Mitsubishi MOTORS Pajero 2001 Workshop Manual Supplement
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Mitsubishi MOTORS Pajero 2001 Workshop Manual Supplement

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WORKSHOP
MANUAL
SUPPLEMENT
FOREWORD
This manual outlines changes in servicing
procedures related to the chassis including
vehicle inspections and adjustments in the
newly added models. Use the following
manuals in combination with this manual as
required.
TECHNICAL INFORMATION MANUAL
WORKSHOP MANUAL
ENGINE GROUP
CHASSIS GROUP
PWJE9086-G(Supplement)
PWJE9086-H(Supplement)
ELECTRICAL WIRING PHJE9026(Basic)
PHJE9026-D(Supplement)
PHJE9026-E(Supplement)
PHJE9026-F(Supplement)
PHJE9026-G(Supplement)
PHJE9026-H(Supplement)
PARTS CATALOGUE
All information, illustrations and product
descriptions contained in this manual are
current as at the time of publication. We,
however, reserve the right to make changes
at any time without prior notice or obligation.
Mitsubishi Motors Corporation
E
PYJE9002
PWEE____
(Looseleaf edition)
PWJE9086(Basic)
PWJE9086-I(Supplement)
PHJE9026-I(Supplement)
B60356A2Aj
May 2001
General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Interior and Supplemental
Restraint System (SRS) . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
00
11
12
13
14
15
16
17
52
54

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Summary of Contents for Mitsubishi MOTORS Pajero 2001

  • Page 1: Table Of Contents

    B60356A2Aj All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation. Mitsubishi Motors Corporation May 2001...

  • Page 2: General

    00-1 GENERAL - How to Use This Manual/Vehicle Identification GROUP 00 GENERAL HOW TO USE THIS MANUAL INDICATION OF TIGHTENING TORQUE Tightening torques (units: N·m) are set to take into account the central value and the allowable tolerance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques.
  • Page 3 00-2 GENERAL - Vehicle Identification CHASSIS NUMBER The chassis number is stamped on the side wall of the frame near the right rear wheel. Items Contents Fixed figure Asia Distribution channel Japan channel Destination For Europe, left hand drive Body style 4 or 2-door with tailgate(back door) Transmission type 5-speed manual transmission...
  • Page 4 00-3 GENERAL - GENERAL - Major Specifications Major Specifications MAJOR SPECIFICATIONS 2-DOOR MODELS Items V24W NDGL6Y GNDGL6Y Vehicle Overall length 4,075 dimensions Overall width 1,695 1,785 Overall height (unladen) 1,835 1,845 Wheelbase 2,420 Track-front 1,420 1,465 Track-rear 1,435 1,480 Ground clearance (unladen) Overhang-front Overhang-rear...
  • Page 5 00-4 GENERAL - Major Specifications 4-DOOR MODELS Items V44W NDGL6Y GNDGL6Y Vehicle Overall length 4,655 dimensions Overall width 1,695 1,775 Overall height (unladen) 1,890 1,900 Wheelbase 2,725 Track-front 1,420 1,465 Track-rear 1,435 1,480 Ground clearance (unladen) Overhang-front Overhang-rear 1,280 Vehicle Kerb weight 1,875 1,930...
  • Page 6 00-5 GENERAL - Standard Part/Tightening-Torque Table STANDARD PART/TIGHTENING-TORQUE TABLE Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
  • Page 7 NOTES...
  • Page 8 11-1 ENGINE CONTENTS ENGINE <4D5-Step III> ... . . ON-VEHICLE SERVICE ..... Injection Timing Check and Adjustment .

  • Page 9: Engine <4D5-Step Iii

    General/General Information/Service 11-2 ENGINE <4D5-Step III> - Specifications ENGINE <4D5-Step III> GENERAL OUTLINE OF CHANGES Some service procedures have been revised as the following changes have been made to comply to the Emission Regulation Step III. The injection timing check and adjustment procedure and the idle speed check procedure have been changed.

