MITSUBISHI MONTERO 2000 Service Repair Manual

DIESEL FUEL <4M4>
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13C-1
DIESEL FUEL
<4M4>
CONTENTS
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 5.......................
ON-VEHICLE SERVICE 42...................
Injection Timing Check and Adjustment 42.........
Idle Speed Check and Adjustment 42.............
Accelerator Pedal Position Sensor (APS)
Adjustment 42.................................
Control Relay Continuity Check 43................
Accelerator Pedal Position Sensor (APS) Check 43.Idle Switch Check 43...........................
Boost Air Temperature Sensor (Intake Air
Temperature Sensor) Check 44..................
Engine Coolant Temperature Sensor Check 44.....
Evacuation of Water from Fuel Filter 45...........
Fuel Filter Cartridge Replacement 45.............
Evacuation of Air from Fuel Line 45...............
Fuel Injection Pump Check 46...................
Intake Air Restriction Equipment Check 48.........
Injection Nozzle Check and Adjustment 49.........
INJECTION NOZZLE 50......................
INJECTION PUMP 56........................
ENGINE-ECU 59............................


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DIESEL FUEL <4M4> -General Information13C-2
GENERAL INFORMATION
The electronically-controlled fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuators
which operate according to control commands from the engine-ECU.
The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing control
and idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions which
make troubleshooting easier in the event that a problem develops.
FUEL INJECTION RATE CONTROL
The fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure that
the optimum amount of fuel is supplied to the engine in accordance with gradual changes in the engine
running condition.
Before fuel injection starts, the solenoid-type spill valve is on (energized), so that the valve is closed.
As the plunger turns and rises, fuel is sent out under pressure, and when the fuel flow rate reaches
the target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spill
valve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamber
and fuel injection is completed.
FUEL INJECTION TIMING CONTROL
The position of the injection pump timer piston is controlled so that fuel injection is carried out at the
optimum timing in accordance with the engine running condition.
The timer piston position is determined by duty control of the timing control solenoid valve which is located
in the line between the high-pressure chamber and the low-pressure chamber of the timer piston.
The fuel injection timing is advanced by increasing the control duty of the timing control solenoid valve.
IDLE SPEED CONTROL
Controlling the fuel injection rate in accordance with the engine running condition maintains the idle speed
at the optimum condition.
SELF-DIAGNOSIS FUNCTION
DWhen an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates
to warn the driver.
DWhen an abnormality is detected in any of the sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is output.
DThe RAM data relating to the sensors and actuators which is stored in the engine-ECU can be read
using the MUT-II. In addition, the actuators can be force-driven under certain conditions.
OTHER CONTROL FUNCTIONS
1. Power Supply Control
When the ignition switch is turned to ON, the relay turns on and power is supplied to components
such as the timing control solenoid valve.
2. Intake Air Throttle Control
When the engine is idling after having warmed up, the throttle valve is half opened to restrict the
amount of intake air in order to reduce vibration and noise.
3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF
4. Fan motor relay control
The radiator fan and condenser fan operating speeds are controlled in accordance with the engine
coolant temperature and the vehicle speed.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.


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DIESEL FUEL <4M4> -Service Specifications/Sealant13C-3
SERVICE SPECIFICATIONS
ItemStandard value
Accelerator pedal position sensor reference voltage V0.985 - 1.085
Accelerator pedal position sensor resistance kW3.5 - 6.5
Boost air temperature sensor (Intake air temperatureWhen the temperature is 20_C2.3 - 2.9
sensor) resistance kWWhen the temperature is 80_C0.30 - 0.39
Engine coolant temperature sensor resistance kWWhen the temperature is 20_C2.3 - 2.6
When the temperature is 80_C0.30 - 0.34
Fuel cut solenoid valve resistanceW6.8 - 9.2
Timing control valve resistanceW10.8 - 11.2
Timer piston position sensor resistanceWConnector terminals No.1 - No.2160 - 168
Connector terminals No.1 - No.380 - 84
Connector terminals No.2 - No.380 - 84
Control sleeve position sensor resistanceWConnector terminals No.4 - No.1211.2 - 12.4
Connector terminals No.4 - No.85.6 - 6.2
Connector terminals No.8 - No.125.6 - 6.2
GE actuator (electronic governor) resistanceWConnector terminals No.6 - No.100.64 - 0.72
Fuel temperature sensor resistance kWConnector terminals No.7 - No.111.4 - 2.6
Engine speed sensor resistance kW2.15
Main/sub throttle solenoid valve resistanceW36 - 44
SEALANT
ItemSpecified sealant
Engine coolant temperature sensor3M Nut Locking Part No.4171 or equivalent


