manual pajero 4x4 exterior.docx

8/11/2019 manual pajero 4x4 exterior.docx

1/32

51-1

EXTERIORCONTENTS 51109000296

FRONT

BUMPER

. . . . . . . . . . . . . . . . . . . . . . .

2 WINDSHIELD

WIPER

ANDWASHER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16REAR

BUMPER

. . . . . . . . . . . . . . . . . . . . . . . .

4SERVICE SPECIFICATION . . . . . . . . . . . . . 16

BUMPER

GUARD

. . . . . . . . . . . . . . . . . . . . . .

6WINDSHIELD WIPERAND WASHER . . . 16

GRILLE, MOULDINGANDGARNISH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 REAR WIPERAND WASHER . . . . . . . . . . 19

SERVICE SPECIFICATION . . . . . . . . . . . . . 19SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . .7

REAR WIPERAND WASHER . . . . . . . . . . 19GRILLE, MOULDINGAND GARNISH . . . . .7

HEADLAMP

WASHER

. . . . . . . . . . . . . . . . .

22EXTERIOR PARTS . . . . . . . . . . . . . . . . . . . . . 9

MARKS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24WIDE

FENDER

. . . . . . . . . . . . . . . . . . . . . . . .

10DOOR

MIRROR

. . . . . . . . . . . . . . . . . . . . . . .

28SIDE

STEP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

SPECIAL

TOOL

. . . . . . . . . . . . . . . . . . . . . . .

28

SIDE

STEP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . . . 28


2/32

51-2 EXTERIOR Front Bumper

FRONT BUMPER 51100140263

REMOVALAND INSTALLATION

1

3

2

2

1A A

Removal steps

1. Front

bumper

side

stay2. Front

turn

signal

lamp3. Front

bumper

assembly

SectionA A

2

3


3/32

51-3EXTERIOR Front Bumper

DISASSEMBLY AND REASSEMBLY

2

51100160306

1

2

2.5 Nm

3 52.5 Nm

5A 7

A6 B

B

C7C

43

86

Clip

Disassembly steps

1. Front

bumper

beam

assembly2. Front

bumper

side

reinforcement3. Front

bumper

side

extension4. Licence

plate

bracket5. Fog

lamp

bracket

6. Fog

lamp

bezel7. Fog

lamp

8. Front

bumper

face

SectionA A

8 Clip

1

Section B B

8

1

Section C C

8

Clip

2


4/32

51-4 EXTERIOR Rear Bumper

REAR BUMPER 51100190282

REMOVAL AND INSTALLATION

1A

A

2

Removal steps

1. Rear

bumper

step2. Rear

bumper

assembly

Section

A

A 1

2

Clips

Pre-removal and Post-installation Operation

Luggage FloorBox,RearRemoval and Installation


5/32

51-5EXTERIOR Rear Bumper

DISASSEMBLYAND REASSEMBLY 51100210247

3 1 2

2A

4A1

B

B

5 4

Disassembly steps

1. Rear

bumper

side

reinforcement2. Rear

bumper

side

bracket3. Rear

bumper

reinforcementassembly

4. Rear

fog

lamp5. Rear

bumper

face

SectionA A

1

5

Clip

Section B B

5

Clip


6/32

51-6 EXTERIOR Bumper Guard

BUMPER GUARD 51101090017


2

5

4

2

3

1

4

Removal

steps

1. Licence

plate

2. Bumper

guard

side

plate3. Bumper

guard

lower

plate

4. Bumper

guard

side

5. Bumper

guard

center


Front Bumper Removal and Installation(Refer to P.51-2.)


7/32

51-7EXTERIOR Grille, Moulding andGarnish

GRILLE, MOULDINGAND

SPECIAL

TOOL

GARNISH 51100060248

GRILLE,

REMOVAL

MOULDINGAND GARNISH 51100350109

AND INSTALLATION

2

13 Nm

33

2

4

B1BA

A

]A}]B}

1. Radiator

grille2. Roof

drip

mouldingFront

deck garnish removal steps

3. Wiper

arm

and

blade

assembly(Refer to P.51-16.)

4. Front

deck

garnish

SectionA A

4

Clip

Clip

Section B B

Clip

Roofpanel

Tool Number Name Use

MB990449 Window

moulding

removerRoof

drip

moulding

removal


8/32

51-8 EXTERIOR Grille, Moulding andGarnish

A

A6

5 Nm7.5 Nm

7

8

5

NOTE

:Resinclipposition

:

Stud

position

Tailgate garnish removal steps

5. Licence

plate

lamp6. Rear

wiper

arm

and

bladeassembly

(Refer

to

P.51-19.)

7.

Grommet

(Refer

to

P.51-19.)

Tailgate

lower

trim8.

Tailgate

garnish

REMOVAL SERVICE POINTS

]A}RADIATOR GRILLE REMOVAL

1. Remove the screw at the centre of the radiator grille.2. Removetheradiatorgrillebypushingthetaboftheradiato

grille

clips

in

the

direction

of

the

arrows

with

a

flat-tipped

screwdriver,while lightly pulling the radiatorgrille towardyou.

]B}ROOF DRIP MOULDING REMOVAL

Use

the

special

tool

to

lever

out

the

moulding.

CautionDo not reuse the warped moulding.

MB990449

SectionA A

Nut

8Stud

Clip


9/32

51-9EXTERIOR Exterior

Parts

EXTERIOR PARTS 51101750014


21

3

4

78 Nm

78 Nm

7

65

78 Nm

Roof rail removal steps

Headlining1. Roof

rail

Roof spoiler removal steps

2. Spoiler

cover3. Roof

spoiler4. High-mounted

stop

lamp

Rear

under

guard

bar

removalsteps

5. Towing

hook6. Tie

down

bracket7. Rear

under

guard

bar}A]

INSTALLATION SERVICE POINT

}A]SPOILER COVER INSTALLATION

Installwiththearrowshownontherearsurfacefacingforward.


10/32

51-10 EXTERIOR Wide Fender

WIDE FENDER 51101380053


A

A2

A

A

3

11

NOTE:

Resin

clip

position

Removal steps

1. Rivet2. Front

flare3. Rear

flare

]A} }A]

REMOVAL SERVICE POINT

]A}RIVET REMOVAL

Use a drill ($4.0 5.5 mm) to break thehole, and remove the rivet.

rivet

by

drilling

a

Rivet

Wide fender

Drill

Section

A

A

2,3Clip


Mud Guard Removal and Installation


11/32

51-11EXTERIOR Wide Fender


}A]RIVET INSTALLATION

1.2.3.

Insert the rivet into the body panel and flare.Insert

A

of

the

rivet

into

the

riveter.Pressingtheflangesurfaceoftherivet,movethehandleof

the

riveter.The thinnest point ofA is cut and the rivet is held in

the

position.

4.

1

Riveter

Bodypanel Flare

A

Rivet

2

3 Riveter

Flange surface

4

Rivet


12/32


13/32

51-13EXTERIOR Side Step

SIDE STEP 51101150067


6

2.5Nm

22

4 3

A

7 2

12 NmA

8

NOTE:

Resin

clip

position 15

2

Double-sided tape [23 mm

Removal steps

}A] 1. Side step moulding

5. Side

step

cover6. Side

step

rear

reinforcement

(A)7. Side

step

inner

plate8. Side

step

pipe

assembly]A} }B] 2. Rivet

3. Side

step

rear

cover

4. Side

step

rear

reinforcement

(B)

REMOVAL

]A}RIVET

SERVICE

POINT

REMOVAL

Use a drill ($3.0 3.2 mm) to break the rivet by drilling ahole, and remove the rivet.

Rivet

Sidestepcover

Drill

1

Adhesivetape:

width

and

0.8

mm

thickness]

SECTION A A

8 2

Clip

7Clip 1


14/32

51-14 EXTERIOR Side Step

INSTALLATION SERVICE POINTS

}A]SIDE STEP MOULDING INSTALLATION

Double-sided tape affixing to the side step moulding(when reusing)

1. Scrape off the double-sided tape with a resin spatulaor gasket scraper.

2. Wipe

off

the

side

step

moulding

adhesion

surface

and

cleanitwithashoptowelmoistenedwithisopropylalcohol.Affix the specified double-sided tape to the side stepmoulding.

Specified adhesive tape:Double-sided tape 23 mm width and 0.8 mmthickness

3.

4. Remove

strip

paper

from

the

pressure

sensitive

double-sided tape.

NOTEAffixdouble-sidedtapetotheendofstrippaperforeaseof

strip

paper

removal.

Install the side step moulding.

NOTEIf

it

is

hard

to

affix

the

double-sided

tape

in

winter,

heat

the

application

surfaces

at

both

the

side

step

cover

andthe side step moulding.

Side step cover 40 60 C

Side step moulding 20 30 C

Apply

pressure

fully

to

the

side

step

moulding.

5.Adhesive tape

Backing paper


15/32

51-15EXTERIOR Side Step

}B]RIVET INSTALLATION

1.2.3.

Insert the rivet into the body panel and flare.InsertA of the rivet into the riveter.Pressing

the

flange

surface

of

the

rivet,

move

the

handle

of the riveter.The thinnest point ofA is cut and the rivet is held inthe position.

4.

Flare

1

ace

Body panel

A

Rivet

2

3Flange surf

4

Rivet

ve er


16/32


17/32


18/32

51-18 EXTERIOR Windshield

Wiper

and

Washer

Intermittent WiperInspection)

Relay (Intermittent Operation

1.2.3.

Connect the column switch connector.Turn

the

ignition

switch

to

ACC.Inspect the intermittent operation time when the wiperswitch is turned to INT.

Vehicles with variable intermittent control

FAST:

Approx.

2

secondsSLOW:Approx. 15 seconds

WIPER

MOTOR

CHECK 51101260142

Checkthewipermotorafterdisconnectingthewiringharnessconnector, and with the wiper motor remaining installed tothe body.

Wiper Motor at Low Speed and High Speed Operation

Connectabatterytothewipermotorasshownintheillustrationand inspect motor operation at low speed and high speed.

Wiper

Motor

at

Stop

Position

Operation1. Run

the

wiper

motor

at

low

speed,

disconnect

the

battery,and stop the motor.

2. Reconnect

the

battery

as

shown

in

the

illustration,

and

confirm thatafter the motor starts turningat lowspeed,it stops at the automatic stop position.

WASHER MOTOR CHECK 51101270060

1. With the washer motor installed to the washer tank, fillthe washer tank with water.

2. Check

that

the

water

squirts

out

strongly

when

battery

voltage is applied to terminals (1) and (2).

WASHER FLUID EJECTION POINTS CHECK 51100770202

Adjust

the

ejection

angle

by

moving

a

ball

in

the

nozzle.

B D

Ceramic end lineB:170mm

D:70mm E:50mm

A A

C

E

A:310mm

C:265mm

Inspection while operating

Lowspeed HighspeedInspection while stopped

Lowspeed Automatic

stop


19/32

51-19EXTERIOR Rear Wiper andWasher

REAR WIPERAND WASHER

SERVICE

SPECIFICATION

51100030249

REAR

WIPER

AND

WASHER 51100850210


67

2

34

65 7.5 Nm

5 Nm

8

9

NOTE

For

removal

and

installation

of

the

column

switch

assembly

(rear

wiper

and

washer

switch),

refer

to

GROUP

37ASteeringWheelandShaft.

1.

Rear

intermittent

wiper

relay

Wiper

motor removal steps

}B] 2.Wiper arm and blade assembly

Washer

tank

and

motor removal

steps

Quarter trim lower (Refer toGROUP

52A Trims.)

Washer

fluid

draining6.

Washer

hose8. Washer

tank9. Washer

motor

}A] 3. Grommet

Tailgate

garnish

(Refer

to

P.51-8.)4. Grommet5. Wiper

motor

Washer

hose

removal steps

Quarter

trim,

lower

(Refer

to

GROUP

52A Trims.)

6. Washer

hose7. Washer

nozzle

1

Item Standard

value

Rear

wiper

blade

installation

position

mm 65

75


20/32

51-20 EXTERIOR Rear Wiper and Washer

INSTALLATION SERVICE POINTS

}A]GROMMET INSTALLATION

Install the grommet so that the arrow points downwards.

}B]WIPERARMAND BLADE ASSEMBLYINSTALLATION

Install the wiper blade so that the tip stops at the standar position (standardvalue), and also so that the lowersectionofthewiperbladeentersthemiddleofthedefoggerpattern.

Standard value (A): 65 75 mm

INSPECTION

COLUMN SWITCH CHECK

Rear

Wiper

and

Washer

Switch

51100950118

Switch

position Terminal

No.

2 3 4 8

Wiper

switch INT

ON

Washer

switch ON

Switch

position Terminal

No.

2 3 4 10

Wiper

switch INT

ON

Washer

switch ON

. . . .

Ceramic sectionA

Defogger

pattern

Grommet

Arrow


21/32

51-21EXTERIOR Rear Wiper and Washer

WIPER MOTOR CHECK 51101290110

Check the wiper motor after first disconnecting the wiringharness connector, and with the wiper motor remaininginstalled to the body.

Wiper

Motor

Operation

Connectabatterytothewipermotorasshownintheillustration

and

inspect

the

motor

operation.Wiper

Motor

at

Stop

Position Operation

1. Run the wiper motor, disconnect the battery, and stopthe

motor.2. Reconnect the battery as shown in the illustration, and

confirm

that

after

the

motor

starts

turning

it

stops

at

the

automatic stop position.

INTERMITTENT WIPER RELAY CHECK 51101300097

1. Check that there iscontinuitybetween terminals (1)and(2).Connect terminals (4), (5) to the battery (+) terminal.Check

that

there

is

battery

voltage

at

terminal

(2)

forintermittent periods of eight seconds when terminal (7)is

connected

to

the

battery

() terminal.

2.3.

WASHER MOTOR CHECK 51101310106

1. With the washer motor installed to the washer tank, fillthe washer tank with water.

2. When the battery is connected as shown in the figure,check that the washer squirts out strongly.

Rear intermittentwiper relay

Operation check

Stop position check


22/32

51-22 EXTERIOR HeadlampWasher

HEADLAMP WASHER 51100970138


4

5 Nm4

5 Nm

2

3

1.

Headlamp

washer

relay NOTE1. For

removal

and

installation

of

the

column

switch

assembly

(built-in

headlamp

washer

switch),

refer

to

GROUP

37ASteeringWheelandShaft.

Washer nozzle and check valve

removal steps

Washer

fluid

draining

Front

bumper

(Refer

to

P.51-2.)2. Washer

hose3. Check

valve

4. Washer

nozzle

2. For

removal

and

installation

of

the

washer

tank,

refer

to

P.51-16.

INSPECTION 51100980070Connector

ACOLUMN SWITCH (HEADLAMP WASHER SWITCH)CHECK

Check the continuity between terminal (2) of connectorandterminal(1)ofconnectorBwithheadlampwasherswitchin ON position.

ConnectorB

1


23/32

51-23EXTERIOR Headlamp Washer

HEADLAMP WASHER RELAY CHECK 51101320062

1. Connectbatteryandtest lamptotherelayas illustrated.

2. The

relay

is

normal

if

the

lamp

lights

for

approximately0.5 second upon connection of terminal (3) to battery().

CHECK VALVE CHECK 51101330041

Apply pressure to the inlet of the check valve to check itsopening pressure.

Opening pressure: 78 kPa

HEADLAMP WASHER MOTOR CHECK 51101340044

1. Withtheheadlampwashermotorinstalledtothewashertank, fill the washer tank with water.

2. Check

that

the

water

squirts

out

strongly

when

battery

voltage is applied to terminals (1) and (2).

STEP 2 Test lamp

STEP 1 Test lamp


24/32

51-24 EXTERIOR Marks

MARKS

REMOVAL

51101180189

AND INSTALLATION

2

1

6

57 43

8

10

11

9

1. Top

mark2. V6

mark3. Fender

pin

stripe

tape4. Front

door

pin

stripe

tape5. Rear

door

pin

stripe

tape

6. Side

pin

stripe

tape7. MITSUBISHI

mark8. MITSUBISHI

mark

}A]}A]}A]

}A]}A]

}A]}A] 9. PAJERO SPORT mark (rear)}A] 10. 4WD decal}A] 11. GLX or GLS mark


25/32

51-25EXTERIOR Marks


}A]MARKS INSTALLATION

1. INSTALLATION POSITIONAttach

to

the

position

shown

in

the

illustration.PIN STRIPE TAPE

Align the notch at the section a with the end of the door panel.Fold the sections of protruding from the end of the fender panel and door panel inward.

Fender panelend lineFender pin

stripe tapeFrontdoorpanelend line Reardoorpanelend line Reardoor

pinstripe tape

a a

A A A B BAAlign tape end to frontwide fenderprotector end

Front

door

pin Align

to

the

two-toneAlign

to

the

two-toneline stripe

tape parting surfaceparting surface

Quarter outercorner centerextension end lineSidepinstripe tape

CC

Align

tape

end

to

rearwide

fender

protector

end Align tape end to sideAlign to the two-tone partingline panelend linesurface

SectionA A Section B B Section C C


26/32


27/32

51-27EXTERIOR Marks

2. INSTALLATION PROCEDURE

(1) Clean the mark installation surfaces on the body withunleaded petrol.

(2) Peel

off

the

backing

paper

from

the

reverse

side

of

the

marks, and then attach the marks to the vehicle bodyso

that

they

fit

properly

into

position.

Caution

When attaching the marks, the surroundingtemprerature

shouldbe2038Cand the air should

be

completely free

from

dust.If the surrounding temperature is lower than 20 C themarks and theplaces on thebody where themark are to be attached should be heated to 20 38 C.


28/32


29/32

51-29EXTERIOR Door Mirror

REMOVAL SERVICE POINT

]A}MIRROR REMOVAL

1. Tilt the mirror upward by hand, insert a flat-tippedscrewdriver

onto

which

protective

tape

has

been

wound,

and then pry the claws off of the actuator.

2.

Pull

the

mirror

downward

to

release

the

hooks.

INSPECTION 51100650162

REMOTE CONTROLLED MIRRORASSEMBLY CHECK

Check tobesure that the mirrormovesasdescribed in thetable when each terminal is connected to the battery.

Battery

connection

terminal Direction

operation

1 2 3

UP

DOWN

RIGHT

LEFT

A

A

Hook

SectionA A

Mirror Hook

Actuator

ClawsA

A

SectionA A

Mirror Claw

Actuator


30/32

51-30 EXTERIOR Door Mirror

1. Check to be sure that the mirror moves as described

in

the

table

when

each

terminal

is

connected

to

the

battery.2. Check

(2).if there is continuity between terminals (1) and

REMOTE CONTROLLED MIRROR SWITCHCONTINUITY CHECK 51101350108

Switch

position Terminal

No.

2 3 4 6 7 8 9

Left

side UP

DOWN

LEFT

RIGHT

Right

side UP

DOWN

LEFT

RIGHT

Battery

connection

terminal Direction

operation

5 6 7 1 4UP

DOWM

Printed

heating

wire

RIGHT

LEFT


31/32

51-31EXTERIOR Door Mirror

SWITCHAND RELAY OF DOOR MIRROR PRINTEDHEATING WIRE CHECK 51101360033

The printed heating wire of the door mirror operates inconjunction with the rear window defogger.Theswitchand relayareused for therearwindowdefoggeralso, so refer to GROUP 54 for inspection service points.


32/32

NOTES

Documents

manual pajero 4x4 exterior.docx