table contents MITSUBISHI MONTERO 2000 Service Repair Manual

00-1
GENERAL
CONTENTS
HOW TO USE THIS MANUAL 2..............
Scope of Maintenance, Repair and Servicing
Explanations 2.................................
Definition of Terms 2...........................
Indication of Tightening Torque 2................
Model Indications 3............................
Explanation of Manual Contents 4...............
HOW TO USE
TROUBLESHOOTING/INSPECTION SERVICE
POINTS 6....................................
Troubleshooting Contents 6.....................
Diagnosis Function 7...........................
How to Use the Inspection Procedures 10.......
Connector Measurement Service Points 11.......
Connector Inspection 12........................
Inspection Service Points for a Blown Fuse 13...
Points to Note for Intermittent Malfunctions 13....
TREATMENT BEFORE/AFTER THE FORDING
A STREAM 14..............................
Inspection and Service before Fording a Stream
14 ............................................
Inspection and Service after Fording a Stream
15 ............................................
VEHICLE IDENTIFICATION 16...............
Vehicle Information Code Plate 16...............
Models 16.....................................
Model Code 18................................
Chassis Number 19............................
Engine Model Number 20.......................
Theft Protection 21...............
MAJOR SPECIFICATIONS 23................
PRECAUTIONS BEFORE SERVICE 29.......
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) 33....................................
SUPPORT LOCATIONS FOR LIFTING AND
JACKING 37................................
Support Positions for a Garage Jack 37.........
Support Positions for axle stands and a
Single-Post Lift or Double-Post Lift 38...........
STANDARD PARTS-TIGHTENING-TORQUE
TABLE 39..................................


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GDI -Troubleshooting 13A-13
FAIL-SAFE FUNCTION REFERENCE TABLE
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning itemControl contents during malfunction
Air flow sensor1. Suspends lean burn operation.
2. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre-set mapping.
Intake air temperature sensorControls as if the intake air temperature is 25_
C.
Throttle position sensor (2nd
channel)1. Suspends lean burn operation.
2. Controls the throttle opening angle feedback (half as much as the opening
rate in the normal condition) by using signals from the throttle position sensor
(1st channel). However, this controlling system is not applied if the throttle
position sensor (1st channel) and throttle position sensor (2nd channel)
combination output voltage is outside 4 - 6 V.
3. Refrains from controlling the throttle opening angle feedback if the throttle
position sensor (1st channel) is also defective.
Engine coolant temperature
sensorControls as if the engine coolant temperature is 80_
C. (Moreover, the control system
is working until the ignition switch is turned OFF if the sensor signal returns to normal.)
Camshaft position sensorCuts the fuel supply once a malfunction is detected. (Only when there has been
no occasion of detecting No.1 cylinder top dead centre after the ignition switch
is turned ON.)
Vehicle speed sensor1. Suspends lean burn operation. However, the control is cancelled as a certain
time passes by with the engine speed of 1,500 r/min or more.
2. Suspends lean burn operation during the engine idling.
Barometric pressure sensorControls as if the barometric pressure is 101 kPa.
Detonation sensorFixes the ignition timing as that for standard petrol.
Injector1. Suspends lean burn operation.
2. Suspends the exhaust gas recirculation.
Ignition coil (incorporating pow-
er transistor)1. Suspends lean burn operation.
2. Cuts off the fuel supply to cylinders with an abnormal ignition signal.
Fuel pressure sensor1. Controls as if the fuel pressure is 5MPa.
2
. Suspends fuel injection. (when the low pressure is detected and the engine
speed is more than 3,000r/min)
Alternator FR terminalRefrains from controlling to suppress the alternator output to electrical load.
(Operated as a normal alternator)
Accelerator pedal position sen-
sor (2nd channel)1. Suspends lean burn operation.
2. Controls the throttle valve position by using signals from the accelerator pedal
position sensor (1st channel). (However, the control system is not applicable
if the difference from the accelerator pedal position sensor (1st channel) output
voltage is 1.0 V or higher.)
3
. Suspends the electronic controlled throttle valve system if accelerator pedal
position sensor (1st channel) is also defective.


