relay MITSUBISHI MONTERO 2000 Service Manual PDF

DIESEL FUEL <4D5-stepIII>-General/General Information13E-2
GENERAL
OUTLINE OF CHANGE
An electronically-controlled injection pump has been added in order to comply with Regulation STEP
III. Due to this, the following service procedures have been added.
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-ECU detects an abnormality in any of the sensors or actuators, the throttle valve
is half opened to restrict the amount of intake air in order to prevent the vehicle from running away.
3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF
4. Condenser Fan Motor Relay Control
Controls the condenser fan motor relay based on the A/C switch, engine coolant temperature and
vehicle speed input signals.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-15
Code No. 21 Crank angle sensor systemProbable cause
Range of Check
DEngine cranking
Set Conditions
DSensor output voltage does not change for 2 seconds (no pulse signal input)DMalfunction of crank angle sensor
DOpen circuit or short-circuit in crank angle sensor
circuit, or poor connector contact
DEngine-ECU inoperative
Range of Check
DIgnition switch: ON
DNot during the engine cranking
DPump speed sensor circuit: Normal
Set Conditions
DWhen crank angle sensor signal is being input normally, suddenly no sensor
signal is input for 0.3 seconds or more
OK
Check the harness between the
crank angle sensor and the engine
control relay, and repair if necessary.
OKNG(1) NGMeasure at crank angle sensor
connector B-52.
DConnect the connector.
(Test harness: MB998478 used)
DVoltage between 2 (black clip)
and the earth
OK:0.4 - 4.0 V
(Engine: cranking)
1.5 - 2.5 V
(Engine: idling)
NG
Replace the crank angle sensor.
Replace the engine-ECU.
OKRepair
Check the following connector:
D-113
NG
OK
Repair NG
Check the harness between the
engine-ECU and the crank angle
sensor.NG
Check the trouble symptoms.
Replace the engine-ECU.
Check the harness between the
crank angle sensor and the earth,
and repair if necessary. OKRepair NG
Check the following connector:
B-52
Check the trouble symptoms.
Measure at crank angle sensor
connector B-52.
DDisconnect the connector and
measure at the harness side.
(1) Voltage between 3 and the earth
(Ignition switch: ON)
OK:System voltage
(2) Continuity between 2 and the
earth (Ignition switch: ON)
OK:4.6 - 5.4 V
(3) Continuity between 1 and the
earth
OK:Continuity(2) NG
(3) NG


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-20
Code No. 41 Throttle solenoid valve systemProbable cause
Range of Check
DIgnition switch: OFF
DBarometric pressure is 95.4 kPa or over (equivalent to an altitude of 500 m).
Set Conditions
DBoost pressure sensor output does not change.DThrottle solenoid valve inoperative
DThrottle solenoid valve open circuit, short circuit, or
connector contact inoperative
DEngine-ECU inoperative
DMalfunction of throttle actuator
Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
NG
OK
Check the trouble symptoms.
OK
Check and repair the harness between the
control relay and the solenoid valve
connector. NG
OKMeasure at B-62 throttle solenoid valve
connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 2 and the earth
(Ignition switch: ON)
OK:System voltage
OK
Replace
Throttle actuator check
(Refer to P.13E-63.)NG
OK
Throttle solenoid valve check
(Refer to P.13E-62.)
Replace the engine-ECU. OK
RepairCheck the following connector:D-110
Check the trouble symptoms.NGReplace NG
Check the following connector:
B-62NG
RepairNGMeasure at D-110 engine-ECU connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 14 and the earth
(Ignition switch: ON)
OK:System voltage
NG


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-21
Code No. 43 Timing control valve systemProbable cause
Range of Check
DEngine coolant temperature 80_C or higher and the engine running
Set Conditions
DTarget value minus actual value is 0.64 V or more for 5 secondsDTiming control valve inoperative
DTiming control valve open circuit, short circuit, or
connector contact inoperative
DEngine-ECU inoperative
DBlockage in fuel system
OK
OK
Check and repair the harness between the
control relay and the injection pump
assembly connector.
Timing control valve check
(Refer to P.13E-61.)
Replace the engine-ECU. OK
RepairCheck the following connector:D-110
Check the trouble symptoms.NG NG NG
Check the following connector:B-38NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 3 and the earth
(Ignition switch: ON)
OK:11 V or higherOK
Measure at B-38 injection pump assembly
connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 5 and the earth
(Ignition switch: ON)
OK:System voltage
Replace injection pump assembly.
Check and repair the harness between the
engine-ECU and the injection pump
assembly connector.
Fuel system blockage check
DFuel filter blocked
DFuel hose blocked or bent
DFuel tank filter blockedOK
Replace NG
NG


