service MITSUBISHI MONTERO 2000 Service Manual PDF
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2000, Model line: MONTERO, Model: MITSUBISHI MONTERO 2000Pages: 1839, PDF Size: 29.19 MB
Page 721 of 1839
INTAKE AND EXHAUST -Turbocharger and Exhaust
Manifold <4M4>15-15
INSTALLATION SERVICE POINT
"
AA
TURBOCHARGER ASSEMBLY INSTALLATION
1. Check the internal surface, the eye bolt and the
mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.
2. If deposits of carbon are accumulated on the
turbocharger oil passage, remove them and clean
using the compressed air.
Caution
Be careful not to allow foreign material to enter the
turbocharger.
3. Add clean engine oil through the oil feed pipe port
on the turbocharger.
INSPECTION
Check the following points; replace the part if a problem is
found.
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and a thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
TURBOCHARGER ASSEMBLY CHECK
DVisually check the turbine wheel and the compressor
wheel for cracking or other damage.
DCheck whether the turbine wheel and the compressor
wheel can be easily turned by hand.
DCheck for oil leakage from the turbocharger assembly.
DCheck whether or not the waste gate valve remains open.
If any problem is found, replace the part after disassembly.
OIL PIPE AND OIL RETURN PIPE CHECK
Check the oil pipe and oil return pipe for clogging, bending,
or other damage. If there is clogging, clean it.
EXHAUST MANIFOLD CHECK
Damage or cracking of any part.
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Page 733 of 1839
15-1
INTAKE AND
EXHAUST
CONTENTS
GENERAL 2.................................
Outline of Changes 2...........................
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
ON-VEHICLE SERVICE 4.....................
Turbocharger Supercharging Check 4............
Supercharging Pressure Control
System Check 5...............................
Variable Geometry Actuator Check 6.............Variable Geometry Solenoid Valve Check 6.......
INTAKE MANIFOLD AND THROTTLE BODY
<4M4> 7.....................................
INTAKE MANIFOLD AND EXHAUST
MANIFOLD, THROTTLE BODY AND
TURBOCHARGER <4D5> 10..................
TURBOCHARGER AND EXHAUST
MANIFOLD <4M4> 12........................
EXHAUST PIPE AND MAIN MUFFLER
<4D5> 14....................................
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Page 735 of 1839
INTAKE AND EXHAUST -General Information/Service Specifications/Sealant15-3
At starting and driving at low speed, the duty control
value of the variable geometry solenoid valve is
increased to apply the vacuum pressure of the
vacuum pump to the variable geometry actuator.
Applying the vacuum pressure to the variable
geometry actuator pulls the actuator rod so that
it can move towards the direction of closing the
variable nozzle of the variable geometry
turbocharger. As closing the nozzle reduces the
exhaust gas mass, the speed of exhaust gas flow
will be increased and efficiency will be improved.
Since the characteristic of boost pressure becomes
a low speed type, boost pressure will suddenly
rise from low speed.
At driving at high speed, the duty control value
of the variable geometry solenoid valve is
decreased to reduce the vacuum pressure from
the vacuum pump so that the actuator rod can
return to the deactivated status and move towards
the direction of opening the nozzle of the variable
geometry turbocharger.Opening the nozzle allows the characteristic of
boost pressure to become a high speed type so
that the appropriate boost pressure can be
maintained.
Therefore, boost pressure can be controlled by
appropriate duty control of the variable geometry
solenoid valve. The engine-ECU calculates the
correct boost pressure based on the engine speed
and fuel injection amount. Furthermore, the duty
control of the variable geometry solenoid valve is
given feedback of the signals from the variable
geometry control pressure sensor and the boost
pressure sensor so that the variable nozzle opening
angle of the variable geometry turbocharger can
be quickly adjusted to obtain the desired boost
pressure.
SERVICE SPECIFICATIONS
ItemsStandard value
Variable geometry actuator activation vacuum
(Approximately 1 mm stroke) kPaApproximately 10.5 - 12.5
Variable geometry solenoid valve coil resistance
(at 20°C)Ω29 - 35
SEALANT
ItemSpecified sealantRemarks
Thread of the intake manifold mounting
bolts3M Stud Locking No.4170 or equivalentAnaerobic sealant
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Page 745 of 1839
INTAKE AND EXHAUST -Turbocharger and Exhaust
Manifold <4M4>15-13
INSTALLATION SERVICE POINT
"AATURBOCHARGER ASSEMBLY INSTALLATION
1. Check the internal surface, the eye bolt and the
mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.
