Outlander

0-1
GROUP 0
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 0-2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-3
PRECAUTIONS BEFORE SERVICE. 0-2 SERVICING THE ELECTRICAL SYSTEM . 0-4
PROTECTING THE VEHICLE . . . . . . . . . . 0-2 APPLICATION OF ANTI-CORROSION
DOING SERVICE WORK IN GROUPS AGENTS AND UNDERCOATS . . . . . . . . . . 0-4
OF TWO OR MORE MECHANICS . . . . . . . 0-2 PRE-INSPECTION CONDITION . . . . . . . . . 0-4
REMOVAL AND DISASSEMBLY . . . . . . . . 0-2 VEHICLE WASHING . . . . . . . . . . . . . . . . . . 0-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 0-3 MULTI USE TESTER (M.U.T.-III)
PARTS TO BE REPLACED . . . . . . . . . . . . 0-3 SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 0-4
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 IN ORDER TO PREVENT VEHICLES
FROM FIRE . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
TUBES AND OTHER RUBBER PARTS . . . 0-3
ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 0-5
0-2 GENERAL
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

M6000000100060
This manual contains Pre-delivery inspection and Group 0 and 1 have the contents for all vehicle mod-
Periodic inspection and maintenance. els, and Group 2 has contents for the relevant vehi-
cle models.
PRECAUTIONS BEFORE SERVICE

PROTECTING THE VEHICLE REMOVAL AND DISASSEMBLY
M6001000100041 M6001000300045
AC305590 AC305591
If there is a likelihood of damaging interior or exterior When checking a malfunction, find the cause of the
parts during service operations, protect them with problem. If it is determined that removal and/or dis-
suitable covers (such as seat covers, fender covers, assembly is necessary, perform the work by following
etc.). the procedures contained in this manual.
DOING SERVICE WORK IN GROUPS OF

TWO OR MORE MECHANICS
M6001000200048
AC305592
If punch marks or mating marks are made to avoid

error in assembly and facilitate the assembly work,
AC305283 be sure to make them in locations which will have no
detrimental effect on performance and/or appear-
If the service work is to be done by two or more ance. If an area having many parts, similar parts,
mechanics working together, all the mechanics and/or parts which are symmetrical right and left is
involved should take safety into consideration while disassembled, be sure to arrange the parts so that
they work. they do not become mixed during the assembly proc-
ess.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which
are to be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to
use only the exact size specified.
GENERAL
0-3
SPECIAL TOOLS When replacing parts, use MITSUBISHI genuine
M6001000400053 parts.
TUBES AND OTHER RUBBER PARTS

M6001000700043
AC305593
If other tools are substituted for the special tools to

do service of repair work, there is the danger that AC305595
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe- Be careful to avoid spilling any petrol, oil, etc.,
cial tool whenever doing any work for which the use because if it adheres to any tubes or other rubber
of one is specified. parts, they might be adversely affected.
PARTS TO BE REPLACED LUBRICANTS

M6001000800040
M6001000500049
AC305594 AC305596
If any of the following parts are removed, they must In accordance with the instructions in this manual,
be replaced with new parts. apply the specified lubricants in the specified loca-
• Oil seals tions during assembly and installation.
• Gaskets (except rocker cover gasket)
• Packings BRAKE FLUID
M6001000900047
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
PARTS
M6001000600046
AC305285
Be careful to avoid spilling any brake fluid, because if

it adheres to the vehicle body, the paint coat might be
discoloured.
AC305284
0-4 GENERAL
SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING

M6001001000047 M6001001300048
Approx.
40 cm
ACX00880AD ACX00881AE
Before replacing a component related to the electri- If high-pressure car-washing equipment or steam
cal system and before undertaking any repair proce- car-washing equipment is used to wash the vehicle,
dures involving the electrical system, be sure to first be sure to note the following information in order to
disconnect the negative (-) cable from the battery in avoid damage to plastic components, etc.
order to avoid damage caused by short-circuiting. • Spray nozzle distance: Approx. 40 cm or more
CAUTION • Spray pressure: 3,900 kPa or less
Before connecting or disconnecting the negative • Spray temperature: 82°C or less
(-) cable, be sure to turn off the ignition switch • Time of concentrated spray to one point: within
and the lighting switch. (If this is not done, there 30 sec.
is the possibility of semiconductor parts being
damaged.)
MULTI USE TESTER (M.U.T.-III) SUB
ASSEMBLY
APPLICATION OF ANTI-CORROSION M6001001900125
Refer to the "M.U.T.-III OPERATING INSTRUC-
AGENTS AND UNDERCOATS TIONS" for instructions on handling the M.U.T.-III.
M6001001100055
If oil or grease gets onto the oxygen sensor, it will AC302297
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
M6001001200052
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec- MB991910
tion can be carried out. If you see the words "Set the
vehicle to the pre-inspection condition" in this man- Diagnosis connector
ual, it means to set the vehicle to the following condi-
MB991824
tion.
• Engine coolant temperature: 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
• A/T: P range
MB991827 AC601854AB
Connect the M.U.T.-III to the diagnosis connector as

shown in the illustration.
CAUTION
Turn the ignition switch to the LOCK (OFF) posi-
tion before connecting or disconnecting the
M.U.T.-III.
GENERAL
0-5
IN ORDER TO PREVENT VEHICLES Other precautions:
FROM FIRE • Avoid prolonged and repeated contact with oils,
M6001001500097 particularly used engine oils.
"Improper installation of electrical or fuel related parts • Wear protective clothing, including impervious
could cause a fire. In order to retain the high quality gloves where practicable.
and safety of the vehicle, it is important that any • Avoid contaminating clothes, particularly under-
accessories that may be fitted or modifica- pants, with oil.
tions/repairs that may be carried out which involve • Do not put oily rags in pockets, the use of overalls
the electrical or fuel systems, must be carried out in without pockets will avoid this.
accordance with MMC's information/Instructions". • Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
ENGINE OILS cleaned regularly and kept separately from per-
M6001001600094
sonal clothing.
HEALTH WARNING • Where there is a risk of eye contact, eye protec-
Prolonged and repeated contact with mineral oil will tion should be worn, for example, chemical gog-
result in the removal of natural fats from the skin, gles or face shields; in addition an eye wash
leading to dryness, irritation and dermatitis. In addi- facility should be provided.
tion, used engine oil contains potentially harmful con- • Obtain first aid treatment immediately for open
taminants which may cause skin cancer. Adequate cuts and wounds.
means of skin protection and washing facilities must • Wash regularly with soap and water to ensure all
be provided. oil is removed, especially before meals (skin
cleansers and nail brushes will help). After clean-
RECOMMENDED PRECAUTIONS ing, the application of preparations containing
The most effective precaution is to adapt working lanolin to replace the natural skin oils is advised.
practices which prevent, as far as practicable, the • Do not use petrol, kerosine, diesel fuel, gas oil,
risk of skin contact with mineral oils, for example by thinners or solvents for cleaning skin.
using enclosed systems for handling used engine oil • Use barrier creams, applying them before each
and by degreasing components, where practicable, work period, to help the removal of oil from the
before handling them. skin after work.
• If skin disorders develop, obtain medical advice
without delay.
NOTES
1-1
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-10

13. TYRE AND SPARE TYRE
PAINTWORK TERMS . . . . . . . . . . . . 1-5 PRESSURES . . . . . . . . . . . . . . . . . . . . . . . 1-10
14. SUSPENSION SYSTEM . . . . . . . . . . . . 1-11
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 15. STEERING LINKAGE AND
1. CONNECTION OF DARK CURRENT SPLIT PINS . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 1-6 16. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-11
BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 BEFORE ROAD TEST . . . . . . . . . . . . 1-12

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-6 17. SEAT ADJUSTERS AND
3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-8 SEATBACK LATCHES . . . . . . . . . . . . . . . . 1-12
4. OPERATION OF DOOR LOCKING 18. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-12
SYSTEMS AND DOOR HINGES . . . . . . . . 1-8 19. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-12
5. OPERATION OF DOOR MIRRORS, 20. INSTRUMENT PANEL CONTROLS . . . 1-12
WINDOWS AND SUNROOF . . . . . . . . . . . 1-8 21. METERS, GAUGES, WARNING LAMPS
AND INDICATION LAMPS . . . . . . . . . . . . . 1-12
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-9 22. AIR CONDITIONER, HEATER AND
6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-9 DEFROSTER SYSTEM. . . . . . . . . . . . . . . . 1-12
7. BRAKE MASTER CYLINDER FLUID 23. WIPERS AND WASHERS. . . . . . . . . . . 1-13
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 24. OPERATION OF SERVICE BRAKES
8. CLUTCH MASTER CYLINDER FLUID AND PARKING BRAKES . . . . . . . . . . . . . . 1-13
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 25. CLUTCH OPERATION . . . . . . . . . . . . . 1-13
9. WASHER FLUID LEVEL. . . . . . . . . . . . . 1-9 26. OPERATION OF SEAT BELTS,
10. BATTERY CONDITION AND SHOULDER BELTS AND RETRACTORS . 1-14
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-10
11. POWER STEERING FLUID LEVEL . . . 1-10 Continued on next page
12. ELECTRICAL WIRING . . . . . . . . . . . . . 1-10
1-2
ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-14 38. AUTOMATIC TRANSMISSION

