Mitsubishi L400 Repair Service Manual 1994-1999
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi L400 1994-1999, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi L400 1994-1999 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Mitsubish
YEAR: 1994, 1995, 1996, 1997, 1998, 1999 (2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 applicable)
MODEL: Delica L400 (Space Gear, Starwagon)
PRODUCT DETAILS:
Total Pages: 2,211 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Chassis & Engine....1
'95....1
PWEE9410_L400_95_CHASSIS_00....1
GENERAL....1
HOW TO USE THIS MANUAL....2
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS....2
DEFINITION OF TERMS....2
INDICATION OF TIGHTENING TORQUE....2
MODEL INDICATIONS....3
EXPLANATION OF MANUAL CONTENTS....4
HOW TO USE TROUBLESHOOTING / INSPECTION SERVICE POINTS....6
TROUBLESHOOTING CONTENTS....6
HOW TO USE THE INSPECTION PROCEDURES....7
CONNECTOR MEASUREMENT SERVICE POINTS....8
CONNECTOR INSPECTION....9
INSPECTION SERVICE POINTS FOR A BLOWN FUSE....10
POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS....10
VEHICLE IDENTIFICATION....11
VEHICLE INFORMATION CODE PLATE....11
MODELS....12
MODEL CODE....13
CHASSIS NUMBER....14
ENGINE MODEL NUMBER....15
MAJOR SPECIFICATIONS....16
PRECAUTIONS BEFORE SERVICE....19
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)-AIR BAG....22
SUPPORT LOCATIONS FOR LIFTING AND JACKING....26
SUPPORT POSITIONS (OR A GARAGE JACK AND AXLE STANDS....26
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT AND H-BAR LIFT....27
STANDARD PARTS-TIGHTENING-TORQUE TABLE....28
MAIN SEALANT AND ADHESIVE TABLE....29
PWEE9410_L400_95_CHASSIS_11....31
ENGINE....31
4G6....33
GENERAL INFORMATION....34
SERVICE SPECIFICATIONS....36
SEALANT....36
SPECIAL TOOLS....37
SERVICE ADJUSTMENT PROCEDURES <CARBURETTOR>....39
DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....39
IGNITION TIMING INSPECTION AND ADJUSTMENT....40
IDLE SPEED INSPECTION AND ADJUSTMENT....41
IDLE FEEDBACK CHECK....42
IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT FOR ABS....44
COMPRESSION PRESSURE INSPECTION....45
INTAKE MANIFOLD VACUUM INSPECTION....46
LASH ADJUSTER CHECK....47
SERVICE ADJUSTMENT PROCEDURES <MPI>....49
DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....49
IGNITION TIMING INSPECTION AND ADJUSTMENT....49
IDLE SPEED INSPECTION....50
IDLE MIXTURE INSPECTION....51
COMPRESSION PRESSURE INSPECTION....51
INTAKE MANIFOLD VACUUM INSPECTION....53
LASH ADJUSTER CHECK....53
CAMSHAFT....54
CAMSHAFT OIL SEAL....56
OIL PAN, OIL SCREEN....59
CYLINDER HEAD GASKET....61
TIMING BELT, TIMING BELT B....68
CRANKSHAFT FRONT OIL SEAL....74
CRANKSHAFT REAR OIL SEAL....76
ENGINE ASSEMBLY....78
4D5....84
GENERAL INFORMATION....85
SERVICE SPECIFICATIONS....87
SEALANTS....87
SPECIAL TOOLS....88
SERVICE ADJUSTMENT PROCEDURES....89
DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....89
VALVE CLEARANCE INSPECTION AND ADJUSTMENT....91
INJECTION TIMING INSPECTION AND ADJUSTMENT....92
IDLE SPEED INSPECTION AND ADJUSTMENT....95
IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT-FOR A/C....95
IDLE-UP MECHANISM INSPECTION AND ADJUSTMENT - FOR ABS....96
COMPRESSION PRESSURE INSPECTION....96
TIMING BELT TENSION ADJUSTMENT....98
TIMING BELT "B" TENSION ADJUSTMENT....99
CRANKSHAFT PULLEY....100
CAMSHAFT, CAMSHAFT OIL SEAL....101
OIL PAN, OIL SCREEN....104
CYLINDER HEAD GASKET....106
TIMING BELT/TIMING BELT B....109
CRANKSHAFT FRONT OIL SEAL....113
CRANKSHAFT REAR OIL SEAL....114
ENGINE ASSEMBLY....116
PWEE9410_L400_95_CHASSIS_12....120
LUBRICATION....120
GENERAL INFORMATION....121
LUBRICANTS....122
SERVICE ADJUSTMENT PROCEDURES....122
ENGINE OIL INSPECTION....122
ENGINE OIL REPLACEMENT....122
OIL FILTER REPLACEMENT....124
OIL LEVEL WARNING SYSTEM INSPECTION....124
ENGINE OIL COOLER <4D56>....126
