Mitsubishi I-MIEV Service Repair Manual - Safety Precautions

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

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . 0-4
PRECAUTIONS BEFORE SERVICING THE ELECTRICAL
SERVICE . . . . . . . . . . . . . . . . . . . . . . 0-2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PROTECTING THE VEHICLE . . . . . . . . . . 0-2 APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS . . . . . . . . . . 0-4
DOING SERVICE WORK IN GROUPS
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)
SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 0-5
PARTS TO BE REPLACED . . . . . . . . . . . . 0-3
IN ORDER TO PREVENT VEHICLES
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
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 PARTS

M6001000400053 M6001000600046
AC305593 AC305284
If other tools are substituted for the special tools to When replacing parts, use MITSUBISHI genuine
do service of repair work, there is the danger that parts.
vehicle parts might be damaged, or the technician
might be injured; therefore, be sure to use the spe- TUBES AND OTHER RUBBER PARTS
M6001000700043
cial tool whenever doing any work for which the use
of one is specified.
PARTS TO BE REPLACED
M6001000500049
AC305595
Be careful to avoid spilling any petrol, oil, etc.,

because if it adheres to any tubes or other rubber
parts, they might be adversely affected.
AC305594
If any of the following parts are removed, they must LUBRICANTS

M6001000800040
be replaced with new parts.
• Oil seals
• Gaskets (except rocker cover gasket)
• Packings
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
AC305596
In accordance with the instructions in this manual,

apply the specified lubricants in the specified loca-
tions during assembly and installation.
0-4 GENERAL
BRAKE FLUID APPLICATION OF ANTI-CORROSION

M6001000900047
AGENTS AND UNDERCOATS
M6001001100055
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
M6001001200193
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
AC305285
tion can be carried out. If you see the words "Set the
Be careful to avoid spilling any brake fluid, because if vehicle to the pre-inspection condition" in this man-
it adheres to the vehicle body, the paint coat might be ual, it means to set the vehicle to the following condi-
discoloured. tion.
• Engine coolant temperature: 80 to 90°C
SERVICING THE ELECTRICAL SYSTEM • Lamps, electric cooling fan and all accessories:
M6001001000100
OFF
CAUTION • M/T: Neutral
Before connecting or disconnecting the negative • A/T, CVT: P range
(-) cable, be sure to turn off the ignition switch
and the lighting switch. (If this is not done, there VEHICLE WASHING
is the possibility of semiconductor parts being M6001001300145
damaged.)
Approximately
40 cm or more
AC300832AC
ACX00880AD If high-pressure car-washing equipment or steam

car-washing equipment is used to wash the vehicle,
Before replacing a component related to the electri-
be sure to note the following information in order to
cal system and before undertaking any repair proce-
dures involving the electrical system, be sure to first avoid damage to plastic components, etc.
• Spray nozzle distance: Approximately 40 cm or
disconnect the negative (-) cable from the battery in
more
order to avoid damage caused by short-circuiting.
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
30 sec.
GENERAL 0-5
MULTI USE TESTER (M.U.T.-III) SUB ENGINE OILS

M6001001600210
ASSEMBLY
M6001001900181 HEALTH WARNING
Refer to the "M.U.T.-III OPERATING INSTRUC- Prolonged and repeated contact with mineral oil will
TIONS" for instructions on handling the M.U.T.-III. result in the removal of natural fats from the skin,
CAUTION leading to dryness, irritation and dermatitis. In addi-
Turn the ignition switch to the LOCK (OFF) position, used engine oil contains potentially harmful con-
tion before connecting or disconnecting the taminants which may cause skin cancer. Adequate
M.U.T.-III. means of skin protection and washing facilities must
be provided.
AC302297
RECOMMENDED PRECAUTIONS
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
MB991910 before handling them.
Diagnosis connector Other precautions:

• Avoid prolonged and repeated contact with oils,
MB991824 particularly used engine oils.
• Wear protective clothing, including impervious
gloves where practicable.
• Avoid contaminating clothes, particularly under-
pants, with oil.
• Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
• Do not wear heavily soiled clothing and
MB991827 AC601854AB
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from per-
Connect the M.U.T.-III to the diagnosis connector as
sonal clothing.
shown in the illustration.
• Where there is a risk of eye contact, eye protec-
IN ORDER TO PREVENT VEHICLES tion should be worn, for example, chemical gog-
gles or face shields; in addition an eye wash
FROM FIRE facility should be provided.
M6001001500097
"Improper installation of electrical or fuel related parts • Obtain first aid treatment immediately for open
could cause a fire. In order to retain the high quality cuts and wounds.
and safety of the vehicle, it is important that any • Wash regularly with soap and water to ensure all
accessories that may be fitted or modifica- oil is removed, especially before meals (skin
tions/repairs that may be carried out which involve cleansers and nail brushes will help). After clean-
the electrical or fuel systems, must be carried out in ing, the application of preparations containing
accordance with MMC's information/Instructions". lanolin to replace the natural skin oils is advised.
• Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
• Use barrier creams, applying them before each
work period, to help the removal of oil from the
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 . . . . . . . . . . . . . . . . 1-14

13. TYRE AND SPARE TYRE
PAINTWORK TERMS . . . . . . . . . . . . 1-5 PRESSURES . . . . . . . . . . . . . . . . . . . . . . . 1-14
14. SUSPENSION SYSTEM . . . . . . . . . . . . 1-15
FIRST STEP . . . . . . . . . . . . . . . . . . . . 1-6 15. STEERING LINKAGE AND
1. CONNECTION OF DARK CURRENT SPLIT PINS . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . 1-6 16. UNDER BODY. . . . . . . . . . . . . . . . . . . . 1-15
BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 BEFORE ROAD TEST . . . . . . . . . . . . 1-16

2. WRAP FILM . . . . . . . . . . . . . . . . . . . . . . 1-7 17. SEAT ADJUSTERS AND
3. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . 1-12 SEATBACK LATCHES . . . . . . . . . . . . . . . . 1-16
4. OPERATION OF DOOR LOCKING 18. INHIBITOR SWITCH . . . . . . . . . . . . . . . 1-16
SYSTEMS AND DOOR HINGES . . . . . . . . 1-12 19. IDLE CONTROL KNOB . . . . . . . . . . . . . 1-16
5. OPERATION OF DOOR MIRRORS, 20. INSTRUMENT PANEL CONTROLS . . . 1-16
WINDOWS AND SUNROOF . . . . . . . . . . . 1-12 21. METERS, GAUGES, WARNING
LAMPS AND INDICATION LAMPS . . . . . . . 1-16
UNDER HOOD . . . . . . . . . . . . . . . . . . 1-13 22. AIR CONDITIONER, HEATER
6. ENGINE OIL LEVEL . . . . . . . . . . . . . . . . 1-13 AND DEFROSTER SYSTEM . . . . . . . . . . . 1-16
7. BRAKE MASTER CYLINDER FLUID 23. WIPERS AND WASHERS. . . . . . . . . . . 1-17
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 24. OPERATION OF SERVICE BRAKES
8. CLUTCH MASTER CYLINDER AND PARKING BRAKES . . . . . . . . . . . . . . 1-17
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-13 25. CLUTCH OPERATION . . . . . . . . . . . . . 1-17
9. WASHER FLUID LEVEL. . . . . . . . . . . . . 1-13 26. OPERATION OF SEAT BELTS,
10. BATTERY CONDITION AND SHOULDER BELTS AND
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 1-14 RETRACTORS . . . . . . . . . . . . . . . . . . . . . . 1-18
11. POWER STEERING FLUID LEVEL . . . 1-14
12. ELECTRICAL WIRING . . . . . . . . . . . . . 1-14 Continued on next page
1-2
ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-18 37. MANUAL TRANSMISSION

27. ENGINE PERFORMANCE AND AND TRANSFER (4WD) OIL LEVEL . . . . . 1-20
EXHAUST GAS. . . . . . . . . . . . . . . . . . . . . . 1-18 38. AUTOMATIC TRANSMISSION
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 1-21
28. TRANSMISSION IN ALL RANGES. . . . 1-18
29. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 1-19 39. ENGINE, TRANSMISSION,
STEERING GEAR BOX AND
30. STEERING CONTROL . . . . . . . . . . . . . 1-19 DIFFERENTIAL FOR LEAKS . . . . . . . . . . . 1-21
31. VIBRATION AND RATTLES . . . . . . . . . 1-19 40. FRONT AND REAR DIFFERENTIAL
32. ELECTRICAL EQUIPMENT . . . . . . . . . 1-19 OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . 1-21
41. HOSES, FLUID LINES AND
AFTER ROAD TEST . . . . . . . . . . . . . 1-20 CONNECTIONS LOCATED
33. IDLE SPEED . . . . . . . . . . . . . . . . . . . . . 1-20 UNDER VEHICLE . . . . . . . . . . . . . . . . . . . . 1-21
34. IGNITION TIMING. . . . . . . . . . . . . . . . . 1-20
35. RADIATOR COOLANT LEVEL . . . . . . . 1-20
FINAL STEPS . . . . . . . . . . . . . . . . . . . 1-22
42. HEADLAMP AIMING . . . . . . . . . . . . . . . 1-22
CONNECTIONS LOCATED 43. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 1-22
UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . 1-20 44. EXTERIOR AND INTERIOR . . . . . . . . . 1-22
45. OWNER INSTRUCTIONS . . . . . . . . . . . 1-22
PRE-DELIVERY INSPECTION 1-3
NOTES CONCERNING ENTRIES

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
PAINTWORK TERMS
M6010200100162
Term Definition Remark

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. decolouration.
Contact mark A mark on the painted surface as a result of
contact by hands or clothing at the time of
paint application.
Crack A crack 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 CONFIRMATION OF PRODUCTION DATE
CONNECTOR OF MAIN BATTERY
M6010300100482
Confirm the production date of the main battery to
CONNECTING PROCEDURE check whether the elapsed period after the main bat-
CAUTION tery has been produced exceeds an estimated trans-
Turn the electric motor switch to the LOCK (OFF) portation period. If it exceeds, compensate the BMU
position before connecting storage connector. by referring to the Workshop Manual.
For example:
<LHD> Storage connector If the estimated transportation period is three months
and the production date of the main battery is April:
• Before July 31: Compensation is not necessary
because the elapsed period does not exceed
three months
• After August 1: Compensation is necessary
because the elapsed period exceeds three
months
Junction block
ACA02852 AB
<RHD>
Left rear tyre
Storage connector
Junction block Bar-code Production Date
ACA02853 AB
Press down the storage connector. After the connec-

tor has been pressed down once, never pull up it.
CAUTION
Never disconnect the negative terminal of the
auxiliary battery. (including long-term storage) Serial number
AKA00558 AC
1. Location of production date

• The production date is labelled on the rear side of
the main battery, and can be identified through
the rear left wheelhouse.
2. Estimated vehicle transportation period
• Europe: Three months
BODY
BODY
2. WRAP FILM Distributors are required to remove the wrap film
M6010400100241 immediately after receiving vehicles, which is neces-
sary for PDI operations. Please refer to the following
chart for the procedures.
AC305606
Vehicles may be shipped from the assembly plant to

the distributors with a white plastic film or coating
(wrap film) applied for the purpose of protecting the
painted exterior from environmental elements where
the assembly plant and point of embarkation is
located.
REMOVAL PROCEDURE
Flow Chart of Wrap Film Removal
Wrap film removal Peel off from the corners of the wrap film. High temperature or
low temperature may cause wrap film to become brittle. For
easier removal, the recommended Wrap Film temperature is
below 40˚C. (i.e.: If the surface of the vehicle is hot, lower it to
40˚C or less by sprinkling water so the peeling off will be
easier.)
Rinse off debris such as sand and dust thoroughly. Then dry
Water washing the surface thoroughly.
If adhesive residue is left on the painted surface, wipe it off

with kerosene or white gasoline. If the residue is still visible,
Cleaning of border use a polishing compound for a fine finish. If you use such
solvents or compound, make sure to wipe it off.
Dispose removed film according to local

regulations. ACB04862 AB
BODY
The procedures to re-apply the wrap film
ACB04328
If there is an environment that the vehicles in stock

may be exposed to elements such as acid rain, dust
particles, it may be recommendable to re-apply the
wrap film for the purpose of protecting the painted
exterior from the environment. Please refer to the fol-
lowing chart for the procedures to re-apply the wrap
film.
Steps. Process Tips

1 Remove old wrap film Follow the "flow chart of removing the wrap film"
2 Prepare the surface to adhere the wrap Make sure there is no debris such as sand or dust. Dry
film the surface thoroughly. The temperature of the area to
apply the wrap film should be below 40°C for workability.
3 Re-apply the wrap film The area to re-apply the wrap film is the same area
where the original wrap film was applied.
1. Begin adhering the wrap film from the low part of the
vehicle and move upward. Maintain some tension on
the wrap film so it will not get wrinkled or trap air
bubbles. Although air bubbles it self will not damage
the paint, you can avoid trapping air by adhering the
wrap film from the centre to the out side of the
vehicle. Use a tool such as a squeezer to adhere the
wrap film firmly to the vehicle.
2. For moving panels such as the hood and trunk lid, or
portion where parts such as windshield washer
nozzles are pointing out, cut the wrap film
accordingly, so it will adhere to the paint surface
firmly.
3. If the top side of the film (the side without the
adhesive) is left to contact the painted surface, it may
damage the paint surface. (for example, become
lusterless). The edges of the wrap film and
overlapping portions should be firmly adhered to
prevent entry of rain under the wrap film.
4. To prevent colour difference to be recognised
between the areas wrapped and unwrapped due to
exposure to sunlight etc. during storage, we
recommend the boundary of wrapped and
unwrapped areas be on a vertical location.
BODY
Steps. Process Tips

CAUTION
• Be careful not to damage the paint surface while cutting the wrap film.
• Once the wrap film is adhered to the vehicle, it should remain on the vehicle for no more than 6
months. If it is necessary, a new wrap film should be adhered to the vehicle following the steps
above, based on your inventory management schedule.
Guidelines to give you an estimate of the How to acquire the wrap film
labour costs It will be a direct transaction between O-WELL. Fill
Approximate labour time to adhere wrap film the necessary information, contact information;*1
and ordering quantity;*2 in the specified portion of
area to apply wrap film (m2) labour time (min) the document attached below and send to O-WELL
3.5 - 5.5 10 - 15 Corporation. The necessary information is stated in
the document attached below. O-WELL will give you
5.5 - 7.0 15 - 20
a quotation in return.
BODY
BODY
BODY
3. EXTERIOR 6. Verify that all doors can be locked by the lock

M6010400200237 buttons.
1. Visually inspect the entire exterior.
NOTE: Adjust and lubricate the door latches,
(1) Paint condition
strikers and locks as required.
(2) Corrosion, scratches
(3) Bent edges, dented panels
2. Coated surfaces maintenance
Touch up minor paint chips and flaws.
(Refer to Paintwork terms)
4. OPERATION OF DOOR LOCKING

SYSTEMS AND DOOR HINGES
M6010400300171
Child-protection knob
AC305610 AB
7. Verify that the rear doors can't be opened by the

inner door handle when the child protection knob
at the end of the door is shifted to the "LOCK"
position with the inside lock plunger raised.
NOTE: Set the lock to the "FREE" position on child
protection of both rear doors. (For four door models)
Front
AC305608 AB 5. OPERATION OF DOOR MIRRORS,
WINDOWS AND SUNROOF
M6010400400123
1. Door mirrors
Check that the mirror operate properly.
2. Door windows
Close all door windows to the fully closed position
to check ease of operation.
3. Power windows
Check that the door windows operate when the
AC210253AB respective switches are operated. Check that
1. Open each door to check the release mechanism when the lock switches are depressed, the
and ease of operation. respective door windows can no more be opened
or closed.
2. Close the door to check the latch and striker.
4. Slide window
3. Open the door, operate the lock lever and close
the door to check the lock. Close the slide window to the fully closed position
4. Partially close the door to check the open-door to check operation.
detent. 5. Sunroof
5. Unlock each door with the key to check lock Close the sunroof to the fully closed position to
operation. check operation.
UNDER HOOD
UNDER HOOD
6. ENGINE OIL LEVEL 8. CLUTCH MASTER CYLINDER FLUID
M6010500100301
LEVEL
M6010500300071
MAX
MIN
AC702169
Check that the oil level is between "MAX" and "MIN". AC305613
If it is at or below "MIN", add the necessary amount Check the fluid level.
of the specified engine oil referring to GROUP 2, If it is below the "MIN" mark, replenish fresh brake
Periodic Inspection and Maintenance. fluid up to the "MAX" mark.
Specified Brake Fluid: DOT3 or DOT4
7. BRAKE MASTER CYLINDER FLUID
LEVEL 9. WASHER FLUID LEVEL
M6010500200160 M6010500400120
AC702028 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.
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 2. Tyre pressures
M6010600100096 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
caps.
AC305618
1. Tyre specification
Check the correct tyre specification.
UNDER VEHICLE
14. SUSPENSION SYSTEM 15. STEERING LINKAGE AND SPLIT PINS

M6010600200189 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
steering linkage are not bent and that the tie rod
REMOVE FRONT SPRING RESTRAINTS end lock nuts are securely tightened.
3. Steering components
CAUTION
(1) Check that each of the steering components is
It is very important that these restraints must be
tightened.
removed during pre-delivery inspection. Failure
to do so could cause ride and handling com- (2) Check the tie rod end, nuts and split pins for
plaints. proper installation.
(3) Check the condition of bellows-type dust
Spring seals.
restraints 4. Split pins
Check the front axle nuts and rear wheel spindle
nuts for split pins.
16. UNDER BODY

M6010600400042
Check under body and under body coating for dam-
age.
AC305605
With the vehicle correctly positioned on the

sub-frame contact points, and the suspension fully
extended, remove the rubber restraints from the front
springs.
BEFORE ROAD TEST
BEFORE ROAD TEST

17. SEAT ADJUSTERS AND SEATBACK 21. METERS, GAUGES, WARNING
LATCHES LAMPS AND INDICATION LAMPS
M6010700100101 M6010700500046
AC305622 AC305624
Check the operation of the various parts of the seats. 1. Check the meters and gauges are functioning
1. Mechanical adjusters of the seats properly.
2. Operation of the latch for tilting the seatbacks 2. Check each indicator lamp and warning lamp
forward and backward. functions properly.
18. INHIBITOR SWITCH 22. AIR CONDITIONER, HEATER AND
M6010701100041
On models with an automatic transmission, be sure DEFROSTER SYSTEM
M6010700600139
the engine starts in both "P" and "N" position, and
Check the systems for proper operation.
does not start in other positions.
19. IDLE CONTROL KNOB

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
AC305625
2. Headlamps
3. Exterior and interior lamps 1. Air conditioner
4. Instrument panel lamps (1) Operate the air conditioner system.
5. Instrument brightness control (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
(4) Operate the blower motor switch in all ranges.
BEFORE ROAD TEST
24. OPERATION OF SERVICE BRAKES

AND PARKING BRAKES
M6010700800326
Depress the brake pedal

with approximately 500
N force
AC305626
2. Heater and defroster

(1) After the engine has warmed up, turn on the AC305628 AB
heater.
(2) Operate the blower motor switch in all ranges. 1. Service brakes
(3) Move the control to "Defrost" position. (1) Check the clearance between the brake pedal
A: From front and side defroster and the floorboard when the brake pedal is
depressed.
B: From centre ventilators
C: From side ventilators
D: From under the instrument panel
E: From under the front seat (some models
only)
23. WIPERS AND WASHERS

M6010700700040
AC305629
(2) Verify correct brake pedal free play.

NOTE: For inspection and adjustment of the
service brake, refer to GROUP 2, Periodic
Inspection and Maintenance.
2. Parking brake
AC305627
Check the parking brake drag and lever travel.
NOTE: For inspection and adjustment of the park-
1. Front wiper and washer ing brake, refer to GROUP 2, Periodic Inspection
(1) Check operation of the front wipers in all and Maintenance.
ranges.
(2) Check the aim of the front washer stream. 25. CLUTCH OPERATION
M6010700900323
(3) Check the wiper blade-stop positions.
(4) Verify that the interval between cycles of
wiping is shifted when timer knob is turned to
any position.
(5) Verify that the front wipers function by
operating the washer switch.
2. Rear wiper and washer
(1) Check the operation of the rear wiper.
(2) Check the aim of the rear washer stream.
AC305630
(3) Check the wiper blade-stop positions.
1. Check the clutch operation in all driving ranges.
ROAD TEST
2. Check the pedal to floorboard clearance when the 26. OPERATION OF SEAT BELTS,
clutch is just disengaged. SHOULDER BELTS AND RETRACTORS
M6010701000044
AC305631
AC305632
3. Verify correct clutch pedal free play.
1. Verify that the seat belt warning lamp operates
NOTE: For inspection and adjustment of the
properly.
clutch pedal, refer to GROUP 2, Periodic Inspec-
tion and Maintenance. 2. Check all seat belts and harnesses to assure that
they connect and hold properly.
3. Lean forward to check that the shoulder
harnesses allow movement.
4. Check the condition of the belts and anchors.
5. Check for proper seat belt retraction.
ROAD TEST
27. ENGINE PERFORMANCE AND 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
gas leaks.
(2) Verify that no black smoking is emitted from
the end of the exhaust pipe (diesel-powered
vehicles).
ROAD TEST
30. STEERING CONTROL

M6010800400046
Button
AC305635 AB
AC305636
2. Automatic transmission
(1) Make sure shift indicator lines up properly in 1. Check for excessive play or looseness.
all ranges. 2. Check the steering wheel centre.
(2) Depress the accelerator completely to check
that the manual kickdown is operating 31. VIBRATION AND RATTLES
M6010800500043
correctly. 1. Locate squeaks, rattles and unusual vibrations.
(3) Stop the vehicle on a steep incline. 2. Verify that no noise occurs from the engine,
Put the automatic transmission in "P" position transmission, axle and body.
and slowly release the service brakes to see if
"P" position lock holds. If it does not hold, the 32. ELECTRICAL EQUIPMENT
transmission requires further service. M6010800600040
29. BRAKES
M6010800300049
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 AC305637
the transmission in "N" position, and set the
parking brakes. 1. Radio
(2) Slowly release the service brakes to see if the Tune the radio to a local broadcasting station and
parking brakes will hold. 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:
(1) Check the operation of the tape feeder and
rewind.
(2) Check the ejection.
(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
M6010900100224
Check the engine idle speed. CONNECTIONS LOCATED UNDER HOOD
M6010900400236
NOTE: For specific idle speed adjustment proce- CAUTION
dure, refer to GROUP 2, Periodic Inspection and Remember that the air conditioner system is
Maintenance. under pressure.
34. IGNITION TIMING
M6010900200221
AC305643
AC305641
1. Check all brake, fuel, power steering and air
conditioner lines and connections; verify proper
Check the ignition timing. Except MPI vehicles with routing, check connections for leaks, tighten loose
crankshaft-mounted crankshaft angle sensor. connector as required.
NOTE: For the inspection and adjustment of the igni- 2. Inspect routing and connections of all vacuum,
tion timing, refer to GROUP 2, Periodic Inspection and radiator and heater houses.
and Maintenance.
NOTE: Keep in mind that an oily residue around
an air conditioner connector does not necessarily
35. RADIATOR COOLANT LEVEL
M6010900300176 indicate a leak. Oil is used to lubricate fittings dur-
CAUTION ing assembly. Be sure lines are not twisted or
Do not remove the radiator cap while the cooling kinked.
system is under pressure.
When removing the radiator cap, be careful of
37. MANUAL TRANSMISSION AND
steam and boiling water. Add coolant only to the TRANSFER (4WD) OIL LEVEL
M6010900500255
reserve tank if it is required.
Transmission oil
AC305644 AB
AC305642
1. Remove the filler plug.
1. Check that the coolant level in the reserve tank is
2. Check the oil level. If the oil level is at or slightly
at or above "LOW" mark at normal engine
below the filler hole, it is in satisfactory condition.
operating temperature. And check cooling system
for leaks. 3. If the level is low, replenish the transmission and
transfer case with fresh oil by using a lubricator.
2. Check that the coolant concentration is 30% to
60%. NOTE: For the specified oil, refer to GROUP 2,
Periodic Inspection and Maintenance.
AFTER ROAD TEST
38. AUTOMATIC TRANSMISSION FLUID TYPE 1 TYPE 2

LEVEL
M6010900600274
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.
3. If the level is below the lower notch, replenish fluid
until the level reaches the upper notch.
NOTE: For the specified automatic transmission
CONNECTIONS LOCATED UNDER
fluid, refer to GROUP 2, Periodic Inspection and VEHICLE
M6010901000112
Maintenance.
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

OIL LEVELS AC305647
M6010900800353
1. Remove the filler plug. 1. Check all hoses, fluid lines and connections for
leaks.
2. Check the oil level. If the oil level is at or slightly
below the filler hole, it is in satisfactory condition. 2. Check all hoses and fluid lines for proper routing
away from sharp edges and moving components.
FINAL STEPS
FINAL STEPS
42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR
M6011000100161 M6011000300198
Finally check and clean the exterior and interior.
1. Wash the vehicle to remove all traces of road
Screen grime and other dirt on the vehicle as a result of
Headlamp
new vehicle preparations.
2. Clean exterior and interior glass surface.
3. Remove all protective covers.
Level surface 4. Remove undercoat overspray, excess window
sealer, and excess weatherstrip adhesive.
AC305648 AB
5. Verify that the secondary key can not unlock the
glove box and tailgate/boot lid (if so equipped).
Check condition for headlamp aiming. 6. Remove shipping and inspection stickers.
NOTE: For headlamp aiming procedures, refer to the
Workshop Manual for that model. 45. OWNER INSTRUCTIONS
M6011000400117
43. EQUIPMENT 1. Verify that the owner's manual and service

M6011000200210 booklet is in the glove box.
2. Place the spare keys in envelope in the glove box
before delivery.
AC305649
Check the installation of the various equipment.

1. Trunk room floor mats
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. . . . . . . . . . . . . . . . . . . 2-19
C1. CHECK SUSPENSION SYSTEM
OPERATIONS INSIDE THE FOR DAMAGE AND LOOSENESS. . . . . . . 2-19
ELECTRIC MOTOR UNIT ROOM . . . 2-4 C2. CHECK SUSPENSION ARM
A1.CHECK HIGH VOLTAGE CABLE FOR BALL JOINTS FOR PLAY, AND
DAMAGE AND PROPER CONNECTION DUST COVERS FOR DAMAGE . . . . . . . . . 2-20
(EXCEPT MAIN BATTERY) . . . . . . . . . . . . 2-4 C3. CHECK DRIVESHAFT BOOTS
A2. CHECK MOTOR COOLANT LEVEL FOR GREASE LEAKS AND DAMAGE . . . . 2-20
IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . 2-7 C4. CHECK STEERING LINKAGE FOR
A3. CHANGE MOTOR COOLANT . . . . . . . 2-8 DAMAGE AND LOOSE CONNECTIONS
(INCLUDING SEALS AND BOOTS) . . . . . . 2-20
C5. CHECK TRANSMISSION FOR
OPERATIONS INSDIE THE
OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . 2-20
BONNET ROOM . . . . . . . . . . . . . . . . 2-11
C6. CHANGE GEAR OIL IN
B1.CHECK RADIATOR HOSES TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 2-21
AND HEATER HOSES FOR DAMAGE
AND PROPER CONNECTION . . . . . . . . . . 2-11
OPERATIONS INSIDE
B2.CHECK HEATER FLUID LEVEL
IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . 2-15 THE VEHICLE. . . . . . . . . . . . . . . . . . . 2-22
B3.CHANGE HEATER FLUID . . . . . . . . . . 2-15 D1. CHECK BRAKE PEDAL
FOR FREE PLAY . . . . . . . . . . . . . . . . . . . . 2-22
B4. CHECK FLUID LEVEL IN
BRAKE RESERVOIR . . . . . . . . . . . . . . . . . 2-16 D2. CHECK PARKING BRAKE
LEVER STROKE AND PLAY . . . . . . . . . . . 2-23
B5. CHANGE BRAKE FLUID . . . . . . . . . . . 2-16
D3. REPLACE AIR PURIFIER FILTER . . . . 2-24
B6. CHECK BATTERY CONDITION
(EXCEPT MAIN BATTERY) . . . . . . . . . . . . 2-18
Continued on next page
2-2
OPERATIONS OUTSIDE E5. CHECK BRAKE SHOE LININGS

THE VEHICLE . . . . . . . . . . . . . . . . . . 2-24 AND DISCS FOR WEAR, AND
WHEEL CYLINDERS LEAKAGE . . . . . . . . 2-27
E1. CHECK WHEEL ALIGNMENT . . . . . . . 2-24
E2. CHECK FRONT AND REAR
WHEEL BEARINGS FOR PLAY . . . . . . . . . 2-26
OTHERS . . . . . . . . . . . . . . . . . . . . . . . 2-28
F1. CHECK BODY CONDITION
E3. CHECK BRAKE HOSES AND
FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . 2-28
PIPES FOR LEAKAGE . . . . . . . . . . . . . . . . 2-26
F2. ROAD TEST . . . . . . . . . . . . . . . . . . . . . 2-28
E4. CHECK BRAKE PADS AND
DISCS FOR WEAR. . . . . . . . . . . . . . . . . . . 2-27
PERIODIC INSPECTION AND MAINTENANCE 2-3
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

M6020100102076
For items which indicate both distance and time (in months), the inspection should be made at whichever
(distance or time) comes first.
Maintenance item Maintenance Maintenance interval
operation
OPERATIONS INSIDE THE ELCTRIC MOTOR UNIT ROOM
A1 Check high voltage cable for damage and Inspection Every 40,000 km or every 2 years
proper connection (Except main battery)
A2 Check motor coolant level in reservoir Inspection Every 40,000 km or every 2 years
A3 Change motor coolant Change Every 20 years
OPERATIONS INSIDE THE BONNET ROOM
B1 Check radiator hoses and heater hose for Inspection Every 40,000 km or every 2 years
damage and proper connection
B2 Check heater fluid level in reservoir Inspection Every 40,000 km or every 2 years
B3 Change heater fluid Change Every 20 years
B4 Check fluid level in brake reservoir Inspection Every 20,000 km or every 12 months
B5 Change brake fluid Change Every 40,000 km or every 2 years
B6 Check battery condition (Except main Inspection Every 20,000 km or every 12 months
battery)
OPERATIONS UNDER THE VEHICLE
C1 Check suspension system for damage and Inspection Every 40,000 km or every 2 years
looseness
C2 Check suspension arm ball joints for play, Inspection Every 40,000 km or every 2 years
and dust covers for damage
C3 Check driveshaft boots for grease leaks and Inspection Normal Every 40,000 km or every 2
damage usage years
Severe Every 10,000 km
usage
C4 Check steering linkage for damage and Inspection Every 20,000 km or every 12 months
loose connections (including seals and
boots)
C5 Check transmission for oil leakage Inspection Every 20,000 km or every 12 months
C6 Change gear oil in transmission Change Normal Every 100,000 km
usage
Severe Every 40,000 km
usage
OPERATIONS INSIDE THE VEHICLE
D1 Check brake pedal for free play Inspection Every 20,000 km or every 12 months
D2 Check parking brake lever stroke and play Inspection Every 20,000 km or every 12 months
D3 Replace air purifier filter Replace Every 20,000 km or every 12 months
2-4 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ELECTRIC MOTOR UNIT ROOM
Maintenance item Maintenance Maintenance interval

operation
OPERATIONS OUTSIDE THE VEHICLE
E1 Check wheel alignment Inspection Every 20,000 km or every 12 months
E2 Check front and rear wheel bearings for Inspection Every 60,000 km or every 3 years
play
E3 Check brake hoses and pipes for leakage Inspection Every 40,000 km or every 2 years
E4 Check brake pads and discs for wear Inspection Normal Every 20,000 km or every 12
usage months
Severe Every 10,000 km or every 6
usage months
E5 Check brake shoe linings and drums for Inspection Normal Every 40,000 km or every 2
wear, and wheel cylinders leakage usage years
Severe Every 20,000 km or every 12
usage months
OTHERS
F1 Check body condition for damage Inspection Every year
F2 Road test Inspection Every 20,000 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. Frequent, sudden application of brakes.
4. Use as a taxi or as a rent-a-car.
5. When more than 50% of driving is at 120 km/h or more and the ambient temperature is 30°C or more.

A1.CHECK HIGH VOLTAGE CABLE FOR • Inverter
DAMAGE AND PROPER CONNECTION • On board charger/DC-DC converter
• Motor (electric motor unit)
(EXCEPT MAIN BATTERY) • Heater
M6020700600033
HIGH-VOLTAGE COMPONENTS • A/C COMPRESSOR

• Regular charging connector
The high-voltage components are described below.
• Quick charging connector
Also, wiring harness and connectors of high-voltage
• Service plug
circuit are unified with a colour of orange.
• Wiring harness and connector
• Main battery
SERVICE PRECAUTIONS
DANGER
Cut on the carpet
When adjusting the high-voltage compo-
nents, be sure to disconnect the service plug Front seat Service lid
in order to shut off the high voltage. (LH) tip
Hook-and-loop
Front seat (LH) fastener
Vehicle
front AC901193 AB
3. Slide the front seat (LH) to the end, and turn up

the carpet under the front seat (LH).
Front of vehicle
Service plug
ACA02416 AB
Remove the service plug under the front seat (LH)

according to the following procedure, which shuts off
the high voltage to the high-voltage system.Also,
when installing the service plug and the service lid,
follow the service plug and service lid installation
Service lid
steps.
ACA02486AB
SERVICE PLUG AND SERVICE LID

4. Remove the service lid mounting nut, and then
REMOVAL STEPS remove the service lid.
1. Turn the electric motor switch to "LOCK" (OFF).
DANGER
WARNING • Wear the electric insulation gloves when
• To avoid causing any trouble to the elec- pulling out the service plug.
tric motor unit components, do not dis- • Do not lift the lever of service plug by
connect the auxiliary battery negative halve. It is dangerous because the current
terminal for 1 minute after turning the is supplied during the lifting operation. Be
electric motor switch to "LOCK" (OFF). sure to remove the service plugs all at
• The voltage of the smooth condenser in once.
the inverter must be decreased thor- WARNING
oughly. Therefore, do not remove the The voltage of the smooth condenser in the
service plug for 5 minutes after the nega- inverter must be decreased thoroughly.
tive terminal of the auxiliary battery is dis- Therefore, do not remove the service plug for
connected. 5 minutes after the negative terminal of the
2. Disconnect the negative terminal of the auxiliary auxiliary battery is disconnected.
battery.
DANGER
Front seat (LH)
Lever
Service plug
Service plug
ACA02416AC
ACA02431AB
<Lever-pulled-up state>
After removing the service plug, insulate the
Front seat (LH) plug installed part of the main battery
securely.
Lever 6. Remove the service plug.
Service plug
ACA02417AB
5. Lift the service plug lever.

HIGH VOLTAGE CABLE CHECK
Motor Regular charging

connector
(electric motor unit)
Inverter
Heater
Quick charging
connector
On board charger/
DC-DC converter (OBC)
Main battery
A/C compressor
ACA02850AE
Check the high voltage cable for the following items: A2. CHECK MOTOR COOLANT LEVEL IN
RESERVOIR
M6020201001076
1. Remove the luggage compartment floor carpet.
Electric motor unit

inspection lid
ACC04637
• Check the connections for looseness by wiggling

connectors or checking tightening torque of
threaded fasteners. AC902617AB
• Visually check electrical wires for damage and

2. Remove the electric motor unit inspection lid.
wire clamps for looseness.
• Check that electrical wires do not interfere with
surrounding components.
CAUTION WARNING
Do not operate the water pump when the coolant Be very careful because the coolant may be
level in the radiator condenser tank is lower than very hot.
the "L" line. If the water pump is operated, the
3. Remove the radiator condenser tank cap.
water pump bearing may sustain damage, result-
ing in a water pump breakdown or service life
reduction.
Radiator plug
View A
A
AC901831AB
4. Remove the plug at the radiator upper section.

AC902633AB
5. Remove the radiator drain plug, and drain the
3. Check that the coolant level in the radiator coolant.
condenser tank is in the range between the "F"
line and "L" line.
4. Check that the coolant is not contaminated with oil
and others.
5. Install the electric motor unit inspection lid.
6. Install the luggage compartment floor carpet.
A3. CHANGE MOTOR COOLANT

M6020201101783
CAUTION ACC02933AB
Do not operate the water pump when the coolant

6. Disconnect the radiator piping hose R at the
is empty. If the water pump is operated, the water
motor (electric motor unit) side to drain the
pump bearing may become damaged, resulting
coolant.
in a water pump breakdown or service life reduc-
tion. 7. Connect the radiator piping hose R.
COOLANT DRAINING 8. Tighten the radiator drain plug securely.
1. Remove the luggage compartment floor carpet. 9. Tighten the radiator upper section plug to the
specified torque.
Tightening torque: 2.0 ± 0.4 N⋅m
Electric motor unit

inspection lid
AC902617AB

COOLANT REFILLING c. Within seven seconds, press the ASC-OFF

switch at least 10 times.
CAUTION
Use the MITSUBISHI MOTORS GENUINE SUPER (2) When using M.U.T.-III
LONG LIFE COOLANT PREMIUM without adding a. After setting the electric motor switch to the
water because the concentration is preadjusted "LOCK" (OFF) position, connect the
to 50%. M.U.T.-III to the diagnosis connector.
b. Set the electric motor switch to the "ON"
1. Prepare the required volume of coolant using a
position.
jug so as to avoid running out of coolant during
the refilling and causing any damage to the water c. From the system selection screen of
pump. M.U.T.-III, select "EV-ECU".
d. From the EV-ECU screen, select "Actuator
Recommended antifreeze: MITSUBISHI
test".
MOTORS GENUINE SUPER LONG LIFE
COOLANT PREMIUM or equivalent* e. Select the item No. 3 "Water pump
actuate".
NOTE: *similar high quality ethylene glycol
based non-silicate, non-amine, non-nitrate 5. There will be a wait time of 20 seconds after the
and non-borate coolant with long life hybrid start of "Coolant refilling control" until the
organic acid technology. actuation of water pump. During this period, hold
Quantity: 5.1 L the prepared jug, and insert the jug tip into the
(including 1.1 L in the radiator condenser radiator condenser tank filler port to be ready to fill
tank) the coolant.
6. After the 20-second wait time, the water pump
2. Remove the radiator condenser tank cap if it is
repeats the operation (4 seconds) and stop (30
still mounted.
seconds). So, refill the coolant with an amount
3. Fill the coolant to near the radiator condenser tank decreased by the water pump operation.
filler port.
NOTE: In a case if the prepared coolant becomes
4. According to either of the procedures below, start about to run out, turn the electric motor switch to
the "Coolant refilling control". the "LOCK" (OFF) position beforehand, and stop
(1) Not using M.U.T.-III the "Coolant refilling control" (at this time, perform
a. Pull the parking brake lever. the work with two people).
b. Set the electric motor switch to the "ON" NOTE: Including the wait time, "Coolant refilling
position. control" will be completed within seven minutes
<LH drive vehicles> from the start (during this period, 12 times of
4-second operation are included).
ASC OFF switch If the coolant change is not completed, or if the
control is stopped during the work, the refilling can
be resumed by starting "Coolant refilling control"
once again.
7. Until the coolant level stops decreasing by the
water pump operation, repeat the step 6 above.
NOTE: The coolant refilling will be complete in
ACA02389AB
about 3 to 4 minutes.
<RH drive vehicles>
8. For the air bleeding of cooling system, operate the
water pump for at least one minute according to
ASC OFF switch either of the procedures below.
(1) Not using M.U.T.-III
a. Set the electric motor switch to the
"START" position.
b. Have the Ready indicator illuminated, and
maintain the READY status for at least 15
minutes.
ACA02689AB
NOTE: In the READY status, the water pump oper- 11.If the coolant level in radiator condenser tank is at
ates intermittently when the coolant temperature is the "L" or lower, fill the coolant to the "F" line, and
low. then perform the air bleeding of above step 8
By maintaining the READY status for 15 minutes or again.
longer, the total duration of water pump operation will 12.Adjust the coolant level so that the coolant level in
be 1 minute or longer. radiator condenser tank comes to near the "F" line
(2) When using M.U.T.-III when the water pump is stopped.
a. After setting the electric motor switch to the
"LOCK" (OFF) position, connect the
M.U.T.-III to the diagnosis connector.
b. Set the electric motor switch to the
"START" position.
c. Have the Ready indicator illuminated, and
achieve the READY status.
Lock position
d. From the system selection screen of
M.U.T.-III, select "EV-ECU".
e. From the EV-ECU screen, select "Actuator AC901833AB
test".
f. Select the item No. 9 "Water pump actuate 13.Securely install the radiator condenser tank cap to
2". the lock position of radiator condenser tank (until it
clicks in place).
9. Set the electric motor switch to the "LOCK" (OFF)
position to stop the water pump. 14.Install the electric motor unit inspection lid.
15.Install the luggage compartment floor carpet.
View A
A
AC902633AB
10.When the coolant level in radiator condenser tank

is at the "L" line or higher, the air bleeding is
complete.
OPERATIONS INSDIE THE BONNET ROOM

B1.CHECK RADIATOR HOSES AND HEATER HOSES FOR DAMAGE AND
PROPER CONNECTION
M6020209200015
CHECK RADIATOR HOSE
Inverter Onboard charger/DC-DC converter
Motor
(electric motor unit) Radiator
condenser
tank
Radiator Water pump
ACA02851AB
1. Check entire circumference and length of hoses,

using a mirror as required.
2. Check that hoses installed in grommets pass
Electric motor unit
through the centre of the grommets. inspection lid
3. Check all clamps for tightness and connections
for leakage.
COOLANT LEAK CHECK

<When the special tool radiator cap tester is used>
1. Remove the luggage compartment floor carpet. AC902617AB

3. According to either of the procedures below,
pressurise the cooling system.
3. According to either of the procedures below, start

the "Coolant refilling control".
a. Pull the parking brake lever.
b. Set the electric motor switch to the "ON"
position.
MB992193-A
<LH drive vehicles>
MB992193-B ASC OFF switch
MB992190-A ACA02389AB
<RH drive vehicles>
AC901834AB ASC OFF switch
(1) Use the special tool below.

• Radiator cap tester (MB992193)
• A: Tester
• B: Adapter
• Radiator cap tester adapter set (MB992190)
• A: System adapter
ACA02689AB
CAUTION
Do not pressurise 44 kPa or more. c. Within seven seconds, press ASC OFF
(2) Mount the special tool to the radiator switch for the minimum of 10 times.
condenser tank, and perform the (2) When using M.U.T.-III
pressurisation. a. After setting the electric motor switch to the
4. Check for any coolant leak from the radiator, "LOCK" (OFF) position, connect the
water pump, radiator hose, device connecting M.U.T.-III to the diagnosis connector.
hoses, and others. b. Set the electric motor switch to the "ON"
5. Install the electric motor unit inspection lid. position.
6. Install the luggage compartment floor carpet. c. From the system selection screen of
<When the special tool radiator cap tester is not d. From the EV-ECU screen, select "Actuator
used> test".
1. Remove the luggage compartment floor carpet. e. Select the item No. 3 "Water pump
actuate".
4. There will be a wait time of 20 seconds after the
start of "Coolant refilling control" until the
Electric motor unit
inspection lid actuation of water pump. During this period, hold
the prepared jug, and insert the jug tip into the
radiator condenser tank filler port to be ready to fill
the coolant.
AC902617AB

5. After the 20-second wait time, the water pump 8. Set the electric motor switch to the "LOCK" (OFF)
repeats the operation (4 seconds) and stop (30 position to stop the water pump.
seconds). So, refill the coolant with an amount
decreased by the water pump operation.
NOTE: In a case if the prepared coolant becomes
about to run out, turn the electric motor switch to
the "LOCK" (OFF) position beforehand, and stop View A
A
the "Coolant refilling control" (at this time, perform
the work with two people).
NOTE: Including the wait time, "Coolant refilling
control" will be completed within seven minutes
from the start (during this period, 12 times of AC902633AB
4-second operation are included).
If the coolant change is not completed, or if the 9. When the coolant level in radiator condenser tank
control is stopped during the work, the refilling can is at the "L" line or higher, the air bleeding is
be resumed by starting "Coolant refilling control" complete.
once again. 10.If the coolant level in radiator condenser tank is at
6. Until the coolant level stops decreasing by the the "L" or lower, fill the coolant to the "F" line, and
water pump operation, repeat the step 6 above. then perform the air bleeding of above step 8
again.
NOTE: The coolant refilling will be complete in
about 3 to 4 minutes. 11.Adjust the coolant level so that the coolant level in
radiator condenser tank comes to near the "F" line
7. For the air bleeding of cooling system, operate the
when the water pump is stopped.
water pump for the minimum of 1 minute
according to either of the procedures below.
a. Set the electric motor switch to the
"START" position.
b. Have the Ready indicator illuminated, and
maintain the READY status for the
minimum of 15 minutes. Lock position
NOTE: In the READY status, the water pump oper-

ates intermittently when the coolant temperature is AC901833AB
low.
By maintaining the READY status for 15 minutes or 12.Securely install the radiator condenser tank cap to
longer, the total duration of water pump operation will the lock position of radiator condenser tank (until it
be 1 minute or longer. clicks in place).
(2) When using M.U.T.-III 13.Check for any coolant leak from the radiator,
a. After setting the electric motor switch to the water pump, radiator hose, device connecting
"LOCK" (OFF) position, connect the hoses, and others.
M.U.T.-III to the diagnosis connector. 14.Install the electric motor unit inspection lid.
b. Set the electric motor switch to the 15.Install the luggage compartment floor carpet.
"START" position.
c. Have the Ready indicator illuminated, and
achieve the READY status.
d. From the system selection screen of
e. From the EV-ECU screen, select "Actuator
test".
f. Select the item No. 9 "Water pump actuate
2".
CHECK HEATER HOSE
Heater unit and blower assembly

(with integrated evaporator)
Heater condenser tank

(water heater fluid)
Heater
ACA02990 AB
1. Check entire circumference and length of hoses,

MB992193-B
using a mirror as required. MB992190-A MB992193-A
2. Check that hoses installed in grommets pass
through the centre of the grommets.
3. Check all clamps for tightness and connections
for leakage.
HEATER FLUID LEAK CHECK

CAUTION
AC902737AB
Do not pressurise 44 kPa or more.
1. Use the following special tools to pressurise the • Radiator cap tester (MB992193)
heater system and visually check the heater water • A: Tester
pump assembly and the hose connecting each • B: Adapter
equipment for water leakage. • Radiator cap tester adapter set (MB992190)
• A: System adapter
2. Check the hose connecting each equipment for
deterioration and damage, and the clamp for
looseness.
B2.CHECK HEATER FLUID LEVEL IN

RESERVOIR Heater
M6020209300012
CAUTION
Do not operate the water pump with the water
heater fluid level in the heater condenser tank
lowered to the "L" line or below. If it is operated,
the bearing of the water pump is damaged, and A
the water pump may be broken or the service life A
may be shortened..
AC903199
Drain plug
Section A - A Drain plug
A
Washer ring
AC903201
View A ACA02353AB
AC903298AB
1. Check that the water heater fluid level in the
heater condenser tank stays a range between the 3. Remove the drain plug on the heater and drain
"F" line and "L" line. the water heater fluid.
2. Check that the water heater fluid is not 4. After the water heater fluid is completely drained,
contaminated with an oil or others. fill up water through the heater condenser tank
filler port and wash out the passage for the water
B3.CHANGE HEATER FLUID heater fluid.
M6020209400020
5. Before tightening the drain plug, replace the
DRAIN THE WATER HEATER FLUID. washer ring.
1. Remove the heater condenser tank cap.
WARNING FILL UP THE WATER HEATER FLUID.
Be careful of the water heater fluid because it CAUTION
may be hot. After fill up the water heater fluid, activate the
2. Remove the front floor cover A. heater and check that the water heater fluid cir-
culates throughout the heater condenser tank.
1. Fill the water heater fluid up to the FULL mark on
the heater condenser tank.
2. Allow the Ready indicator to illuminate.
3. Activate the heater.
NOTE: When the heater is activated, the heater
water pump assembly operates.
4. When the level in the heater condenser tank
becomes low, add the fluid as necessary.
5. Activate the heater and check that the water
heater fluid circulates throughout the heater
condenser tank.
6. Let the pump drive for 1 minute after the heater
water pump assembly is activated. (Air purge
operation)
7. Turn OFF the electric motor switch and fill the
heater condenser tank up to the FULL mark .
B4. CHECK FLUID LEVEL IN BRAKE

RESERVOIR
M6020203000358
Lock position
AC903193AB
8. Install the heater condenser tank cap securely

onto the lock position of the heater condenser ACA02856 AB
tank until a click is heard.
1. Check that the fluid level is between the "MAX"
FILLING WATER HEATER FLUID (WHEN and "MIN" mark.
THE HEATER CANNOT BE OPERATED) 2. If it is below the "MIN" marks, replenish with fresh
1. Turn the air volume control dial OFF and the brake fluid up to the "MAX" mark.
temperature adjusting dial to the middle position.
Then turn the electric motor switch ON. B5. CHANGE BRAKE FLUID
M6020201601108
2. Fill water heater fluid up to the middle position
(tank seam) between LOW and FULL marks at
the heater condenser tank.
3. Wait for one minute, and then add water heater
fluid to compensate for reduced level.
4. Press the A/C switch and hold it for at least five
seconds to activate the heater water pump
assembly (the A/C indicator will flash when the
heater water pump assembly is activated).If
necessary, add water heater fluid to compensate AC305659
for reduced level.
1. Remove the cap of the bleeder screw, connect a
5. Wait for one minute, and then press the A/C
vinyl tube, and place its other end in a receptacle.
switch again to deactivate the heater water pump
assembly. CAUTION
6. Repeat steps 2 to 5. If the reservoir tank completely runs out of fluid
during operation, air will find way into the brake
7. Fill water heater fluid up to the FULL mark at the
line. Pay attention, therefore, to the fluid level
heater condenser tank.
and replenish as necessary.
2. Loosen the bleeder screw and depress the brake
pedal; supply new brake fluid when the level of
the fluid within the reservoir tank decreases.
Lock position Specified brake fluid: DOT3 or DOT4
AC903193AB
8. Install the heater condenser tank cap securely

onto the lock position of the heater condenser
tank until a click is heard.
CAUTION MASTER CYLINDER BLEEDING

Use the specified brake fluid. Avoid using a mix- Because a master cylinder without check valve is
ture of the specified brake fluid and other fluid. If adopted, the air bleeding of brake pipe line becomes
brake fluid is exposed to the air, it will absorb easier when the master cylinder air bleeding is per-
moisture; as water is absorbed from the atmos- formed as described below. (When no brake fluid is
phere, the boiling point of the brake fluid will in the master cylinder)
decrease and the braking performance will be 1. Fill the brake fluid reservoir with the brake fluid.
seriously impaired. For this reason use a hermet- 2. Depress and hold the brake pedal.
ically sealed 1 L or 0.5 L brake fluid container.
Firmly close the cap of the brake fluid container <LHD>
after use.
3. When fresh fluid has come to flow out from the
vinyl tube, tighten the bleeder screw.
NOTE: This change from existing to fresh fluid
can be judged by change in colour of fluid that
flows out.
<LHD>
ACA02471AB
4 1
<RHD>
Front of
vehicle
2 3
ACA03019 AB
<RHD>
ACA03404AB
2 3
3. Another operator closes the master cylinder
outlets with his fingers.
4. In this condition, release the brake pedal.
Front of
5. Repeat Steps 2 to 4 for 3 or 4 times to fill the
vehicle
master cylinder with the brake fluid.
4 1
ACA03020AB
4. Repeat above steps for other bleeder screws.

B6. CHECK BATTERY CONDITION 2. Use a specific gravity meter and a thermometer to
(EXCEPT MAIN BATTERY) measure the specific gravity.
M6020203100344 Standard value: 1.220 − 1.290 (electrolyte
CAUTION temperature 20°C)
• If the battery is used with the electrolyte level The specific gravity of the battery electrolyte
below the LOWER LEVEL indicator, there is changes according to the temperature, so the spe-
the danger that explosions may occur, so add cific gravity when the electrolyte is at a temperature
water to the battery until the electrolyte level of 20°C can be calculated using the following for-
is between the LOWER LEVEL and UPPER mula. Use the converted value to judge whether the
LEVEL indications. electrolyte is okay or not.
• If too much water is added to make the level
D20 = (t − 20) × 0.0007 + Dt
rise above the UPPER LEVEL indication, the
electrolyte may leak out, so adjust so that the D20: Specific gravity converted to a value for
electrolyte level is between the LOWER electrolyte temperature of 20°C
LEVEL and UPPER LEVEL indications. t: Electrolyte temperature at the time of
Thermometer Hydrometer measurement
Dt: Actual specific gravity
Battery fluid
AC504567AB
1. Check that the battery electrolyte level is between

the UPPER LEVEL and LOWER LEVEL
indications.