27. ENGINE PERFORMANCE AND FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-17
EXHAUST GAS. . . . . . . . . . . . . . . . . . . . . . 1-14 39. ENGINE, TRANSMISSION,
STEERING GEAR BOX AND
28. TRANSMISSION IN ALL RANGES. . . . 1-14
DIFFERENTIAL FOR LEAKS . . . . . . . . . . . 1-17
29. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-15
40. FRONT AND REAR DIFFERENTIAL
30. STEERING CONTROL . . . . . . . . . . . . . 1-15 OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . 1-17
31. VIBRATION AND RATTLES . . . . . . . . . 1-15 41. HOSES, FLUID LINES AND
32. ELECTRICAL EQUIPMENT . . . . . . . . . 1-15 CONNECTIONS LOCATED UNDER
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
AFTER ROAD TEST . . . . . . . . . . . . . 1-16
33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-16 FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-18
34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-16 42. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-18
35. RADIATOR COOLANT LEVEL . . . . . . . 1-16 43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-18
36. HOSES, FLUID LINES AND 44. EXTERIOR AND INTERIOR . . . . . . . . . 1-18
CONNECTIONS LOCATED UNDER HOOD 1-16 45. OWNER INSTRUCTIONS . . . . . . . . . . . 1-18
37. MANUAL TRANSMISSION AND
TRANSFER (4WD) OIL LEVEL . . . . . . . . . 1-16
PRE-DELIVERY INSPECTION
NOTES CONCERNING ENTRIES
1-3
M6010100100187
This section describes the details and the inspection methods employed for the pre-delivery inspection of
vehicles.
The inspection should be conducted according to the sequence described in the TABLE OF PRE-DELIVERY
INSPECTION.
Inspection methods are described following the TABLE OF PRE-DELIVERY INSPECTION.
NOTE: The spaces for model, C/# (Chassis number), E/# (engine number), aggregate distance travelled in
kilometres (miles), date of inspection, name of person conducting the inspection, and body colour must be
completed without fail.
NOTE: The spaces for place of inspection, and name of owner should be completed as required.
1-4 PRE-DELIVERY INSPECTION
TABLE OF PRE-DELIVERY INSPECTION
Model
Chassis number
Engine number Before Road Test
Distance Travelled km 17. Seat adjusters and seat back latches
Owner 18. Choke system and inhibitor switch
Date of inspection
19. Idle control knob
Place of inspection
20. Instrument panel controls
Inspector
21. Meters, gauges, warning lamps and indication lamps
Body colour
22. Air conditioning, heater and defroster systems
Symbols to be used 23. Wipers and washers
24. Operation of service brakes and parking brakes
Needs Needs
Good A T 25. Clutch operation
adjustment retightening
26. Operation of seat belts, shoulder belts and retractors
Needs
Needs
Needs replenishment Road Test
C L X replenishment
cleaning of lubricant,
of repair 27. Engine performance and exhaust gas
water, etc.
28. Transmission in all ranges
INSPECTION PROCEDURE
29. Brakes
First Step
30. Steering control
1. Connection of the dark current connector
31. Vibration and rattles
Body
32. Electrical equipment
2. Wrap film
3. Exterior
After Road Test
4. Operation of door locking systems and door hinges
33. Idle speed
5. Operation of door mirrors, windows and sunroof
34. Ignition timing
Under Hood
35. Radiator coolant level
6. Engine oil level
36. Hoses, fluid lines and connections located under hood
7. Brake master cylinder fluid level
37. Manual transmission and transfer (4WD) oil level
8. Clutch master cylinder fluid level
38. Automatic transmission fluid level
9. Washer fluid level
39. Engine, transmission, steering gear box and
10. Battery condition and connections differential for leaks
11. Power steering fluid level 40. Front and rear differential oil levels
12. Electrical wiring 41. Hoses, fluid lines and connections located under vehicle
Under Vehicle Final Steps
13. Tyre and spare tyre pressures 42. Headlamp aiming
14. Suspension system 43. Equipment
15. Steering linkage and split pins 44. Exterior and interior
16. Under body 45. Owner instructions
AC401525
AC306353
PAINTWORK TERMS
1-5
PAINTWORK TERMS
M6010200100054
Term Definition Remarks

Blister A raised bubble in the paint (from the base
or the undercoat) caused by abnormal
moisture. The bubble may contain either
water or air.
Change in tone The colour tone of the painted surface is not Including wrong colour, discoloration and
uniform. decoloration.
Contact mark A mark on the painted surface as a result of
contact by hands or clothing at the time of
paint application.
Crack A crack in the painted surface. Cracks may be either shallow or deep.
Dirt in paintwork Rough surface resulting from foreign
material in the paint or from dust deposited
on wet paint during painting or storage.
Filed or ground Deep scratches in sheet metal surface,
traces resulting from improper use of buffer or
sander, are not completely covered, and are
visible through paint coating.
Orange peel The painted surface has the appearance of
an orange peel.
Peeling The paint flakes off (partly or over a wide The peeling may be minor, medium, or
area). major.
Pin holes Tiny holes in the painted surface.
Runs A visible trickle of dried paint on the surface. Either undercoat or top-coat.
Scratches Scratches on the painted surface.
Shrink The painted surface "shrinks", causing
wrinkles.
Smears Spots of soot or other material deposited on Including stains and water spots.
the painted surface.
Spray mist The painted surface includes fine particles of
other paint.
Uneven lustre The lustre of the painted surface is not
uniform.
Uneven metallic The metallic dispersion of the painted
dispersion surface is not uniform.
Visibly incomplete A part of the undercoating visible.
topcoating
FIRST STEP
FIRST STEP
1. CONNECTION OF DARK CURRENT Press down the storage connector.
CONNECTOR
M6010300100181
CONNECTING PROCEDURE
Relay box Storage connector
AC602562AB
BODY
2. WRAP FILM To protect the exterior finish of vehicles prior to
M6010400100069 dealer delivery, a protective coating is used. The
coating is a thin white resin film. It is applied to all
painted exterior horizontal surfaces of the vehicle
and is held in place with a tacky adhesive backing.
AC305606
BODY
1-7
Removal procedure
Peel off slowly from corners keeping parallel to the body. When
Wrap film removal the body temperature is high, lower it to 50ºC or less by
sprinkling water so that adhesive may not remain on the body.
Water washing
Wipe-off by kerosene or white gasoline, etc.

Cleaning of border
If it is considerably visible, use polishing compound.
Disposal of removed film: Burning is appropriate
AC306352 AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are There should be no leftover adhesive, swelling or
checked. discoloration of the paint film, or other defects.
4 Treatment of parts where film is to be Treat the defects on the parts where film is to be
reapplied. reapplied. If a solvent is used to remove leftover
adhesive, wipe off the solvent thoroughly.
5 Reapplication 1. Basically, the parts where the film is to be applied
should be the same as the film that is to be applied.
2. Apply the film from the lower portion of the body,
working upward progressively. Apply pressure using
a plastic squeegee or similar tool.
3. As necessary, cut the film at the various parts such as
windshield washer nozzles, hood and trunk lid.
CAUTION
• Apply the film with the body at a temperature of 10 − 40°C. (Workability is good in this temperature
range.)
• If the outside surface of the film (the side with no adhesive) is brought into direct contact with the
paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not
get folded under or otherwise make contact with the paint film.
• Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort
should be made to prevent air bubbles from being trapped under the film by applying pressure
from the centre of the film outward toward the edges during application.
• To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of
the film securely.
BODY
3. EXTERIOR 4. Partially close the door to check the open-door

M6010400200118 detent.
5. Unlock each door with the key to check lock
operation.
6. Verify that all doors can be locked by the lock
buttons.
NOTE: Adjust and lubricate the door latches,
strikers and locks as required.
AC305607
1. Visually inspect the entire exterior.

