2000 MITSUBISHI MONTERO Service Repair Manual

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D998388
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DIESEL FUEL <4M4>
Click on the applicable bookmark to selected the required model year.


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13C-1
DIESEL FUEL
<4M4>
CONTENTS
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 5.......................
ON-VEHICLE SERVICE 42...................
Injection Timing Check and Adjustment 42.........
Idle Speed Check and Adjustment 42.............
Accelerator Pedal Position Sensor (APS)
Adjustment 42.................................
Control Relay Continuity Check 43................
Accelerator Pedal Position Sensor (APS) Check 43.Idle Switch Check 43...........................
Boost Air Temperature Sensor (Intake Air
Temperature Sensor) Check 44..................
Engine Coolant Temperature Sensor Check 44.....
Evacuation of Water from Fuel Filter 45...........
Fuel Filter Cartridge Replacement 45.............
Evacuation of Air from Fuel Line 45...............
Fuel Injection Pump Check 46...................
Intake Air Restriction Equipment Check 48.........
Injection Nozzle Check and Adjustment 49.........
INJECTION NOZZLE 50......................
INJECTION PUMP 56........................
ENGINE-ECU 59............................


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DIESEL FUEL <4M4> -General Information13C-2
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 is idling after having warmed up, the throttle valve is half opened to restrict the
amount of intake air in order to reduce vibration and noise.
3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF
4. Fan motor relay control
The radiator fan and condenser fan operating speeds are controlled in accordance with the engine
coolant temperature and the vehicle speed.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.


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DIESEL FUEL <4M4> -Service Specifications/Sealant13C-3
SERVICE SPECIFICATIONS
ItemStandard value
Accelerator pedal position sensor reference voltage V0.985 - 1.085
Accelerator pedal position sensor resistance kW3.5 - 6.5
Boost air temperature sensor (Intake air temperatureWhen the temperature is 20_C2.3 - 2.9
sensor) resistance kWWhen the temperature is 80_C0.30 - 0.39
Engine coolant temperature sensor resistance kWWhen the temperature is 20_C2.3 - 2.6
When the temperature is 80_C0.30 - 0.34
Fuel cut solenoid valve resistanceW6.8 - 9.2
Timing control valve resistanceW10.8 - 11.2
Timer piston position sensor resistanceWConnector terminals No.1 - No.2160 - 168
Connector terminals No.1 - No.380 - 84
Connector terminals No.2 - No.380 - 84
Control sleeve position sensor resistanceWConnector terminals No.4 - No.1211.2 - 12.4
Connector terminals No.4 - No.85.6 - 6.2
Connector terminals No.8 - No.125.6 - 6.2
GE actuator (electronic governor) resistanceWConnector terminals No.6 - No.100.64 - 0.72
Fuel temperature sensor resistance kWConnector terminals No.7 - No.111.4 - 2.6
Engine speed sensor resistance kW2.15
Main/sub throttle solenoid valve resistanceW36 - 44
SEALANT
ItemSpecified sealant
Engine coolant temperature sensor3M Nut Locking Part No.4171 or equivalent


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S
PEC IA L TO OLS
T o ols N
um ber N
am e A
pplic a tio n M
B991502 M
UT-II su b
a sse m bly E
le ctr o nic a lly co ntr o lle d fu el in je ctio n syste m
c h eck M
B991529 D
ia gnosis co de
c h eck harn ess D
ia gnosis co de re adin g M
B991348,
M B991658 T
e st harn ess se t M
B990767 E
nd yo ke hold er H
old in g th e cra nksh aft p ulle y M
B998754 C
ra nksh aft pulle y
h old er pin M
H062567 G
ear pulle r I
n je ctio n pum p gear asse m bly re m ova l 1
57992 -2 820
( z e xce l) P
la te R
eta in in g nutre m ova la nd in sta lla tio n 1
05789 -0 010
( z e xce l) N
ozzle cle anin g
t o ol C
le anin g of nozzle and needle va lv e

T
R O UBLE SH O OTIN G
S TA NDARD FLO W OF DIA G NO STIC
T R O UBLE SH O OTIN G
R efe r to GRO UP 00 -H ow to Use Tro uble sh ootin g/In sp ectio n
S erv ic e Poin ts .
D IA G NO SIS FU NCTIO N
E N G IN E WARNIN G LA M P (C HEC K EN G IN E LA M P)
E ngin e warn in g la m p is lit w hen any abnorm alit y ta ke s pla ce
i n th e it e m re la te d to ele ctr o nic a lly co ntr o lle d fu el in je ctio n
s yste m sh ow n in th e fo llo w in g ta ble .
I f th e malf u nctio n in dic a to r la m p has been on and/o r is lit
w hen th e engin e is in opera tio n, ch eck th e dia gnosis outp ut.
E ngin e warn in g la m p ch eck it e m s
A cce le ra to r pedalp osit io n se nso r (m ain ) A
cce le ra to r pedalp osit io n se nso r (s u b) B
oost pre ssu re se nso r (B oost se nso r) E
ngin e sp eed se nso r C
ontr o lsle eve posit io n se nso r T
im er pis to n posit io n se nso r M
ain th ro ttle so le noid va lv e G
E actu ato r I
d le sw it c h (b uilt - in ) E
ngin e-E C U