PWEE9410_L400_95_CHASSIS_13....127
FUEL....127
MULTIPOINT FUEL INJECTION (MPI)....129
GENERAL INFORMATION....130
SERVICE SPECIFICATIONS....133
SEALANT....133
SPECIAL TOOLS....133
TROUBLESHOOTING....135
SERVICE ADJUSTMENT PROCEDURES....207
THROTTLE BODY (THROTTLE VALVE AREA) CLEANING....207
IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT....207
FIXED SAS ADJUSTMENT....209
BASIC IDLE SPEED ADJUSTMENT....209
FUEL PRESSURE TEST....211
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)....214
FUEL PUMP OPERATION CHECK....214
ON-VEHICLE INSPECTION OF MPI COMPONENTS....215
COMPONENT LOCATION....215
CONTROL RELAY INSPECTION....218
INTAKE AIR TEMPERATURE SENSOR INSPECTION....219
ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....219
THROTTLE POSITION SENSOR INSPECTION....220
IDLE POSITION SWITCH INSPECTION....220
OXYGEN SENSOR INSPECTION....221
INJECTOR INSPECTION....222
IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) INSPECTION....223
PURGE CONTROL SOLENOID VALVE INSPECTION....223
EGR CONTROL SOLENOID VALVE INSPECTION....223
INJECTOR....224
THROTTLE BODY....226
ELECTRONIC CONTROLLED CARBURETTOR....227
GENERAL INFORMATION....228
SERVICE SPECIFICATIONS....229
SEALANT....230
SPECIAL TOOLS....230
SERVICE ADJUSTMENT PROCEDURES....231
CARBURETTOR APPEARANCE....231
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT....232
CARBURETTOR SECONDARY VALVE OPERATION INSPECTION....232
CARBURETTOR ACCELERATION PUMP INSPECTION....233
CHOKE VALVE INSPECTION....233
ELECTRIC AUTO CHOKE INSPECTION....234
ELECTRIC CHOKE HEATER INSPECTION....235
ELECTRIC CHOKE RELAY INSPECTION....235
CHOKE BREAKER SYSTEM INSPECTION....236
CHOKE BREAKER OPENING INSPECTION AND ADJUSTMENT....236
FAST IDLE INSPECTION AND ADJUSTMENT....237
AUXILIARY ACCELERATOR PUMP (AAP) INSPECTION....239
VACUUM SWITCH CONTROL VACUUM INSPECTION....239
FUEL PUMP CONTROL SYSTEM INSPECTION....240
INSPECTION PROCEDURES USING THE ECI CHECKER....241
COMPONENT LOCATION....243
ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....245
THROTTLE POSITION SENSOR (TPS) INSPECTION....245
ENGINE SPEED SENSOR (IGNITION COIL (-) TERMINAL) INSPECTION....246
VACUUM SWITCH INSPECTION....246
OXYGEN SENSOR INSPECTION....247
FEEDBACK SOLENOID VALVE (FBSV) INSPECTION....247
STOW CUT SOLENOID VALVE (SCSV) INSPECTION....248
CARBURETTOR....249
DIESEL FUEL....250
GENERAL INFORMATION....251
SERVICE SPECIFICATIONS....251
SPECIAL TOOL....251
SERVICE ADJUSTMENT PROCEDURES....251
FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT....251
ENGINE IDLING SPEED INSPECTION AND ADJUSTMENT....251
FUEL DISCHARGE PREVENTION....251
EVACUATION OF WATER FROM FUEL FILTER....252
EVACUATION OF AIR FROM FUEL LINE....252
FUEL FILTER CARTRIDGE REPLACEMENT....252
FUEL INJECTION PUMP INSPECTION....253
BOOST COMPENSATOR INSPECTION....253
INJECTION NOZZLE INSPECTION AND ADJUSTMENT....253
INJECTION NOZZLE....255
INJECTION PUMP....257
FUEL SUPPLY AND ENGINE CONTROL....259
GENERAL INFORMATION....260
SERVICE ADJUSTMENT PROCEDURES....260
ACCELERATOR CABLE INSPECTION AND ADJUSTMENT....260
FUEL FILTER CARTRIDGE REPLACEMENT <Diesel-powered Vehicles>....261
POWER RELAY CHECK <Diesel-powered Vehicles>....261
FUEL TANK....262
ACCELERATOR CABLE AND PEDAL....265
FUEL FILTER <PETROL-POWERED VEHICLES>....267
FUEL FILTER <DIESEL-POWERED VEHICLES>....268
PWEE9410_L400_95_CHASSIS_14....270
COOLING....270
GENERAL INFORMATION....271
SERVICE SPECIFICATIONS....271
LUBRICANT....271
SEALANTS....272
SERVICE ADJUSTMENT PROCEDURES....272
RADIATOR CAP VALVE OPENING PRESSURE....272
ENGINE COOLANT REPLACEMENT....272
CONCENTRATION MEASUREMENT....274
COOLING FAN....275
THERMOSTAT....277
WATER PUMP....280
WATER HOSE AND WATER PIPE....282
RADIATOR....285
PWEE9410_L400_95_CHASSIS_15....287
INTAKE AND EXHAUST....287
SERVICE SPECIFICATIONS....288
SPECIAL TOOL....288