(1) Paint condition
(2) Corrosion, scratches
(3) Bent edges, dented panels
2. Coated surfaces maintenance Child-protection knob
Touch up minor paint chips and flaws. AC305610 AB
(Refer to Paintwork terms) 7. Verify that the rear doors can't be opened by the
inner door handle when the child protection knob
4. OPERATION OF DOOR LOCKING at the end of the door is shifted to the "LOCK"
SYSTEMS AND DOOR HINGES position with the inside lock plunger raised.
M6010400300096
CAUTION
Set the lock to the "FREE" position on child pro-
tection of both rear doors. (For four door models)
5. OPERATION OF DOOR MIRRORS,

WINDOWS AND SUNROOF
M6010400400048
Front
AC305608 AB
AC305607
1. Door mirrors
Check that the mirror operate properly.
AC210253AB 2. Door windows
Close all door windows to the fully closed position
1. Open each door to check the release mechanism to check ease of operation.
and ease of operation. 3. Power windows
2. Close the door to check the latch and striker. Check that the door windows operate when the
3. Open the door, operate the lock lever and close respective switches are operated. Check that
the door to check the lock. when the lock switches are depressed, the
respective door windows can no more be opened
or closed.
UNDER HOOD
1-9
4. Slide window 5. Sunroof
Close the slide window to the fully closed position Close the sunroof to the fully closed position to
to check operation. check operation.
UNDER HOOD
6. ENGINE OIL LEVEL 8. CLUTCH MASTER CYLINDER FLUID
M6010500100044
LEVEL
M6010500300071
MAX
MIN
AC305611 AB
Check that the oil level is between "MAX" and "MIN". AC305613
If it is at or below MIN, add the necessary amount of Check the fluid level.
the specified engine oil referring to GROUP 2, Peri- If it is below the "MIN" mark, replenish fresh brake
odic Inspection and Maintenance P.2-3. fluid up to the "MAX" mark.
7. BRAKE MASTER CYLINDER FLUID Specified Brake Fluid: DOT3 or DOT4
LEVEL 9. WASHER FLUID LEVEL
M6010500200085 M6010500400045
AC305612 AC305614
Check the fluid level. Check the fluid level; if it is low, replenish the washer
If it is below the "MIN" mark, replenish fresh brake fluid at the up to MAX mark.
fluid up to the "MAX" mark. 1. Windshield washer reservoir
Specified Brake Fluid: DOT3 or DOT4 2. Rear window washer reservoir
UNDER VEHICLE
10. BATTERY CONDITION AND 2. If the fluid is added, start the engine and turn the
CONNECTIONS steering wheel from stop to stop several times to
M6010500500097 expel air from the system.
Specified gear oil: Automatic transmission
fluid DEXRON III or DEXRON II
12. ELECTRICAL WIRING

M6010500700046
AC305615
Inspect the battery connections. Verify that they are

tightened.
NOTE: Do not wipe the lubricant from the battery
posts and cable clamps. AC305617
11. POWER STEERING FLUID LEVEL 1. Each electrical wiring harness and connector
M6010500600146
(1) Check each harness to be correctly routed
and securely clipped.
(2) Confirm that all connections are tight.
2. Ignition cable
Be sure that all ignition cables are firmly attached
to the spark plugs, distributor cap (or crank angle
sensor) and ignition coil.
AC305616
1. Check that the fluid level is between "MAX" and

"MIN".
UNDER VEHICLE
13. TYRE AND SPARE TYRE PRESSURES 1. Tyre specification
M6010600100096 Check the correct tyre specification.
2. Tyre pressures
Adjust each tyre pressure.
NOTE: Recommended pressure is shown on the
tyre pressure label.
3. Valve stem extensions
Verify that the valve stem extensions are installed
where necessary.
4. Install the wheel covers, wheel rings and hub
AC305618 caps.
UNDER VEHICLE
1-11
14. SUSPENSION SYSTEM 15. STEERING LINKAGE AND SPLIT PINS
M6010600200048 M6010600300045
AC305609 AC305604
Check to be sure that each installation bolt and nut is 1. Steering linkage retaining nuts and split pins
tightened. If split pins are used, make sure that they Check visually and by feel that the steering
are properly installed. linkage retaining nuts are correctly tightened and
1. Lower arm, Upper arm the split pins are correctly installed.
2. Stabilizer bar 2. Tie rods and relay rod
3. Strut assembly Check that the tie rods and relay rod of the
REMOVE FRONT SPRING RESTRAINTS steering linkage are not bent and that the tie rod
end lock nuts are securely tightened.
Spring 3. Steering components
restraints (1) Check that each of the steering components is
tightened.
(2) Check the tie rod end, nuts and split pins for
proper installation.
(3) Check the condition of bellows-type dust
seals.
4. Split pins
AC305605 Check the front axle nuts and rear wheel spindle
With the vehicle correctly positioned on the nuts for split pins.
sub-frame contact points, and the suspension fully
extended, remove the rubber restraints from the front
16. UNDER BODY
M6010600400042
springs. Check under body and under body coating for dam-
CAUTION age.
It is very important that these restraints must be
removed during predelivery-inspection. Failure
to do so could cause ride and handling com-
plaints.
BEFORE ROAD TEST
BEFORE ROAD TEST

17. SEAT ADJUSTERS AND SEATBACK 1. Check the meters and gauges are functioning
LATCHES properly.
M6010700100101 2. Check each indicator lamp and warning lamp
functions properly.
22. AIR CONDITIONER, HEATER AND

DEFROSTER SYSTEM
M6010700600054
Check the systems for proper operation.
AC305622
Check the operation of the various parts of the seats.

1. Mechanical adjusters of the seats
2. Operation of the latch for tilting the seatbacks
forward and backward.
18. INHIBITOR SWITCH AC305625
M6010701100041
On models with an automatic transmission, be sure 1. Air conditioner
the engine starts in both "P" and "N" position, and (1) Operate the air conditioner system.
does not start in other positions. (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
19. IDLE CONTROL KNOB (4) Operate the blower motor switch in all ranges.
M6010700300042
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.
20. INSTRUMENT PANEL CONTROLS

M6010700400102
Check the operation of the following
1. Horn
2. Headlamps
3. Exterior and interior lamps
4. Instrument panel lamps AC305626
5. Instrument brightness control

2. Heater and defroster
21. METERS, GAUGES, WARNING (1) After the engine has warmed up, turn on the
heater.
LAMPS AND INDICATION LAMPS
M6010700500046 (2) Operate the blower motor switch in all ranges.
(3) Move the control to "Defrost" position.
A: From front and side defroster
B: From centre ventilators
C: From side ventilators
D: From under the instrument panel
E: From under the front seat (some models only)
AC305624
BEFORE ROAD TEST
1-13
23. WIPERS AND WASHERS
M6010700700040
AC305629
AC305627 (2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the
1. Front wiper and washer service brake, refer to GROUP 2, Periodic
(1) Check operation of the front wipers in all Inspection and Maintenance P.2-3.
ranges. 2. Parking brake
(2) Check the aim of the front washer stream. Check the parking brake drag and lever travel.
(3) Check the wiper blade-stop positions. NOTE: For inspection and adjustment of the park-
(4) Verify that the interval between cycles of ing brake, refer to GROUP 2, Periodic Inspection
wiping is shifted when timer knob is turned to and Maintenance P.2-3.
any position.
(5) Verify that the front wipers function by 25. CLUTCH OPERATION
operating the washer switch. M6010700900226
2. Rear wiper and washer

(1) Check the operation of the rear wiper.
(2) Check the aim of the rear washer stream.
(3) Check the wiper blade-stop positions.
24. OPERATION OF SERVICE BRAKES

AND PARKING BRAKES
M6010700800218
AC305630
1. Check the clutch operation in all driving ranges.

Depress the brake pedal
with approximately 500
2. Check the pedal to floorboard clearance when the
N force clutch is just disengaged.
AC305628 AB
1. Service brakes
(1) Check the clearance between the brake pedal
and the floorboard when the brake pedal is
depressed.
AC305631
3. Verify correct clutch pedal free play.

NOTE: For inspection and adjustment of the
clutch pedal, refer to GROUP 2, Periodic Inspec-
tion and Maintenance P.2-3.
ROAD TEST
26. OPERATION OF SEAT BELTS, 1. Verify that the seat belt warning lamp operates
SHOULDER BELTS AND RETRACTORS properly.
M6010701000044 2. Check all seat belts and harnesses to assure that
they connect and hold properly.
3. Lean forward to check that the shoulder
harnesses allow movement.
4. Check the condition of the belts and anchors.
5. Check for proper seat belt retraction.
AC305632
ROAD TEST
27. ENGINE PERFORMANCE AND 28. TRANSMISSION IN ALL RANGES
M6010800200042
EXHAUST GAS
M6010800100045
AC305634
AC305633
1. Manual transmission
1. Engine performance Check the transmission in all forward ranges and
Check the engine for proper performance and in reverse.
accelerator pedal for smooth operation.
2. Exhaust system
(1) Check the exhaust system components for Button
gas leaks.
(2) Verify that no black smoking is emitted from
the end of the exhaust pipe (diesel-powered
vehicles).
AC305635 AB
2. Automatic transmission
(1) Make sure shift indicator lines up properly in
all ranges.
(2) Depress the accelerator completely to check
that the manual kickdown is operating
correctly.
ROAD TEST
1-15
(3) Stop the vehicle on a steep incline. 31. VIBRATION AND RATTLES
Put the automatic transmission in "P" position M6010800500043
and slowly release the service brakes to see if 1. Locate squeaks, rattles and unusual vibrations.
"P" position lock holds. If it does not hold, the 2. Verify that no noise occurs from the engine,
transmission requires further service. transmission, axle and body.
29. BRAKES 32. ELECTRICAL EQUIPMENT

M6010800300049 M6010800600040
1. Service Brake
Put the vehicle in gear and apply the brakes while
the vehicle is in motion. Be sure brake operation
is smooth and positive.
2. Parking Brake
(1) Stop the vehicle on a steep incline.
With the service brakes firmly applied, place
the transmission in "N" position, and set the
parking brakes.
(2) Slowly release the service brakes to see if the AC305637
parking brakes will hold.

1. Radio
30. STEERING CONTROL Tune the radio to a local broadcasting station and
M6010800400046 check the following:
(1) Operate the volume, tone, balance and fader
controls, etc.
(2) Pull out the pushbuttons, dial another station
and set each pushbuttons.
(3) Operate the AM/FM switch.
2. Tape player
Insert a cassette tape in the tape player and
check as follows:
AC305636 (1) Check the operation of the tape feeder and
rewind.
1. Check for excessive play or looseness. (2) Check the ejection.
2. Check the steering wheel centre. (3) Check the operation of volume, tone, balance
and fader controls, etc.
AFTER ROAD TEST
AFTER ROAD TEST

33. IDLE SPEED 36. HOSES, FLUID LINES AND
M6010900100116
Check the engine idle speed. CONNECTIONS LOCATED UNDER HOOD
M6010900400162
NOTE: For specific idle speed adjustment proce-
dure, refer to GROUP 2, Periodic Inspection and
Maintenance P.2-3.
34. IGNITION TIMING

M6010900200113
AC305643
1. Check all brake, fuel, power steering and air

conditioner lines and connections; verify proper
routing, check connections for leaks, tighten loose
connector as required.
AC305641
2. Inspect routing and connections of all vacuum,
Check the ignition timing. Except MPI vehicles with and radiator and heater houses.
crankshaft-mounted crankshaft angle sensor.
CAUTION
NOTE: For the inspection and adjustment of the igni- Remember that the air conditioner system is
tion timing, refer to GROUP 2, Periodic Inspection under pressure.
and Maintenance P.2-3 .
NOTE: Keep in mind that an oily residue around
an air conditioner connector does not necessarily
35. RADIATOR COOLANT LEVEL
M6010900300110 indicate a leak. Oil is used to lubricate fittings dur-
ing assembly. Be sure lines are not twisted or
kinked.
37. MANUAL TRANSMISSION AND

TRANSFER (4WD) OIL LEVEL
M6010900500158
AC305642
Transmission oil
1. Check that the coolant level in the reserve tank is
at or above "LOW" mark at normal engine
operating temperature. And check cooling system
for leaks.
2. Check that the coolant concentration is 30% to
AC305644 AB
60%.
CAUTION 1. Remove the filler plug.
Do not remove the radiator cap while the cooling 2. Check the oil level. If the oil level is at or slightly
system is under pressure. below the filler hole, it is in satisfactory condition.
When removing the radiator cap, be careful of
3. If the level is low, replenish the transmission and
steam and boiling water. Add coolant only to the
transfer case with fresh oil by using a lubricator.
reserve tank if it is required.
NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance P.2-3.
AFTER ROAD TEST
1-17
38. AUTOMATIC TRANSMISSION FLUID
•
TYPE 1 TYPE 2
LEVEL
M6010900600177
8 mm Gear oil
Upper
limit
Lower
limit
AC305646AC
Type 1 only: Remove the filler plug, and check the

AC005861AD
gear oil level. Check that gear oil level is not 8
mm below the bottom of filler plug hole.
1. Remove the dipstick and check the fluid level. 3. If the level is low, replenish the front and/or rear
2. Fluid level is okay if it is in the specified range as differential with fresh oil by using a lubricator.
illustration at normal engine operating NOTE: For the specified oil, refer to GROUP 2,
temperature. Periodic Inspection and Maintenance P.2-3.
3. If the level is below the lower notch, replenish fluid
until the level reaches the upper notch. 41. HOSES, FLUID LINES AND
Automatic transmission fluid: DIA QUEEN ATF CONNECTIONS LOCATED UNDER
SP III VEHICLE
M6010901000112
CAUTION
Do not overfill.
39. ENGINE, TRANSMISSION, STEERING

GEAR BOX AND DIFFERENTIAL FOR
LEAKS
M6010900700118
Check the engine, transmission, steering gear box
and differential for oil leaks.
40. FRONT AND REAR DIFFERENTIAL

AC305647
OIL LEVELS 1. Check all hoses, fluid lines and connections for
M6010900800171 leaks.
1. Remove the filler plug.
2. Check all hoses and fluid lines for proper routing
2. Check the oil level. If the oil level is at or slightly away from sharp edges and moving components.
below the filler hole, it is in satisfactory condition.
FINAL STEPS
FINAL STEPS
42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR
M6011000100161 M6011000300110
Screen
Headlamp
Level surface
AC305648 AB AC305650
Check condition for headlamp aiming. Finally check and clean the exterior and interior.
NOTE: For headlamp aiming procedures, refer to the 1. Wash the vehicle to remove all traces of road
Workshop Manual for that model. grime and other dirt on the vehicle as a result of
new vehicle preparations.
43. EQUIPMENT 2. Clean exterior and interior glass surface.
M6011000200113
3. Remove all protective covers.
4. Remove undercoat overspray, excess window
sealer, and excess weatherstrip adhesive.
5. Verify that the secondary key can not unlock the
glove box and tailgate/boot lid (if so equipped).
6. Remove shipping and inspection stickers.
45. OWNER INSTRUCTIONS

M6011000400117
1. Verify that the owner's manual and service
AC305649
booklet is in the glove box.
Check the installation of the various equipment. 2. Place the spare keys in envelope in the glove box
1. Floor mats before delivery.
2. Spare tyre
3. Jack, jack handle and tool set
2-1
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
PERIODIC INSPECTION AND OPERATIONS UNDER

