charging MITSUBISHI MONTERO 2000 Service Repair Manual
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Page 308 of 1839
GDI -Troubleshooting
Inspection procedure 19
Low alternator output voltage (approx.12.3 V)
Probable cause
The cause is probably a malfunction of the alternator or one of the problems
listed at right.DMalfunction of the charging system
DOpen circuit between the alternator G terminal and
the engine-ECU
DMalfunction of the engine-ECU
NG
Repair
OK
Replace the engine-ECU.
OK
Check the alternator. (Refer to GROUP
16 - Charging System.)
OK
Check the following connectors:
B-41, B-59, D-119
Measure at the alternator connector
B-59.
DConnect the connector. (Use the
test harness MB991519)
DVoltage between 1 (black clip)
and earth
(Engine: Idling)
(Radiator fan: Not operating)
(Headlamp: OFF®ON)
(Stoplamp: OFF®ON)
(Rear defogger switch: OFF®
ON)
OK:
Voltage increased by
0.2 - 3.5 V.NGMeasure at the alternator connector
B-59.
DDisconnect the connector, and
measure at the harness side.
DDisconnect the engine-ECU
connector.
DContinuity between 1 and earth
OK:
No continuityNGCheck the harness wire between the
alternator and the engine-ECU, and
repair if necessary.
Inspection procedure 20
Idling speed is improper when A/C is operating
Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the throttle control
servo to control idle-up operation.
The A/C-ECU judges if theloadcaused by air conditioner operation ishigh or low,
and converts it to voltage signal (high or low voltage) and inputs the signal to the
engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (forhigh
or low load).DMalfunction of the A/C control system
DImproper connector contact,opencircuit or
short-circuited harness wire
DMalfunction of the engine-ECU
NG
Repair
Measure at the engine-ECU connector D-117.
DConnect the connector.
DVoltage between 65 and earth (Engine: at idle, outside air
temperature: 25_C or more)
OK:
0 - 3 V [When A/C is MAX. COOL condition (when the
load by A/C is high)]
System voltage [When A/C is MAX. HOT condition (when
the load by A/C islow)]OKCheck the following connector:
D-117
OK
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)
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Page 400 of 1839
Page 707 of 1839
15-1
INTAKE AND
EXHAUST
CONTENTS
SERVICE SPECIFICATIONS 2.................
SEALANT 2..................................
SPECIAL TOOL 2............................
ON-VEHICLE SERVICE 2.....................
Intake Manifold Vacuum Check <6G7> 2.........
Turbocharger Supercharging Check <4D5> 2.....
Waste Gate Actuator Check <4D5> 3..........
Waste Gate Actuator Check <4M4> 3..........
AIR CLEANER 4.............................
INTERCOOLER<4D5, 4M4> 5.................
INTAKE MANIFOLD <6G7> 6.................
INTAKE MANIFOLD AND THROTTLE BODY
<4M4> 8.....................................EXHAUST MANIFOLD <6G7> 11..............
INTAKE MANIFOLD AND EXHAUST
MANIFOLD, TURBOCHARGER <4D5> 12...
TURBOCHARGER AND EXHAUST
MANIFOLD <4M4> 14.....................
TURBOCHARGER <4D5> 16.................
TURBOCHARGER <4M4> 19.................
EXHAUST PIPE AND MAIN MUFFLER
<6G7> 21...................................
EXHAUST PIPE AND MAIN MUFFLER
<4D5> 23...................................
EXHAUST PIPE AND MAIN MUFFLER
<4M4> 25...................................
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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 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 758 of 1839
ENGINE ELECTRICAL -Charging System16-10
14. If the voltage reading conforms to the value
in the voltage regulation, then the voltage
regulator is operating normally.
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator
or of the alternator.
15. After the test, lower the engine speed to the
idle speed.
16. Turn the ignition switch off.17. Remove the tachometer or the MUT-II.
18. Disconnect the negative battery cable.
19. Disconnect the ammeter and voltmeter.
20. Connect the alternator output wire to the
alternator “B” terminal.
21. Remove the special tool, and return the
connector to the original condition.
22. Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminalVoltage regulator ambient temperature_
CVoltage V
Terminal “S”-2014.2 - 15.4
2013.9 - 14.9
6013.4 - 14.6
8013.1 - 14.5
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Page 1572 of 1839
54A-2
CHASSIS
ELECTRICAL
CONTENTS
BATTERY 4
..............................
SERVICE SPECIFICATIONS 4..................
ON-VEHICLE SERVICE 4......................
Electrolyte Level and Specific Gravity Check 4..
Charging 5.................................
Battery Test 5...............................
IGNITION SWITCH AND IMMOBILIZER
SPECIAL TOOLS 6............................
TROUBLESHOOTING 6........................
IGNITION SWITCH AND
IMMOBILIZER-ECU 11.........................
IGNITION SWITCH AND IMMOBILIZER
<4D56> 14...............................
SPECIAL TOOLS 14...........................
TROUBLESHOOTING 14.......................
IGNITION SWITCH AND IMMOBILIZER-ECU
19 ............................................
COMBINATION METER 23................
SERVICE SPECIFICATIONS 23.................
SEALANTS 24................................
SPECIAL TOOLS 24...........................
TROUBLESHOOTING 24.......................
ON-VEHICLE SERVICE 30.....................
Speedometer Check 30......................
Tachometer Check 30........................
Fuel Gauge Unit Check 31....................Engine Coolant Temperature Gauge Unit Check
32 .........................................
COMBINATION METER 33.....................
HEADLAMP ASSEMBLY 36...............
SERVICE SPECIFICATIONS 36.................
SPECIAL TOOLS 36...........................
TROUBLESHOOTING 36.......................
ON-VEHICLE SERVICE 36.....................
Headlamp Aiming Adjustment 36..............
Luminance Measurement 38..................
Headlamp Bulb Replacement 39...............
HEADLAMP ASSEMBLY 40....................
FOG LAMPS 41..........................
SERVICE SPECIFICATIONS 41.................
SPECIAL TOOLS 41...........................
TROUBLESHOOTING 41.......................
ON-VEHICLE SERVICE 41.....................
Fog Lamp Aiming Check 41...................
FOG LAMPS 44...............................
SIDE TURN-SIGNAL LAMPS 45...........
SPECIAL TOOLS 45...........................
SIDE TURN-SIGNAL LAMPS 46................
ROOM LAMP 46.........................
TROUBLESHOOTING 46.......................
CONTINUED ON NEXT PAGE
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Page 1575 of 1839
CHASSIS ELECTRICAL-Battery54A-5
CHARGING
1. Remove the battery from the vehicle.
2. The normal charging current is a value in amperes which is 1/10th of the battery capacity. If the
battery needs to be charged rapidly because of reasons such as time limitations, the maximum charging
current for rapid charging is the battery capacity expressed as an ampere value.
Battery typeCapacity (5-hour rate)Normal charging currentRapid charging current
75D2354 A5.4 A54 A
80D2658 A5.8 A58 A
95D3170 A7.0 A70 A
3. Determine when charging is finished.
DWhen the specific gravity of the battery electrolyte is constantly within 1.250 - 1.290 for a continuous
period of one hour or more
DWhen the voltage per cell during charging is 2.5 - 2.8 V constantly for a continuous period of one hour
or more
Caution
1. The battery plugs should be removed during charging.
2. The battery electrolyte level may rise and overflow from the battery during charging.
3. Explosions may occur if the battery is brought close to naked flames during charging.
4. Be careful to avoid tasks that might produce sparks or other danger while the battery is charging.
5. After charging is complete, replace the battery plugs, pour water over the battery to rinse
away any sulphuric acid, and let the battery stand to dry.
6. Charge the battery in a well-ventilated location.
7. Do not let the battery electrolyte temperature rise above approximately 45
°C (approximately
55
°C during rapid charging).
BATTERY TEST
Test procedure
OK
NG
Replace
Re-test
OK
Normal
(1) Connect a battery tester to the battery.
(2) Apply aloadwith the specified current to the battery.(Refer
to Table 1.)
(3) After measuring the battery voltage after 15 seconds,
remove the loadcurrent.
(4) Compare the measurement value with the specified
minimum voltage.(Refer to Table 2.)
OK:Higher than the minimum voltage
Measure the battery discharge voltage.
OK:12.4 V or more (specific gravity 1.240)NGCharge the battery at 5 A (constant current charging). (Refer
to Table 1.)
(1) Turn on the headlamps for 15 seconds.
(2) Turn off the headlamps and let the battery stand for 2
minutes to allow the battery voltage to stabilise.
(3) Disconnect the battery cables.
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Page 1748 of 1839
55A-2
HEATER, AIR
CONDITIONER AND
VENTILATION
CONTENTS
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
TROUBLESHOOTING
TROUBLESHOOTING
ON-VEHICLE SERVICE 9.....................
Refrigerant Level Test through Performance Test 9.
Magnetic Clutch Test 10.........................
Receiver Drier Test 10..........................
Compressor Drive Belt Adjustment 10.............
Dual Pressure Switch Check 10..................
Charging 11...................................
Performance Test 15............................
Front Blower Relay and Rear Blower Relay
Continuity Check 18............................
Continuity Check of A/C Compressor Relay and
Condernser Fan Relay 18.......................
PTC Heater Relay Continuity Check 19...........
Idle-up Operation Check
Vacuum Actuator Check
Idle-up Solenoid Valve Check 21.................
Clean Air Filter Replacement Procedure 22........
FRONT A/C 23..............................
Air Conditioner Control Panel Assembly and
A/C Switch 23.................................
Heater Unit and Blower Assembly 26.............
Blower Motor and Resistor 29....................
Inside/Outside Air Changeover Damper Motor 30...
Automatic Compressor-ECU and
Air Thermo Sensor Assembly 31.................
REAR HEATER AND REAR COOLER 32.....
Rear A/C Switch, Front Rear Fan Switch 32.......
Rear A/C Control Unit 34........................
Rear Heater Unit 34............................
Rear Heater Unit and Rear Blower Assembly 37....
HEAT SWITCH 40...........................
COMPRESSOR 41...........................
CONDENSER ASSEMBLY AND
CONDENSER FAN 45........................
REFRIGERANT LINE 47.....................
ENGINE COOLANT TEMPERATURE SWITCH
51 ..........................................
IDLE-UP SYSTEM 53........................
DUCTS 54..................................
VENTILATION 56............................
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Page 1763 of 1839
HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service55A-17
REFRIGERANT LEAK REPAIR
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system. (See procedure.)
2. Charge the system with approximately one
pound of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
6. Replace receiver drier.
Caution
Replacement filter-drier units must be
sealed while in storage. The drier used in
these units will saturate water quickly upon
exposure to the atmosphere. When
installing a drier, have all tools and supplies
ready for quick reassembly to avoid keeping
the system open any longer than necessary.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are
produced in the system when it is operating.
Extreme care must be exercised to make sure that
all connections are pressure tight. Dirt and moisture
can enter the system when it is opened for repair
or replacement of lines or components. The
following precautions must be observed. The
system must be completely discharged before
opening any fitting of connection in the refrigeration
system. Open fittings with caution even after the
system has been discharged. If any pressure is
noticed as a fitting is loosened, allow trapped
pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use
the correct line for the installation you are servicing.
A good rule for the flexible hose lines is keep the
radius of all bends at least 10 times the diameter
of the hose.
Sharper bends will reduce the flow of refrigerant.
The flexible hose lines should be routed so that
they are at least 80 mm from the exhaust manifold.
It is good practice to inspect all flexible hose lines
at least once a year to make sure they are in good
condition and properly routed.
Unified plumbing connections with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or
any other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets,
or a loose clutch assembly. Verify accessory drive
belt tension (power steering or alternator).
Improper accessory drive belt tension can cause
a misleading noise when the compressor is
engaged and little or no noise when the compressor
is disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure),
restrict air flow through condenser. Install
manifold gauge set to make sure discharge
pressure doesn’t exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt.
Check to assure clutch coil is tight (no rotation
or wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge. (See “Charging
System”.)
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.
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