  • Page 10: Sealant

    11-3 ENGINE <4D5-Step III> - Sealant/Special Tools SEALANT Items Specified sealant Remarks Oil pan MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent Semi-circular packing and rocker 3M ATD Part No. 8660 or equivalent cover seal, and cylinder head seal SPECIAL TOOLS Tools Number Name...

  • Page 11: On-Vehicle Service

    11-4 ENGINE <4D5-Step III> - On-vehicle Service ON-VEHICLE SERVICE INJECTION TIMING CHECK AND ADJUSTMENT The cold start device (wax type) has been discontinued as an electronically controlled injection pump has been used. The other inspection and adjustment procedures are the same as before.

  • Page 12: Oil Pan And Oil Screen

    11-5 ENGINE <4D5-Step III> - Oil Pan and Oil Screen OIL PAN AND OIL SCREEN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Skid Plate and Under Cover Removal and Installation. Engine Oil Draining and Supplying. Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Muffler.) 4 mm 19 ±...
  • Page 13 11-6 ENGINE <4D5-Step III> - Oil Pan and Oil Screen REMOVAL SERVICE POINT MD998727 MD998727 AA" OIL PAN REMOVAL INSTALLATION SERVICE POINTS "AA OIL PAN INSTALLATION 1. Remove sealant from oil pan and cylinder block mating surfaces. 2. Degrease the sealant-coated surface and the engine mating surface.

  • Page 14: Timing Belt And Timing Belt B

    11-7 ENGINE <4D5-Step III> - Timing Belt and Timing B TIMING BELT AND TIMING BELT B REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Intercooler Removal and Installation (Refer to GROUP 15.) Cooling Fan Removal and Installation. 26 ± 3 N·m 26 ±...
  • Page 15 11-8 ENGINE <4D5-Step III> - Timing Belt and Timing B REMOVAL SERVICE POINTS Timing marks AA" CRANKSHAFT PULLEY REMOVAL 1. Turn the crankshaft clockwise, align the timing marks to set No.1 cylinder to TDC of its compression stroke. Caution Never turn the crankshaft anticlockwise. 2.
  • Page 16 11-9 ENGINE <4D5-Step III> - ENGINE <4D5-Step III> - Timing Belt and Timing Belt B Timing Belt and Timing Belt B INSTALLATION SERVICE POINTS "AA TIMING BELT B INSTALLATION Timing mark 1. Align the timing marks of the 3 sprockets. 2.
  • Page 17 11-10 ENGINE <4D5-Step III> - ENGINE <4D5-Step III> - Timing Belt and Timing Belt B Timing Belt and Timing Belt B 5. Turn the crankshaft clockwise and stop at the second lobe of the camshaft sprocket. Camshaft sprocket Caution (1) When turning the crankshaft in item (5), strictly observe the specified amount of rotation (2 teeth on the camshaft sprocket) in order to apply a 2 teeth...

  • Page 18: Cylinder Head Gasket

    11-11 ENGINE <4D5-Step III> - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Intake and Exhaust Manifold Removal Timing Belt Installation (Refer to P.11-4.) (Refer to GROUP 15.) Intake and Exhaust Manifold Installation Timing Belt Removal (Refer to P.11-4.) (Refer to GROUP 15.) Engine Coolant Draining.
  • Page 19 11-12 ENGINE <4D5-Step III> - Cylinder Head Gasket REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE DISCONNECTION After making mating marks on the radiator upper hose and the hose clamp, disconnect the radiator upper hose. AB" FUEL INJECTION PIPE REMOVAL When loosening nuts at both ends of injection pipe, hold Delivery holder the delivery holder (for pump side) and the injection nozzle assembly (for nozzle side) with wrench and loosen nut.
  • Page 20 11-13 ENGINE <4D5-Step III> - Cylinder Head Gasket INSTALLATION SERVICE POINTS "AA CYLINDER HEAD GASKET INSTALLATION When replacing the cylinder head gasket only, confirm the gasket identification mark, and then select a replacement part according to the table below: Spec Identification mark (size) Parts num-...
  • Page 21 11-14 ENGINE <4D5-Step III> - Cylinder Head Gasket 5. Tighten the cylinder head bolts according to the following procedure (angle-tightening procedure.) (1) Use the special tool to tighten the cylinder head bolts in the order of the illustrated numbers to 29 ± 2 N·m. MD998051 Front of engine (2) Place the special tool in a wrench to tighten the...
  • Page 22 12-1 LUBRICATION - General/Lubricant GROUP 12 LUBRICATION GENERAL OUTLINE OF CHANGE The engine oil quantity has been changed as variable geometry (VG) turbocharger has been used. LUBRICANT 4D5-Step III 4D5-Step III Items Items Engine oil quantity L Oil filter Oil cooler Total...
  • Page 23 NOTES...
  • Page 24 13-1 FUEL CONTENTS FUEL SYSTEM <4D5-step III> ..Control Relay Continuity Check ....Accelerator Pedal Position Sensor (APS) GENERAL .

  • Page 25: Fuel System <4D5-Step Iii

    13-2 FUEL SYSTEM <4D5-step III> - General/General Information FUEL SYSTEM <4D5-step III> 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 Step III. An electronic-controlled fuel injection pump has been used. A crankshaft position sensor has been used as the electronic-controlled fuel injection pump has been used.
  • Page 26 13-3 FUEL SYSTEM <4D5-step III> - General Information SELF-DIAGNOSIS FUNCTION When an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates to warn the driver. When an abnormality is detected in any of the sensors or actuators, a diagnosis code number corresponding to the problem which occurred is output.
  • Page 27 13-4 FUEL SYSTEM <4D5-step III> - General Information CONTROL SYSTEM DIAGRAM L1. Pump speed sensor l1. GE actuator (electronic governor) Engine- L2. Crank angle sensor l2. Timing control valve L3. Engine coolant temperature sensor l3. EGR control solenoid valve No. 1 L4.

  • Page 28: Service Specifications

    13-5 FUEL SYSTEM <4D5-step III> - Service Specifications/Sealant/Special Tools SERVICE SPECIFICATIONS Item Standard value Fuel injection initial pressure kPa 14,710 - 15,490 Accelerator pedal position sensor reference voltage V 0.985 - 1.085 Accelerator pedal position sensor resistance kΩ 3.5 - 6.5 Boost air temperature sensor (Intake air temperature When the temperature is 20_C 2.3 - 3.0...
  • Page 29 13-6 FUEL SYSTEM <4D5-step III> - Special Tools Tool Number Name MB991658 Test harness set APS adjustment Inspection using an analyzer MD998478 Test harness Crank angle sensor check (3-pin, square) Inspection using an analyzer MB990767 End yoke holder Holding the fuel injection pump sprocket MD998719 Crankshaft pulley holder...