MAINTENANCE SCHEDULE . . . . . . 2-3 THE VEHICLE. . . . . . . . . . . . . . . . . . . 2-11
B1. CHECK SUSPENSION SYSTEM
OPERATIONS INSIDE THE ENGINE FOR DAMAGE AND LOOSENESS. . . . . . . 2-11
COMPARTMENT . . . . . . . . . . . . . . . . 2-6 B2. CHECK SUSPENSION ARM
A1. CHECK V-BELT FOR CRACKS, BALL JOINTS FOR PLAY, AND
FRAYING, WEAR, AND ADJUST ITS DUST COVERS FOR DAMAGE . . . . . . . . . 2-12
TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 B3. CHECK DRIVESHAFT BOOTS
A2. CHECK INTAKE AIR HOSE FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-12
FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-6 B4. CHECK STEERING LINKAGE FOR
A3. REPLACE ENGINE TIMING BELT DAMAGE AND LOOSE CONNECTIONS
<EXCEPT VEHICLES WITH TIMING CHAIN> 2-6 (INCLUDING SEALS AND BOOTS) . . . . . . 2-12
A4. CHECK RADIATOR HOSES FOR B5. CHECK GEAR OIL LEVEL IN
DAMAGE AND PROPER CONNECTION. . 2-6 MANUAL TRANSMISSION . . . . . . . . . . . . . 2-13
A5. CHECK ENGINE COOLANT LEVEL B6. CHECK GEAR OIL LEVEL IN
IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . 2-6 TRANSFER CASE (4WD) . . . . . . . . . . . . . . 2-13
A6. CHANGE ENGINE COOLANT . . . . . . . 2-7 B7. CHANGE GEAR OIL IN MANUAL
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-13
A7. CHECK AIR CLEANER ELEMENT
FOR CLOGGING AND DAMAGE . . . . . . . . 2-8 B8. CHANGE GEAR OIL IN TRANSFER
CASE (4WD) . . . . . . . . . . . . . . . . . . . . . . . . 2-13
A8. REPLACE AIR CLEANER ELEMENT . 2-8
B9. CHECK GEAR OIL LEVEL IN
A9. CHECK FLUID LEVEL IN
FRONT AND REAR DIFFERENTIAL . . . . . 2-14
BRAKE RESERVOIR AND CLUTCH
RESERVOIR (For hydraulic type clutch). . . 2-8 B10. CHANGE GEAR OIL IN
FRONT AND REAR DIFFERENTIAL . . . . . 2-14
A10. CHANGE BRAKE FLUID . . . . . . . . . . 2-9
B11. CHECK EXHAUST PIPE
A11. CHECK BATTERY ELECTROLYTE
CONNECTIONS FOR GAS LEAKAGE,
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
AND CHECK PIPE INSTALLATION . . . . . . 2-14
A12. REPLACE FUEL FILTER . . . . . . . . . . 2-10
Continued on next page
2-2
OPERATIONS INSIDE THE VEHICLE 2-14 D5. CHECK BRAKE SHOE LININGS
C1. CHECK BRAKE PEDAL AND AND DISCS FOR WEAR. . . . . . . . . . . . . . . 2-20
CLUTCH PEDAL FOR FREE PLAY . . . . . . 2-14 D6. CHECK FUEL HOSES AND PIPES
FOR LEAKAGE OR DETERIORATION . . . 2-21
C2. CHECK PARKING BRAKE LEVER
STROKE AND PLAY. . . . . . . . . . . . . . . . . . 2-15
C3. REPLACE AIR PURIFIER FILTER. . . . 2-16 OPERATIONS AFTER ENGINE IS
WARMED UP . . . . . . . . . . . . . . . . . . . 2-22
OPERATIONS OUTSIDE E1. CHANGE ENGINE OIL . . . . . . . . . . . . . 2-22
THE VEHICLE . . . . . . . . . . . . . . . . . . 2-17 E2. REPLACE ENGINE OIL FILTER . . . . . 2-22
D1. CHECK UNEVEN TYRE WEAR. . . . . . 2-17 E3. CHECK ENGINE IDLING SPEED. . . . . 2-22
D2. CHECK FRONT AND REAR WHEEL E4. CHECK EXHAUST GAS
BEARINGS FOR PLAY. . . . . . . . . . . . . . . . 2-18 RECIRCULATION (EGR) SYSTEM . . . . . . 2-23
D3. CHECK BRAKE HOSES AND PIPES
FOR LEAKAGE. . . . . . . . . . . . . . . . . . . . . . 2-19 OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-23
D4. CHECK BRAKE PADS AND DISCS F1. CHECK BODY CONDITION FOR
FOR WEAR. . . . . . . . . . . . . . . . . . . . . . . . . 2-20 DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
F2. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-23
PERIODIC INSPECTION AND MAINTENANCE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
2-3
M6020100100445
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
•: Applicable for OUTLANDER
Maintenance item Maintenance Maintenance interval Application
operation
OPERATIONS INSIDE THE ENGINE COMPARTMENT
A1 Check V-belt for cracks, fraying, wear, and Inspection Every 15,000 km or every 12 •
adjust its tension months
A2 Check intake air hose for damage (vehicles Inspection Every 30,000 km or every 2 •
with turbocharger) years
A3 Replace engine timing belt Replace Every 120,000 km •
A4 Check radiator hoses for damage and Inspection Every 30,000 km or every 2 •
proper connection years
A5 Check engine coolant level in reservoir Inspection Every 30,000 km or every 2 •
years
A6 Change engine coolant Change Every 60,000 km or every 4 •
years
A7 Check air cleaner element for clogging and Inspection Normal Every 15,000 km •
damage usage or every 12 months
Severe Every 7,500 km or •
usage every 6 months
A8 Replace air cleaner element Replace Normal Every 45,000 km •
usage or every 3 years
Severe More frequently •
usage
A9 Check fluid level in brake reservoir and Inspection Every 15,000 km or every 12 •
clutch reservoir (for hydraulic type clutch) months
A10 Change brake fluid Change Every 30,000 km or every 2 •
years
A11 Check battery electrolyte level Inspection Every 15,000 km or every 12 •
months
A12 Replace fuel filter Replace Every 30,000 km or every 2 •
years
OPERATIONS UNDER THE VEHICLE
B1 Check suspension system for damage and Inspection Every 30,000 km or every 2 •
looseness years
B2 Check suspension arm ball joints for play, Inspection Every 30,000 km or every 2 •
and dust covers for damage years
B3 Check driveshaft boots for damage Inspection Normal Every 30,000 km •
Severe Every 7,500 km •
usage
2-4 PERIODIC INSPECTION AND MAINTENANCE

operation
B4 Check steering linkage for damage and Inspection Every 15,000 km or every 12 •
loose connections (including seals and months
boots)
B5 Check gear oil level in manual transmission Inspection Every 15,000 km or every 12 •
months
B6 Check gear oil level in transfer case (4WD) Inspection Every 15,000 km or every 12 •
months
B7 Change gear oil in manual transmission Change Normal Every 195,000 km •
B8 Change gear oil in transfer case (4WD) Change Every 75,000 km or every 5 •
years
B9 Check gear oil level in front and rear Inspection Every 30,000 km or every 2 •
differential years
B10 Change gear oil in front and rear differential Change Normal Every 90,000 km •
B11 Check exhaust pipe connections for gas Inspection Every 30,000 km or every 2 •
leakage, and check pipe installation years
OPERATIONS INSIDE THE VEHICLE
C1 Check brake pedal and clutch pedal for Inspection Every 15,000 km or every 12 •
free play months
C2 Check parking brake lever stroke and play Inspection Every 15,000 km or every 12 •
months
C3 Replace air purifier filter Replace Every 15,000 km or every 12 •
months
OPERATIONS OUTSIDE THE VEHICLE
D1 Check uneven tyre wear Inspection Every 30,000 km or every 2 •
years
D2 Check front and rear wheel bearings for Inspection Every 60,000 km or every 4 •
play years
D3 Check brake hoses and pipes for leakage Inspection Every 30,000 km or every 2 •
years
D4 Check brake pads and discs for wear Inspection Normal Every 15,000 km •
usage or every 12 months
Severe Every 7,500 km or •
usage every 6 months
D5 Check brake shoe linings and discs for Inspection Normal Every 30,000 km •
wear usage or every 2 years
usage or every 12 months
2-5
operation
D6 Check fuel hoses and pipes for leakage or Inspection Every 30,000 km or every 2 •
deterioration years
OPERATIONS AFTER ENGINE IS WARMED UP
E1 Change engine oil VW 50501 / 50601 Change Every 15,000 km or every 12 •
months
E2 Replace engine oil VW 50501 / 50601 Replace Every 15,000 km or every 12 •
filter months
E3 Check engine idling speed Inspection Every 15,000 km or every 12 •
months
E4 Check exhaust gas recirculation (EGR) Inspection Every 60,000 km or every 4 •
system years
OTHERS
F1 Check body condition for damage Inspection Every year •
F2 Road test Inspection Every 15,000 km or every 12 •
months
NOTE: "Severe usage" specifications apply to only vehicles used under severe operating conditions.
Severe operating conditions include the followings cases:
.
1. Driving in dusty area.
2. Driving on rough roads, on submerged roads, or hilly areas.
3. Driving cold zones.
4. Engine idling for a long time or short-distance travel during cold weather.
5. Frequent, sudden application of brakes.
6. Towing of a trailer.
7. Use as a taxi or as a rent-a-car.
8. When more than 50% of driving is in heavy city traffic and the ambient temperature is 32°C or more.
9. When more than 50% of driving is at 120 km/h or more and the ambient temperature is 30°C or more.

A1. CHECK V-BELT FOR CRACKS, A3. REPLACE ENGINE TIMING BELT
FRAYING, WEAR, AND ADJUST ITS <EXCEPT VEHICLES WITH TIMING
TENSION CHAIN>
M6020200100367 M6020200600254
V-BELT CONDITION For information concerning the replacement proce-

Check the whole rounds of the V-belt for cracks, fray- dures, refer to the Workshop Manual.
ing and wear.
A4. CHECK RADIATOR HOSES FOR
V-BELT TENSION DAMAGE AND PROPER CONNECTION
M6020200900341
ALTERNATOR DRIVE BELT TENSION Condenser tank
CHECK
Auto-tensioner
Indicator mark
A AC602559AB
1. Check entire circumference and length of hoses,

AC504415AB using a mirror as required.
2. Check that hoses installed in grommets pass
CAUTION
through the centre of the grommets.
Check the drive belt tension after turning the
crankshaft clockwise one turn or more. 3. Check all clamps for tightness and connections
for leakage.
1. Make sure that the indicator mark is with in the
area marked with A in the illustration. A5. CHECK ENGINE COOLANT LEVEL IN
2. If the mark is out of the area, replace the drive RESERVOIR
belt. M6020201000329
NOTE: The drive belt tension check is not neces-

sary as auto-tensioner is adopted
A2. CHECK INTAKE AIR HOSE FOR

DAMAGE
M6020200500224
Turbocharger AC602560AB
Check that the coolant level is between the "FULL"

and "LOW" lines when the engine is at the normal
operating temperature.
AC508128AB
1. Inspect the intake air hoses for cracks or dam-

age.
2-7
A6. CHANGE ENGINE COOLANT Engine oil cooler Engine oil cooler
M6020201100412
hose
1. Stop the engine after it is fully warmed up.
2. Add detergent to the engine coolant in order to
flush the cooling system, and start the engine.
Engine oil pan
AC504232 AB
2. Drain the water in the water jacket by disconnect

