2000 MITSUBISHI MONTERO egr valve

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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DIESEL FUEL <4M4> -Troubleshooting13C-11
ENGINE-ECU CHECK
TERMINAL VOLTAGE TABLE
Terminal No.Check itemInspection conditions (engine status)Normal condition
14Throttle body assembly (1)Ignition switch: ON (Engine stops)9 V or more
17EGR motorIgnition switch: ON (Engine stops)System voltage
18Throttle body assembly (2)Ignition switch: ON (Engine stops)9 V or more
19Throttle body assembly (3)Ignition switch: ON (Engine stops)9 V or more
20Throttle body assembly (4)Ignition switch: ON (Engine stops)9 V or more
33A/C load signalEngine: Idle
A/C switch: ONDuring weak cooling or
heatingSystem voltage
During normal cooling0-1V
During strong coolingChanges repeatedly
between 0 V and 12 V
37Clutch switch Clutch pedal depressed0-1V
Inhibitor switch Ignition switch:
ON (Engine stops)Move selector lever to N
or P0-1V
Move selector lever to D,
2, L or RSystem voltage
38Control relay (no immobi-
lizer)
Ignition switch: ON0-1V
lizer)
Ignition switch: ON→OFF (after approx. 8
seconds)System voltage
41Select switch Ignition switch:
ON (Engine stops)Move shift lever to 4st or
RSystem voltage
421st - 2nd switch Ignition switch:
ON (Engine stops)Move shift lever to 1st or
2ndSystem voltage
433rd - 4th switch Ignition switch:
ON (Engine stops)Move shift lever to 3rd or
4thSystem voltage
445th - R switch Ignition switch:
ON(Enginestops)
Move shift lever to 5th0-1V
ON(Engine stops)
Move shift lever to RSystem voltage
58TachometerDuring idlingChanges repeatedly
between 0 V and 12 V
90EGR valve sensorDuring racingChanges between 0.5
V and 4.5 V


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13E-1
DIESEL FUEL
<4D5-STEPIII
>
CONTENTS
GENERAL 2.................................
Outline of Change 2............................
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 4.................
SEALANT 4..................................
SPECIAL TOOLS 5...........................
TROUBLESHOOTING 6.......................
ON-VEHICLE SERVICE 55....................
Injection Nozzle Check and Adjustment 55.........
Injection Timing Check and Adjustment 55.........
Idle Speed Check and Adjustment 55.............
Accelerator Pedal Position Sensor (APS)
Adjustment 56.................................
Control Relay Continuity Check 57................
Accelerator Pedal Position Sensor (APS)
Check 57......................................Idle Switch Check 58............................
Boost Air Temperature Sensor (Intake Air
Temperature Sensor) Check 58..................
Engine Coolant Temperature Sensor Check 59.....
Evacuation of Water from Fuel Filter 59............
Fuel Filter Cartridge Replacement 60..............
Evacuation of Air from Fuel Line 60...............
EGR Valve Position Sensor Check 60.............
Fuel Injection Pump Check 61....................
Throttle Solenoid Valve Check 62.................
Throttle Actuator Check 63......................
Variable Geometry Solenoid Valve Check 63.......
EGR Control Solenoid Valve Check 63............
FUEL INJECTION NOZZLE 64.................
FUEL INJECTION PUMP 64...................
CRANKSHAFT POSITION SENSOR 66.........
ENGINE-ECU 66.............................


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DIESEL FUEL <4D5-stepIII>-General/General Information13E-2
GENERAL
OUTLINE OF CHANGE
An electronically-controlled injection pump has been added in order to comply with Regulation STEP
III. Due to this, the following service procedures have been added.
GENERAL INFORMATION
The electronically-controlled fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuators
which operate according to control commands from the engine-ECU.
The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing control
and idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions which
make troubleshooting easier in the event that a problem develops.
FUEL INJECTION RATE CONTROL
The fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure that
the optimum amount of fuel is supplied to the engine in accordance with gradual changes in the engine
running condition.
Before fuel injection starts, the solenoid-type spill valve is on (energized), so that the valve is closed.
As the plunger turns and rises, fuel is sent out under pressure, and when the fuel flow rate reaches
the target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spill
valve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamber
and fuel injection is completed.
FUEL INJECTION TIMING CONTROL
The position of the injection pump timer piston is controlled so that fuel injection is carried out at the
optimum timing in accordance with the engine running condition.
The timer piston position is determined by duty control of the timing control solenoid valve which is located
in the line between the high-pressure chamber and the low-pressure chamber of the timer piston.
The fuel injection timing is advanced by increasing the control duty of the timing control solenoid valve.
IDLE SPEED CONTROL
Controlling the fuel injection rate in accordance with the engine running condition maintains the idle speed
at the optimum condition.
SELF-DIAGNOSIS FUNCTION
DWhen an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates
to warn the driver.
DWhen an abnormality is detected in any of the sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is output.
DThe RAM data relating to the sensors and actuators which is stored in the engine-ECU can be read
using the MUT-II. In addition, the actuators can be force-driven under certain conditions.
OTHER CONTROL FUNCTIONS
1. Power Supply Control
When the ignition switch is turned to ON, the relay turns on and power is supplied to components
such as the timing control solenoid valve.
2. Intake Air Throttle Control
When the engine-ECU detects an abnormality in any of the sensors or actuators, the throttle valve
is half opened to restrict the amount of intake air in order to prevent the vehicle from running away.
3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF
4. Condenser Fan Motor Relay Control
Controls the condenser fan motor relay based on the A/C switch, engine coolant temperature and
vehicle speed input signals.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.