SEALANT....288
SERVICE ADJUSTMENT PROCEDURES....289
INTAKE MANIFOLD VACUUM INSPECTION....289
TURBOCHARGER SUPERCHARGING INSPECTION....289
WASTE GATE ACTUATOR INSPECTION....289
AIR TEMPERATURE SWITCH INSPECTION....290
POWER RELAY CHECK....290
AIR CLEANER....291
INTERCOOLER AND INTERCOOLER FAN-ECU....294
INTAKE MANIFOLD....295
<4G63 (CARBURETTOR)>....295
<4G63 (MPI), 4G64>....297
INTAKE AND EXHAUST MANIFOLD, TURBOCHARGER <4D56>....299
EXHAUST MANIFOLD <4G63, 4G64>....301
EXHAUST PIPE AND MAIN MUFFLER....302
PWEE9410_L400_95_CHASSIS_16....305
ENGINE ELECTRICAL....305
CHARGING SYSTEM....306
GENERAL INFORMATION....306
SERVICE SPECIFICATIONS....307
SPECIAL TOOL....308
SERVICE ADJUSTMENT PROCEDURES....308
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST....308
OUTPUT CURRENT TEST....309
REGULATED VOLTAGE TEST....311
CHECKING WITH AN ANALYZER....313
ALTERNATOR....315
STARTING SYSTEM....316
GENERAL INFORMATION....316
IGNITION SYSTEM....317
GENERAL INFORMATION....317
SERVICE SPECIFICATIONS....319
LUBRICANT....320
SPECIAL TOOLS....320
SERVICE ADJUSTMENT PROCEDURES....320
CENTRIFUGAL ADVANCE CONTROL DEVICE INSPECTION <Carburettor>....320
VACUUM ADVANCE CONTROL DEVICE INSPECTION <Carburettor>....321
IGNITION COIL INSPECTION....321
POWER TRANSISTOR INSPECTION <MPI>....322
RESISTIVE CODE INSPECTION....323
SPARK PLUG CHECK AND CLEANING....323
WAVE-FORM INSPECTION USING AN ANALYZER (Ignition Primary and Secondary Voltage wawe-forms)....324
DISTRIBUTOR....331
GLOW SYSTEM....333
GENERAL INFORMATION....333
SERVICE SPECIFICATIONS....334
SEALANT....334
SERVICE ADJUSTMENT PROCEDURES....335
SELF-REGULATING GLOW SYSTEM INSPECTION....335
GLOW CONTROL UNIT INSPECTION....336
GLOW PLUG RELAY INSPECTION....338
GLOW PLUG INSPECTION....338
ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....339
GLOW PLUG....340
PWEE9410_L400_95_CHASSIS_17....341
EMISSION CONTROL....341
EMISSION CONTROL <MPI>....343
GENERAL INFORMATION....343
EMISSION CONTROL DEVICE REFERENCE TABLE....343
SERVICE SPECIFICATIONS....344
SEALANT....344
VACUUM HOSE....344
VACUUM HOSE PIPING DIAGRAM....344
VACUUM CIRCUIT DIAGRAM....345
VACUUM HOSE INSPECTION....345
VACUUM HOSE INSTALLATION....345
CRANKCASE EMISSION CONTROL SYSTEM....346
GENERAL INFORMATION....346
SYSTEM DIAGRAM....346
COMPONENT LOCATION....346
POSITIVE CRANKCASE VENTILATION SYSTEM INSPECTION....347
PCV VALVE INSPECTION....347
EVAPORATIVE EMISSION CONTROL SYSTEM....348
GENERAL INFORMATION....348
SYSTEM DIAGRAM....348
COMPONENT LOCATION....348
PURGE CONTROL SYSTEM INSPECTION....349
PURGE PORT VACUUM INSPECTION....349
PURGE CONTROL SOLENOID VALVE INSPECTION....350
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....351
GENERAL INFORMATION....351
OPERATION....351
SYSTEM DIAGRAM....351
COMPONENT LOCATION....351
EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM INSPECTION....352
EGR VALVE INSPECTION....352
EGR PORT VACUUM INSPECTION....353
EGR CONTROL SOLENOID VALVE INSPECTION....353
CATALYTIC CONVERTER....354
GENERAL INFORMATION....354
CANISTER....355
TWO-WAY VALVE....356
EMISSION CONTROL <ELECTRONIC CONTROLLED CARBURETTOR>....357
GENERAL INFORMATION....357
EMISSION CONTROL DEVICE REFERENCE TABLE....358
SERVICE SPECIFICATION....358
SEALANT....358
VACUUM HOSE....359
VACUUM HOSE PIPING DIAGRAM....359
VACUUM HOSE INSPECTION....359
VACUUM HOSE INSTALLATION....359
CRANKCASE EMISSION CONTROL SYSTEM....360
EVAPORATIVE EMISSION CONTROL SYSTEM....360
GENERAL INFORMATION....360
SYSTEM DIAGRAM....360
COMPONENT LOCATION....360
PURGE CONTROL SYSTEM INSPECTION....361
PURGE CONTROL VALVE INSPECTION....361
THERMO VALVE INSPECTION....361
PURGE PORT (D NIPPLE) VACUUM INSPECTION....362
BOWL VENT VALVE INSPECTION....363
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....364
GENERAL INFORMATION....364
SYSTEM DIAGRAM....364
COMPONENT LOCATION....364
EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM INSPECTION....365
VACUUM REGULATOR VALVE INSPECTION....365
EGR VALVE INSPECTION....365
THERMO VALVE INSPECTION....365
EGR PORT VACUUM INSPECTION....366
SECONDARY AIR SUPPLY SYSTEM....367
GENERAL INFORMATION....367
SYSTEM DIAGRAM....367
COMPONENT LOCATION....368
SECONDARY AIR SUPPLY SYSTEM INSPECTION....368
SECONDARY AIR CONTROL VALVE INSPECTION....368
SECONDARY AIR CONTROL SOLENOID VALVE INSPECTION....369
VACUUM TANK INSPECTION....369
INTAKE AIR TEMPERATURE CONTROL SYSTEM....370
GENERAL INFORMATION....370
SYSTEM DIAGRAM....370
INTAKE AIR TEMPERATURE CONTROL SYSTEM INSPECTION....370
AIR CONTROL VALVE INSPECTION....371
THERMO SENSOR INSPECTION....371
MIXTURE CONTROL VALVE (MCV)....372
GENERAL INFORMATION....372
MIXTURE CONTROL VALVE (MCV) INSPECTION....372
CATALYTIC CONVERTER....373
GENERAL INFORMATION....373
CANISTER....374
TWO-WAY VALVE....374
EMISSION CONTROL <DIESEL>....375
GENERAL INFORMATION....375
SERVICE SPECIFICATIONS....375
SEALANT....375
SPECIAL TOOL....375
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....376
GENERAL INFORMATION....376
SYSTEM DIAGRAM....376
COMPONENT LOCATION....376
FUNCTION INSPECTION....377
EGR SOLENOID VALVE OPERATION INSPECTION....377
EGR SOLENOID VALVE RESISTANCE INSPECTION....378
LEVER POSITION SENSOR (LPS) ADJUSTMENT....378
ENGINE SPEED SENSOR INSPECTION....379
ENGINE COOLANT TEMPERATURE SENSOR INSPECTION....379
CHECK AT THE GLOW AND EGR CONTROL UNIT....380
TWO-WAY VALVE....381
PWEE9410_L400_95_CHASSIS_21....382
CLUTCH....382
<CABLE TYPE>....383
GENERAL INFORMATION....383
SERVICE SPECIFICATIONS....383
SERVICE ADJUSTMENT PROCEDURES....383
CLUTCH PEDAL INSPECTION AND ADJUSTMENT....383
CLUTCH PEDAL....385
CLUTCH CONTROL....387
<HYDRAULIC TYPE>....388
GENERAL INFORMATION....388
SERVICE SPECIFICATIONS....388
LUBRICANTS....388
SERVICE ADJUSTMENT PROCEDURES....388
CLUTCH PEDAL INSPECTION AND ADJUSTMENT....388
BLEEDING....389
CLUTCH PEDAL....390
CLUTCH CONTROL....392
CLUTCH MASTER CYLINDER....394
PWEE9410_L400_95_CHASSIS_22....395
MANUAL TRANSMISSION....395
GENERAL INFORMATION....396
SERVICE SPECIFICATION....397
LUBRICANTS....397
SEALANTS....397
SERVICE ADJUSTMENT PROCEDURES....397
OIL LEVEL CHECK....397
OIL REPLACEMENT....398
4WD DETECTION SWITCH CONTINUITY INSPECTION <4WD>....399
HIGH/LOW DETECTION SWITCH CONTINUITY INSPECTION <4WD>....399
TRANSMISSION CONTROL <2WD-COLUMN SHIFT>....400
TRANSMISSION CONTROL <2WD-FLOOR SHIFT>....403
TRANSMISSION CONTROL <4WD-FLOOR SHIFT>....404
TRANSMISSION ASSEMBLY <2WD>....407
TRANSMISSION ASSEMBLY <4WD>....410
4WD INDICATOR-ECU....412
PWEE9410_L400_95_CHASSIS_23....414
AUTOMATIC TRANSMISSION....414
GENERAL INFORMATION....415
SERVICE SPECIFICATIONS....415
LUBRICANTS....416
SPECIAL TOOLS....416
TROUBLESHOOTING....417
SERVICE ADJUSTMENT PROCEDURES....423
AUTOMATIC TRANSMISSION FLUID INSPECTION....423
AUTOMATIC TRANSMISSION FLUID CHANGE....424
THROTTLE CABLE CHECK AND ADJUSTMENT....424
INHIBITOR SWITCH CONTINUITY INSPECTION....425
INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT....425
A/T CONTROL COMPONENT LOCATION....426
A/T CONTROL COMPONENT INSPECTION....427
CONVERTER STALL TEST....428
HYDRAULIC PRESSURE TEST....429
GOVERNOR PRESSURE TEST....429
HYDRAULIC CIRCUIT....431
TRANSMISSION CONTROL....443
TRANSMISSION ASSEMBLY....447
TRANSMISSION OIL COOLER....451
PWEE9410_L400_95_CHASSIS_25....452
PROPELLER SHAFT....452
GENERAL INFORMATION....453
SERVICE SPECIFICATIONS....454
LUBRICANT....454
SPECIAL TOOLS....454
PROPELLER SHAFT....455
PWEE9410_L400_95_CHASSIS_26....463
FRONT AXLE....463
GENERAL INFORMATION....464
SERVICE SPECIFICATIONS....466
LUBRICANTS....466
SEALANTS....467
SPECIAL TOOLS....467
SERVICE ADJUSTMENT PROCEDURES....471
WHEEL BEARING PLAY INSPECTION....471
FRONT AXLE TOTAL BACKLASH CHECK....471