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-23
Code No. 48 GE actuator (in the middle of control sleeve
position sensor inoperative) systemProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DTarget value minus actual value is 1 V or more for 1 secondDControl sleeve position sensor inoperative
DGE actuator inoperative
DControl sleeve position sensor open circuit, short
circuit, or connector contact inoperative
DEngine-ECU inoperative
OK
OK
Check and repair the harness between the
control relay and the injection pump
assembly connector.
GE actuator check (Refer to P.13E-61.)
Replace the engine-ECU. OK
RepairCheck the following connector:D-110
Check the trouble symptoms.NGNG NG
Check the following connector:B-38NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 1 and the earth
(Ignition switch: ON)
OK:9 V or higherOK
Measure at B-38 injection pump assembly
connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 6 and the earth
(Ignition switch: ON)
OK:System voltage
Replace injection pump assembly.
Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-24
Code No. 49 Over boostProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DBoost pressure is higher than the barometric pressure + 133 kPaDMalfunction of the variable geometry actuator
DMalfunction of variable geometry solenoid valve
DVariable geometry solenoid valve open circuit, short
circuit, or connector contact inoperative
DEngine-ECU inoperative
OKOK
Check and repair the harness between the
control relay and the solenoid valve
connector.
Replace the engine-ECU.OK
ReplaceVariable geometry solenoid valve check
(Refer to GROUP 15 - On-vehicle Service.)
Check the trouble symptoms.NG
NG
Check the following connector:B-61NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 17 and earth
(Ignition switch: ON)
OK:System voltageOK
Measure at B-61 variable geometry solenoid
valve connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 2 and earth
(Ignition switch: ON)
OK:System voltage
Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
ReplaceVariable geometry actuator check (Refer to
GROUP 15 - On-vehicle Service.)NG
OK
Repair
Check the following connector:D-110NG
NG
Replace the turbocharger assembly. YESConnect a boost gauge to the boost
pressure sensor hose. When the vehicle is
driven at 1st gear with full throttle, does
boost pressure exceed 133 kPa
momentarily?
NO


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-31
INSPECTION PROCEDURE 5
No initial combustion (unable to start)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
glow system, and power supply system.DControl system inoperative
DInjection pump inoperative
DIntake system inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKCheck the following items in order:
DGlow plug, glow plug relay
DBattery
DInjection nozzle
DThrottle body assembly
DInjection pump
DCompression pressure
DExistence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 6
Starting performance is bad when the engine is cold
(unable to start)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, intake system, and glow system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DGlow plug, glow plug relay
DInjection nozzle, fuel filter
DThrottle body assembly
DExistence of starter switch signal input
DEngine oil
DInjection pump
DExistence of mixing foreign objects (water, kerosene) with
the fuel


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-33
INSPECTION PROCEDURE 10
Low idling speed (improper idling speed)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
and fuel.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DInjection nozzle
DInjection pump
INSPECTION PROCEDURE 11
Idling instable (rough idling, hunting)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, glow system, intake system, and EGR system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DGlow system inoperative
DEGR system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DGlow plug, glow plug relay
DEGR system
DInjection nozzle
DCompression pressure
DValve clearance
DThrottle body assembly
DInjection timing
DFuel line bleeding
DInjection pump
INSPECTION PROCEDURE 12
The engine stalls after running for a while.
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, and intake system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DThrottle body assembly
DFuel filter
DInjection pump


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-35
INSPECTION PROCEDURE 16
Abnormal black smoke
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, intake system, and EGR system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DEGR system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DAir cleaner
DInjection nozzle
DThrottle body assembly
DEGR system
DTurbocharger
DInjection pump
INSPECTION PROCEDURE 17
Abnormal white smoke
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, intake system, EGR system, and glow system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DEGR system inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DGlow plug, glow plug relay
DInjection nozzle
DThrottle body assembly
DEGR system
DTurbocharger
DInjection pump
INSPECTION PROCEDURE 18
Hunting during driving
Probable cause
Probable causes can be found in troubles with control system, injection pump,
and fuel system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DInjection nozzle
DInjection pump


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-36
INSPECTION PROCEDURE 19
A/C condenser fan operating problem
Probable cause
The power transistor inside the engine-ECU turns on and off to control the A/C
condenser fan motor relay.DMalfunction of A/C condenser fan motor relay
DMalfunction of A/C condenser fan motor
DMalfunction of thermostat
DOpen circuit or short-circuit in circuit, or poor
connector contact
DMalfunction of engine-ECU
Check the following connector:D-110
OK
Measure at engine-ECU connector D-110.
DDisconnect the connector and measure at the harness
side.
DCheck the A/C condenser fan condition.
(Ignition switch: ON)
OK:Fan stopped
DVoltage between 7 and the earth
(Ignition switch: ON)
OK:System voltage
DShort out 7 and the earth
(Ignition switch: ON)
OK:A/C condenser fan turnsNGA/C condenser fan motor circuit check
(Refer to the wiring harness configuration diagram.)
OK
MUT-IIData list
02 Engine coolant temperature sensor
OK:When engine is idling after having warmed up, the en-
gine coolant temperature and the MUT-IIdisplay temper-
ature are identicalNGEngine coolant temperature sensor check
(Refer to Code 15 on P.13E-59.)
Check the trouble symptoms.OK
Replace the engine-ECU.NG
Repair
Thermostat checkNG
NGReplace
OK


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk