service MITSUBISHI MONTERO 2000 Service Manual PDF

ENGINE AND EMISSION CONTROL -EngineControlSystem/EmissionControl
System <4D5-Step III>17-2
ENGINE CONTROL SYSTEM
GENERAL
OUTLINE OF CHANGE
Electronic-controlled throttle valve system has been used instead of a conventional cable-type accelerator
mechanism <4D5>.
Its service procedure is the same as for previous models with 6G7 or 4M4 engine.
EMISSION CONTROL SYSTEM <4D5-STEP
III>
GENERAL
OUTLINE OF CHANGES
Some service procedures have been established as the following changes have been made due to the
compliance with the Emission Regulation Step III.
DAn electronic-controlled EGR valve and EGR cooler have been used.
DA catalytic converter has been added.
GENERAL INFORMATION
The electronically-controlled EGR system reduces
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.2
DEGR valve position sensorElectronically-controlled EGR system
Single type
ON-OFF solenoid valve
ON-OFF solenoid valve
Variable resistor type
SERVICE SPECIFICATIONS
ItemsStandard value
EGR solenoid valve Nos. 1 and 2 resistance (at 20_C)Ω36 - 44


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21-1
CLUTCH
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
ON-VEHICLE SERVICE 2.....................
Clutch Pedal Inspection and Adjustment 2.......Clutch Pedal Position Switch
Continuty Check 3.............................
Bleeding 3.....................................
CLUTCH PEDAL 4...........................
CLUTCH CONTROL 5........................
Clutch Master Cylinder 8.......................


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22-1
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION 2..................
LUBRICANTS 2..............................
SEALANTS 2................................
SPECIAL TOOL 2............................
TROUBLESHOOTING 3.............
ON-VEHICLE SERVICE 6.....................
Transmission Oil Check 6.......................
Oil Replacement 6.............................4WD Detection Switch Continuity Check
7...................................
High/Low Detection Switch Continuity Check
7...................................
TRANSMISSION CONTROL 8.......
TRANSMISSION CONTROL 9.......
TRANSMISSION ASSEMBLY 10..............
4WD INDICATOR-ECU/TRANSFER-ECU 17....


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MANUAL TRANSMISSION -Troubleshooting 22-3
TROUBLESHOOTING
For items other than the following service procedures, refer to GROUP 23 - Troubleshooting .
INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis
codeDiagnosis itemReference page
21Lever position sensor (LPS) system <4D5>Open circuit/Malfunc-
tion of sensor22-3
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No.21 Lever position sensor (LPS) system <4D5>Probable cause
If the LPS output voltage becomes 0.2 V or less at idling, code No.21 will be
set as opencircuit or maladjustment of the LPS.DMalfunction of the LPS
DMalfunction of harness or connector
DMalfunction of transfer-ECU
DMalfunction of the glow-ECU
NGOK
NG
Repair
MUT-II Data list
DNo.1 LPS
OK:Refer to P.23-5, DATA LIST
REFERENCE TABLE.
NG
ReplaceCheck the LPS.
(Refer to GROUP 17 - Emission
Control System)
OK
NG
Repair
OK
Check the following connector:
B-02
OK
OK
Check the following connector:D-114
Repair
NG
Repair
NG
Repair
OK
OK
Check the following connector:D-114
Measure at glow-ECU connector
D-114.
DECU terminal voltage
measurement
DIgnition switch: ON
DVoltage between terminal 7 and
earth
OK:4.8 - 5.2 V
NGNG
NGCheck the trouble symptoms.
OK
Measure at LPS connector B-02.
DDisconnect the connector and
measure at the harness side.
DVoltage between 2 and earth
(Ignition switch: ON)
OK:4.8 - 5.2 V
To the nextpage
Intermittent malfunction
(Refer to GROUP 00 - Points to
Note for Transient Malfunctions.)
OK
Check the harness wire between the
LPS and the glow-ECU, and repair if
necessary.
Check the harness wire between the
LPS and the glow-ECU, and repair if
necessary.
Replace the glow-ECU.