FRONT AXLE GEAR OIL LEVEL CHECK....472
DRIVE SHAFT AXIAL PLAY CHECK....472
DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT....472
SOLENOID VALVE OPERATION CHECK....473
FRONT HUB ASSEMBLY <2WD>....475
FRONT HUB ASSEMBLY <4WD>....478
KNUCKLE <2WD>....482
KNUCKLE <4WD>....484
DRIVE SHAFT....489
INNER SHAFT....497
DIFFERENTIAL CARRIER....501
FREE-WHEELING CLUTCH....521
PWEE9410_L400_95_CHASSIS_27....527
REAR AXLE....527
GENERAL INFORMATION....528
SERVICE SPECIFICATIONS....530
LUBRICANTS....532
SEALANTS....532
SPECIAL TOOLS....533
SERVICE ADJUSTMENT PROCEDURES....536
REAR AXLE TOTAL BACKLASH CHECK....536
AXLE SHAFT AXIAL PLAY CHECK....536
AXLE SHAFT AXIAL PLAY ADJUSTMENT <2WD (without ABS)>....536
GEAR OIL LEVEL CHECK....537
LIMITED SLIP DIFFERENTIAL PRELOAD MEASUREMENT....538
AXLE HOUSING OIL SEAL REPLACEMENT....538
AXLE ASSEMBLY....539
AXLE SHAFT <VEHICLES WITH DRUM BRAKE>....543
AXLE SHAFT <VEHICLES WITH DISC BRAKE>....551
DIFFERENTIAL CARRIER....557
LIMITED SLIP DIFFERENTIAL CASE ASSEMBLY <2WD 4G63>....576
LIMITED SLIP DIFFERENTIAL CASE ASSEMBLY <EXCEPT 2WD VEHICLES WITH 4G63 ENGINE>....581
PWEE9410_L400_95_CHASSIS_31....587
WHEEL AND TYRE....587
GENERAL INFORMATION....588
SERVICE SPECIFICATIONS....588
TROUBLESHOOTING....589
SERVICE ADJUSTMENT PROCEDURES....590
TYRE INFLATION PRESSURE CHECK....590
TYRE WEAR CHECK....590
WHEEL RUNOUT CHECK....590
WHEEL AND TYRE....590
PWEE9410_L400_95_CHASSIS_32....591
POWER PLANT MOUNT....591
GENERAL INFORMATION....592
SPECIAL TOOLS....593
FRONT ENGINE MOUNT <2WD>....594
FRONT ENGINE MOUNT <4WD>....595
REAR ENGINE MOUNT....596
FRONT DIFFERENTIAL MOUNT....597
FRONT DIFFERENTIAL MOUNT INSULATOR REPLACEMENT....598
SUSPENSION CROSSMEMBER ASSEMBLY <2WD>....599
SUSPENSION CROSSMEMBER ASSEMBLY <4WD>....601
PWEE9410_L400_95_CHASSIS_33....603
FRONT SUSPENSION....603
GENERAL INFORMATION....604
SERVICE SPECIFICATIONS....606
SEALANTS....606
SPECIAL TOOLS....607
SERVICE ADJUSTMENT PROCEDURES....609
FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT....609
SHOCK ABSORBER AND LOWER ARM....612
UPPER ARM....617
TORSION BAR....621
STRUT BAR <2WD>....624
STABILIZER BAR....625
PWEE9410_L400_95_CHASSIS_34....628
REAR SUSPENSION....628
GENERAL INFORMATION....629
SERVICE SPECIFICATIONS....631
SPECIAL TOOLS....631
SERVICE ADJUSTMENT PROCEDURES....632
REAR WHEEL ALIGNMENT....632
REAR SUSPENSION ASSEMBLY <LEAF SPRING TYPE>....633
REAR SUSPENSION ASSEMBLY <COIL SPRING TYPE>....636
STABILIZER BAR <COIL SPRING TYPE>....638
PWEE9410_L400_95_CHASSIS_35....640
SERVICE BRAKES....640
BASIC BRAKE SYSTEM....642
GENERAL INFORMATION....643
SERVICE SPECIFICATIONS....645
LUBRICANTS....646
SEALANTS....646
SPECIAL TOOLS....646
TROUBLESHOOTING....647
SERVICE ADJUSTMENT PROCEDURES....650
BRAKE PEDAL INSPECTION AND ADJUSTMENT....650
STOP LAMP SWITCH INSPECTION....651
BRAKE BOOSTER OPERATING TEST....651
CHECK VALVE OPERATION CHECK....652
BRAKE BOOSTER VACUUM SWITCH CHECK <DIESEL-POWERED VEHICLES>....652
BLEEDING....652
LOAD SENSING SPRING LENGTH CHECK AND ADJUSTMENT....653
LOAD SENSING PROPORTIONING VALVE FUNCTION TEST....654
DISC BRAKE PAD CHECK AND REPLACEMENT....655
FRONT DISC BRAKE ROTOR INSPECTION....657
REAR BRAKE DISC RUN-OUT CHECK....658
REAR BRAKE DISC RUN-OUT CORRECTION....658
REAR BRAKE DISC THICKNESS CHECK....659
BRAKE LINING THICKNESS CHECK <VEHICLES WITH REAR DRUM BRAKE>....659
BRAKE DRUM INSIDE DIAMETER CHECK <VEHICLES WITH REAR DRUM BRAKE>....660
BRAKE LINING AND BRAKE DRUM CONNECTION CHECK <VEHICLES WITH REAR DRUM BRAKE>....660
BRAKE LINING THICKNESS CHECK <VEHICLES WITH REAR DISC BRAKE>....660
BRAKE DRUM INSIDE DIAMETER CHECK <VEHICLES WITH REAR DISC BRAKE>....661
BRAKE LINING AND BRAKE DRUM CONNECTION CHECK <VEHICLES WITH REAR DISC BRAKE>....661
BRAKE PEDAL....662
MASTER CYLINDER AND BRAKE BOOSTER....665
LOAD SENSING PROPORTIONING VALVE....671