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DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-7
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 = 30 % fixed
DVoid EGR control
Idle switchVoid idling speed control.
Engine speed sensorDEngine controlled at low speed
DVoid EGR control
DVoid variable geometry turbocharger control
Boost air temperature sensorDMaintain the intake air temperature at 50_C.
DVoid EGR control
Vehicle speed sensorDVoid idling speed control.
DVoid EGR control
Engine coolant temperature sensorDMaintain the engine coolant temperature at 80_C (However, the system
assumes the coolant temperature as 0_C).
DVoid EGR control
Control sleeve position sensorDEngine controlled at low speed
DVoid EGR control
DVoid variable geometry turbocharger control
Timer piston position sensorDInjection timing stabilizing control
DVoid EGR control
Barometric pressure sensor (ECU
built-in)DKeep the barometric pressure at 101 kPa.
DVoid EGR control
DVoid variable geometry turbocharger control
Fuel temperature sensorMaintain the fuel temperature at 40_C.
Boost pressure sensorDKeep the boost pressure as barometric pressure (101 kPa).
DVoid EGR control
DVoid variable geometry turbocharger control
Injection volume adjusting ROMVoid correction.
GE actuatorDEngine controlled at low speed
DVoid EGR control
DVoid variable geometry turbocharger control
Over boostDVoid variable geometry turbocharger control
DEngine controlled at low fuel injection
Timing control valveDInjection timing stabilizing control
DVoid EGR control
EGR valve position sensorVoid EGR control
Variable geometry control pressure
sensorDVoid EGR control
DVoid variable geometry turbocharger control


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DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-8
INSPECTION CHART FOR DIAGNOSIS CODES
Code No.Diagnosis itemReference
page
11Accelerator pedal position sensor (main) system13E-9
12*Boost pressure sensor system13E-10
13Barometric pressure sensor (ECU built-in) system13E-11
14Fuel temperature sensor system13E-11
15Engine coolant temperature sensor system13E-12
16Boost air temperature sensor system13E-12
17Vehicle speed sensor system13E-13
18Pump speed sensor system13E-14
21Crank angle sensor system13E-15
23Idle switch (accelerator pedal position sensor built-in) system13E-16
25*Timer piston position sensor system13E-17
26*Control sleeve position sensor system13E-18
27Accelerator pedal position sensor (sub) system13E-19
41*Throttle solenoid valve system13E-20
43Timing control valve system13E-21
46Injection volume adjusting ROM system13E-22
48*GE actuator (in the middle of control sleeve position sensor inoperative) system13E-23
49*Over boost (variable geometry control pressure sensor system malfunction)13E-24
51EGR valve position sensor system13E-25
52Variable geometry control pressure sensor system13E-26
54Immobilizer system13E-27
Caution
If the above-mentioned diagnosis code number with the asterisks can be displayed along with another
code number in parentheses simultaneously, check the other code number before replacing the
engine-ECU.
12 (41, 49), 26 (48), 25 (43), 41 (12, 49), 48 (26), 49 (12, 41)


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DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-25
Code No. 51 EGR valve position sensor systemProbable cause
Range of Check
DIgnition switch: ON, except during engine cranking
Set Condition
DOutput voltage of EGR valve position sensor for 3 seconds is 4.85 V or
higher, or lower than 0.15 VDEGR valve position sensor inoperative
DEGR valve position sensor open circuit, short
circuit or connector circuit inoperative
DEngine-ECU inoperative
Repair NG
NG
OK
Check the harness between the engine-ECU
and the EGR valve position sensor
connector.
Replace the engine-ECU.
Repair NG
OK
NG
Repair
OK
OK
Check the harness between the
engine-ECU and the EGR valve position
sensor connector.
EGR valve position sensor check
(Refer to P.13E-60.)
OKReplace
Check the following connector:D-113
Check the trouble symptoms.NG
NG
Check the following connector:B-66NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-113 engine-ECU connector
DConnect the connector.
DVoltage between 90 and earth.
OK:0.4 - 0.6 V
(Ignition switch: ON)
4.1 - 4.8 V
(When 60 kPa of negative pressure is
applied to the EGR valve nipple and the
valve is fully open)OK
Measure at B-66 EGR valve position sensor
connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 2 and earth
(Ignition switch: ON)
OK:4.5 - 5.5 V
DContinuity between 3 and earth
OK:Continuity
Replace the engine-ECU.
Replace the engine-ECU.
Check the following connector:D-112NG
Repair
OK
Check the trouble symptoms.
NG


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DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-33
INSPECTION PROCEDURE 10
Low idling speed (improper idling speed)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
and fuel.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DInjection nozzle
DInjection pump
INSPECTION PROCEDURE 11
Idling instable (rough idling, hunting)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, glow system, intake system, and EGR system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DGlow system inoperative
DEGR system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DGlow plug, glow plug relay
DEGR system
DInjection nozzle
DCompression pressure
DValve clearance
DThrottle body assembly
DInjection timing
DFuel line bleeding
DInjection pump
INSPECTION PROCEDURE 12
The engine stalls after running for a while.
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, and intake system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DThrottle body assembly
DFuel filter
DInjection pump


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