2. If deposits of carbon are accumulated on the
turbocharger oil passage, remove them and clean
using the compressed air.
Caution
Be careful not to allow foreign material to enter the
turbocharger.
3. Add clean engine oil through the oil feed pipe port
on the turbocharger.
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Page 749 of 1839
16-1
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM 2................
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 3..............
SPECIAL TOOL 4.........................
ON-VEHICLE SERVICE 5..................
Alternator Output Line Voltage Drop Test 5....
Output Current Test 6.......................
Regulated Voltage Test 8....................
Waveform Check Using An Analyzer 11.......
ALTERNATOR 13.........................
STARTING SYSTEM 23................
GENERAL INFORMATION 23..............
SERVICE SPECIFICATIONS 24............
STARTER MOTOR 24.....................
IGNITION SYSTEM 37.................
GENERAL INFORMATION 37..............
SERVICE SPECIFICATIONS 38............
SPECIAL TOOL 38.......................
ON-VEHICLE SERVICE 38................
Ignition Coil (With Built-in Power Transistor)
Check 38...................................
Spark Plug Check and Cleaning 39...........
Ignition Failure Sensor Check 40.............
Camshaft Position Sensor Check, Crank angle
Sensor Check, Detonation Sensor Check 40...
IGNITION COIL <6G7> 41.................
CRANKSHAFT ANGLE SENSOR
<6G7> 42................................
CAMSHAFT POSITION SENSOR
<6G7> 42................................
DETONATION SENSOR <6G7> 43.........
GLOW SYSTEM 44....................
GENERAL INFORMATION 44..............
SERVICE SPECIFICATIONS 45............
ON-VEHICLE SERVICE 45................
Self-regulating Glow System Check 45........
Glow & EGR Control Unit Check 48..........
Engine ECU Check 49.......................
Glow Plug Relay Check 50..................
Glow Plug Check 51........................
Engine Coolant Temperature Sensor
Check 51...................................
GLOW PLUG 52..........................
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Page 803 of 1839
17-1
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL SYSTEM 3........
GENERAL INFORMATION 3................
SERVICE SPECIFICATIONS 3..............
ON-VEHICLE SERVICE 3..................
Accelerator Cable Check and Adjustment
<4D5> 3...................................
ACCELERAOR CABLE AND PADAL 4......
AUTO-CRUISE CONTROL SYSTEM 7..
GENERAL INFORMATION 7................
SPECIAL TOOL 8.........................
TROUBLESHOOTING 9....................
ON-VEHICLE SERVICE 27................
Auto-cruise Control Main Switch Check 27....
Auto-cruise Control Switch Check 28..........
Auto-cruise Control Component Check 29.....
AUTO-CRUISE CONTROL SWITCH 30.....
EMISSION CONTROL SYSTEM
<6G7> 31.............................
GENERAL INFORMATION 31..............
Emission Control Device Reference
Table 31....................................
SERVICE SPECIFICATIONS 32............
SPECIAL TOOL 32.......................
VACUUM HOSE 32.......................
Vacuum Hose Piping Diagram 32.............
Vacuum Circuit Diagram 33..................
Vacuum Hose Check 33.....................
Vacuum Hose Installation 33.................
CRANKCASE EMISSION CONTROL
SYSTEM 34..............................
General Information 34......................
System Diagram 34.........................
Component Location 34......................
Positive Crankcase Ventilation System
Check 35...................................
PCV Valve Check 35........................
CONTINUED ON NEXT PAGE
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Page 804 of 1839
17-2
EVAPORATIVE EMISSION CONTROL
SYSTEM 36..............................
General Information 36......................
System Diagram 36.........................
Component Location 36......................
Purge Control System Check 37..............
Purge Port Vacuum Check 37................
Purge Control Solenoid Valve Check 38.......
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 39..............................
General Information 39......................
Operation 39................................
System Diagram 39.........................
Component Location 39......................
Exhaust Gas Recirculation (EGR) Control
System Check 40...........................
EGR Valve (Stepper Motor) Check 40........
EGR VALVE 42...........................
CANISTER 43............................
CATALYTIC CONVERTER 44..............
General Information 44......................
EMISSION CONTROL SYSTEM
<4D5> 45.............................
GENERAL INFORMATION 45..............
SERVICE SPECIFICATIONS 45............
SEALANT 45.............................
SPECIAL TOOL 45.......................
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 46..............................
General Information 46......................
System Diagram 46.........................
Component Location 46......................
Function Check 47..........................
EGR Solenoid Valve Operation Check 47.....
EGR Solenoid Valve Resistance Check 48....
Lever Position Sensor (LPS) Adjustment 48...
Engine Speed Sensor Check 49..............
Engine Coolant Temperature Sensor
Check 49...................................
CHECK AT THE GLOW & EGR CONTROL
UNIT 51..................................
EMISSION CONTROL SYSTEM
<4M4-VEHICLES WITH EGR> 52........
GENERAL INFORMATION 52..............
SERVICE SPECIFICATIONS 52............
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 53..............................
General Information 53......................
System Diagram 53.........................
Component Location 53......................
Function Check 54..........................
EGR Solenoid Valve Operation Check 54.....
EGR Solenoid Valve Resistance Check 55....
Accelerator Pedal Position Sensor (APS),
Engine Coolant Temperature Sensor, Intake
Air Temperature Sensor, Fuel Temperature
Sensor Check 55............................
Check at Engine-ECU 55....................
CATALYTIC CONVERTER 55..............
General Information 55......................
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Page 812 of 1839
ENGINE AND EMISSION CONTROL -Auto-cruise Control System17-10
METHOD OF ERASING THE DIAGNOSIS
CODES
Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.
INSPECTION CHART FOR DIAGNOSIS CODES <6G7>
Code No.Diagnosis itemReference page
15Auto-cruise control switch system17-10
21Cancel latch signal system17-11
22Stop lamp switch system17-11
23Engine-ECU
INSPECTION PROCEDURE FOR DIAGNOSIS CODES <6G7>
Code No. 15 Auto-cruise control switch systemProbable cause
This diagnosis code is output if the RESUME and SET switches of the auto-cruise
control switch remain on.DMalfunction of the auto-cruise control switch
DMalfunction of the connector
DMalfunction of the harness
DMalfunction of the throttle valve controller
Repair
Check the auto-cruise control switch. (Refer to P.17-29.)NG
Replace
OK
Check the following connectors:
D-205-3, D-205-2, D-205, E-10, D-11NG
Repair
NGCheck the harness between the auto-cruise control switch and
throttle valve controller.
NG
OK
Replace the throttle valve controller.
OK
Check trouble symptom.
Check trouble symptom.
NG
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Page 854 of 1839
ENGINE AND EMISSION CONTROL -Emission Control System
<4M4-Vehicles with EGR>17-52
EMISSION CONTROL SYSTEM <4M4-VEHICLES WITH
EGR>
GENERAL INFORMATION
The electronically-controlled EGR system and the
fuel injection timing control system (load timer)
reduce the level of exhaust gases (NO
x).
ItemsNameSpecification
Exhaust emission
control systemExhaust gas recirculation system
DEGR valve
DEGR solenoid valve No.1
DEGR solenoid valve No.2Electronically-controlled EGR system
Single type
Duty cycle solenoid valve
ON-OFFsolenoid valve
SERVICE SPECIFICATIONS
ItemsStandard value
EGR solenoid valve No.1/No. 2 resistance (at 20_C)W36 - 44
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Page 859 of 1839
17-1
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL SYSTEM 2........
GENERAL 2...............................
Outline of Change 2.........................
EMISSION CONTROL SYSTEM
<4D5-STEPIII>
2 .....................................
GENERAL 2...............................
Outline of Changes 2........................
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 2..............
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 3................................EGR VALVE AND EGR COOLER 6.........
CATALYTIC CONVERTER 8................
EMISSION CONTROL SYSTEM <4M4>
9 .....................................
GENERAL 9...............................
Outline of Change 9.........................
SERVICE SPECIFICATIONS 9..............
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 9................................
EGR VALVE AND EGR COOLER 11........
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