  • Page 30: Troubleshooting

    13-7 FUEL SYSTEM <4D5-step III> - Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE When replacing the engine-ECU, replace immobilizer-ECU and ignition key as well at the same time. DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) Engine warning lamp is lit when any abnormality takes place...
  • Page 31 13-8 FUEL SYSTEM <4D5-step III> - 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 item Control features in malfunction Accelerator pedal position sensor Accelerator pedal released (idle switch ON) Acceleration opening degree = 0 %...
  • Page 32 13-9 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Accelerator pedal position sensor (main) system 13-10 Boost pressure sensor system 13-11 Barometric pressure sensor (ECU built-in) system 13-12 Fuel temperature sensor system 13-12 Engine coolant temperature sensor system 13-13...
  • Page 33 13-10 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODE Code No. 11 Accelerator pedal position sensor (main) Probable cause system Range of Check D Accelerator pedal position sensor inoperative D Ignition switch: ON, accelerator pedal position sensor (sub) operative, except D Accelerator pedal position sensor open circuit, for during engine cranking short circuit, or connector contact inoperative...
  • Page 34 13-11 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 12 Boost pressure sensor (boost sensor) Probable cause system Range of Check D Boost pressure sensor inoperative D Ignition switch: ON, except for during engine cranking D Boost pressure sensor open circuit, short circuit, Set Conditions or connector contact inoperative D Sensor output voltage for 1 second is 4.5 V or higher...
  • Page 35 13-12 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 13 Barometric pressure sensor system Probable cause Range of Check Engine-ECU inoperative D Ignition switch: ON, except for during engine cranking Set Conditions D The sensor output voltage is for 3 seconds is 4.5 V or higher (the barometric pressure is approximately 114 kPa or over).
  • Page 36 13-13 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 15 Engine coolant temperature sensor system Probable cause Range of Check D Engine coolant temperature sensor inoperative D Ignition switch: ON, except for during engine cranking D Engine coolant temperature sensor open circuit, Set Conditions short circuit, or connector contact inoperative D The sensor output voltage for 3 seconds is 4.9 V or higher (the coolant...
  • Page 37 13-14 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 17 Vehicle speed sensor system Probable cause Range of Check D Vehicle speed sensor inoperative D Ignition switch: ON D Vehicle speed sensor open circuit, short circuit, or D Engine speed: 2,800 r/min or higher connector contact inoperative D Driving with heavy load D Engine-ECU inoperative...
  • Page 38 13-15 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 18 Pump speed sensor system Probable cause Range of Check D Malfunction of pump speed sensor D Ignition switch: ON D Open circuit or short-circuit in pump speed sensor D Not during the engine cranking circuit, or poor sensor contact Set Conditions D Engine-ECU inoperative...
  • Page 39 13-16 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 21 Crank angle sensor system Probable cause Range of Check D Malfunction of crank angle sensor D Engine cranking D Open circuit or short-circuit in crank angle sensor Set Conditions circuit, or poor connector contact D Sensor output voltage does not change for 2 seconds (no pulse signal input) D Engine-ECU inoperative Range of Check...
  • Page 40 13-17 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 23 Idle switch (accelerator pedal position Probable cause sensor built-in) system Range of Check D Accelerator pedal position sensor inoperative Ignition switch: ON, accelerator pedal position sensor (main, sub) operative, D Accelerator pedal position sensor open circuit, except for during engine cranking short circuit, or connector contact inoperative Set Conditions...
  • Page 41 13-18 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 25 Timer piston position sensor system Probable cause Range of Check D Timer piston position sensor inoperative D Ignition switch: OK D Timer piston position sensor open circuit, short D Not during the engine cranking circuit, or connector contact inoperative Set Conditions D Engine-ECU inoperative...
  • Page 42 13-19 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 26 Control sleeve position sensor system Probable cause Range of Check D Control sleeve position sensor inoperative D Ignition switch: ON D Control sleeve position sensor open circuit, short Set Conditions circuit, or connector contact inoperative D The sensor output voltage for 0.3 second is 4.5 V* or more D Engine-ECU inoperative...
