
10.0 dm3(10.6 quarts) <Vehicles with Towing
Package or DOR radiator>
9.Reinstall the radiator cap.
10.Start the engine and let it warm up until the thermostat opens.
11.After repeatedly revving the engine up to 3,000 r/min several
times, stop the engine.
12.Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
Do not overfill the radiator condenser tank assembly.
13.Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
GENERAL <BODY AND CHASSIS>
00-69
MAINTENANCE SERVICE
15. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT)
M10001000097USA0000010000
Inspect the surface of radiator hoses and heater hoses for heat
and mechanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indicate
deterioration of the rubber.
16. DISC BRAKE PADS (INSPECT FOR WEAR)
M10001000032USA0000010000
Check for fluid contamination and wear. Replace the complete
set of pads if any one pad is defective.
Thickness of lining
Minimum limit: 2.0 mm (0.08 in)
The pads for the right and left wheels should be replaced at
the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.
ZC6011040000
17. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS)
M10001000034USA0000010000
Inspection of brake hoses should be included in all brake service
operations.
The hoses should be checked for:
1.Incorrect length, severe surface cracking, pulling, scuffing or
worn spots. (If the fabric casing of the hoses is exposed by
cracks or abrasion in the rubber hose cover, the hoses should
be replaced. Eventual deterioration of the hose and possible
bursting failure may occur).
2.Incorrect installation, twisting or interference with wheel, tire
or chassis.
18. BALL JOINT AND STEERING LINKAGE SEALS
(INSPECT FOR GREASE LEAKS AND DAMAGE)
M10001000035USA0000010000
1.These components, which are permanently lubricated at the
factory, do not require periodic lubrication. Damaged seals
and bellows should be replaced to prevent leakage or grease
contamination.
2.Inspect the dust cover and bellows for proper sealing, leakage
and damage, and replace them if defective.
Bellows
Dust cover
ZC6011060000
GENERAL <BODY AND CHASSIS>
00-70
MAINTENANCE SERVICE
19. DRIVE SHAFT BOOTS (INSPECT FOR GREASE
LEAKS AND DAMAGE)
M10001000036USA0000010000
1.These components, which are permanently lubricated at the
factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
contamination.
2.Inspect the boots for proper sealing, leakage and damage.
Replace them if defective.
Boots
ZC0001090000
20. SUSPENSION SYSTEM (INSPECT FOR
LOOSENESS AND DAMAGE)
M10001000096USA0000010000
Visually inspect the front/rear suspension components for
deterioration and damage. Re-tighten the front/rear suspension
components retaining bolts to specified torque.
21. REAR AXLE OIL (CHECK OIL LEVEL)
M10001000075USA0000010000
Rear differential oil check
1.Remove the filler plug.
2.Check that gear oil level is not 8 mm (0.3 inch) below the
bottom of filler plug hole.
3.Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 N·m (23 ± 2 ft-lb)
Gear oil
Upper
limit
Lower
limit
8 mm (0.3 in)
ZC6011100000
GENERAL <BODY AND CHASSIS>
00-71
MAINTENANCE SERVICE
22. TIRES (ROTATE)
M10001000089USA0000010000
ZC6011110000
Rotate tires regularly to equalize tire wear and help extend tire
life. Recommended tire rotation is every 12,000 km (7,500
miles).
Timing for the rotation may vary according to vehicle condition,
road surface conditions, and individual driver's habits.
When rotating tires, check for uneven wear, damage, and wheel
alignment. Abnormal wear is usually caused by incorrect tire
pressure, improper wheel alignment, out-of balance wheels, or
severe braking.
The first rotation is the most important, to achieve more uniform
wear for all tires on the vehicle.
23. AIR FILTER (REPLACE)
M10001000090USA0000010000
1.Remove the glove box. (Refer to GROUP 52A - Instrument
Panel Removal and Installation P.52A-2)
2.Remove the two screws as shown, and replace the clean air
filter.
3.Install the glove box.
MAIN SEALANT AND ADHESIVE TABLE
M10001000038USA0000010000
Application
3M™ No.
Loctite®/
permatex®No.
ENGINE AND Between rocker cover and
DRIVETRAIN
camshaft
bearing
cap.
Between
rocker
cover,
semicircular packing and
cylinder head. Between oil
pressure switch and engine.
3M™ AAD Part No. 08672 Permatex®Ultra Black 598,
Ultrapro High Temp. Silicone No.82180
Gasket or 3M™ AAD Part No.
8679
Black/8678
Black
Press-In-Place
Silicone
gasket strips
Between engine coolant 3M™ AAD Part No. 08731 Loctite®242 Blue Service
temperature switch, engine Medium
Strength
Blue Tool Removable 24200
coolant temperature sensor, Threadlocker
thermo valve, thermo switch,
joint,
engine
coolant
temperature
gauge
unit
(large-size) and engine
Between oil pan and engine 3M™ AAD Part No. 08672, Permatex®Ultra Gray 599,
block
3M™ AAD Part No. 08704 or No.82194
3M™
AAD
Part
No.