FRONT DISC BRAKE <SINGLE PISTON TYPE>....673
FRONT DISC BRAKE <DUAL PISTON TYPE>....677
REAR DISC BRAKE....682
REAR DRUM BRAKE <2WD>....686
REAR DRUM BRAKE <4WD>....690
ANTI-SKID BRAKING SYSTEM (ABS) <2WD>....692
GENERAL INFORMATION....694
SERVICE SPECIFICATIONS....695
LUBRICANTS....695
SEALANTS....695
SPECIAL TOOLS....695
TROUBLESHOOTING....696
SERVICE ADJUSTMENT PROCEDURES....720
ABS OPERATION CHECK....721
MASTER CYLINDER AND BRAKE BOOSTER....726
HYDRAULIC UNIT....732
WHEEL SPEED SENSOR....734
STEEPING WHEEL SENSOR....736
ELECTRONIC CONTROL UNIT....737
ANTI-SKID BRAKING SYSTEM (ABS) <4WD>....738
GENERAL INFORMATION....739
SERVICE SPECIFICATION....740
SPECIAL TOOLS....740
TROUBLESHOOTING....741
G-SENSOR....750
PWEE9410_L400_95_CHASSIS_36....751
PARKING BRAKES....751
GENERAL INFORMATION....752
SERVICE SPECIFICATIONS....753
LUBRICANTS....753
SEALANT....753
SERVICE ADJUSTMENT PROCEDURES....754
PARKING BRAKE LEVER STROKE CHECK....754
PARKING BRAKE SWITCH CHECK....755
LINING RUNNING-IN....755
PARKING BRAKE LEVER....756
PARKING BRAKE CABLE....757
PARKING BRAKE DRUM....759
PWEE9410_L400_95_CHASSIS_37....761
STEERING....761
GENERAL INFORMATION....762
SERVICE SPECIFICATIONS....764
LUBRICANTS....765
SEALANT....765
SPECIAL TOOLS....765
SERVICE ADJUSTMENT PROCEDURE....767
STEERING WHEEL FREE PLAY CHECK....767
STEERING ANGLE CHECK....767
TIE ROD END BALL JOINT VARIATION CHECK (SHAFT DIRECTION)....768
TIE ROD END BALL JOINT STARTING TORQUE CHECK....768
STATIONARY STEERING EFFORT CHECK....769
CHECKING STEERING WHEEL RETURN TO CENTRE....769
DRIVE BELT TENSION CHECK....769
FLUID LEVEL CHECK....770
FLUID REPLACEMENT....770
BLEEDING....771
OIL PUMP PRESSURE TEST....772
POWER STEERING OIL PRESSURE SWITCH CHECK <PETROL>....774
STEERING WHEEL AND SHAFT....775
POWER STEERING GEAR BOX....781
POWER STEERING OIL PUMP....787
POWER STEERING HOSES....792
PWEE9410_L400_95_CHASSIS_42....798
BODY....798
HOOD....800
FENDER....801
SEALANT....801
SPECIAL TOOL....801
FENDER....802
FUEL FILLER DOOR....803
WINDOW GLASS....804
ADHESIVES....804
SPECIAL TOOLS....804
WINDOW REPAIR....805
WINDSHIELD....807
DELTA WINDOW GLASS....811
REAR WINDOW GLASS....813
QUARTER WINDOW GLASS....815
TAILGATE WINDOW GLASS....817
ROOF WINDOW GLASS....819
FRONT DOOR....821
SERVICE SPECIFICATIONS....821
SEALANT....821
SPECIAL TOOLS....821
TROUBLESHOOTING....822
SERVICE ADJUSTMENT PROCEDURES....831
DOOR FIT ADJUSTMENT....831
DOOR WINDOW GLASS ADJUSTMENT....831
SASH SPAN INSPECTION....831
POWER WINDOW SAFETY MECHANISM INSPECTION....832
DOOR OUTSIDE HANDLE PLAY INSPECTION....832
POWER WINDOW OPERATION CURRENT INSPECTION....832
CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION....832
DOOR INSIDE HANDLE PLAY INSPECTION AND ADJUSTMENT....832
FRONT DOOR ASSEMBLY....833
FRONT DOOR TRIM AND WATERPROOF FILM....835
DOOR GLASS AND REGULATOR....837
FRONT DOOR HANDLE AND LATCH....840
FRONT DOOR RUNCHANNEL....843
FRONT DOOR WEATHERSTRIP....844
SLIDE DOOR....845
SERVICE SPECIFICATIONS....845
SEALANT....845
SPECIAL TOOLS....845
TROUBLESHOOTING....845
SERVICE ADJUSTMENT PROCEDURES....846
DOOR FIT ADJUSTMENT....846
DOOR OUTSIDE HANDLE PLAY INSPECTION AND ADJUSTMENT....847
DOOR INSIDE HANDLE PLAY INSPECTION AND ADJUSTMENT....847
SLIDE DOOR ASSEMBLY....848
SLIDE DOOR TRIM AND WATERPROOF FILM....850
SLIDE DOOR HANDLE AND LATCH....851
SLIDE DOOR WEATHERSTRIP....853
TAILGATE....854
SERVICE SPECIFICATION....854
SEALANT....854
SPECIAL TOOLS....854
TROUBLESHOOTING....854
SERVICE ADJUSTMENT PROCEDURES....855
TAILGATE FIT ADJUSTMENT....855
TAILGATE HANDLE PLAY INSPECTION....855
TAILGATE ASSEMBLY....856
TAILGATE TRIM AND WATERPROOF FILM....858
TAILGATE HANDLE AND LATCH....859
FRONT SUNROOF....861
SERVICE SPECIFICATIONS....861
TROUBLESHOOTING....861
SERVICE ADJUSTMENT PROCEDURES....863
SUNROOF LEAKAGE INSPECTION....863
SUNROOF FIT ADJUSTMENT....863