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GDI -Troubleshooting 13A-110
ACTUATOR TEST REFERENCE TABLE
Item
No.Inspection
itemDrive contentsInspection contentsNormal conditionInspection
procedure
No.Reference
page
01InjectorsCut fuel to No. 1
injectorEngine:
After havingIdling condition
becomes differentCode No.
P020113A-38
02Cut fuel to No. 2
injector
warmed up/Engine
is idling
(Cut the fuel supply(becomes unsta-
ble).
Code No.
P020213A-40
03Cut fuel to No. 3
injectorto each injector in
turn and check
cylinders whichCode No.
P020313A-42
04Cut fuel to No. 4
injectordon’t affect idling.)Code No.
P020413A-44
05Cut fuel to No. 5
injectorCode No.
P020513A-46
06Cut fuel to No. 6
injectorCode No.
P020613A-48
07Fuel pump
(low pressure)Fuel pump
operates and
fuel is recirculated.Ignition switch: ONSound of opera-
tion is heard.Procedure
No. 2913A-101
08Purge
control
solenoid valveSolenoid valve
turns from OFF to
ON.Ignition switch: ONSound of opera-
tion can be heard
when solenoid
valve is
driven.Code No.
P044313A-62
17Basic ignition
timingSet the engine-
ECU to ignition
timing adjustment
modeIdling after engine
warm up5_BTDC--
21Condenser fanDrive the fan motorIgnition switch: ONThe fan motor
operatesProcedure
No.2113A-95
34Electronic-
controlled
throttle valve
systemStop the throttle
control servo.Ignition switch: ONThrottle valve is
opened slightly.Code No.
P122013A-64


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GDI -Troubleshooting 13A-128
FAIL-SAFE FUNCTION REFERENCE TABLE
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning itemControl contents during malfunction
Air flow sensor1. Suspends lean burn operation.
2. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre - set mapping.
Intake air temperature sensorControls as if the intake air temperature is 25_
C.
Throttle position sensor (2nd
channel)1. Suspends lean burn operation.
2. Controls the throttle opening angle feedback (half as much as the opening
rate in the normal condition) by using signals from the throttle position sensor
(1st channel). However, this controlling system is not applied if the throttle
position sensor (1st channel) and throttle position sensor (2nd channel)
combination output voltage is outside 4 - 6 V.
3. Refrains from controlling the throttle opening angle feedback if the throttle
position sensor (1st channel) is also defective.
Engine coolant temperature
sensorControls as if the engine coolant temperature is 80_
C. (Moreover, the control system
is working until the ignition switch is turned OFF if the sensor signal returns to normal.)
Camshaft position sensorCuts the fuel supply once a malfunction is detected. (Only when there has been
no occasion of detecting No.1 cylinder top dead centre after the ignition switch
is turned ON.)
Vehicle speed sensor1. Suspends lean burn operation. However, the control is cancelled as a certain
time passes by with the engine speed of 1,500 r/min or more.
2. Suspends lean burn operation during the engine idling.
Barometric pressure sensorControls as if the barometric pressure is 101 kPa.
Detonation sensorFixes the ignition timing as that for regular gasoline.
Injector1. Suspends lean burn operation.
2. Suspends the exhaust gas recirculation.
Ignition coil (incorporating pow-
er transistor)1. Suspends lean burn operation.
2. Cuts off the fuel supply to cylinders with an abnormal ignition signal.
Fuel pressure sensor1. Controls as if the fuel pressure is 5MPa.
2. Suspends fuel injection. (when the low pressure is detected and the engine
speed is more than 3,000r/min)
Alternator FR terminalRefrains from controlling to suppress the alternator output to electrical load.
(Operated as a normal alternator)
Accelerator pedal position sen-
sor (2nd channel)1. Suspends lean burn operation.
2. Controls the throttle valve position by using signals from the accelerator pedal
position sensor (1st channel). (However, the control system is not applicable
if the difference from the accelerator pedal position sensor (1st channel) output
voltage is 1.0V or higher.)
3
. Suspends the electronic controlled throttle valve system if accelerator pedal
position sensor (1st channel) is also defective.