08679/8678
WEATHERSTRI Between tempered
PPING
FOR body
flanges,
GLASS
weatherstrip
glass, 3M™ AAD Part No. 08509 and Auto Bedding and Glazing
Compound or 3M™ AAD Part
No.
08633
Windo-weld
Resealant
00-72
GENERAL <BODY AND CHASSIS>
MAIN SEALANT AND ADHESIVE TABLE
Application
3M™ No.
Loctite®/
permatex®No.
WEATHERSTRI Between laminated glass and 3M™ AAD Part No. 08633
PPING
FOR weatherstrip
GLASS
INTERIORS
-
Adhesive of vinyl chloride 3M™ AAD Part No. 08088 Permatex®Vinyl Repair Kit
cloth
General Trim Adhesive or No.81786
3M™ AAD Part No. 08064
Vinyl Trim Adhesive
Adhesion of door weatherstrip 3M™ AAD Part No. 08001 Permatex®Super
Black
(yellow) or 3M™ AAD Part Weatherstrip Adhesive No.
No. 08008 (black) Super 82, 81850
Weatherstrip Adhesive or
3M™ AAD Part No. 08011
Black Weatherstrip Adhesive
Sealing of various grommets 3M™ AAD Part No. 08509 or and packing
3M™ AAD Part No. 8678
Adhesion of headliners and 3M™ AAD Part No. 08088 Permatex®Spray
various interior decorative General Trim Adhesive or Adhesive No.82019
materials
3M™ AAD Part No. 08090
Super Trim Adhesive
BODY
SEALANTS
Sealing of sheet metal joints,
drip rail, floor, side panels,
trunk, front panel, tail gate
hinge
3M™ AAD Part No. 08531 Heavy Drip-Check Sealer
(gray) or 3M™ AAD Part No.
08302 Ultrapro Autobody
Sealant (clear) or 3M™ AAD
Part No. 08361 Urethane A/B
Sealant (gray or white)
Miscellaneous body sealants 3M™ AAD Part No. 08633 (original mounted
Windo-weld Resealant
w/adhesive tape)
⦆Waterproof door film
⦆Fender panel
⦆Splash shield
⦆Mud guard
⦆Rear combination light
Fuel Tank and Pad
CHASSIS
SEALANT
3M™ AAD Part No. 08088 Permatex®Spray
General Trim Adhesive or Adhesive No.82019
3M™ AAD Part No. 08090
Super Trim Adhesive
Sealant of various flange 3M™ AAD Part No. 08730 Loctite®272 High Strength
faces and threaded parts.
High
Strength
Red and High Temperature
Packing of fuel gauge unit
Threadlock or 3M™ AAD Part 27200
No. 08731 Medium Strength
Blue Threadlocker
GENERAL <BODY AND CHASSIS>
00-73
MAIN SEALANT AND ADHESIVE TABLE
Application
3M™ No.
Loctite®/
permatex®No.
Sealing of various threaded
parts, dust covers.
Differential carrier packing,
dust covers and ball joint and
linkage. Packing and shims of
steering box, sealing of rack
support cover and top cover of
steering box housing, seal of
junction face of knuckle arm
flange
3M™ AAD Part No. 08672 Permatex®The Right Stuff
Ultrapro High Temp. Silicone No.25223
Gasket or 3M™ AAD Part No.
8679 (black) or 3M™ AAD
Part No. 8678 (black) PressIn-Place Silicone gasket
strips 3M™ AAD Part No.
08661 or 3M™ AAD Part No.
08663 Super Silicone sealant
Seal of brake shoe hold down 3M™ AAD Part No. 08633 pin and wheel cylinder of Windo-weld Resealant
drum brakes
QUICK
FIX ADHESIVE
3M™ AAD Part No. 08155 Loctite®Quicktite
Quick Fix Adhesive
Glue 21309
ANAEROBIC
STRONG
SEALING
AGENT
Fixing of various threads,
bolts, screws. Fixing of
differential drive gear bolt,
Connecting of tilt steering
bolt. Fan, pulley, gear Sealing
of small gaps and flange faces
3M™ AAD Part No. 08730 Loctite®271,
HighHigh Strength Threadlocker Strength
Threadlocker
or 3M™ AAD Part No. 08731 27100 or 27200
Medium
Strength
Threadlocker
UNDER
COATING
AGENT
-
3M™ AAD Part No. 08883 Permatex®Heavy-Duty
Rubberized
Undercoating Undercoating 81833
Aerosol or 3M™ AAD Part No.
08864
Body
Schutz
Undercoating (qt)
Super
00-74
MEMO
GENERAL <BODY AND CHASSIS>
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement