2000 MITSUBISHI MONTERO Service Repair Manual

G
SEN SO R
R EM OVA L AND IN STA LLA TIO N
C au tio n
D o not dro p th e G sen so r or su bje ct it to an y sh ocks.

DIESEL FUEL
<4D5-STEPIII>
Click on the applicable bookmark to selected the required model year.


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

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.............................


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

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.


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

E
ngin e-
E C U

DIESEL FUEL <4D5-stepIII>-Service Specifications/Sealant13E-4
SERVICE SPECIFICATIONS
ItemStandard value
Fuel injection initial pressure kPa14,710 - 15,490
Accelerator pedal position sensor reference voltage V0.985 - 1.085
Accelerator pedal position sensor resistance kΩ3.5 - 6.5
Boost air temperature sensor (Intake air temperature
)itkΩ
When the temperature is 20_C2.3 - 3.0p(p
sensor) resistance kΩWhen the temperature is 80_C0.30 - 0.42
Engine coolant temperature sensor resistance kΩWhen the temperature is 20_C2.1 - 2.7gp
When the temperature is 80_C0.26 - 0.36
Fuel cut solenoid valve resistanceΩ6.8 - 9.2
Timing control valve resistanceΩ10.8 - 11.2
Timer piston position sensor resistanceΩConnector terminals No. 1 - No. 2160 - 168pp
Connector terminals No. 1 - No. 380 - 84
Connector terminals No. 2 - No. 380 - 84
Control sleeve position sensor resistanceΩConnector terminals No. 4 - No. 1211.2 - 12.4p
Connector terminals No. 4 - No. 85.6 - 6.2
Connector terminals No. 8 - No. 125.6 - 6.2
GE actuator (electronic governor) resistanceΩConnector terminals No. 6 - No. 100.64 - 0.72
Fuel temperature sensor resistance kΩConnector terminals No. 7 - No. 111.4 - 2.6
Pump speed sensor resistance kΩ1.36 - 1.84
Throttle solenoid valve resistanceΩ36 - 44
SEALANT
ItemSpecified sealant
Engine coolant temperature sensor3M Nut Locking Part No. 4171 or equivalent


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

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 T
e st harn ess se t M
B991658 T
e st harn ess se t M
D998478 T
e st harn ess
( 3 -p in ,sq uare ) M
B990767 E
nd yo ke hold er H
old in g th e fu elin je ctio n pum psp ro cke t M
D998719 C
ra nksh aft pulle y
h old er pin M
D998388 I
n je ctio n pum p
s p ro cke t pulle r F
uelin je ctio n pum psp ro cke t re m ova l

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 .
N O TE
W hen re pla cin g th e engin e-E C U, re pla ce im mobiliz e r-E C U
a nd ig nit io n ke y as well at th e sa m e tim e.
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 p re ssu re se nso r (B oost se nso r) C
ra nk angle se nso r C
ontr o ls le eve posit io n se nso r T
im er pis to n posit io n se nso r T
hro ttle so le noid va lv e G
E actu ato r V
aria ble geom etr y co ntr o lp re ssu re se nso r B
aro m etr ic pre ssu re se nso r T
im in g co ntr o lv a lv e I
d le sw it c h E
ngin e-E C U