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MANUAL TRANSMISSION -Gneral/Troubleshooting 22-1
GROUP 22
MANUAL TRANSMISSION
GENERAL
OUTLINE OF CHANGE
With additional vehicle with Emission Regulation Step III compatible 4D5 engine, the service procedure
different from service adjustment procedure of the vehicle with 4D5 engine has been established.
TROUBLESHOOTING
INSPECTION CHART FOR DIAGNOSIS CODE
Diagnosis
codeDiagnosis itemReference page
21Accelerator pedal position sensor (APS) system
<4D5>Open circuit/Malfunc-
tion of sensor22-1
INSPECTION PROCEDURE FOR DIAGNOSIS CODE
Code No.21 Accelerator pedal position sensor (APS)
system <4D5>Probable cause
Code No.21 is output to indicate an open circuit in the APS or an incorrect
adjustment when the APS output voltage drops below 0.2 V while the engine is
idling.DMalfunction of APS
DMalfunction of harness or connector
DMalfunction of transfer-ECU
DMalfunction of engine-ECU
NGNG
NG
Repair
MUT-IIData List
DNo. 1 APS
OK:Refer to P.22-2 (Data List
Reference Table).
NG
ReplaceAPS check
OK
NG
Repair
OK
Check the following connector:
D-135
OK
OK
Check the following connector:D-112
Repair
NG
Repair
NG
Repair
OK
DCheck the harness between the
APS and the engine-ECU.
OK
Check the following connectors:
D-135, D-112
Measure at engine-ECU connector
D-112.
DMeasure at ECU terminal.
DIgnition switch: ON
DVoltage between terminal 60 and
earth
OK:4.8 - 5.2 V
NGNG
NGCheck the trouble symptoms.Replace the engine-ECU.
OK
Measure at APS connector D-135
DDisconnect the connector and
measure at the harness side.
DVoltage between terminal 8 and
earth
(Ignition switch: ON)
OK:4.8 - 5.2 V
To the next page
Transient malfunction
(Refer to GROUP 00 - Points to
Note for Transient Malfunctions.)
OK
Replace the engine-ECU.


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23-1
AUTOMATIC
TRANSMISSION
CONTENTS
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
SPECIAL TOOLS 2..........................
TROUBLESHOOTING
3.....................................
>70................................

92 ..........................................
ON-VEHICLE SERVICE 94...................
Basic Adjustment Procedures 94.................
Transfer Oil Check 99...........................
Transfer Oil Change 99.........................
Location of Control Components 101..............
Control Component Checks 102..................
Torque Converter Stall Test 105..................
Fluid Pressure Test 106.........................Hydraulic Circuit 110............................
Line Pressure Adjustment 111...................
Selector Lever Operation Check 111..............
Transfer Shift Lever Operation Check 114........
Transmission Control Cable Adjustment 114......
Transfer-ECU Check 115........................
Position Indicator Lamp Check 115...............
TRANSMISSION CONTROL* 116.............
SHIFT LOCK AND KEY INTERLOCK
MECHANISMS* 120..........................
TRANSMISSION ASSEMBLY 122.............
TRANSMISSION OIL COOLER 127...........
A/T-ECU 129................................
TRANSFER-ECU 130........................
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting
wiring. Other SRS-related components (that mayhave to be removed/installed in connectionwith SRS service or maintenance) are
indicated in the table of contents by an asterisk(*).


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AUTOMATIC TRANSMISSION -Troubleshooting 23-13
INSPECTION PROCEDURES CLASSIFIED BY DIAGNOSIS CODE
Code No. 11 Accelerator pedal position sensor (APS)
short-circuit systemProbable cause
If the APS output during idling is 4.8 V or higher, it is judged that there is
excessiveoutput, and code No. 11 is output.DMalfunction of APS
DMalfunction of harness or connector
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
DMalfunction of engine-ECU <4M4>
NG
NG
NG
NG Replace
(1)NGNG
Repair
APS single part check
(Refer to GROUP 13 - On-vehicle
Service.)
Check the following connector:D-135
MUT-
IIData List
DNo.11 APS
OK:Refer to P.23-61 (Data List
Chart).
Repair
Check the following connectors:
<6G7> D-120,<4M4> D-112
Repair Repair
Transient malfunction
(Refer to GROUP 00 - Points to
Note for Transient Malfunctions.) OK
Measure at APS connector D-135
DDisconnect the connector and
measure at the harness side.
(1) <6G7> Resistance between
terminal 1 and earth
<4M4>Resistance between
terminal 7 and earth
OK:2
Wor less
(2) <6G7> Voltage between terminal
2 and earth
<4M4> Voltage between terminal
8 and earth
(Ignition switch: ON)
OK:4.8 - 5.2 V
DCheck the harness between the
APS and the engine-A/T-ECU.
<6G7>
DCheck the harness between the
APS and the engine-ECU. <4M4>
OK
OK
Replace the engine-A/T-ECU or
engine-ECU.
(2)NG
OK
OKCheck the following connectors:
<6G7> D-121,<4M4>D-108
Check the trouble symptoms.OK
APS adjustment
(Refer to GROUP 13 - On-vehicle
Service.)
Check the following connectors:
<6G7> D-121,<4M4>D-108 NG
OK
Replace the engine-A/T-ECU or
A/T-ECU. OK OK OKNG
NGRepair Repair
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.<4M4> NG NG
NGCheck the trouble symptoms.
Measure at engine-A/T-ECU
connector D-121 <6G7>, or at
A/T-ECU connector D-107 <4M4>.
DMeasure at the ECU terminals
DIgnition switch: ON
D<6G7> Voltage between terminal
95 and earth
D<4M4> Voltage between terminal
45 and earth
OK:Fully close the accelerator
985 - 1,085 mV
fullyopen the accelerator
4,000 mV or more
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the A/T-ECU, and
repair if necessary. <6G7>
NG
Check the following connectors:
<6G7> D-120,<4M4> D-112


