engine MITSUBISHI MONTERO 2000 Service Repair Manual

DIESEL FUEL <4M4> -Troubleshooting13C-8
Code No. 51 EGR valve assembly systemProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DEGR sensor output voltage is continuously 0.5 V or less, or 4.5 V or more
for 1 second or more
DDifference between EGR sensor output voltage target value and output is
continuously 0.5 V or more for 3 seconds or moreDMalfunction of EGR valve assembly
DOpen circuit or short-circuit in EGR valve
assembly circuit or poor connector connection
DMalfunction of engine-ECU
Check and repair the harness
between the engine-ECU and the
EGR valve assembly connector.
NG
OKCheck the trouble symptoms.
OK
Transient malfunction (Refer to
GROUP 00 - Point to Note for
Intermittent Malfunctions.)
NGMeasure at engine-ECU connector
D-113.
DConnector connected
DIgnition switch: ON
DVoltage between (90) and earth
OK:0.5 - 4.5 VCheck the following connector:
D-113NG
Repair OK
Check and repair the harness
between the engine-ECU and the
EGR valve assembly connector.
NG
OKCheck the trouble symptoms.
OK
Transient malfunction (Refer to
GROUP 00 - Point to Note for
Intermittent Malfunctions.)
OKMUT-IIdata list
31 EGR sensor (Target value)
32 EGR sensor (Output value)Transient malfunction (Refer to
GROUP 00 - Point to Note for
Intermittent Malfunctions.)
NGMeasure at EGR valve assembly
connector B-64.
DDisconnect the connector and
measure at the harness side.
DVoltage between (3) and earth
OK:4.5 - 5.5 V
(Ignition switch: ON)
DContinuity between (2) and earth
OK:ContinuityCheck the following connector:
D-112NG
Repair NG
To the next pageOK
Check and repair the harness
between the control relay and the
EGR valve assembly connector.
NG
OKCheck the trouble symptoms.
OK
Transient malfunction (Refer to
GROUP 00 - Point to Note for
Intermittent Malfunctions.)
NGMeasure at EGR valve assembly
connector B-64.
DIgnition switch: ON
DDisconnect the connector and
measure at the harness side.
DVoltage between (6) and earth
OK:System voltageCheck the following connector:
B-25XNG
Repair OK


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DIESEL FUEL <4M4> -Troubleshooting13C-9
Replace the engine-ECU.
Replace the EGR valve assembly.NG
Check the following connector:
D-113NG OK
Check and repair the harness
between the engine-ECU and the
EGR valve assembly connector.
NG
OKCheck the trouble symptoms.
OK
Transient malfunction (Refer to
GROUP 00 - Point to Note for
Intermittent Malfunctions.)
From the previous page
NGMeasure at engine-ECU connector
D-113.
DIgnition switch: ON
DDisconnect the connector and
measure at the harness side.
DVoltage between (17) and earth
OK:System voltageCheck the following connector:
B-64NG
Repair OK
NG
OKCheck the trouble symptoms.Transient malfunction (Refer to
GROUP 00 - Point to Note for
Intermittent Malfunctions.) OKRepair
Check the trouble symptoms.OK
End
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS
Inspection procedure 20
Excessive engine vibration when engine stopped
Probable cause
The cause is probably a malfunction of the throttle body assembly.DMalfunction of throttle body assembly (does not
close)
DOpen circuit or short-circuit in throttle body
assembly circuit or poor connector connection
MUT-IIdiagnosis code
Is a diagnosis code output?Ye sDiagnosis code classification chart (Refer to P.13C-3.)
No
Carry out MUT-IIservice data inspection and actuator test. (Refer
to P.13C-10.)OKCheck for seizure of throttle body assembly (stuck open)
(Refer to P.13C-42*.)
RepairNG
NOTE:
*: Refer to the 2001 PAJERO Workshop Manual (Pub. No. PWJE0001).


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DIESEL FUEL <4M4> -Troubleshooting13C-10
DATA LIST REFERENCE TABLE
Item No.Check itemInspection
conditionsValue to be
determined normalCode No. or
inspection
procedure No.Reference page
31EGR sensor
(Target value)Engine: RacingChanges between 0.5
V and 4.5 VCode No. 5113C-8
32EGR sensor
(Output value)Engine: RacingApproaches EGR
sensor (target value).Code No. 5113C-8
36Throttle body
assembly
(Target value)Engine: Idling30 degCode No. 4113C-6
ACTUATOR TEST TABLE
Item No.Check itemDrive contentsInspection
conditionsValue to be
determined as
normalCode No. or
inspection
procedure No.Reference
page
07Throttle body
assemblyThrottle valve:
Fully closedDIgnition
switch: ON
DVehicle
Operating
sound can be
heard
Code No. 4113C-6
08Throttle valve:
Kept at half-
openDVehicle
speed: 0 km/h
DEngine
speed: 1,000
r/minorlower
heard.
09Throttle valve:
Fully openr/minorlower
28EGR valve
assemblyEGR valve:
OpenDIgnition
switch: ON
DVehicle
Operating
sound can be
heard
Code No. 5113C-8
29EGR valve:
ClosedDVehicle
speed: 0 km/hheard.


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DIESEL FUEL <4M4> -Troubleshooting13C-11
ENGINE-ECU CHECK
TERMINAL VOLTAGE TABLE
Terminal No.Check itemInspection conditions (engine status)Normal condition
14Throttle body assembly (1)Ignition switch: ON (Engine stops)9 V or more
17EGR motorIgnition switch: ON (Engine stops)System voltage
18Throttle body assembly (2)Ignition switch: ON (Engine stops)9 V or more
19Throttle body assembly (3)Ignition switch: ON (Engine stops)9 V or more
20Throttle body assembly (4)Ignition switch: ON (Engine stops)9 V or more
33A/C load signalEngine: Idle
A/C switch: ONDuring weak cooling or
heatingSystem voltage
During normal cooling0-1V
During strong coolingChanges repeatedly
between 0 V and 12 V
37Clutch switch <M/T>Clutch pedal depressed0-1V
Inhibitor switch <A/T>Ignition switch:
ON (Engine stops)Move selector lever to N
or P0-1V
Move selector lever to D,
2, L or RSystem voltage
38Control relay (no immobi-
lizer)
Ignition switch: ON0-1V
lizer)
Ignition switch: ON→OFF (after approx. 8
seconds)System voltage
41Select switch <M/T>Ignition switch:
ON (Engine stops)Move shift lever to 4st or
RSystem voltage
421st - 2nd switch <M/T>Ignition switch:
ON (Engine stops)Move shift lever to 1st or
2ndSystem voltage
433rd - 4th switch <M/T>Ignition switch:
ON (Engine stops)Move shift lever to 3rd or
4thSystem voltage
445th - R switch <M/T>Ignition switch:
ON(Enginestops)
Move shift lever to 5th0-1V
ON(Engine stops)
Move shift lever to RSystem voltage
58TachometerDuring idlingChanges repeatedly
between 0 V and 12 V
90EGR valve sensorDuring racingChanges between 0.5
V and 4.5 V


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MITSUBISHI SC-Troubleshooting13E-6
INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis
code No.Diagnosis itemSC warning lampReference page
27*1SC-ECU power supply system (abnormal voltage drop)Flashes13E-6
51*2Vehicle speed sensor wheel speed sensor system (output
signal abnormality)Flashes13E-7
52Vehicle speed sensor system (open circuit or short-circuit)Flashes13E-8
53*2Wheel speed sensor system (open circuit or short-circuit)Flashes13E-8
55*2G sensor systemFlashes13E-9
71Communication line between the engine-ECU or engine-
A/T-ECU and the systemFlashes13E-10
72Engine-ECU or Engine-A/T-ECU systemIlluminates13E-10
74*2Communication line between the A/T-ECU and the system
<4M4-A/T>Flashes13E-11
81*1The SC - ECU is controlling the system too longFlashes13E-11
NOTE
*1: Code No.27 and 81 are erased from the memory if the condition returns to normal.
*2: For code Nos.51, 53, 55 and 74, a diagnosis code will be set in ten seconds after a failure is detected.
INSPECTION PROCEDURE FOR DIAGNOSIS CODE
Code No. 27 SC-ECU power supply system (abnormal
voltage drop)Probable cause
This diagnosis code will be set if the SC-ECU power supply voltage drops below
a certain level.DMalfunction of battery
DMalfunction of harness or connector
DMalfunction of the SC-ECU
Caution
If the system voltage drops during inspection, this code will be output to indicate a current problem.
And correct problem diagnosis will not be possible. Before carrying out the following procedure,
check the battery and recharge it if necessary.


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MITSUBISHI SC-Troubleshooting MITSUBISHI SC-Troubleshooting13E-7
OK
NG
Repair
OK
Check the trouble symptoms.
NG
OKNG
Repair
OK
(1)NGCheck the following connectors:
B-25X, D-128, E-122,
E-121
NG
Check the harness wire between the engine control relay and
the SC-ECU, and repair if necessary. (2)NG
OK
Check the trouble symptoms.
NG
Replace
NG
Check the harness wire between the battery and the SC-ECU,
and repair if necessary.
Check the following connectors:
D-27, D-223 <L.H.D.>,
D-31 <L.H.D.>, E-13, E-122, E-120
Measure at SC-ECU connectors E-120, E-121.
DDisconnect the connector and measure at the harness
side.
(1) Voltage between terminal 25 and body earth
(Ignition switch: ON)
OK:
System voltage
(2) Voltage between terminal 39 and body earth
OK:
System voltage
NG (1)NG
Check the harness wire between the SC-ECU and the body
earth, and repair if necessary.
Repair
NG
Replace the SC-ECU.
Check the trouble symptoms.
Check the following connectors:
E-120, E-122
NG
(2), (3)NG
Check the harness wire between the SC-ECU and the body
earth, and repair if necessary.
OK
NG
Repair
NGCheck the trouble symptoms.
Check the following connector:
E-121, E-122
OK
Check the trouble symptoms.
Measure at SC-ECU connector E-120, E-121.
DDisconnect the connector and measure at the harness
side.
(1) Continuity between 31 and body earth
OK:
Continuity
(2) Continuity between 13 and body earth
OK:
Continuity
(3) Continuity between 26 and body earth
OK:
Continuity
Check the trouble symptoms.
Check the fusible link No.2 and dedicated fuse No.7
Code No. 51 Vehicle speed sensor systemProbable cause
This diagnosis code will be set when the vehicle speed signal from the vehicle
speed sensor is not the same as that from the wheel speed sensor (FR).DMalfunction of vehicle speed sensor system
DMalfunction of wheel speed sensor system
DMalfunction of the SC-ECU
NG
Check the trouble symptoms.
Replace the SC-ECU.YES
NOCheck the vehicle speed sensor system (Refer to Basic
Manual GROUP 54A - Combination Meter).Does the speedometer operate normally?
YES
NOCheck the ABS system (Refer to Basic Manual GROUP 35B
- ABS).Does the ABS system operate normally?


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MITSUBISHI SC-Troubleshooting13E-10
Code No. 71 Communication line between the
engine-ECU or engine-A/T-ECU and the systemProbable cause
This diagnosis code will be set when an error takes place due to the open or
short circuit in the serial communication line between the SC-ECU and the
engine-ECU or engine-A/T-ECU, internal failure in the ECU or improper shield
line.DMalfunction of harness or connector
DMalfunction of engine-ECU or engine-A/T-ECU
DMalfunction of the SC-ECU
NG
NG
OK
Repair
NG
Check the trouble symptoms.
Replace the SC-ECUNG
OK
Repair
NGCheck the following connectors:
D-118 <6G7-M/T>, D-119
<6G7-A/T>, D - 112 <4M4>, E - 122, E-121
Check the trouble symptoms.
Check the harness wire between engine-ECU or
engine-A/T-ECU and SC-ECU.
Check the trouble symptoms.Replace the engine-ECU or engine-A/T-ECU
Code No. 72 Engine-ECU or Engine-A/T-ECU systemProbable cause
This diagnosis code will be set when the engine-ECU or engine-A/T-ECU detects
a system failure. On the GDI system <6G7> or diesel fuel system <4M4>, the
system failure is transmitted from the engine-ECU or engine-A/T-ECU via a
scenical communication line to the SC-ECU.DMalfunction of GDI system <6G7>
DMalfunction of diesel fuel system <4M4>
DCarry out the troubleshooting regarding the GDI system. <6G7>
(Refer to Basic Manual GROUP 13A - Troubleshooting.)
DCarry out the troubleshooting regarding the diesel fuel system. <4M4>
(Refer to Basic Manual GROUP 13C - Troubleshooting.)


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MITSUBISHI SC-Troubleshooting13E-12
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble SymptomInspection
procedure
No.Reference
page
Communication with MUT-II is not possible.113E-12
Communication with MUT-II and the SC-ECU is not possible.213E-13
The SC warning lamp does not illuminate when the ignition key is turned to ON (engine
stopped).313E-14
The SC warning lamp remains illuminated after the engine has started.413E-14
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS
Inspection procedure 1
Communication with MUT-
IIis not possible.
Probable cause
The cause is probably a malfunction of the diagnosis connector power supply
circuit or earth circuit.DMalfunction of diagnosis connector
DMalfunction of harness or connector
NGCheck the following connectors:
D-27, D-211, D-210, D-23
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness wire between battery and diagnosis
connector, and repair if necessary.
OK
NG
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness wire between diagnosis connector and
earth, and repair if necessary.
OK
NG
Replace the MUT-
II.
Measure at diagnosis connecter D-23.
DVoltage between 16 and body earth
OK:
System voltage
Check the following connector:
D-23Measure at diagnosis connecter D-23.
DContinuity between terminals 4, 5 and body earth
OK:
Continuity
Check the trouble symptoms.


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MITSUBISHI SC-Troubleshooting13E-13
Inspection procedure 2
Communication with MUT-
IIand the SC-ECU is not
possible.
Probable cause
The cause is probably an open circuit in the SC-ECU power supply circuit or an
open circuit in the diagnosis output circuit.DMalfunction of harness or connector
DMalfunction of the SC-ECU
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness wire between SC-ECU and diagnosis
connector, and repair if necessary.
OK
Measure at SC-ECU connector E-121 and diagnosis connector
D-23.
DDisconnect the connectors and measure at the harness
side.
DContinuity between the following terminals:
Between terminals 1 (SC-ECU side) and 1 (diagnosis
connector side)
Between terminals 14 (SC-ECU side) and 7 (diagnosis
connector side)
Between terminals 23 (SC-ECU side) and 14 (diagnosis
connector side)
OK:
ContinuityNGCheck the following connectors:
E-121, E-122, D-128, E-13,
D-33, D-222, D-23
OK
NG
Repair
OK
Check the trouble symptoms.
NG
OKNG
Repair
OK
(1)NGCheck the following connectors:
B-25X, D-128, E-122,
E-121
NG
Check the harness wire between the engine control relay and
the SC-ECU, and repair if necessary. (2)NG
OK
Check the trouble symptoms.
NG
Replace
NG
Check the harness wire between the battery and the SC-ECU,
and repair if necessary.
Check the following connectors:
D-27, D-223 <L.H.D.>,
D-31 <L.H.D.>, E-13, E-122, E-120
Measure at SC-ECU connectors E-120, E-121.
DDisconnect the connector and measure at the harness
side.
(1) Voltage between terminal 25 and body earth
(Ignition switch: ON)
OK:
System voltage
(2) Voltage between terminal 39 and body earth
OK:
System voltage
NG (1)NG
Check the harness wire between the SC-ECU and the body
earth, and repair if necessary.
Repair
NG
Replace the SC-ECU.
Check the trouble symptoms.
Check the following connectors:
E-120, E-122
NG
(2), (3)NG
Check the harness wire between the SC-ECU and the body
earth, and repair if necessary.
OK
NG
Repair
NGCheck the trouble symptoms.
Check the following connector:
E-121, E-122
OK
Check the trouble symptoms.
Measure at SC-ECU connector E-120, E-121.
DDisconnect the connector and measure at the harness
side.
(1) Continuity between 31 and body earth
OK:
Continuity
(2) Continuity between 13 and body earth
OK:
Continuity
(3) Continuity between 26 and body earth
OK:
Continuity
Check the trouble symptoms.
Check the fusible link No.2 and dedicated fuse No.7


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MITSUBISHI SC-Troubleshooting13E-14
Inspection procedure 3
The SC warning lamp does not illuminate when the
ignition key is turned to ON (engine stopped).
Probable cause
When the ignition switch is turned on, the SC-ECU starts to communicate with
the engine-ECU or engine-A/T-ECU. Then the SC-ECU will illuminate the SC
warning lamp if the engine speed is 350 rpm or less. If the SC warning lamp
does not illuminate, the case is probably an open circuit in the SC warning lamp
power supply circuit, a blow lamp bulb or an open circuit between the SC
warning lamp and the SC-ECU.DBlown fuse
DBlown SC warning lamp bulb
DMalfunction of harness or connector
DMalfunction of combination meter
DMalfunction of the SC-ECU
NG
Replace the combination meter.
NG
Repair
OK
NG
Check for a blown bulb.Replace the SC
warning lamp bulb.
OK
NG
Repair
OK
Check the trouble symptoms.
Multi - purpose fuse No. 6 checkNGRefer to Basic Manual GROUP 00 – Inspection service Points
for Blown Fuse.
NG
Check the harness wire.
DBetween the ignition switch and the combination meter
DBetween the combination meter and the SC-ECU
OK
OK
Replace the SC-ECU
Check the following connector:
E-107
NG
RepairCheck the trouble symptoms.OK
NG
Check the following connectors:
D-208, D-210 <L.H.D.>,
D-213 <R.H.D.>, D-01, E-10, E-122, E-120
Measure at the SC-ECU connector E-120.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DWarning lamp condition when terminal 45 is shorted to
body earth
OK:
Illuminates
Inspection procedure 4
The SC warning lamp remains illuminated after the
engine has started.
Probable cause
The cause is probably a short-circuit in the SC warning lamp illumination circuit.DMalfunction of combination meter
DMalfunction of harness (short-circuit)
DMalfunction of the SC-ECU
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible(SC-ECU power
supply is normal) and the diagnosis code is a normal diagnosis code.
When the SC-ECU connector E-120 are disconnected and the
ignition switch is turned to the ON position, does the SC
warning lamp remain illuminated?YES
NO
Replace the SC-ECU.Replace the combination meter.
NG
Repair
OK
Check the harness wire between the combination meter and
the SC-ECU


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