C1. CHECK SUSPENSION SYSTEM FOR 2. Check each installation bolt and nut for looseness
DAMAGE AND LOOSENESS by spanner or similar tool.
M6020300100706
1. Check each portion of suspension for damage
visually.
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
Cracks, bends
and dents
ACA03008 AB
C2. CHECK SUSPENSION ARM BALL C4. CHECK STEERING LINKAGE FOR
JOINTS FOR PLAY, AND DUST COVERS DAMAGE AND LOOSE CONNECTIONS
FOR DAMAGE (INCLUDING SEALS AND BOOTS)
M6020300200587 M6020300500630
LOWER ARM BALL JOINT PLAY CHECK
AC305662
ACA03048AB 1. Move the steering wheel bit by bit to the left or

right, and check to be sure that there is no play or
1. Raise the vehicle.
looseness in the linkage coupling, that the
2. Move the lower arm up and down by hand, and installation is not loose, and that the rod or arm is
check for the ball joint axial play. If there is a play, not bent or damaged.
replace the lower arm assembly.
LOWER ARM BALL JOINT DUST COVER

CHECK
CAUTION
Be careful not to damage the lower arm ball joint
dust cover during maintenance.
1. Using your fingers, press the dust cover to check
for a crack or damage.
2. If the dust cover has any crack or damage, ACA03049AB
replace the lower arm assembly.
2. Check to be sure that the seal and boot of the ball
NOTE: If the dust cover has a crack or damage,
joint are correctly installed (in the correct
the ball joint could be damaged.
position), and that they are not damaged.
If the dust cover is damaged during the mainte-
nance, replace it. 3. Check tie-rod end lock nut for looseness. If lock
nut is loose, adjust toe-in and then tighten lock nut
C3. CHECK DRIVESHAFT BOOTS FOR to the specified torque.
GREASE LEAKS AND DAMAGE Tightening torque: 34 ± 5 N⋅m
M6020300400484
C5. CHECK TRANSMISSION FOR OIL
LEAKAGE
M6020302300513
CHECK OIL LEAKAGE

Check the transmission case for oil leakage visually
or by touching it with hand.
NOTE: If an oil leakage is not detected, the oil level
check is necessary.
AC305661
Check the driveshaft boots for damage.

CHECK OIL LEVEL C6. CHANGE GEAR OIL IN

TRANSMISSION
M6020300801128
Filler plug
Filler plug
ACA03964AB
ACA03964
Drain plug
1. Remove the filler plug and gasket. ACA03964AC
ACA03964
1. Remove the filler plug.

Filler plug hole
2. Remove the drain plug, and drain the oil.
Gasket 3. Install a new gasket to the drain plug, and then
tighten the plug to the specified torque.
Upper
limit
5 mm
Tightening torque: 32 ± 2 N⋅m
Lower 4. Fill the specified oil up to the bottom end of oil
limit
Filler plug filler plug hole.
Transmission oil Transmission oil: MITSUBISHI MOTORS
AC700330AX
GENUINE ATF SP III
2. Check that the oil level is in the range between Quantity: 0.75 L
the upper limit (filler plug hole lower end) and 5. Install a new gasket to the filler plug, and then
lower limit as shown in the figure. tighten the plug to the specified torque.
3. Check that the oil is not excessively foul and has Tightening torque: 32 ± 2 N⋅m
moderate viscosity.
4. If the oil level is not in between the upper limit and
the lower limit, refill the specified gear oil to the
bottom of the oil filler plug hole.
Transmission oil: MITSUBISHI MOTORS
GENUINE ATF SP III
5. Install a new gasket to the oil filler plug, and then
tighten the plug to the specified torque.
Tightening torque: 32 ± 2 N⋅m

D1. CHECK BRAKE PEDAL FOR FREE Stop lamp
PLAY switch
M6020400101018
CAUTION
Do not apply grease or lubricant to the switch
and the switch installation section to avoid mal-
function of the switch. In addition, do not use
gloves which have grease on them.
0.5 – 1.5 mm
BRAKE PEDAL HEIGHT CHECK AND
Pedal stopper
ADJUSTMENT AC706514 AB
1. Turn up the floor carpet under the brake pedal. (4) Press in the stop lamp switch until the thread
section of stop lamp switch comes in contact
with the pedal stopper. Then, secure the stop
lamp switch by turning it clockwise by
approximately 1/4 turn. While doing this, pull
and hold the brake pedal by hand.
Stop lamp
switch (5) Check that the clearance between the stop
lamp switch and the pedal stopper is as shown
in the figure.
Operating rod A
CAUTION
AC706512 AB Make sure that the stop lamp is not illuminated
when the brake pedal is not depressed.
2. Measure the brake pedal height. (6) Connect the stop lamp switch connector.
Standard value (A): 4. Perform the key interlock mechanism check and
157.4 to 163.4 mm <LHD> the shift lock mechanism check.
143.4 to 146.4 mm <RHD>
5. Recover the floor carpet under the brake pedal.
3. When the brake pedal height is not within the 6. After adjusting the brake pedal height, initialize
standard value, adjust the brake pedal in the the brake pedal stroke sensor installed to the
following procedure. brake pedal assembly by performing the EV-ECU
(1) Disconnect the stop lamp switch connector. data list (item No. 178:B/P stroke S initial learning
(2) Loosen the stop lamp switch by turning it complete flag) using M.U.T.-III.
anti-clockwise by approximately 1/4 turn. NOTE: The brake stroke sensor learned value
can be reset even after the auxiliary battery (−)
terminal has been disconnected for 10 seconds or
longer.
Lock nut
AC706513 AB
(3) Loosen the lock nut of operating rod, then turn

the serrated section of operating rod using the
pliers to adjust the brake pedal height to the
standard value.
BRAKE PEDAL PLAY CHECK AND BRAKE PEDAL-TO-FLOOR CLEARANCE

ADJUSTMENT CHECK AND ADJUSTMENT
1. Turn up the floor carpet under the brake pedal.
AC706515 AB
C
AC706516 AB
1. Set the electric motor switch to the LOCK (OFF)
position, and depress the brake pedal two to three 2. Set the electric motor switch to the ON position,
times to relief the brake booster vacuum pressure. then depress the brake pedal with approximately
Then, press the brake pedal with your fingers to 500 N, and measure the clearance between the
check that the pedal stroke until the pedal effort brake pedal and the floor.
becomes heavy (play) is within the standard
Standard value (C):
value.
65 mm or more <LHD>
Standard value (B): 3 to 8 mm 60 mm or more <RHD>
2. When the brake pedal play is not within the 3. If the clearance between the brake pedal and
standard value, check the brake pedal-to-clevis floorboard exceeds the standard value, check the
pin looseness, clevis pin-to-booster operating rod brake lines for air lock, the thickness of the disc
looseness, brake pedal height, and stop lamp brake pad and the brake drum lining and brake
switch position, and adjust or replace as dragging. If necessary, adjust the system or
necessary. replace component(s).
3. After adjusting the brake pedal play, initialize the 4. Recover the floor carpet under the brake pedal.
brake pedal stroke sensor installed to the brake
pedal assembly by performing the EV-ECU data D2. CHECK PARKING BRAKE LEVER
list (item No. 178:B/P stroke S initial learning STROKE AND PLAY
complete flag) using M.U.T.-III. M6020400200885
NOTE: The brake stroke sensor learned value Pull

can be reset even after the auxiliary battery (−)
terminal has been disconnected for 10 seconds or
longer.
Spring scale
Approx.
40 mm
AC604651AB
Attach the spring scale to the centre of the parking

brake lever grip. Then, check that the stroke is within
the standard value when the parking brake lever is
pulled to the vertical direction of the lever with a force
of approximately 200 N.
Standard value: 6 to 7 notches
If the parking brake lever stroke is out of the standard 5. After the parking brake lever stroke is adjusted,
range, adjust as described below: raise the rear of the vehicle. Release the parking
1. Remove the floor console. brake, turn the rear wheels to confirm that the rear
brakes are not dragging.
D3. REPLACE AIR PURIFIER FILTER

M6020400300473
Adjusting nut
AC706782 AB
2. Loosen the adjusting nut to the end of the cable

rod in order to allow slack in the cables.
AC707073AB
3. Repeatedly depress the brake pedal until the
stroke no longer changes. 1. Remove the glove box assembly.
NOTE: The brake shoe clearance will be adjusted 2. Loosen the two lugs as shown to replace the
correctly by depressing the brake pedal repeat- clean air filter.
edly. 3. Install the glove box assembly.
CAUTION
Be careful that the parking brake lever notch
number should be within the standard range. If
the notch number is too low, rear brake dragging
can be caused.
4. Adjust the parking brake lever stroke to the
standard value by turning the adjusting nut. After
the adjustment, ensure that there is no free play
between the adjusting nut and the parking brake
lever.

