2000 MITSUBISHI MONTERO intake manifold

GDI -Troubleshooting 13A-160
Code No.89 Abnormal fuel systemProbable cause
Range of Check
DEngine: Being learning the air - fuel ratio
Set Conditions
DTen seconds or more havebeenpassed while the fuel injection amount
compensation value is too low.
or
DTen seconds or more havebeenpassed while the fuel injection amount
compensation value is too high.DMalfunction of fuel supply system
DMalfunction of oxygen sensor
DMalfunction of intake air temperature sensor
DMalfunction of barometric pressure sensor
DMalfunction of air flow sensor
DMalfunction of engine-A/T-ECU
Repair
OK
MUT-
IIData list
74 Fuel pressure sensor (Refer to
13A-198, DATA LIST
REFERENCE TABLE.)NGCheck fuel leakage around the fuel
pump (high-pressure) line.NG
NO
Check the air intake from the intake
hose and right bank intake manifold.NG
Repair
OK
Check the oxygen sensor (Refer to
P.13A-230.)NG
Replace
MUT-
IISelf-Diag Code
Is any diagnosis code other than
No.89 output?YESRefer to P.13A-130, INSPECTION
CHART FOR DIAGNOSIS CODES.
OK
Check the exhaust gas leaks from
the right bank exhaust manifold.NG
Cleaning
OK
Check the throttle body (around the
throttle valve), and clean if
necessary. (Refer to P.13A-220).NG
Cleaning
OK
MUT-
IIData list
11 Oxygen sensor
12 Air flow sensor
13 Intake air temperature sensor
21 Engine coolant temperature
sensor
25 Barometric pressure sensor
(Refer to 13A-198, DATA LIST
REFERENCE TABLE.)
Reference
If all the service data is normal, go
to “OK.”
If any abnormal service is found, go
to “NG.”NGRefer to the Inspection procedure for
the sensor, which is indicated by the
abnormal service data.
(Refer to P.13A-130, INSPECTION
CHART FOR DIAGNOSIS CODES.)OK
Replace the fuel pump
(high-pressure).
Check the purge control solenoid
valve (Refer to GROUP 17 -
Emission Control).NG
Replace
OK
To the nextpage


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GDI -Troubleshooting 13A-174
Inspection procedure 7
Unstable idling (Rough idling, hunting)
Probable cause
The cause is probably a malfunction of the ignition system, air/fuel ratio control
system, electronic controlled throttle valve system, compression pressure, etc. As
many causes can be suspected, diagnose from easier items.DMalfunction of the ignition system
DMalfunction of the air/fuel ratio control system
DMalfunction of the electronic-controlled throttle
valve system
DPoor compression
DAir sucking into the air intake system
OK
Check that air is sucked in the air intake system.
DBroken intake manifold gasket
DDamaged vacuum hose
DDamaged air intake hoseOK
To the nextpage
OK
MUT-
IIData list
11 Oxygen sensor (Refer to P.13A-198.)
OK:
0 - 400 mV and 600 - 1,000 mV alternates when
the engine is idling(wait for 2 minutes after the en-
gine is started).NGMeasure fuel high-pressure between the fuel pump (high
pressure) and injector. (Refer to P.13A-222.)
OK
MUT-
IIData list
11 Oxygen sensor (Refer to P.13A-198.)
OK:
600 - 1,000 mV when theengine is suddenlyracedNG11 Oxygen sensor system check
(Refer to P. 13A-131, code No.11.)
OK
MUT-
IIActuator Test
08 Purge control solenoid valve (Refer to P.13A-203.)NGCheck the purge control solenoid valve system
(Refer to P.13A-197, Inspection procedure 36.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system (Refer
to P.13A-138, code No.21.)
OK
MUT-
IIData list
25 Barometric pressure sensor (Refer to P.13A-198.)NGCheck the barometric pressure sensor system (Refer to
P.13A-145, code No.25.)
OK
MUT-
IIData list
13 Intake air temperature sensor (Refer to P.13A-198.)NGCheck the intake air temperature sensor system (Refer to
P.13A-135, code No.13.)
NO
MUT-
IIData list
26 Acceleratorpedal positionswitch (Refer to P.13A-198.)NGCheck the acceleratorpedal positionswitch system (Refer to
P.13A-192, Inspection procedure 28.)
OK
Does theidlingspeed fluctuate excessively?YESDClean around the throttle valve. (Refer to P.13A-220)
DAdjust the throttle position sensor (Refer to P.13A-220.)
NO
MUT-
IIData list
79 Throttle position sensor (1st channel) (Refer to P.13A-198.)NGCheck the throttle valve position feedback system
(Refer to P.13A-162, code No.92.)
NO
MUT-
IISelf-Diag Code
Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
CODES.
Has the batterybeen disconnectedrecently?YESAfter warming-up, let theengine run at idling for 10 minutes.


