2000 MITSUBISHI MONTERO Service Repair Manual

4
W D IN DIC ATO R-E C U/T R ANSFE R -E C U
R EM OVA L AND IN STA LLA TIO N

MANUAL TRANSMISSION -4WD Indicator-ECU/Transfer-ECU22-18
Terminal No.Inspection itemInspection condition
1: Ignition switchInspection condition
2: Transfer lever positionTerminal voltage
1Free wheel engageON2HSystem voltage
switch
4H*10V
24WD detectionON2HSystem voltage
switch
4H, 4L0V
3Ignition switch (IG1)OFF-0V
ON-System voltage
6HI/LOW detection
switchONShifting from 4H to 4L
or vice versaSystem voltage
2H, 4H, 4L0V
7Free wheel clutchON4H, 4L0V
changeover solenoid
valve
2H*2System voltage
104WD Indicator lampON2H0V
4H, 4LSystem voltage
NOTE
*1:When vehicle has been moved once.
*2:Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
TRANSFER-ECU
Measure the terminal voltage (Refer to P.22-3).


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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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MANUAL TRANSMISSION -Troubleshooting 22-2
OKOK OK
NG
NG
NG(1), (2)
NG
Check the following connector:D-112Repair OK
DCheck the harness between the
APS and the engine-ECU, and
repair if necessary.OK
Measure at transfer-ECU connector
E-105
DMeasure at ECU terminals.
DIgnition switch: ON
DVoltage between terminal 5 and
earth
OK:Fully close the accelerator
985 - 1,085 mV
fully open the accelerator
4,000 mV or more
Check the following connector:E-105
Check the trouble symptoms.OK
Check the following connectors:
E-105, E-113 NG
Replace the transfer-ECU. OK
NGRepair
Check the harness between the APS
and the transfer-ECU, and repair if
necessary.
Check the harness between the APS
and the transfer-ECU, and repair if
necessary.
From the previous page
(3) NG
Measure at APS connector D-135.
DUse the test harness to connect
only terminals 6, 7 and 8, and
measure at the pickup harness.
DIgnition switch: ON
(1) Voltage between terminal 7 and
earth
OK:0.5 V or less
(2) Voltage between terminal 8 and
earth
OK:4.8 - 5.2 V
(3) Voltage between terminal 6 and
earth
OK:Fully close the accelerator
985 - 1,085 mV
fully open the accelerator
4,000 mV or more
APS adjustment
Check the following connectors:
E-113, E-105
Repair
DATA LIST REFERENCE TABLE
Data
list No.Check itemCheck conditionsNormal condition
1Accelerator ped-
alpositionsen
Engine: Stopped
Sllii
Accelerator pedal: Fully closed985 - 1,085 mV
al position sen-
sor (APS)
<4D5>Selector lever position:
PAccelerator pedal: DepressedGradually increases from
the above value.
<4D5>
Accelerator pedal: Fully open4,000 mV or more
CHECK AT TRANSFER-ECU TERMINAL
Ter-
minal
No.Check itemCheck conditionsStandard value
5Accelerator pedal position
(APS)4D5
Accelerator pedal: Fully closed (engine stopped)0.985 - 1.085 Vpp
sensor (APS) <4D5>Accelerator pedal: Fully open (engine stopped)4.0 V or more


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AUTOMATIC
TRANSMISSION
Click on the applicable bookmark to selected the required model year.


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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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S
ER VIC E SPEC IF IC ATIO NS
I te m S
ta ndard va lu e A
/T flu id te m pera tu re se n- A
t0°C 1
6.7 -20.5 s
o r re sis ta nce kW 7
.3 -8.9 A
t40°C 3
.4 -4.2 A
t60°C 1
.9 -2.2 A
t80°C 1
.0 -1.2 A
t100 °C 0
.5 7 -0.6 9 D
am per clu tc h co ntr o l(D CC)so le noid va lv e co il re sis ta nce (a t 20°C )W L
ow &re ve rs e (L R )so le noid va lv e co il re sis ta nce (a t 20°C )W S
eco nd (2 N D)so le noid va lv e co il re sis ta nce (a t 20°C )W U
nderd riv e so le noid va lv e (U D so le noid va lv e ) co il re sis ta nce (a t 20°C )W O
ve rd riv e so le noid va lv e (O D so le noid va lv e ) co il re sis ta nce (a t 20°C )W R
esis ta nce of re ductio n (R ED )so le noid va lv e co il a t (2 0°C )W S
ta ll s p eed r/m in 6
G 7 2
,2 00 -2,7 00 4
M 4 2
,4 00 -2,9 00 L
in e pre ssu re adju stm ent va lu e kP a 1
,0 10 -1,0 50 B
ra nd Q
uantit y L T
ra nsm is sio n flu id D
IA QUEEN AT F SP II M ,A T F SP III or equiv a le nt 9
.3 T
ra nsfe r oil H
yp oid gear oil S AE 75W -9 0 or 75W -8 5W co nfo rm in g to API
G L-4 2
.8 N
o. N
am e A
pplic a tio n M
B991502 M
UT-II S ub
a sse m bly D
ia gnosis co de ch eckin g M
B991529 D
ia gnosis co de
c h eckin g harn ess M
B991658 T
e st harn ess V
olt a ge measu re m ent of APS M
D998478 T
e st harn ess
( 3 P, tr ia ngle ) V
olt a ge measu re m ent of cra nk angle se nso r

M
D998330
( in clu din g
M D998331) O
il p re ssu re gauge
( 2 ,9 42 kP a) H
yd ra ulic pre ssu re measu re m ent M
D998332 A
dapte r O
il p re ssu re gauge co nnectio n M
D998900 A
dapte r N
o dia gnosis co de
o utp ut (n o abnorm alit y ) A
sk about tr o uble sym pto m s. C
heck th e A/T flu id . N
G R
epla ce th e A/T flu id .
O K C
heck th e tr o uble sym pto m s. R
eadin g of a dia gnosis co de
( R efe r to P.2 3-4 .) C
om munic a tio n
w it h th e MUT-
II
i s not possib le I
n sp ectio n pro ce dure ch eck by
t r o uble sym pto m
P ro ce dure 1(R efe r to P.2 3-4 8.)
D ia gnosis co de outp ut exis ts N
o dia gnosis co de
o utp ut R
oad te st (R efe r to P.2 3-5 .)
D ia gnosis co de outp ut
e xis ts G
o to Dia gnosis Code Lis t
( R efe r to P.2 3-1 2.) N
o dia gnosis co de
o utp ut (a bnorm alit y
e xis ts ) C
heck fo r th e ca use . N
ot fo und
N G N
G R
epair
O K G
o to Tro uble Sym pto m Lis t
( R efe r to P.2 3-4 7.) V
erif ic a tio n te st (ro ad te st)
F
ound E
N D E
ra se of a dia gnosis co de
( R efe r to P.2 3-4 .) T
ra nsie nt m alf u nctio n (R efe r to
G RO UP 00 -Poin ts to Note fo r
T ra nsie nt M alf u nctio ns.) O
K
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