E1. CHECK WHEEL ALIGNMENT TOE-IN
M6020500101134
Standard value:
FRONT WHEEL ALIGNMENT
At the centre of tyre tread: 0 ± 3 mm
1. Before the wheel alignment measurement, main- 0° to 0°18'
tain the front suspension, the steering system
and the wheel tyres in good condition.
2. Park the vehicle on a level surface, and position
the front wheel in the straight- ahead position to
measure the wheel alignment.
CAUTION
Do not apply the vehicle weight to the wheel
bearing while loosening the driveshaft nut.
NOTE: The camber and the caster are pre-adjusted
at factory and not adjustable.
NOTE:
Bellows
clip
Lock nut
AC902201AB
Compensator
1. Loosen the locking nut with tie-rod bellows clip

removed, and then perform the adjustment by
turning the tie-rod left/right at the same degree in
the opposite direction.
NOTE: The toe moves to the outside by turning ACX00712AD
the tie-rod: left to the forward direction, and right
Use the compensator to measure the camber and
to the reverse direction.
caster.
2. Install the tie-rod clip, and tighten the lock nut to
the specified torque. KINGPIN ANGLE
Tightening torque : 34 ± 5 N⋅m Standard value: 15°20'±1°30'
3. Check the toe-in standard value.
REAR WHEEL ALIGNMENT
1. The rear suspension, wheel and tires must be
serviced to normal condition before measuring
the wheel alignment.
2. Measure the wheel alignment with the vehicle
parked on a level surface.
TOE-IN
Standard value:
AC306798 At the centre of tyre tread: 0 ± 3 mm
Toe angle (per wheel): −0°09' to +0°09'
4. Use a turning radius gauge to check that the
steering angle is at the standard value. CAMBER
Standard value: Standard value: 0° 00' ± 30' (difference
Inner wheel 45°10'±2°00' (left/right between right and left wheels must be 0°30'
difference: 2°00' max) or less)
Outer wheel <Reference 37°30'
value>
CAMBER
Compensator
Standard value: 0°00'±0°45' (left/right differ-
ence: 0°30' max)
CASTER
Standard value: 3°30'±0°45' (left/right differ-
ence: 0°30' max) ACX00712AD
As for vehicles with aluminium wheel, use a compen-

sator to measure the camber.
E2. CHECK FRONT AND REAR WHEEL 4. After checking, install the brake disc and the
BEARINGS FOR PLAY caliper assembly, and tighten the caliper mounting
M6020500900397 bolt to the specified torque.
<FRONT WHEEL> Tightening torque: 100 ± 10 N⋅m
1. Remove the caliper assembly and the brake disc,
then retain them using a wire or the like to prevent <REAR WHEEL>
from falling. 1. Remove the brake drum.
AC901236AB AC707155
2. Set a dial gauge as shown in the figure. Move the 2. Set a dial gauge as shown in the figure. Move the
hub in the axial direction and measure the play. hub in the axial direction and measure the play.
Limit value: 0.05 mm Limit value: 0.05 mm
3. If the limit value is exceeded, replace the wheel 3. When the play exceeds the limit value, replace
bearing . the wheel bearing.
E3. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE

M6020500300629
Brake booster
Rear drum brake
Front disc brake AC606571AB
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
E4. CHECK BRAKE PADS AND DISCS BRAKE DISC THICKNESS CHECK
FOR WEAR 1. Remove contaminants or corrosion from the brake
M6020500401049 disc surface.
CAUTION
If there is a significant difference in thickness
between the brake pads at right and left, check
the sliding area of the brake caliper and the brake
disc runout.
Approx. 10 mm
AC706559 AC
2. Use a micrometer to measure the brake disc

thickness at minimum eight points which are 10
mm inward from its circumference.
AC706526AB Standard value: 17.0 mm
Limit value: 15.4 mm
1. Visually check the thickness of brake pad from the
inspection hole of the caliper body. 3. If the brake disc thickness is worn beyond the limit
value at more than one point, replace the brake
Standard value: 10.0 mm
disc and check its runout.
Limit value: 2.0 mm
2. When the thickness is lower than the limit value, E5. CHECK BRAKE SHOE LININGS AND
replace both brake pads (right and left) as a set . DISCS FOR WEAR, AND WHEEL
CYLINDERS LEAKAGE
BRAKE DISC RUN-OUT CHECK M6020500500786
1. Check for wheel bearing looseness in the axial BRAKE LINING THICKNESS CHECK
direction. 1. Remove the brake drum.
2. If the axial play is within the limit value, secure the
brake disc by tightening the nut (M12×1.5) evenly
to the specified torque (100 N⋅m).If the axial play
still exceeds the limit value, replace the wheel
bearing. Then secure the brake disc by tightening
the nut (M12×1.5) evenly to the specified torque A
(100 N⋅m).
AC706531 AB
Approx. 5 mm 2. Measure the thickness of the brake lining at the

area with the worst wear.
Standard value (A): 4.0 mm
Limit value (A): 1.0 mm
CAUTION
AC706529AC
If there is a significant difference in thickness
3. Place a dial gauge ca. 5 mm inward from the between the shoe & lining assemblies in right
circumference of the brake disc to measure its and left, check the sliding status of the piston.
runout. 3. If the thickness of brake lining is less than the limit
Limit: 0.06 mm value, replace both the shoe & lining assemblies
as a complete axle set.
OTHERS
BRAKE DRUM INSIDE DIAMETER CHECK REAR WHEEL CYLINDERS CHECK

1. Remove the brake drum. Wheel cylinder
ACA03238 AB
AC706532 AB 1. Remove the brake drum.

2. Measure the inside diameter of the brake drum at 2. Check if the liquid leaks from around the boot of
two positions or more. the wheel cylinder visually or by touching with
fingers.
Standard value (A): 203.0 mm
Limit value (A): 205.0 mm
3. If the inside diameter of brake drum is less than
the limit value, or if there is a significant uneven
wear, replace the brake drum.
OTHERS
F1. CHECK BODY CONDITION FOR 2. Check efficiency of service brakes and parking
DAMAGE brakes system.
M6020700100414 3. Check driveability of engine.
1. Check underbody coating for damage.
4. Check condition of instruments, gauges
2. Check body painting for damage. indicators, exterior lamps, heater and ventilators.
F2. ROAD TEST 5. Check abnormal noise of each part.
M6020700200693 6. Check the tyres for wear and for the correct air
Drive the vehicle and check for conditions. pressure.
1. Check free play of steering wheel.

Mitsubishi I-MIEV Service Repair Manual - Safety Precautions

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Mitsubishi I-MIEV Service Repair Manual - Safety Precautions

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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

SPECIAL TOOLS PARTS

Be careful to avoid spilling any petrol, oil, etc.,

If any of the following parts are removed, they must LUBRICANTS

In accordance with the instructions in this manual,

BRAKE FLUID APPLICATION OF ANTI-CORROSION

ACX00880AD If high-pressure car-washing equipment or steam

MULTI USE TESTER (M.U.T.-III) SUB ENGINE OILS

Diagnosis connector Other precautions:

NOTES CONCERNING ENTRIES . . . 1-3 UNDER VEHICLE . . . . . . . . . . . . . . . . 1-14

BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 BEFORE ROAD TEST . . . . . . . . . . . . 1-16

ROAD TEST . . . . . . . . . . . . . . . . . . . . 1-18 37. MANUAL TRANSMISSION

NOTES CONCERNING ENTRIES

TABLE OF PRE-DELIVERY INSPECTION

Term Definition Remark

Press down the storage connector. After the connec-

1. Location of production date

Vehicles may be shipped from the assembly plant to

Flow Chart of Wrap Film Removal

If adhesive residue is left on the painted surface, wipe it off

Dispose removed film according to local

The procedures to re-apply the wrap film

If there is an environment that the vehicles in stock

Steps. Process Tips

Steps. Process Tips

3. EXTERIOR 6. Verify that all doors can be locked by the lock

4. OPERATION OF DOOR LOCKING

7. Verify that the rear doors can't be opened by the

12. ELECTRICAL WIRING

Inspect the battery connections. Verify that they are

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

14. SUSPENSION SYSTEM 15. STEERING LINKAGE AND SPLIT PINS

16. UNDER BODY

With the vehicle correctly positioned on the

BEFORE ROAD TEST

19. IDLE CONTROL KNOB

20. INSTRUMENT PANEL CONTROLS

24. OPERATION OF SERVICE BRAKES

Depress the brake pedal

2. Heater and defroster

23. WIPERS AND WASHERS

(2) Verify correct brake pedal free play.

30. STEERING CONTROL

AFTER ROAD TEST

38. AUTOMATIC TRANSMISSION FLUID TYPE 1 TYPE 2

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

39. ENGINE, TRANSMISSION, STEERING

40. FRONT AND REAR DIFFERENTIAL

43. EQUIPMENT 1. Verify that the owner's manual and service

Check the installation of the various equipment.

PERIODIC INSPECTION AND OPERATIONS UNDER

OPERATIONS OUTSIDE E5. CHECK BRAKE SHOE LININGS

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE

Maintenance item Maintenance Maintenance interval

OPERATIONS INSIDE THE ELECTRIC MOTOR UNIT ROOM

HIGH-VOLTAGE COMPONENTS • A/C COMPRESSOR

3. Slide the front seat (LH) to the end, and turn up

Remove the service plug under the front seat (LH)

SERVICE PLUG AND SERVICE LID