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GDI -Troubleshooting 13A-198
DATA LIST REFERENCE TABLE
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1: Injector running time indicates the time where the power voltage is 11 V and the cranking speed
is 250 r/min or less. As the engine speed increases and the time passes by, the injector running
time decreases.
*2: There may be occasions of taking the injector running time approximately 10% longer than usual
when a vehicle has not been driven for a long time (mileage is no more than 500 km.)
*3: It is normal that the idle switch turns from ON to OFF when accelerator pedal position sensor (1st
channel) voltage increases by 200 - 600 mV from the idling position. Moreover, adjust the idle switch
and accelerator pedal position sesor if the idle switch keeps turning after the accelerator pedal is
depressed.
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensorEngine: After having
warmed up
(Air/fuel mixture is
made leaner whenWhen at 4,000 r/min,
engine is deceler-
ated200 mV or lessCode No.
1113A-131
made leaner when
decelerating, and is
made richer when
racing.)
Race the engine sud-
denly.600 - 1,000 mV
Engine: After having
warmed up
(The oxygen sensor
signal is used to
check the air/fuelIdling
(after six minutes)400 mV or less
600 - 1,000 mV
(changes)
check the air/fuel
mixture ratio, and
control condition by
the engine-
A/T-ECU.)
2,500 r/min
12Air flow sen-DEngine coolantIdling22 - 48 HzCode No.13A-133
sortemperature: 80 -
95
_C
Lamps and all
2,500 r/min60 - 100 Hz
12
DLamps and all
accessories: OFF
DTransmission: P
range
RacingFrequency in-
creases in re-
sponse to racing
13Intake air
temperatureIgnition switch: ON or
with engine runningWhen intake air tem-
perature is - 20_
C-20_
CCode No.
1313A-135
sensor
When intake air tem-
perature is 0_
C0_
C
When intake air is
20_
C20_
C
When intake air is
40_
C40_
C


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GDI -Troubleshooting 13A-203
ACTUATOR TEST REFERENCE TABLE
Item
No.Inspection
itemDrive ContentsInspection contentsNormal condi-
tionInspec-
tion pro-
cedure
No.Reference
page
01InjectorCut fuel to the
No.1 injector.Engine:
Idling after warming-upIdling condition
becomes differ-Code
No. 4113A-147
02Cut fuel to the
No.2 injector.
(Cut the fuel supply to each
injector in turn and check
cylinders which does notent (becomes
unstable, or the
engine stalls).
03Cut fuel to the
No.3 injector.affect idling.)
04Cut fuel to the
No.4 injector.
05Cut fuel to the
No.5 injector.
06Cut fuel to the
No.6 injector.
07Fuel pump
(low-pres-
sure)Operates the
fuel pump (low-
pressure) to cir-
culate fuel.Ignition
switch:
ONPinch the return
hose with fin-
gers to feel the
pulse of the fuel
being circulated.Pulse is felt.Proce-
dure
No.2913A-193
Operating
sound can be
heard around
the fuel tank.Sound of opera-
tion can be
heard
08Purge con-
trol solenoid
valveSolenoid valve
turns from OFF
to ON.Ignition switch: ONSound of opera-
tion can be
heard when so-
lenoid valve is
driven.Proce-
dure
No.3613A-197
17Basic ignition
timingSolenoid valve
turns from OFF
to ON.DEngine: Idling
DSet a timing light.
5_BTDC--
21Condenser
fanDrive the fan
motorDIgnition switch: ON
DA/C switch: ON
Fan motor runsProce-
dure
No.2113A-187
34Electronic-
controlled
throttle valve
systemStop the throttle
control servoIgnition switch: ONThe throttle
valve opens
slightlyCode
No. 9113A-161