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GDI -Troubleshooting 13A-175
OK
NG
Air is sucked in the air intake system, or EGR gas leaks.
DBroken intake manifold gasket
DDamaged air intake hose
DDamaged vacuum hose
DFaulty EGR valve seat
Check the trouble symptoms.
OK
Check the following items in that order.
DCheck the sparkplug
DCheck the exhaust gas emission control system
DCheck the EGR control system
DCheck the compression pressure
DCheck if foreign materials (water, kerosine,etc.) got into
fuel.
OK
Check ignition coil spark for each cylinder.
1. Remove the ignition coil.
2. Install a new sparkplug to the removed ignitioncoil.
3. Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
4. Earth the sparkplug electrodesecurely.
5. Check that the sparkplug igniteswhen theengine is
cranked.NGReplace the ignition coil.
Clean around the throttle valve. (Refer to P.13A-220.)
OK
Check the ignition timing. (Refer to GROUP 11A - Engine
Adjustment.)NGCheck that the crankanglesensor andtiming beltcover are
properly installed.
OK
MUT-
IIData list
68 EGR valve (Refer to P.13A-198.)NGCheck the EGR valve system (Refer to P.13A-196, Inspection
procedure 35.)
OK
MUT-
IIData list
14 Throttle position sensor (2nd channel)
After warming-up, let theengine run at idlingwith no load.
OK:
When idling, 3,900 - 4,800 mVNGDClean around the throttle valve. (Refer to P.13A-220)
DAdjust the throttle position sensor (Refer to P.13A-220.)
OK
MUT-
IIData list
67 Stoplampswitch (Refer to P.13A-198.)NGCheck the stoplampswitch system
(Refer to P.13A-195, Inspection procedure 32.)
OK
MUT-
IIData list
28 A/C switch (Refer to P.13A-198.)NGCheck the A/C switch and A/C relay system
(Refer to P.13A-194, Inspection procedure 31.)
OK
MUT-
IIData list
27 Power steering oil pressure switch (Refer to P.13A-198.)NGCheck the power steering oil pressure switch system (Refer to
P.13A-194, Inspection procedure 30.)
From the previouspage
OK
MUT-
IIData list
31 Small lampswitch (Refer to P.13A-198.)NGCheck the smalllampswitch system
(Refer to P.13A-195, Inspection procedure 33.)


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GDI -Troubleshooting 13A-178
Inspection procedure 10
When the engine becomes hot, it stalls at idling. (Die
out)
Probable cause
In such cases as the above, the cause is probably that ignition system, air/fuel
mixture, electronic-controlled throttle valve system, compression pressure is
defective. In addition, if the engine suddenlystalls, the cause may also be a
defective connector contact.DMalfunction of the ignition system
DMalfunction of the air/fuel ratio control system
DMalfunction of the electronic-controlled throttle
valve system
DMalfunction of the throttle body
DImproper connector contact
DDrawing air into intake system
OK
Check that air is sucked in the air intake system.
DBroken intake manifoldgasket
DDamaged vacuum hose
DDamaged air intake hoseOK
To the nextpage
OK
MUT-
IIData list
11 Oxygen sensor (Refer to P.13A-198.)
OK
0 - 400 mV and 600 - 1,000 mV alternates when
the engine is idling(wait for 2 minutes after the en-
gine is started).NGMeasure fuel high-pressure between the fuel pump (high
pressure) and injector. (Refer to P.13A-222.)
OK
MUT-
IIData list
11 Oxygen sensor (Refer to P.13A-198.)
OK
600 - 1,000 mV when theengine is suddenlyraced.NGCheck Oxygen sensor system
(Refer to P.13A-131, code No.11.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system. (Refer
to P.13A-138, code No.21.)
OK
MUT-
IIData list
25 Barometric pressure sensor (Refer to P.13A-198.)NGCheck the barometric pressure sensor system.
(Refer to P.13A-145, code No.25.)
OK
MUT-
IIData list
13 Intake air temperature sensor (Refer to P.13A-198.)NGCheck the intake air temperature sensor system.
(Refer to P.13A-135, code No.13.)
YES
MUT-
IIData list
26 Acceleratorpedal positionswitch
(Refer to P.13A-198.)NGCheck the acceleratorpedal positionswitch system.
(Refer to P.13A-192, Inspection procedure 28.)
NO
MUT-
IIData list
79 Throttle position sensor (1st channel) (Refer to P.13A-198.)NGCheck the throttle valve position feedback system.
(Refer to P.13A-162, code No.92.)
NO
MUT-
IISelf-Diag Code
Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
CODES.
Has the batterybeen disconnectedrecently?YESAfter warming-up, let theengine run at idling for 10 minutes.
OK
Does theenginestall easilyagain?NOWhile carrying out an intermittent malfunction simulation test
(Refer to GROUP 00 - Points to Note for Intermittent
Malfunctions.), check for sudden changes in the signals shown
below.
DCrankanglesensor signal
DInjector activating signal
DLow pressure fuelpumpdrive signal
DAir flow sensor
DPrimary ignition signal
DEngine-A/T-ECU power supply voltage


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GDI -Troubleshooting 13A-180
Inspection procedure 11
The engine stalls when starting the car. (Pass out)
Probable cause
In cases such as the above, the cause is probably misfiring due to a weak
spark, or an inappropriate air/fuel mixture when the acceleratorpedal is
depressed.DMalfunction of the ignition system
DMalfunction of the EGR valve
DAir stuck in the air intake system
OK
MUT-
IIActuator Test
08 Purge control solenoid valve (Refer to P.13A-203.)NGCheck the purge control solenoid valve system
(Refer to P.13A-197, Inspection procedure 36.)
NO
MUT-
IIData list
68 EGR valve (Refer to P.13A-198)NGCheck the EGR valve system (Refer to P.13A-196, Inspection
procedure 35.)
MUT-
IISelf-Diag Code
Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
CODES.
OK
Check the following items in that order.
DCheck the sparkplug
DCheck that air is sucked in the air intake system.
DBroken intakemanifoldgasket
DDamaged or disconnected vacuum hose
DDamaged air intake hose
OK
Check ignition coil spark for each cylinder.
1. Remove the ignition coil.
2. Install a new sparkplug to the removed ignitioncoil.
3. Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 mV is
applied to the injector, or you are seriously injured.
4. Earth the sparkplug electrodesecurely.
5. Check that the sparkplug igniteswhen theengine is
cranked.NGReplace the ignition coil.


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GDI -Troubleshooting 13A-182
Inspection procedure 13
Hesitation, sag, stumble, poor acceleration or surge
Probable cause
The cause is probably a malfunction of the ignition system, air/fuel ratio control
system, electronic controlled throttle valve system, compression pressure, etc.DMalfunction of the ignition system
DMalfunction of the air/fuel ratio control system
DMalfunction of the electronic-controlled throttle
valve system
DImproper compression pressure
DAir stuck in the air intake system
NO
NG
Check that the crankanglesensor andtiming beltcover are
properly installed.
OK
Check that air is sucked in the air intake system.
DBroken intake manifold gasket
DDamaged vacuum hose
DDamaged air intake hose
OK
To the nextpage
MUT-
IIData list
68 EGR valve (Refer to P.13A-198.)NGCheck the EGR valve system (Refer to P.13A-196, Inspection
procedure 35.)
OK
MUT-
IIData list
11 Oxygen sensor (Refer to P.13A-198.)
OK:
0 - 400 mV and 600 - 1,000 mV alternates when
the engine is idling(wait for 2 minutes after the en-
gine is started).NGMeasure fuel high-pressure between the fuel pump (high
pressure) and injector. (Refer to P.13A-222.)
OK
MUT-
IIData list
11 Oxygen sensor (Refer to P.13A-198.)
OK:
600 - 1,000 mV when theengine is suddenlyracedNGCheck the oxygen sensor system. (Refer to P.13A-131, code
No.11.)
OK
MUT-
IIData list
79 Throttle position sensor (1st channel) (Refer to P.13A-198.)NGCheck the throttle valve position feedback system (Refer to
P.13A-162, code No.92.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system (Refer
to P.13A-138, code No.21.)
OK
MUT-
IIData list
25 Barometric pressure sensor (Refer to P.13A-198.)NGCheck the barometric pressure sensor system (Refer to
P.13A-145, code No.25.)
OK
MUT-
IIData list
13 Intake air temperature sensor (Refer to P.13A-198.)NGCheck the intake air temperature sensor system (Refer to
P.13A-135, code No.13.)
OK
MUT-
IIData list
26 Acceleratorpedal positionswitch
(Refer to P.13A-198.)NGCheck the acceleratorpedal positionswitch system.
(Refer to P.13A-192, Inspection procedure 28.)
Check the ignition timing. (Refer to GROUP11A - Engine
Adjustment)
MUT-
IISelf-Diag Code
Is a diagnosis code displayed?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
CODES.
OK