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AUTOMATIC TRANSMISSION -Troubleshooting 23-14
Code No. 12 Accelerator pedal position sensor (APS)
open circuit systemProbable cause
When the APS output is 0.2 V or less while theengine is idling, it is judged that
output is too low and code No. 12 is output.DMalfunction of APS
DMalfunction of harness or connector
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
DMalfunction of engine-ECU <4M4>
NG
NG
NG Replace
NG
NG
Repair
APS single part check (Refer to
GROUP 13 - On-vehicle Service.)
Check the following connectors:
D-135
MUT-
IIData List
DNo.11 APS
OK:Refer to P.23-61 (Data List
Chart).
RepairTransient malfunction
(Refer to GROUP 00 - Points to
Note for Transient Malfunctions.) OK
Measure at APS connector D-135
DDisconnect the connector and
measure at the harness side.
D<6G7>Voltage between terminal
2 and earth
D<4M4>Voltage between terminal
8 and earth
OK:4.8 - 5.2 V
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.<4M4> OK
Check the following connectors:
<6G7> D-120,<4M4> D-112
OK
Measure at APS connector D-135.
DUse the test harness
(MB991658) to connect only
terminals 1, 2 and 3 <6G7>, or
only terminals 6, 7 and 8 <4M4>,
and then measure at the pickup
harness.
DIgnition switch: ON
(1) <6G7> Voltage between terminal
2 and earth
<4M4> Voltage between terminal
8 and earth
OK:4.8 - 5.2 V
(2) <6G7> Voltage between terminal
3 and earth
<4M4> Voltage between terminal
6 and earth
OK:Fully close the accelerator
985 - 1,085 mV
fullyopen the accelerator
4,000 mV or more
(1)NGCheck the following connectors:
<6G7> D-120,<4M4> D-112 OK OK NG
Repair
Measure at engine-A/T-ECU
connector D-120 <6G7>, or at
engine-ECU connector D-112 <4M4>.
DMeasure at the ECU terminals
DIgnition switch: ON
D<6G7> Voltage between terminal
46 and earth
D<4M4> Voltage between terminal
60 and earth
OK:4.8 - 5.2 VOK
Repair
RepairCheck the following connectors:
<6G7> D-120,<4M4> D-112
NG
Check the trouble symptoms.OKReplace the engine-A/T-ECU or
engine-ECU.
OK
APS adjustment (Refer to GROUP
13 - On-vehicle Service.)
Check the following connectors:
<6G7> D-121,<4M4>D-108OK (2)NG
OK
Repair OK
NG
NG NG
NG
To the nextpage
DCheck the harness between the
APS and the engine-A/T-ECU.
<6G7>
DCheck the harness between the
APS and the engine-ECU. <4M4>
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.<4M4>
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.<4M4>