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S
PEC IA L TO OLS
T o ols N
um ber N
am e A
pplic a tio n M
B991502 M
UT-II su b
a sse m bly E
le ctr o nic a lly co ntr o lle d fu el in je ctio n syste m
c h eck M
B991529 D
ia gnosis co de
c h eck harn ess D
ia gnosis co de re adin g M
B991348,
M B991658 T
e st harn ess se t M
B990767 E
nd yo ke hold er H
old in g th e cra nksh aft p ulle y M
B998754 C
ra nksh aft pulle y
h old er pin M
H062567 G
ear pulle r I
n je ctio n pum p gear asse m bly re m ova l 1
57992 -2 820
( z e xce l) P
la te R
eta in in g nutre m ova la nd in sta lla tio n 1
05789 -0 010
( z e xce l) N
ozzle cle anin g
t o ol C
le anin g of nozzle and needle va lv e

T
R O UBLE SH O OTIN G
S TA NDARD FLO W OF DIA G NO STIC
T R O UBLE SH O OTIN G
R efe r to GRO UP 00 -H ow to Use Tro uble sh ootin g/In sp ectio n
S erv ic e Poin ts .
D IA G NO SIS FU NCTIO N
E N G IN E WARNIN G LA M P (C HEC K EN G IN E LA M P)
E ngin e warn in g la m p is lit w hen any abnorm alit y ta ke s pla ce
i n th e it e m re la te d to ele ctr o nic a lly co ntr o lle d fu el in je ctio n
s yste m sh ow n in th e fo llo w in g ta ble .
I f th e malf u nctio n in dic a to r la m p has been on and/o r is lit
w hen th e engin e is in opera tio n, ch eck th e dia gnosis outp ut.
E ngin e warn in g la m p ch eck it e m s
A cce le ra to r pedalp osit io n se nso r (m ain ) A
cce le ra to r pedalp osit io n se nso r (s u b) B
oost pre ssu re se nso r (B oost se nso r) E
ngin e sp eed se nso r C
ontr o lsle eve posit io n se nso r T
im er pis to n posit io n se nso r M
ain th ro ttle so le noid va lv e G
E actu ato r I
d le sw it c h (b uilt - in ) E
ngin e-E C U

DIESEL FUEL <4M4> -Troubleshooting13C-6
FAIL-SAFE, BACKUP FUNCTIONS
When abnormalities in the major sensors are detected by diagnosis functions, pre-set control logic operates
to maintain a safe driving condition for the vehicle.
Diagnosis itemControl features in malfunction
Accelerator pedal position sensorD
Accelerator pedal released (idle switch ON)
Acceleration opening degree = 0%
D
Accelerator pedal applied (idle switchOFF)
Engine controlled at low speed
Acceleration opening degree = 20% fixed
Idle switchD
Void idling speed control.
D
Void cruise control.
Engine speed sensorD
Engine controlled at low speed
D
Void cruise control.
Boost air temperature sensorMaintain the intake air temperature at 50_
C.
Vehicle speed sensorD
Void idling speed control.
D
Void cruise control.
Engine coolant temperature sensorMaintain the engine coolant temperature at 80_
C.
Control sleeve position sensorD
Engine controlled at low speed
D
Void cruise control.
Timer piston position sensorD
Injection timing stabilizing control
D
Void cruise control.
Barometric pressure sensor (ECU
built-in)Keep the barometric pressure at 101 kPa.
Fuel temperature sensorMaintain the fuel temperature at 50_
C.
Boost pressure sensorKeep the boost pressure as barometric pressure (101 kPa).
Injection correction ROMVoid correction.
GE actuatorD
Engine controlled at low speed
D
Void cruise control.
Over boostVoid cruise control.
Timing control valveD
Injection timing stabilizing control
D
Void cruise control.


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DIESEL FUEL <4M4> -Troubleshooting13C-7
INSPECTION CHART FOR DIAGNOSIS CODES
Code No.Diagnosis itemReference
page
11Accelerator pedal position sensor (main) system13C-8
12*Boost pressure sensor system13C-9
13Barometric pressure sensor (ECU built-in) system13C-10
14Fuel temperature sensor system13C-10
15Engine coolant temperature sensor system13C-11
16Boost air temperature sensor system13C-11
17Vehicle speed sensor system13C-12
18Engine speed sensor (backup) system13C-13
21Engine speed sensor system13C-14
23Idle switch (accelerator pedal position sensor built-in) system13C-15
25*Timer piston position sensor system13C-16
26*Control sleeve position sensor system13C-17
27Accelerator pedal position sensor (sub) system13C-18
41*Main throttle solenoid valve system13C-19
43Timing control valve system13C-20
46Injection correction ROM system13C-21
48*GE actuator (in the middle of control sleeve position sensor inoperative) system13C-21
49*Over boost (turbocharger waste gate malfunction)13C-22
54Immobilizer system13C-22
Caution
If the the above-mentioned diagnosis code number with the asterisks can be displayed along with
another code number in parentheses simultaneously, check the other code number before replacing
the engine-ECU.
12 (41, 49), 26 (48), 25 (43), 41 (12, 49), 48 (26), 49 (12, 41)


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DIESEL FUEL <4M4> -Troubleshooting13C-8
INSPECTION PROCEDURE FOR DIAGNOSIS CODE
Code No. 11 Accelerator pedal position sensor systemProbable cause
Range of Check
DIgnition switch: ON, acceleratorpedal positionsensor (sub) operative, except
for during enginecranking
Set Conditions
DOutput voltage of accelerator pedal positionsensor (sub) for one second is
0.2 V or higher and lower than 2.5V. Output voltage of acceleratorpedal
position sensor (main) for one second is 4.5V or higher, or lower than 0.2V.
Range of Check
DIgnition switch:ON, except for duringenginecranking
Set Conditions
DThe output voltage of accelerator pedal positionsensor (main and sub) for
0.2 second is 0.2V or higher, or lower than 4.5V and the difference in
sensor output voltage between themain and sub is 1V or higher, or idle
switch:ON, and sensormain output voltage is 1.875V or higher.DAcceleratorpedal positionsensor inoperative
DAcceleratorpedal positionsensoropencircuit,
short circuit, or connector contact inoperative
DEngine-ECU inoperative
OK
OK
Measure at D-135 acceleratorpedal position
sensor connector
DDisconnect the connector and measure
at the harness side.
DVoltage between 2 and earth
(Ignition switch: ON)
OK:
4.5 - 5.5 V
DContinuity between 1 and earth
OK:
ContinuityNGCheck the following connector:
D-113NG
Repair
OK
OKRepair
NGAcceleratorpedal positionsensor check
(Refer to P.13C-37.)Replace
Check the trouble symptoms.
Replace the engine-ECU.NG
Check the trouble symptoms.
NG
Replace the engine-ECU.
NG
RepairCheck the following connectors:
D-113, D-135
OK NG
NG
Check the following connector:
D-113NG
Repair
OK
Check the harness between the
engine-ECU and the accelerator pedal
position sensor connector.
Check the trouble symptoms.
OK
Measure at D-113 engine-ECU connector
DConnect the connector.
DVoltage between 84 and the earth
(Ignition switch: ON)
OK:
0.9 - 1.1 V
(Throttle leveridling position)
4.1 V or higher
(Throttle lever fullyopened position)
Check the harness between the
engine-ECU and the accelerator pedal
position sensor connector.


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DIESEL FUEL <4M4> -Troubleshooting13C-9
Code No. 12 Boost pressure sensor (boost sensor)
systemProbable cause
Range of Check
DIgnition switch: ON, except for duringenginecranking
Set Conditions
DSensor output voltage for one second is 4.5 Vor higher
(boost pressure is approximately 306.7kPa).
or
DSensor output voltage for one second is 0.2 Vor lower
(boost pressure is approximately 20kPa or lower)
Range of Check
DEngine speed is 1600 r/min or higher and the accelerationopening degree is
60% or more.
Set Conditions
DBoost pressure is lower than the barometric pressure + 13 kPa for two
seconds.DBoost pressure sensor inoperative
DBoost pressure sensoropencircuit, short circuit,
or connector contact inoperative
DBoost pressure sensor hose disconnected
DEngine-ECU inoperative
Check the harness between the
engine-ECU and the boost pressure
sensor connector.
NG
Check the trouble symptoms.
Replace the engine-ECU.
Check the following connector:
D-113
NGOK
NG
Repair
RepairOK
NG
Replace the engine-ECU.
OKOK
OK
Check the following connector:
A-120NG
Check the trouble symptoms. NG
Repair
NG
NG
Check the vacuum hose between the
boost pressure sensor and the intake
manifold.
Replace the boost pressure sensor.
OK OK OK
Repair
NG
Repair
Check the trouble symptoms.
Check the harness between the
engine-ECU and the boost pressure
sensor connector, and repair if
necessary.
NG OK
NG
RepairCheck the following connector:
B-08NG
Measure at B-08 boost pressure
sensor connector
DConnect the connector.
(Test harness: MB991348 used)
DVoltage between 1 and the earth
(Engine: Idling)
OK:
1.2 - 1.6 V
DVoltage between 1 and the earth
OK:
When the accelerator pedal
is suddenly pressed from
the idling condition, the
voltage temporarily in-
creases from 1.2 V to 1.6
V.
Measure at D-113 engine-ECU
connector
DConnect the connector.
DVoltage between 85 and the
earth (Engine: Idling)
OK:
1.2 - 1.6 V
Check the harness between the
engine-ECU and the boost pressure
sensor connector.
Measure at B-08 boost pressure
sensor connector
DDisconnect the connector and
measure at the harness side.
DVoltage between 3 and the earth
(Ignition switch: ON)
OK:
4.5 - 5.5 V
DContinuity between 2 and the
earth
OK:
Continuity


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