the engine oil cooler hose.
3. Remove the radiator condenser tank and drain
AC305655 the coolant.
4. Install the radiator condenser tank.
3. Loosen the drain plug, remove the radiator can
5. Drain the coolant then clean the path of the
and drain the coolant.
coolant by injecting water from the radiator
4. Feed fresh water into the cooling system through condenser tank cap area.
the filler port of the radiator in order to wash the
6. Connect the engine oil cooler hose.
cooling system, and then tighten the drain plug.
7. Securely tighten the radiator plug.
5. Drain the coolant from the radiator condenser
tank. Radiator condenser tank
6. Install the radiator condenser tank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause the corrosion of the aluminium com- ''FULL'' line
ponents.
7. Depending upon conditions of operation, AC604157 AB
determine the amount of long life coolant,
antifreeze or antirust to be added to the coolant. CAUTION
Do not use alcohol or methanol anti-freeze or any
Recommended antifreeze: BASF Glysantin
engine coolants mixed with alcohol or methanol
Alu Protect Premium/G30
anti-freeze. The use of an improper anti-freeze
8. Fill the cooling system with soft water through the can cause corrosion of the aluminium compo-
filler port, and add long life coolant, if necessary. nents.
9. Fill the radiator condenser tank with coolant. 8. By referring to the section on coolant, select an
10.Install the radiator condenser tank cap. appropriate concentration for safe operating
11.Recheck the engine coolant level after a road test. temperature within the range of 50%. Refill the
REMOVAL OF ENGINE COOLANT FROM coolant to the "FULL" line of the radiator
condenser tank as slowly as possible. A
THE CYLINDER BLOCK DRAIN PLUG convenient mixture is a 50% water and 50%
1. Drain the water from the radiator, heater core and antifreeze solution.
engine after unplugging the radiator plug and Recommended antifreeze: BASF Glysantin Alu
removing the radiator condenser tank cap. Protect Premium/G30
Quantity: 8.0 L
9. Start the engine and let the engine run at 2,000
r/min (heater temperature adjustment: MAX
COOL, air volume adjustment: OFF).
10.When the coolant in the radiator condenser tank 3. Wipe off dust on the air cleaner interior.
is gone, refill the coolant again to the "FULL" line 4. Install the air cleaner body.
of the radiator condenser tank as slowly as
possible. A8. REPLACE AIR CLEANER ELEMENT
M6020201300320
11.Repeat steps 9 and 10 until the coolant in the
The air cleaner element will become dirty and loaded
radiator condenser tank stops reducing.
with dust during use, and the filtering effect will be
12.If the coolant in the radiator condenser tank substantially reduced. Replace it with a new one.
stopped reducing, let the engine run at 2,000
r/min (heater temperature adjustment: MAX
COOL, air volume adjustment: OFF) until the
cooling fan starts running.
13.When the cooling fan starts running, let the
engine idle until the cooling fan stops running.
14.When the cooling fan has started running, let the
engine run at 2,000 r/min (heater temperature
adjustment: MAX HOT, air volume adjustment:
MAX) for 3 minutes and check that the coolant in AC602561AB
the radiator condenser tank is not reducing. If the
coolant reduces, refill the coolant to the "FULL" 1. Unclasp the air cleaner cover clip.
line of the radiator condenser tank. 2. Remove the air cleaner element and install a new
15.Stop the engine and wait until the coolant cools one.
down. Check that the coolant in the radiator 3. Be sure to close the air cleaner cover completely
condenser tank is not reduced excessively. when clamping it.
NOTE: If the reduction is approximately 10 mm,
the change can be attributed to hot and cold sta- A9. CHECK FLUID LEVEL IN BRAKE
tuses of the coolant. Thus, it is judged good. RESERVOIR AND CLUTCH RESERVOIR
(For hydraulic type clutch)
A7. CHECK AIR CLEANER ELEMENT M6020202300066
FOR CLOGGING AND DAMAGE

M6020201200282
MAX
MIN
AC507763
AC507627
1. Check that the fluid level is between the "MAX"
and "MIN" mark.
1. Check air cleaner element for clogging and 2. If it is below the "MIN" marks, replenish with fresh
damage. brake fluid up to the "MAX" mark.
2. Clean deposited dust from the element in the
following manner.
(1) Lightly tap the element against the top of a
bench.
(2) Blow compressed air from inside the element.
2-9
A10. CHANGE BRAKE FLUID <L.H. drive vehicles>
M6020201600376
4 1
Front of
vehicle
2 3
AC607427AB
AC305659 <R.H. drive vehicles>

2 3
1. Remove the cap of the bleeder screw, connect a
vinyl tube, and place its other end in a receptacle.
CAUTION
If the reservoir tank completely runs out of fluid Front of
during operation, air will find way into the brake vehicle
line. Pay attention, therefore, to the fluid level
4 1
and replenish as necessary.
2. Loosen the bleeder screw and depress the brake AC607428AB
pedal; supply new brake fluid when the level of

the fluid within the reservoir tank decreases. 4. Repeat above steps for other bleeder screws.
Specified brake fluid: DOT3 or DOT4 MASTER CYLINDER BLEEDING
When removed the master cylinder assembly, bleed
CAUTION the master cylinder in the following procedure to
Use the specified brake fluid. Avoid using a mix- make bleeding of the brake pipeline easier (When no
ture of the specified brake fluid and other fluid. If brake fluid is in the master cylinder).
brake fluid is exposed to the air, it will absorb 1. Fill the brake fluid reservoir with the brake fluid.
moisture; as water is absorbed from the atmos-
2. Depress and hold the brake pedal.
phere, the boiling point of the brake fluid will
decrease and the braking performance will be
seriously impaired. For this reason use a hermet-
ically sealed 1 L or 0.5 L brake fluid container.
Firmly close the cap of the brake fluid container
after use.
3. When fresh fluid has come to flow out from the
vinyl tube, tighten the bleeder screw.
NOTE: This change from existing to fresh fluid Outlet
Master cylinder
can be judged by change in colour of fluid that
flows out. AC606715AB
3. Another operator closes the master cylinder

outlets with his fingers.
4. In this condition, release the brake pedal.
5. Repeat Steps 2 to 4 for 3 or 4 times to fill the
master cylinder with the brake fluid.
A11. CHECK BATTERY ELECTROLYTE 3. The specific gravity of the battery fluid varies with
LEVEL the temperature, so use the following formula to
M6020201700395 calculate the specific gravity for 20°C. Use the
Thermometer Hydrometer calculated value to determine whether or not the
specific gravity is satisfactory.
D20 = (t - 20) × 0.0007 + Dt
D20: Specific gravity of the battery fluid calcu-
lated for 20°C.
t: Actually measured temperature
Battery fluid
Dt: Actually measured specific gravity
A12. REPLACE FUEL FILTER

M6020201900377
AC504567AB
CAUTION
Fuel filter
• If the battery fluid is below the LOWER
LEVEL, the battery could explode in using.
• If the battery fluid is over the UPPER LEVEL,
leakage could result.
1. Inspect whether or not the battery fluid is between
the UPPER LEVEL and LOWER LEVEL marks.
2. Use a hydrometer and thermometer to check the
specific gravity of the battery fluid. AC607841AB
Standard value: 1.220 − 1.290 [20°C] • Unclasp the fuel filter bracket clamp.
2-11
B1. CHECK SUSPENSION SYSTEM FOR
DAMAGE AND LOOSENESS
M6020300100289
FRONT SUSPENSION
Deterioration
and sagging
Bends and
damage
Noise and
oil leakage
Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Bends and
damage
Deterioration
and sagging
Bends and
damage
Cracks, bends
and dents
AC606684 AB
B2. CHECK SUSPENSION ARM BALL B4. CHECK STEERING LINKAGE FOR
JOINTS FOR PLAY, AND DUST COVERS DAMAGE AND LOOSE CONNECTIONS
FOR DAMAGE (INCLUDING SEALS AND BOOTS)
M6020300200297 M6020300500306
LOWER ARM BALL JOINT AXIAL PLAY

CHECK
Dust cover
AC305662
Lower arm 1. Move the steering wheel bit by bit to the left or
AC507631AB right, and check to be sure that there is no play or
looseness in the linkage coupling, that the
1. Raise the vehicle. installation is not loose, and that the rod or arm is
2. Move the lower arm up and down with your hands not bent or damaged.
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly.
DUST COVERS FOR DAMAGE

Check dust covers for damage.
B3. CHECK DRIVESHAFT BOOTS FOR

DAMAGE
M6020300400291
AC507632AB
2. Check to be sure that the seal and boot of the ball

joint are correctly installed (in the correct
position), and that they are not damaged.
3. Check tie-rod end lock nut for looseness. If lock
nut is loose, adjust toe-in and then tighten lock nut
to the specified torque.
Tightening torque: 51 ± 2 N⋅m
AC305661
Check the driveshaft boots for damage.

2-13
B5. CHECK GEAR OIL LEVEL IN MANUAL B7. CHANGE GEAR OIL IN MANUAL
TRANSMISSION TRANSMISSION
M6020300600198 M6020300800233
Driveshaft <LH>
Filler plug hole
Filler plug
Drain plug
Transmission oil Filler plug
AC210553 AB AC406030AE
1. Remove the filler plug. 1. Remove the filler plug.