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AUTOMATIC TRANSMISSION -Troubleshooting AUTOMATIC TRANSMISSION -Troubleshooting AUTOMATIC TRANSMISSION -Troubleshooting 23-15
OK
OK
From the previouspage
OK
Replace the engine-A/T-ECU or
A/T-ECU. OK
Measure at engine-A/T-ECU
connector D-121 <6G7>, or at
A/T-ECU connector D-107 <4M4>.
DMeasure at the ECU terminals
DIgnition switch: ON
D<6G7> Voltage between terminal
95 and earth
D<4M4> Voltage between terminal
45 and earth
OK:Fully close the accelerator
985 - 1,085 mV
fullyopen the accelerator
4,000 mV or moreNG
NG
NG
Repair
Check the following connectors:
<6G7> D-121,<4M4>D-108
NG
Repair
Check the trouble symptoms.
Check the following connectors:
<6G7> D-121,<4M4>D-108
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the A/T-ECU, and
repair if necessary.<4M4>
Code No. 14 Accelerator pedal position sensor (APS)
incorrect adjustment systemProbable cause
If the APS output is 0.2 V or less or 1.2 V or higher while theengine is idling,
it is judged that the APS isincorrectly adjusted, and code No. 14 is output.DMalfunction of APS
DMalfunction of harness or connector
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
DMalfunction of engine-ECU <4M4>
NGNO
YES
YES
MUT-
IISelf-Diag Code
DIs code No. 11 output?Code No. 11 Acceleratorpedal
position sensor (APS) short-circuit
system check (Refer to P.23-13.)
Code No. 12 Acceleratorpedal
position sensor (APS) short-circuit
system check (Refer to P.23-14.)
MUT-
IIData List
DNo.11 APS
OK:Refer to P.23-61 (Data List
Chart).
NG
ReplaceAPS single part check
(Refer to GROUP 13 - On-vehicle
Service.)
OK
NG
Repair
OK
Check the following connector:
D-135OK NO
Transient malfunction
(Refer to GROUP 00 - Points to
Note for Transient Malfunctions.)
MUT-
IISelf-Diag Code
DIs code No. 12 output?
To the nextpage


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AUTOMATIC TRANSMISSION -Troubleshooting 23-16
NG
OK
Check the following connectors:
<6G7> D-120,<4M4> D-112
Repair
NG
Repair
NG
Repair
OK
OK
Check the following connectors:
<6G7> D-120,<4M4> D-112
engine-A/T-ECU connector D-120
<6G7>
Measure at engine-ECU connector
D-112 <4M4>
DMeasure at the ECU terminals
DIgnition switch: ON
D<6G7> Voltage between terminal
46 and earth
D<4M4> Voltage between terminal
6 and earth
OK:4.8 - 5.2 V
NGNG
NGCheck the trouble symptoms.Replace the engine-A/T-ECU or
engine-ECU.
OK
Measure at APS connector D-135
DDisconnect the connector and
measure at the harness side.
D<6G7>Voltage between terminals
2 and earth
D<4M4>Voltage between terminals
8 and earth
(Ignition switch: ON)
OK:4.8 - 5.2 VOK
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.<4M4>
DCheck the harness between the
APS and the engine-A/T-ECU.
<6G7>
DCheck the harness between the
APS and the engine-ECU. <4M4>
From the previouspage
OK
NG
NG
(1)NGCheck the following connectors:
<6G7> D-120,<4M4> D-112
(2)NG
Measure at engine-A/T-ECU
connector D-121 <6G7>, or at
A/T-ECU connector D-107 <4M4>.
DMeasure at the ECU terminals.
DIgnition switch: ON
D<6G7> Voltage between terminal
95 and earth
D<4M4> Voltage between terminal
45 and earth
OK:Fully close the accelerator
985 - 1,085 mV
fullyopen the accelerator
4,000 mV or more
OKCheck the following connectors:
<6G7> C-121,<4M4>C-108
Check the trouble symptoms.OK
Check the following connectors:
<6G7> D-121,<4M4>D-108 NGOK
Replace the engine-A/T-ECU or
A/T-ECU. OK
NG
(3)NG
OK
APS adjustment
(Refer to GROUP 13 - On-vehicle
Service.)
NG
Check the following connectors:
<6G7> D-121,<4M4>D-108
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.<4M4>
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the A/T-ECU, and
repair if necessary.<4M4>
DCheck the harness between the
APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
DCheck the harness between the
APS and the A/T-ECU, and
repair if necessary.<4M4> NG
Measure at APS connector D-135.
DUse the test harness
(MB991658) to connect only
terminals 1, 2 and 3 <6G7>, or
only terminals 6, 7 and 8 <4M4>,
and then measure at the pickup
harness.
DIgnition switch: ON
(1) <6G7> Voltage between terminal
1 and earth
<4M4> Voltage between terminal
7 and earth
OK:0.5 V or less
(2) <6G7> Voltage between terminal
2 and earth
<4M4> Voltage between terminal
8 and earth
(Ignition switch: ON)
OK:4.8 - 5.2 V
(3) <6G7> Voltage between terminal
3 and earth
<4M4> Voltage between terminal
6 and earth
OK:Fully close the accelerator
985 - 1,085 mV
fullyopen the accelerator
4,000 mV or moreRepair
Repair
RepairOK
Repair


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