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GDI -Troubleshooting13A-5
DATA LIST REFERENCE TABLE
The data list has been changed as the engine-ECU and the engine-A/T-ECU have been changed. The
other items are the same as for M/T.
Item
No.Inspection
itemInspection contentsNormal conditionInspec-
tion pro-
cedure
No.Refer-
ence
page
22Crank angle
sensorDEngine: Cranking
DTachometer:
ConnectedCompare the engine
speed readings on
the tachometer and
the MUT-II.AccordCode
No.
P033513A-56*
DEngine: Idling
DIdle position
switch: ONWhen engine
coolant temperature
is - 20_C1,300 - 1,500
r/min
When engine
coolant temperature
is 0_C1,300 - 1,500
r/min
When engine
coolant temperature
is 20_C1,250 - 1,450
r/min
When engine
coolant temperature
is 40_C1,100 - 1,300
r/min
When engine
coolant temperature
is 80_C (more than
four minutes later
after engine has
started)600 - 800 r/min
A1LOxygen
sensorEngine: After having
warmed up. (Air/fuel
mixture is made
leaner when deceler-When at 4,000
r/min, engine is
decelerated200 mV or lessCode
No.
P013013A-28*
leanerwhendeceler
ating, and is made
richer when racing.)Rev the engine.600 - 1000 mV
Engine: After having
warmed up (The
oxygen sensor signal
is used to check the
air/fuel mixture ratio,
and control condition
isalsocheckbythe
Engine is idling
(more than 4
minutes later after
engine has started)Voltage should
alternate between
400 mV or less
and 600 - 1,200
mV (more than 4
minutes after the
enginehasisalso checkbythe
engine-ECU
or engine-A/T-ECU
.)
2,500 r/min
enginehas
started).
24LVehicle
speed sen-
sorDrive at 40 km/hApproximately 40
km/hCode
No.
P050013A-63*


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DIESEL FUEL <4M4> -Troubleshooting13C-10
DATA LIST REFERENCE TABLE
Item No.Check itemInspection
conditionsValue to be
determined normalCode No. or
inspection
procedure No.Reference page
31EGR sensor
(Target value)Engine: RacingChanges between 0.5
V and 4.5 VCode No. 5113C-8
32EGR sensor
(Output value)Engine: RacingApproaches EGR
sensor (target value).Code No. 5113C-8
36Throttle body
assembly
(Target value)Engine: Idling30 degCode No. 4113C-6
ACTUATOR TEST TABLE
Item No.Check itemDrive contentsInspection
conditionsValue to be
determined as
normalCode No. or
inspection
procedure No.Reference
page
07Throttle body
assemblyThrottle valve:
Fully closedDIgnition
switch: ON
DVehicle
Operating
sound can be
heard
Code No. 4113C-6
08Throttle valve:
Kept at half-
openDVehicle
speed: 0 km/h
DEngine
speed: 1,000
r/minorlower
heard.
09Throttle valve:
Fully openr/minorlower
28EGR valve
assemblyEGR valve:
OpenDIgnition
switch: ON
DVehicle
Operating
sound can be
heard
Code No. 5113C-8
29EGR valve:
ClosedDVehicle
speed: 0 km/hheard.


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13E-1
MITSUBISHI STABILITY
CONTROL
(MITSUBISHI SC)
CONTENTS
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 4..............
SPECIAL TOOLS 4........................
TROUBLESHOOTING 5....................
ON-VEHICLE SERVICE 18.................
Operation Test of MITSUBISHI SC 18.........Wheel Speed Sensor (FR) Check 18..........
Vehicle Speed Sensor Check 18..............
SC-ECU* 19...............................
G SENSOR 20.............................
WHEEL SPEED SENSOR (FR) 20..........
VEHICLE SPEED SENSOR 20..............
WARNINGS 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 the 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: front impact sensors, SRS-ECU, SRS warning lamp, air bag module, clock spring and
interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or
maintenance) are indicated in the table of contents by an asterisk (*).


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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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