FRONT SUNROOF....864
REAR SUNROOF....871
SERVICE SPECIFICATION....871
TROUBLESHOOTING....871
SERVICE ADJUSTMENT PROCEDURES....874
SUNROOF LEAKAGE INSPECTION....874
SUNROOF FIT ADJUSTMENT....874
REAR SUNROOF....875
CRYSTAL LITE ROOF SUNSHADE....884
UNDER COVER....886
PWEE9410_L400_95_CHASSIS_51....887
EXTERIOR....887
FRONT BUMPER....889
REAR BUMPER....890
GRILLES, GARNISHES AND MOULDINGS....891
SPECIAL TOOL....891
GRILLES, GARNISHES AND MOULDINGS....891
WINDSHIELD WIPER AND WASHER....892
SERVICE SPECIFICATION....892
WINDSHIELD WIPER AND WASHER....892
INSPECTION....894
COLUMN SWITCH INSPECTION....894
REAR WIPER AND WASHER....895
SERVICE SPECIFICATION....895
REAR WIPER AND WASHER....895
INSPECTION....897
COLUMN SWITCH INSPECTION....897
INTERMITTENT WIPER RELAY INSPECTION....897
WASHER MOTOR INSPECTION....898
HEADLAMP WASHER....899
INSPECTION....900
DOOR MIRROR....901
SPECIAL TOOL....901
DOOR MIRROR....901
INSPECTION....902
REAR UNDER GUARD <4WD>....903
ADHESIVE....903
REAR UNDER GUARD....903
STEP <4WD>....904
ADHESIVE....904
STEP....904
PWEE9410_L400_95_CHASSIS_52....905
INTERIOR....905
INTERIOR....907
ADHESIVE....908
SPECIAL TOOL....908
INSTRUMENT PANEL....908
TRIMS....913
HEADLINING (PASTE TYPE)....921
HEADLINING (MOULDED TYPE)....923
SEAT....926
FRONT SEAT....926
SECOND SEAT (BENCH TYPE)....928
SECOND SEAT (SEPARATE TYPE)....930
THIRD SEAT....932
HEATED SEAT SWITCH....934
SEAT BELT....935
FRONT SEAT BELT....935
SECOND SEAT BELT....936
THIRD SEAT BELT....937
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....938
SERVICE PRECAUTIONS....939
SERVICE SPECIFICATIONS....941
SPECIAL TOOLS....941
TEST EQUIPMENT....942
TROUBLESHOOTING....942
POST-COLLISION DIAGNOSIS....965
INDIVIDUAL COMPONENT SERVICE....968
WARNING/CAUTION LABELS....968
FRONT IMPACT SENSORS....969
SRS DIAGNOSIS UNIT (SOU)....971
AIR BAG MODULE AND CLOCK SPRING....974
AIR BAG MODULE DISPOSAL PROCEDURES....980
UNDEPLOYED AIR BAG MODULE DISPOSAL....980
DEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES....985
SENSOR CABLE INSTALLATION PROCEDURES....987
PWEE9410_L400_95_CHASSIS_54....989
CHASSIS ELECTRICAL....989
BATTERY....992
SERVICE SPECIFICATION....992
SERVICE ADJUSTMENT PROCEDURES....992
FLUID LEVEL AND SPECIFIC GRAVITY INSPECTION....992
VISUAL INSPECTION....992
CHARGING....993
BATTERY TESTING PROCEDURE....994
IGNITION SWITCH....995
TROUBLESHOOTING....995
IGNITION SWITCH....997
COMBINATION METERS....1001
SERVICE SPECIFICATIONS....1001
SEALANT....1002
SPECIAL TOOLS....1002
TROUBLESHOOTING....1003
SERVICE ADJUSTMENT PROCEDURES....1006
SPEEDOMETER INSPECTION....1006
TACHOMETER INSPECTION....1006
FUEL GAUGE SIMPLE INSPECTION....1007
FUEL GAUGE UNIT INSPECTION....1008
ENGINE COOLANT TEMPERATURE GAUGE SIMPLE INSPECTION....1009
ENGINE COOLANT TEMPERATURE GAUGE UNIT INSPECTION....1010
COMBINATION METERS....1010
MULTI-METER....1014
TROUBLESHOOTING....1014
SERVICE ADJUSTMENT PROCEDURE....1016
VOLTMETER SIMPLE INSPECTION....1016
MULTI-METER....1017
OUTSIDE TEMPERATURE SENSOR, INSIDE TEMPERATURE SENSOR....1018
SERVICE SPECIFICATIONS....1018
OUTSIDE TEMPERATURE SENSOR, INSIDE TEMPERATURE SENSOR....1018
HEADLAMP....1019
SERVICE SPECIFICATIONS....1019
SPECIAL TOOL....1019
TROUBLESHOOTING....1019
SERVICE ADJUSTMENT PROCEDURES....1021
HEADLAMP AIMING....1021
INTENSITY MEASUREMENT....1022
BULB REPLACEMENT....1022
HEADLAMP....1023
FRONT TURN-SIGNAL LAMP....1027
SIDE TURN-SIGNAL LAMP....1028
REAR COMBINATION LAMP, TAILGATE LAMP....1030
REAR FOG LAMP....1032
SPECIAL TOOL....1032
REAR FOG LAMP....1032
INTERIOR LAMP....1034
RHEOSTAT....1036
SPECIAL TOOL....1036
RHEOSTAT....1036
HAZARD LAMP SWITCH....1037
SPECIAL TOOL....1037
HAZARD LAMP SWITCH....1037
HORN....1038
CIGARETTE LIGHTER....1039
SPECIAL TOOL....1039
CIGARETTE LIGHTER....1039
ACCESSORY SOCKET....1041
CLOCK....1042
SPECIAL TOOL....1042
CLOCK....1042
RADIO AND TAPE PLAYER....1043
SPECIAL TOOL....1043
TROUBLESHOOTING....1043
QUICK-REFERENCE TROUBLESHOOTING CHART....1043
RADIO AND TAPE PLAYER WITH ANTI-THEFT SYSTEM....1059
RADIO AND TAPE PLAYER....1062
SPEAKER....1063
ANTENNA....1065
SPECIAL TOOL....1065
ANTENNA....1065
REAR WINDOW DEFOGGER....1067
SPECIAL TOOL....1067
SERVICE ADJUSTMENT PROCEDURE....1067
PRINTED-HEATER LINE INSPECTION....1067
REAR WINDOW DEFOGGER SWITCH....1068
PWEE9410_L400_95_CHASSIS_55....1070
HEATER, AIR CONDITIONER AND VENTILATION....1070
GENERAL INFORMATION....1072
SAFETY PRECAUTIONS....1073
SERVICE SPECIFICATIONS....1074
LUBRICANTS....1074
SEALANT....1075
SPECIAL TOOLS....1075
TROUBLESHOOTING....1075
SERVICE ADJUSTMENT PROCEDURES....1085
COMPRESSOR DRIVE BELT ADJUSTMENT....1085
SIGHT GLASS REFRIGERANT LEVEL TEST....1085
MAGNETIC CLUTCH TEST....1085
RECEIVER DRIER TEST....1085
CHARGING....1086
PERFORMANCE TEST....1090
REFRIGERANT LEAK REPAIR....1092
COMPRESSOR NOISE....1092
DUAL PRESSURE SWITCH CHECK....1093
POWER RELAY CHECK....1093
IDLE-UP OPERATION CHECK....1095
VACUUM ACTUATOR CHECK <4G63>....1096
IDLE-UP SOLENOID VALVE CHECK <4G63, 4D56>....1097
FRONT PANEL ASSEMBLY, REAR HEATER SWITCH AND FRONT A/C SWITCH....1099
FRONT HEATER UNIT AND FRONT HEATER CORE....1103
FRONT BLOWER MOTOR ASSEMBLY AND RESISTOR....1104
FRONT EVAPORATOR AND A/C-ECU....1106
REAR PANEL ASSEMBLY AND REAR A/C SWITCH <BUILT-IN TYPE>....1109
REAR EVAPORATOR ASSEMBLY <BUILT-IN TYPE>....1112
REAR EVAPORATOR ASSEMBLY <OVERHEAD TYPE>....1116
REAR HEATER UNIT <UNDER SEAT TYPE>....1120
REAR HEATER CORE, REAR BLOWER MOTOR ASSEMBLY AND RESISTOR <BUILT-IN TYPE>....1121
REAR HEATER CORE, REAR BLOWER MOTOR ASSEMBLY, BLOWER MOTOR LO RELAY AND RESISTOR <UNDER SEAT TYPE>....1124
HEATER HOSE....1126
COMPRESSOR AND TENSION PULLEY....1130
FRONT CONDENSER AND CONDENSER FAN MOTOR....1138
SIDE CONDENSER AND CONDENSER FAN MOTOR <DUAL A/C>....1140
REFRIGERANT LINE....1142
ENGINE COOLANT TEMPERATURE SWITCH....1149
IDLE-UP SYSTEM <4G63-Carburettor, 4D56>....1151
VENTILATORS....1152
VENTILATORS (INSTRUMENT PANEL)....1153
REAR VENTILATORS <BUILT-IN TYPE>....1155
ROOF DUCT <BUILT-IN TYPE>....1156
PWEE9410_L400_95_CHASSIS_COVER....1157
'96....1160
PWWE9410-A_L400_96_CHASSIS....1160
GENERAL....1162
MULTI POINT FUEL INJECTION (MPI)....1168
DIESEL FUEL....1171
MANUAL TRANSMISSION....1172
SERVICE BRAKES....1172
ANTISKID BRAKE SYSTEM (ABS) <4WD>....1173
EXTERIOR....1175
INTERIOR....1176
CHASSIS ELECTRICAL....1177
'97....1191
PWWE9410-B_L400_97_CHASSIS....1191
GENERAL....1193
MULTIPOINT FUEL INJECTION (MPI)....1199
GENERAL....1200
OUTLINE OF CHANGE....1200
GENERAL INFORMATION....1200
GENERAL SPECIFICATIONS....1200
TROUBLESHOOTING....1201
SERVICE ADJUSTMENT PROCEDURES....1203
CONTROL RELAY AND FUEL PUMP RELAY CONTINUITY CHECK....1203
REAR AXLE....1204
SERVICE BRAKES....1205
BASIC BRAKE SYSTEM....1205
ANTI-SKID BRAKE SYSTEM (ABS) <2WD>....1206
BODY....1209
INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....1214
INTERIOR....1214
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....1220
CHASSIS ELECTRICAL....1235
'98....1243
PWWE9410-C_L400_98_CHASSIS_00....1243
GENERAL....1243
VEHICLE IDENTIFICATION....1244
MODELS....1244
CHASSIS NUMBER....1246
MAJOR SPECIFICATIONS....1247
PWWE9410-C_L400_98_CHASSIS_13....1251
MULTIPOINT FUEL INJECTION (MPI)....1251
GENERAL INFORMATION....1252
OUTLINE OF CHANGES....1252
GENERAL SPECIFICATIONS....1252
SERVICE SPECIFICATIONS....1253
TROUBLESHOOTING....1254
ON-VEHICLE SERVICE....1315
PWWE9410-C_L400_98_CHASSIS_37A....1317
PWWE9410-C_L400_98_CHASSIS_42....1318
PWWE9410-C_L400_98_CHASSIS_51....1320
PWWE9410-C_L400_98_CHASSIS_52....1322
PWWE9410-C_L400_98_CHASSIS_54....1323
PWWE9410-C_L400_98_CHASSIS_COVER....1326
EWD....1328
Mitsubishi L400 Repair Service Manual 1994-1999