2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and drain the oil.
the filler plug hole. 3. Tighten the drain plug to the specified torque.
3. Check that the oil is not noticeably dirty. Tightening torque: 32 ± 2 N⋅m
4. Tighten the filler plug to the specified torque. 4. Fill the transmission fresh oil by using a lubricator.
Tightening torque: 32 ± 2 N⋅m 5. Fill with specified oil till the level comes to the
lower portion of oil filler plug hole.
B6. CHECK GEAR OIL LEVEL IN Specified transmission oil: Dia Queen NEW
TRANSFER CASE (4WD) MULTI GEAR OIL API classification GL-3,
M6020300700195
SAE 75W − 80
Quantity:2.0 L
Oil filler plug hole 6. Tighten the oil filler plug to the specified torque.
B8. CHANGE GEAR OIL IN TRANSFER

CASE (4WD)
M6020300900218
Oil filler plug
Transfer oil
Filler plug
AC103664AE
1. Remove the filler plug of the transfer case.

2. Oil level should be at the lower portion of the filler
plug hole.
3. Check that the transfer oil is not noticeably dirty,
and that it has a suitable viscosity.
Drain plug
4. Tighten the filler plug to the specified torque.
AC607312AB
1. Remove oil filler plug and oil drain plug.
2. Drain the gear oil.
3. Before installing the plug, remove iron powder
attached to the magnet of the drain plug.
Tighten the oil drain plug to the specified torque.
4. Fill the transfer case fresh oil by using a lubricator.
5. Fill with specified oil till the level comes to the 2. Fit the drain plug and tighten it to the specified
lower portion of oil filler plug hole. torque.
Specified transfer oil: Gear oil API classifica- Tightening torque: 32 ± 2 N⋅m
tion GL- 5 SAE 90
Quantity: 0.54 L
Filler plug
6. Tighten the oil filler plug to the specified torque.
B9. CHECK GEAR OIL LEVEL IN FRONT

AND REAR DIFFERENTIAL Drain plug
M6020301000263
AC508618AB
Gear oil 3. Remove the filler plug and add the specified gear
oil up to the bottom end of the filler plug hole.
Upper Specified gear oil: Gear oil API classification
limit GL- 5, SAE 80W
Lower Quantity: 0.5 L
limit 8 mm
4. Fit the filler plug and tighten it to the specified
AC102739 AD torque.
1. Remove the filler plug. Tightening torque: 32 ± 2 N⋅m
2. Check that the gear oil level is not 8mm below the
B11. CHECK EXHAUST PIPE
bottom of filler plug hole.
CONNECTIONS FOR GAS LEAKAGE,
3. Tighten the filler plug to the specified torque.
AND CHECK PIPE INSTALLATION
Tightening torque: 32 ± 2 N⋅m M6020301200289
1. Confirm that the exhaust pipe does not interfere
B10. CHANGE GEAR OIL IN FRONT AND with any body components.
REAR DIFFERENTIAL 2. Check the exhaust pipe for damage by stones,
M6020301100301
1. Remove the drain plug to discharge the gear oil. etc.
3. Start the engine and check for gas leaks from the
exhaust pipe connections.

C1. CHECK BRAKE PEDAL AND CLUTCH 1. With the engine stopped, depress the brake pedal
PEDAL FOR FREE PLAY 2 or 3 times to relief the vacuum in the brake
M6020400100305 booster. Then, press the brake pedal with your
Brake pedal free play finger and check if the pedal stroke until the pedal
becomes heavy (play) is within the standard
value.
Standard value (B): 3 − 8 mm
2. When the brake pedal play is not within the
standard value, check the brake pedal-to-clevis
pin looseness, clevis pin-to-booster operating rod
looseness, brake pedal height, and stop lamp
switch position, and adjust or replace as
B
necessary.
AC505506AC
2-15
Clearance between brake pedal and floor-
board
1. Turn up the floor carpet under the brake pedal.
AC311474 AC
AC505506AD
2. Start the engine and depress the brake pedal with

approximately 500 N, and measure clearance
between the brake pedal and the floorboard.
Standard value (C): 80 mm or more C
3. When the clearance is not within the standard
value, check for the air in the brake line and AC311475AC
thickness of the disc brake pad, and correct or 4. Check that the clutch pedal height (B) and the
replace as necessary. clearance (C) between the clutch pedal and the
4. Recover the floor carpet under the brake pedal. toe board when the clutch is disengaged are
within the standard value.
Clutch pedal free play Standard value (B): 151 ± 3 mm
NOTE: This clutch pedal assembly is unadjustable Standard value (C): 77 mm or more
because of its structure. 5. When the clutch pedal height and the clearance
between the clutch pedal and toe board when the
clutch is disengaged are not within the standard
value, the air may be intruded into the hydraulic
system, or either the clutch master cylinder or the
clutch release cylinder may be faulty. In this case,
perform air bleeding, or check the clutch master
cylinder or the clutch release cylinder, and replace
it if necessary.
A
AC601326AB C2. CHECK PARKING BRAKE LEVER
STROKE AND PLAY
1. Measure the clutch pedal looseness (A). M6020400200335
Standard value (A): 1.5 mm or less Pull the parking brake lever with a force of approx.
200 N and count the number of notches.
2. When the clutch pedal looseness is not within the
standard value, the clutch pedal assembly or the Standard value: 3 − 5 notches
clutch master cylinder may be faulty. In this case, 1. If the parking brake lever stroke is not the
check the clutch pedal assembly or the clutch standard value, adjust as described below.
master cylinder, and replace it if necessary. (1) Remove the floor console assembly.
3. Turn up the floor carpet under the clutch pedal.
Cable rod Cable rod

Adjusting nut Adjusting nut
AC505182AB AC505182AB
(2) Loosen the adjusting nut to move it to the CAUTION

cable rod end so that the cable will be free. Be careful that the parking brake lever notch
Adjuster number should be within the standard range. If
the notch number is too low, rear brake dragging
can be caused.
(4) Adjust the parking brake lever stroke to the
standard value by turning the adjusting nut.
After the adjustment, ensure that there is no
free play between the adjusting nut and the
parking brake lever.
(5) After the parking brake lever stroke is
AC202320 AB adjusted, raise the rear of the vehicle.
Release the parking brake and turn the rear
(3) Remove the rear brake adjusting hole plug. wheels to confirm that the rear brakes are not
Then insert a flat-tipped screwdriver to turn the dragging.
adjuster to the arrow direction (to expand the
shoe) until the parking brake shoe makes C3. REPLACE AIR PURIFIER FILTER
M6020400300246
contact and the disc can no longer be turned.
Back off the adjuster to the opposite direction
by five notches. Air purifier cover
AC506352AD
1. Remove the glove box.

2. Remove the air purifier cover and the air purifier
assembly.
3. Install a new air purifier assembly and install the
air purifier cover.
4. Install the glove box.
2-17
D1. CHECK UNEVEN TYRE WEAR 2. Install the clip and tighten the lock nut to the
M6020500700047 specified torque.
FRONT WHEEL ALIGNMENT Tightening torque: 51 ± 2 N⋅m
Check the entire periphery of the tyres for uneven
wear. If any tyre shows uneven wear, check the 3. Confirm that the toe-in is at the standard value.
toe-in and toe-out, and adjust if necessary.
TOE-IN
AC306798
4. Use a turning radius gauge to check that the

steering angle is at the standard value.
Standard value:
Inner wheel 38°40' ± 1°30'
Outer wheel 32°20'
<Reference value>
CAMBER, CASTER AND KINGPIN

INCLINATION
AC305666
MB991004
Using a toe-in gauge, measure toe-in.
Toe-in = B − A
Standard value: 1 ± 2 mm
Bellows 160 ± 16 N·m

AC208980AE
clip
Standard value:
Item Specifications
Camber 0°20' ± 0°30'*
Caster 2°35' ± 0°30'*
Lock nut
AC506665AB
Kingpin inclination 12°45' ± 1°30'
1. Adjust the toe-in by undoing the clip and lock nut, NOTE: The*: difference between right and left
and turning the left and right tie rod turnbuckles by wheels must be less than 30'
the same amount (in opposite directions). NOTE: The camber and the caster are pre-adjusted
NOTE: The toe moves to the outside by turning at factory and not adjustable.
the tie-rod: left to the forward direction, and right
to the reverse direction.
NOTE: For vehicles with aluminium wheels, attach CAMBER

the camber/caster/kingpin gauge to the driveshaft by
Standard value: − 0°25' ± 0°30' (left/right dif-
using special tool wheel alignment gauge attachment
ference 0°30' max)
(MB991004). Tighten the special tool to the same
torque 160 ± 16 N⋅m as the driveshaft nut. NOTE: Camber is preset at the factory and can not
be adjusted.
CAUTION
Do not apply the vehicle weight to the wheel
bearing while loosening the driveshaft nut.
MB991004
REAR WHEEL ALIGNMENT
1. The rear suspension, wheels and tyres should be
serviced to normal condition prior to
measurement of wheel alignment.
2. Measure the wheel alignment with the vehicle
160 ± 16 N·m
parked on a level surface. AC208980AE
TOE-IN
NOTE: For vehicles with aluminium wheels, attach
Standard value: 3 ± 2 mm the camber/caster/kingpin gauge to the driveshaft by
If toe-in is not within the standard value, adjust by fol- using special tool wheel alignment gauge attachment
lowing procedures. (MB991004). Tighten the special tool to the same
torque 160 ± 16 N⋅m as the driveshaft nut.
Toe adjusting bolt
D2. CHECK FRONT AND REAR WHEEL
BEARINGS FOR PLAY
M6020500200235
<Front>
1. Remove the caliper assembly, and retain it with a
wire and the like to prevent from falling.
AC506806AB
Turn the toe adjusting bolt (the mounting bolt inside

the body on the control link) to adjust.
Left wheels: Clockwise (+) Toe in
Right wheels: Clockwise (-) Toe in
NOTE: The scale has gradations of approximately
2.6 mm (single side toe angle equivalent to 16')
AC102438
2. Set a dial gauge as shown in the figure. Move the

hub in the axial direction and measure the
looseness.
Limit: 0.05 mm
2-19
<Rear> 3. When the looseness exceeds the limit value,
1. Remove the caliper assembly and the brake disc. replace the rear wheel hub assembly.
Retain the caliper assembly with a wire and the
like to prevent from falling.
AC511300AC
2. Set a dial gauge as shown in the figure. Move the

hub in the axial direction and measure the
looseness.
Limit: 0.05 mm
D3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300306
Brake booster
Rear disc brake
Front disc brake

AC606571AC
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
D4. CHECK BRAKE PADS AND DISCS BRAKE DISC RUN-OUT CHECK
FOR WEAR 1. Remove the brake assembly, and then hold it with
M6020500400347 wire.
2. Temporarily install the disc with the hub nut.
AC102396AF
1. Check the brake pad thickness through the caliper ACX00669AF
body check port.

3. Place a dial gauge approximately 5 mm from the
Standard value: 10.0 mm outer circumference of the brake disc, and
Limit: 2.0 mm measure the run-out of the disc.
2. When the thickness is less than the limit, always Limit:
replace the pads at an axle set. <Front> 0.04 mm
<Rear> 0.04 mm
D5. CHECK BRAKE SHOE LININGS AND

DISCS FOR WEAR
M6020500500269
BRAKE LINING THICKNESS CHECK

1. Remove the brake disc.
ACX00668AF
3. Using a micrometer, measure disc thickness at

eight positions, approximately 45° apart and 10 A
mm in from the outer edge of the disc.
Standard value:
<Front > 24.0 mm
<Rear> 10.0 mm ACX00708AE
Limit:
<Front > 22.4 mm 2. Measure the thickness of the brake lining at the
<Rear> 8.4 mm place worn the most.
4. If the disk thickness is less than the limits, replace Standard value (A): 2.8 mm
it with a new one. Limit (A): 1.0 mm
3. Replace the shoe and lining assembly as an axle
set if brake lining thickness is less than the limit.
2-21
BRAKE DISC INSIDE DIAMETER CHECK
ACX00709AD
1. Measure the inside diameter of the brake disc at

two positions or more.
Standard value (A): 190.0 mm
Limit (A): 191.0 mm
2. If the inside diameter is more than limit value or if
there is excessive wear, replace the brake disc.
D6. CHECK FUEL HOSES AND PIPES FOR LEAKAGE OR DETERIORATION

M6020500600307
Fuel filter assembly
Unit injector
Fuel tank assembly
AC605478AC
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.

E1. CHANGE ENGINE OIL E3. CHECK ENGINE IDLING SPEED
M6020600300422 M6020601300049
1. Start the engine and allow it to warm up until the 1. Set the vehicle to the pre-inspection condition.
temperature of the coolant reaches 80 °C to 90
°C. Diagnosis connector
CAUTION
Use care as engine oil could be hot.
2. Remove the engine oil filler cap. MB991910
Engine oil pan drain plug
MB991824
AC607301AB
3. Remove the engine oil pan drain plug to drain

engine oil.
4. Tighten the engine oil pan drain plug to the
MB991827
specified torque. AC505420AB
Tightening torque: 30 N⋅m 2. Turn the ignition switch to "LOOK" (OFF) position,
5. Install the lid of the lower under cover panel R.H. and connect the diagnosis connector to the
M.U.T.-III.
6. Refill with specified quantity of engine oil.
3. Start the engine, and let it run at idle.
Specified Engine Oil: VW 50501/50601 or
higher 4. Check the idle speed. Select item No. 2 and take
a reading of the idle speed.
Total quantity (Includes volume inside engine
oil filter): 5.5 L Standard value: 830 ± 50 r/min
7. Install the engine oil filler cap. 5. If the idle speed is not within the standard value,
8. Check engine oil level. inspect the diesel system (Refer to WORKSHOP
MANUAL GROUP 13 - Troubleshooting).
E2. REPLACE ENGINE OIL FILTER 6. Turn the ignition switch to the "LOCK" (OFF)
M6020600400281 position and then remove the M.U.T.-III.
Oil filter bracket AC608422AB
1. Remove the oil filter bracket.

2. Replace the oil filter element.
OTHERS
2-23
E4. CHECK EXHAUST GAS
RECIRCULATION (EGR) SYSTEM
M6020600800331
Emission control
solenoid assembly
AC606690AB
Visually check the emission control solenoid

assembly and vacuum hose for damage.
OTHERS
F1. CHECK BODY CONDITION FOR Drive the vehicle and check for conditions.
DAMAGE 1. Check free play of steering wheel.
M6020700100210 2. Check efficiency of service brakes and parking
1. Check underbody coating for damage. brakes system.
2. Check body painting for damage. 3. Check driveability of engine.
F2. ROAD TEST 4. Check condition of instruments, gauges
M6020700200273 indicators, exterior lamps, heater and ventilators.
5. Check abnormal noise of each part.
6. Check the tyres for wear and for the correct air
pressure.
AC508542
NOTES

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0-1

HOW TO USE THIS MANUAL. . . . . . 0-2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 0-3

HOW TO USE THIS MANUAL

PRECAUTIONS BEFORE SERVICE

DOING SERVICE WORK IN GROUPS OF

If punch marks or mating marks are made to avoid

TUBES AND OTHER RUBBER PARTS

If other tools are substituted for the special tools to

PARTS TO BE REPLACED LUBRICANTS

Be careful to avoid spilling any brake fluid, because if

SERVICING THE ELECTRICAL SYSTEM VEHICLE WASHING

Connect the M.U.T.-III to the diagnosis connector as

NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-10

BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 BEFORE ROAD TEST . . . . . . . . . . . . 1-12

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-14 38. AUTOMATIC TRANSMISSION

TABLE OF PRE-DELIVERY INSPECTION

Term Definition Remarks

Wipe-off by kerosene or white gasoline, etc.

Disposal of removed film: Burning is appropriate

3. EXTERIOR 4. Partially close the door to check the open-door

1. Visually inspect the entire exterior.

5. OPERATION OF DOOR MIRRORS,

12. ELECTRICAL WIRING

Inspect the battery connections. Verify that they are

1. Check that the fluid level is between "MAX" and

BEFORE ROAD TEST

22. AIR CONDITIONER, HEATER AND

Check the operation of the various parts of the seats.

18. INHIBITOR SWITCH AC305625

20. INSTRUMENT PANEL CONTROLS

5. Instrument brightness control

AC305627 (2) Verify correct brake pedal free play.

2. Rear wiper and washer

24. OPERATION OF SERVICE BRAKES

1. Check the clutch operation in all driving ranges.

3. Verify correct clutch pedal free play.

29. BRAKES 32. ELECTRICAL EQUIPMENT

parking brakes will hold.

AFTER ROAD TEST

34. IGNITION TIMING

1. Check all brake, fuel, power steering and air

37. MANUAL TRANSMISSION AND

Type 1 only: Remove the filler plug, and check the

39. ENGINE, TRANSMISSION, STEERING

40. FRONT AND REAR DIFFERENTIAL

45. OWNER INSTRUCTIONS

PERIODIC INSPECTION AND OPERATIONS UNDER

Maintenance item Maintenance Maintenance interval Application

OPERATIONS INSIDE THE ENGINE COMPARTMENT

V-BELT CONDITION For information concerning the replacement proce-

1. Check entire circumference and length of hoses,

NOTE: The drive belt tension check is not neces-

A2. CHECK INTAKE AIR HOSE FOR

Check that the coolant level is between the "FULL"

1. Inspect the intake air hoses for cracks or dam-

Engine oil pan

2. Drain the water in the water jacket by disconnect

FOR CLOGGING AND DAMAGE

AC305659 <R.H. drive vehicles>

pedal; supply new brake fluid when the level of

3. Another operator closes the master cylinder

A12. REPLACE FUEL FILTER

LOWER ARM BALL JOINT AXIAL PLAY