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DIESEL FUEL <4M4> -Troubleshooting13C-9
Code No. 12 Boost pressure sensor (boost sensor)
systemProbable cause
Range of Check
DIgnition switch: ON, except for duringenginecranking
Set Conditions
DSensor output voltage for one second is 4.5 Vor higher
(boost pressure is approximately 306.7kPa).
or
DSensor output voltage for one second is 0.2 Vor lower
(boost pressure is approximately 20kPa or lower)
Range of Check
DEngine speed is 1600 r/min or higher and the accelerationopening degree is
60% or more.
Set Conditions
DBoost pressure is lower than the barometric pressure + 13 kPa for two
seconds.DBoost pressure sensor inoperative
DBoost pressure sensoropencircuit, short circuit,
or connector contact inoperative
DBoost pressure sensor hose disconnected
DEngine-ECU inoperative
Check the harness between the
engine-ECU and the boost pressure
sensor connector.
NG
Check the trouble symptoms.
Replace the engine-ECU.
Check the following connector:
D-113
NGOK
NG
Repair
RepairOK
NG
Replace the engine-ECU.
OKOK
OK
Check the following connector:
A-120NG
Check the trouble symptoms. NG
Repair
NG
NG
Check the vacuum hose between the
boost pressure sensor and the intake
manifold.
Replace the boost pressure sensor.
OK OK OK
Repair
NG
Repair
Check the trouble symptoms.
Check the harness between the
engine-ECU and the boost pressure
sensor connector, and repair if
necessary.
NG OK
NG
RepairCheck the following connector:
B-08NG
Measure at B-08 boost pressure
sensor connector
DConnect the connector.
(Test harness: MB991348 used)
DVoltage between 1 and the earth
(Engine: Idling)
OK:
1.2 - 1.6 V
DVoltage between 1 and the earth
OK:
When the accelerator pedal
is suddenly pressed from
the idling condition, the
voltage temporarily in-
creases from 1.2 V to 1.6
V.
Measure at D-113 engine-ECU
connector
DConnect the connector.
DVoltage between 85 and the
earth (Engine: Idling)
OK:
1.2 - 1.6 V
Check the harness between the
engine-ECU and the boost pressure
sensor connector.
Measure at B-08 boost pressure
sensor connector
DDisconnect the connector and
measure at the harness side.
DVoltage between 3 and the earth
(Ignition switch: ON)
OK:
4.5 - 5.5 V
DContinuity between 2 and the
earth
OK:
Continuity


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DIESEL FUEL <4M4> -General/Service Specifications/Troubleshooting13C-2
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 StepIII.
DThe intake manifold cover and injection pump cover have been reshaped.
DThe throttle body assembly has been changed.
DThe EGR valve assembly has been changed.
SERVICE SPECIFICATIONS
ItemStandard value
Throttle body assembly resistanceΩat - 10 - 50_C12 - 20
at 50 - 100_C12 - 23
TROUBLESHOOTING
FAIL-SAFE, BACKUP FUNCTIONS
When abnormalities in the major sensors are detected by diagnosis functions, pre-set control logic operates
to maintain a safe driving condition for the vehicle.
Diagnosis itemControl features in malfunction
Accelerator pedal position sensorDAccelerator pedal released (idle switch ON)
Acceleration opening degree = 0 %
DAccelerator pedal applied (idle switch OFF)
Engine controlled at low speed
Acceleration opening degree = 40 % , 28 %
DVoid cruise control
Idle switchDVoid idling speed control
DVoid cruise control
Engine speed sensorDEngine controlled at low speed
DVoid cruise control
Boost air temperature sensorMaintain the intake air temperature at 50_C
Vehicle speed sensorDVoid idling speed control
DVoid cruise control
DWith accelerator pedal released (when idle switch is on)
Accelerator opening angle = 0 %
DWith accelerator pedal depressed (when idle switch is off)
Accelerator opening angle = Fixed at 40 % (M/T), 28 % (A/T)
Engine coolant temperature sensorMaintain the engine coolant temperature at 80_C (engine running), 0_C
(engine stopped or just started)
Control sleeve position sensorDWith accelerator pedal released (when idle switch is on)
Engine speed = 800 r/min
DWith accelerator pedal depressed (when idle switch is off)
Engine speed = 2,000 r/min
DVoid cruise control
Timer piston position sensorDOpen control by means of engine speed
DVoid cruise control
Barometric pressure sensor (ECU built-in)Keep the barometric pressure at 101 kPa


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