  • Page 43 13-20 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 27 Accelerator pedal position sensor (sub) Probable cause system Range of Check D Accelerator pedal position sensor inoperative D Ignition switch: ON, accelerator pedal position sensor (main) operative, except D Accelerator pedal position sensor open circuit, for during engine cranking short circuit, or connector contact inoperative Set Conditions...
  • Page 44 13-21 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 41 Throttle solenoid valve system Probable cause Range of Check D Throttle solenoid valve inoperative D Ignition switch: OFF D Throttle solenoid valve open circuit, short circuit, or D Barometric pressure is 95.4 kPa or over (equivalent to an altitude of 500 m). connector contact inoperative Set Conditions D Engine-ECU inoperative...
  • Page 45 13-22 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 43 Timing control valve system Probable cause Range of Check D Timing control valve inoperative D Engine coolant temperature 80_C or higher and the engine running D Timing control valve open circuit, short circuit, or Set Conditions connector contact inoperative D Target value minus actual value is 0.64 V or more for 5 seconds...
  • Page 46 13-23 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 46 Injection volume adjusting ROM system Probable cause Range of Check D Injection volume adjusting ROM inoperative D Ignition switch: ON D Engine-ECU inoperative Set Conditions D When communication fails Repair Measure at A-134 injection volume adjusting Check the following connector: C-130 ROM connector.
  • Page 47 13-24 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 48 GE actuator (in the middle of control sleeve Probable cause position sensor inoperative) system Range of Check D Control sleeve position sensor inoperative D Ignition switch: ON D GE actuator inoperative Set Conditions D Control sleeve position sensor open circuit, short D Target value minus actual value is 1 V or more for 1 second...
  • Page 48 13-25 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 49 Over boost Probable cause Range of Check D Malfunction of the variable geometry actuator D Ignition switch: ON D Malfunction of variable geometry solenoid valve Set Conditions D Variable geometry solenoid valve open circuit, short D Boost pressure is higher than the barometric pressure + 133 kPa circuit, or connector contact inoperative D Engine-ECU inoperative...
  • Page 49 13-26 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 51 EGR valve position sensor system Probable cause Range of Check D EGR valve position sensor inoperative D Ignition switch: ON, except during engine cranking D EGR valve position sensor open circuit, short Set Condition circuit or connector circuit inoperative D Output voltage of EGR valve position sensor for 3 seconds is 4.85 V or...
  • Page 50 13-27 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 52 Variable geometry control pressure sensor Probable cause system Range of Check D Variable geometry control pressure sensor D Ignition switch: ON, except during engine cranking inoperative Set Condition D Variable geometry control pressure sensor open D 4.5 V or higher, or 0.2 V or lower circuit, short circuit or connector contact Range of Check...
  • Page 51 13-28 FUEL SYSTEM <4D5-step III> - Troubleshooting Code No. 54 Immobilizer system Probable cause Range of Check D Radio interference of encrypted codes D Ignition switch: ON D Incorrect encrypted code Set Conditions D Malfunction of harness or connector D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU D Engine-ECU inoperative NOTE...
  • Page 52 13-29 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble Symptom Inspection Reference procedure page No communication can No communication can be established with all systems. 13-30 established established tween MUT-II and the No communication can be established only with the 13-30 engine-ECU engine-ECU.
  • Page 53 13-30 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 No communication can be established between MUT-II Probable cause and all systems. Probable cause can be found in troubles with the power supply circuit and the D Diagnosis connector inoperative earth circuit to the diagnosis connector.
  • Page 54 13-31 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 3 Immediately after the ignition switch is “ON”, the engine Probable cause warning lamp does not turn on. The engine-ECU turns on the engine warning lamp for 5 seconds immediately D The engine warning lamp blown after turning on the ignition switch to check the bulb for being blown.
  • Page 55 13-32 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (unable to start) Probable cause Probable causes can be found in troubles with control system, injection pump, D Control system inoperative glow system, and power supply system. D Injection pump inoperative D Intake system inoperative D Glow system inoperative...
  • Page 56 13-33 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 7 Starting performance is bad regardless of whether the Probable cause engine is hot or cold (unable to start) Probable causes can be found in troubles with control system, injection pump, D Control system inoperative fuel system, and intake system.
  • Page 57 13-34 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 10 Low idling speed (improper idling speed) Probable cause Probable causes can be found in troubles with control system, injection pump, D Control system inoperative and fuel. D Injection pump inoperative D Fuel system inoperative D Engine-ECU inoperative MUT-II Self-Diag code...
  • Page 58 13-35 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 13 The engine stalls during idling. Probable cause Probable causes can be found in troubles with control system, injection pump, D Control system inoperative intake system, EGR system, and power supply. D Injection pump inoperative D Fuel system inoperative D Intake system inoperative...
  • Page 59 13-36 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 16 Abnormal black smoke Probable cause Probable causes can be found in troubles with control system, injection pump, D Control system inoperative fuel system, intake system, and EGR system. D Injection pump inoperative D Fuel system inoperative D Intake system inoperative D EGR system inoperative...
  • Page 60 13-37 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 19 A/C condenser fan operating problem Probable cause The power transistor inside the engine-ECU turns on and off to control the A/C D Malfunction of A/C condenser fan motor relay condenser fan motor relay. D Malfunction of A/C condenser fan motor D Malfunction of thermostat D Open circuit or short-circuit in circuit, or poor...
  • Page 61 13-38 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 20 Intercooler fan malfunction Probable cause The power transistor inside the engine-ECU turns on and off to control the D Malfunction of intercooler fan motor relay intercooler fan motor relay. D Malfunction of intercooler fan motor D Open circuit or short - circuit in circuit, or poor connector contact D Engine-ECU inoperative...
  • Page 62 13-39 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 21 Engine-ECU power supply and earth circuit check (1) NG Repair Measure at C-41, C-42, C-43 Check the following connectors: engine-ECU connectors. C-26, C-61 D Disconnect the connector and (2), (3) NG measure at the harness side.
  • Page 63 13-40 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 23 EGR control solenoid valve No. 1 circuit inspection EGR control solenoid valve No. 1 Replace check (Refer to GROUP 17 - Service Adjustment Procedures.) Check the harness between the Measure at EGR control solenoid control relay and the EGR control valve No.
  • Page 64 13-41 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE 25 Glow plug relay inspection Glow plug relay check. (Refer to Replace GROUP 16 - Glow System.) Repair Measure at glow plug relay Check the following connector: connector A-101. C-41 D Disconnect the connector and measure at the harness side.
  • Page 65 13-42 FUEL SYSTEM <4D5-step III> - Troubleshooting DATA LIST REFERENCE TABLE Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Boost air Ignition switch: ON or When the intake air - 20_C Code No.
  • Page 66 13-43 FUEL SYSTEM <4D5-step III> - Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Vehicle When driving Compare the engine Matched Code No. 13-14 speed speed displayed in the sensor speed meter with that in MUT-II...
  • Page 67 13-44 FUEL SYSTEM <4D5-step III> - Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Accelerator Ignition switch: ON Accelerator pedal: Code No. 13-20 pedal Idling position position position Accelerator pedal:...
  • Page 68 13-45 FUEL SYSTEM <4D5-step III> - Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Condenser Ignition switch: ON A/C switch: OFF Procedure 13-37 fan relay (engine coolant No.
  • Page 69 13-46 FUEL SYSTEM <4D5-step III> - Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. EGR control Engine: After warming Idling (stable condition) Procedure 13-40 solenoid up the engine No.
  • Page 70 13-47 FUEL SYSTEM <4D5-step III> - Troubleshooting Item Check item Drive Con- Inspection Value to be determined Code No. Reference tents conditions as normal or inspec- page tion proce- dure No. GE actuator Turn the GE Ignition Measure the wave Code No.
  • Page 71 13-48 FUEL SYSTEM <4D5-step III> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement Terminal Check item Inspection conditions (engine status) Normal condition: GE actuator Ignition switch: ON (Engine stops) 9 V or higher Fuel cut solenoid valve Other than below 0 - 1 V...

  • Page 72: Engine Cooling

    13-49 FUEL SYSTEM <4D5-step III> - Troubleshooting Terminal Check item Inspection conditions (engine status) Normal condition: Glow plug relay Engine coolant temperature: 40_C or lower System voltage (In about 8 seconds: at 20_C) → 0 Ignition switch: OFF → ON - 1 V Variable geometry Engine: After warm-...
  • Page 73 13-50 FUEL SYSTEM <4D5-step III> - Troubleshooting Terminal Check item Inspection conditions (engine status) Normal condition: Fuel temperature: 0_C 3.2 - 3.6 V Fuel temperature sen- Ignition switch: ON Fuel temperature: 20_C 2.3 - 2.7 V Fuel temperature: 40_C 1.5 - 1.9 V Fuel temperature: 80_C 0.4 - 0.8 V Boost air temperature...
  • Page 74 13-51 FUEL SYSTEM <4D5-step III> - Troubleshooting 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem. Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Inspection item Normal condition (Check condition) 1 - 15 GE actuator 0.64 - 0.72 Ω...
  • Page 75 13-52 FUEL SYSTEM <4D5-step III> - Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 83 - 61 Engine coolant temperature sensor 5.1 - 6.5 kΩ (when the engine coolant temperature is 0_C) 2.1 - 2.7 kΩ (when the engine coolant temperature is 20_C) 0.9 - 1.3 kΩ...
  • Page 76 13-53 FUEL SYSTEM <4D5-step III> - Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER CRANK ANGLE SENSOR An analyzer can be used to observe the wave pattern in order to visually check the crankshaft rotation and abnormalities in the sensor output. Measurement Method Analyzer 1.
  • Page 77 13-54 FUEL SYSTEM <4D5-step III> - Troubleshooting Standard wave pattern 1 engine revolution Crank angle BTDC9_ sensor output ATDC wave pattern ATDC BTDC35_ Explanation of Wave Pattern The crank angle sensor detects the rotation of a sensing plate. Accordingly, the period T (seconds) can be measured and the engine speed can be calculated from the following formula.
  • Page 78 13-55 FUEL SYSTEM <4D5-step III> - Troubleshooting PUMP SPEED SENSOR An analyzer can be used to observe the wave pattern in order to visually check the pump shaft rotation and abnormalities in the sensor output. Measurement Method Analyzer 1. Disconnect the pump speed sensor connector and Sensor side connector connect the special tool (test harness: MD991658) in between.
  • Page 79 13-56 FUEL SYSTEM <4D5-step III> - Troubleshooting Standard wave pattern 0.85 Pump speed sensor output wave pattern - 0.85 1 cranking Explanation of Wave Pattern The pump speed sensor detects the rotation of the pump shaft. Accordingly, the period T (seconds) can be measured and the engine speed can be calculated from the following formula.
  • Page 80 13-57 FUEL SYSTEM <4D5-Step III> - On-vehicle Service ON-VEHICLE SERVICE INJECTION TIMING CHECK AND ADJUSTMENT Refer to GROUP 11 - Engine Adjustment. IDLE SPEED CHECK AND ADJUSTMENT Refer to GROUP 11 - Engine Adjustment. INJECTION NOZZLE CHECK AND ADJUSTMENT Caution Never touch the injection spray that is injected from the nozzle.

  • Page 81: Accelerator Pedal Position Sensor (Aps) Adjustment

    13-58 FUEL SYSTEM <4D5-Step III> - On-vehicle Service 2. Check to be sure that no fuel drips after injection is completed. 3. If there are any drips, disassemble the nozzle, clean it and reinspect, or replace the nozzle. NOZZLE FUEL-TIGHT CHECK 1.

  • Page 82: Control Relay Continuity Check

    13-59 FUEL SYSTEM <4D5-Step III> - On-vehicle Service CONTROL RELAY CONTINUITY CHECK Connect a tester Battery voltage Normal condition 2 - 4 Not applied Continuity Not applied No continuity 1 - 3 Applied: Connect Continuity the positive bat- Control relay tery cable to No.

  • Page 83: Idle Switch Check

    13-60 FUEL SYSTEM <4D5-Step III> - On-vehicle Service IDLE SWITCH CHECK 1. Disconnect the accelerator pedal position sensor (APS) connector. 2. Check the continuity between the idle switch connector terminal No. 4 (idle switch) and terminal No. 5 (earth). Connector at the equipment Normal condition: Accelerator pedal...

  • Page 84: Engine Coolant Temperature Sensor Check

    13-61 FUEL SYSTEM <4D5-Step III> - On-vehicle Service FUEL SYSTEM <4D5-Step III> - On-vehicle Service ENGINE COOLANT TEMPERATURE SENSOR Engine coolant CHECK temperature sensor 1. Remove the engine coolant temperature sensor. 2. Measure the resistance between the terminals of the connectors while immersing the sensor part of the engine coolant temperature sensor in the hot water.

  • Page 85: Fuel Injection Pump Check

    13-62 FUEL SYSTEM <4D5-Step III> - On-vehicle Service FUEL INJECTION PUMP CHECK Fuel cut FUEL CUT SOLENOID VALVE CHECK solenoid valve Operation noise check 1. Attach the sound scope to the fuel cut solenoid valve to check for running noise when the ignition switch is “ON”...

  • Page 86: Throttle Solenoid Valve Check

    13-63 FUEL SYSTEM <4D5-Step III> - On-vehicle Service CONTROL SLEEVE POSITION SENSOR CHECK Connector at the 1. Disconnect the injection pump connector (12 pin). equipment (12 pin) 2. Measure the resistance between the following terminals. Standard value: Terminal No. 4 - Terminal No. 12 11.2 - 12.4 Ω...

  • Page 87: Throttle Actuator Check

    13-64 FUEL SYSTEM <4D5-Step III> - On-vehicle Service Standard value: Jumper lead Nipple A Normal condition Open Negative pressure Connected leaks Closed Negative pressure maintained Disconnected Open Negative pressure maintained COIL RESISTANCE CHECK 1. Measure the resistance between the solenoid valve terminals.

  • Page 88: Fuel Injection Pump

    13-65 FUEL SYSTEM <4D5-Step III> - Fuel Injection Pump FUEL INJECTION PUMP REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining. Timing Belt Installation (Refer to GROUP 11.) Battery and Battery Tray Removal Intercooler Installation (Refer to GROUP 15.) Intercooler Removal (Refer to GROUP 15.) Battery and Battery Tray Installation Timing Belt Removal (Refer to GROUP 11.)

  • Page 89: Crankshaft Position Sensor

    13-66 FUEL SYSTEM <4D5-Step III> - Fuel Injection Pump/Crankshaft position sensor AB" FUEL INJECTION PUMP SPROCKET REMOVAL 1. Use the special tool to stop the fuel injection pump sprocket MB990767 from turning, and remove the fuel injection pump sprocket mounting bolt. MD998719 2.

  • Page 90: Accelerator Pedal

    13-67 FUEL SYSTEM <4D5-Step III> - Accelerator Pedal ACCELERATOR PEDAL REMOVAL AND INSTALLATION Post-installation Operation Accelerator Pedal Position Sensor Check and Adjustment (Refer to P.13-58.) 3.5 ± 1.0 N·m 5.0 ± 1.0 N·m 10 ± 2 N·m Removal steps 1. Accelerator pedal position sensor 8.
  • Page 91 NOTES...
  • Page 92 14-1 COOLING CONTENTS GENERAL ....... . . General Specification ......Outline of Change .
  • Page 93 14-2 COOLING - Outline of Changes/Specifications GENERAL OUTLINE OF CHANGES With the modification below by additional emission regulation step III compatible 4D56 engine, the service procedure of the part that is different from previous service procedure has been established. The turbocharger has been changed to a Variable Geometry (VG) type. Due to this change, an EGR cooler has been added and section ”Water hose and water pipe”...
  • Page 94 14-3 COOLING - Water Hose and Water Pipe <4D5-Step III> WATER HOSE AND WATER PIPE <4D5-Step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying. 14 ± 1 N·m 11 ± 1 N·m 14 ± 1 N·m 22 ±...
  • Page 95 14-4 COOLING - Water Hose and Water Pipe <4D5-Step III> INSTALLATION SERVICE POINTS "AA WATER HOSE INSTALLATION EGR cooler side The identification mark on the water hose end should face toward the EGR cooler. Identification Water hose mark Hose protector INSTALLATION SERVICE POINTS "BA O-RING INSTALLATION Rinse the mounting location of the O-ring and water pipe...
  • Page 96 15-1 INTAKE AND EXHAUST CONTENTS GENERAL ....... . . Variable Geometry Actuator Check .

  • Page 97: General

    15-2 INTAKE AND EXHAUST - General/General Information GENERAL OUTLINE OF CHANGES With the modification below by additional emission regulation step compatible 4D5 engine, the service procedure of the part that is different from previous service procedure has been established. The turbocharger has been changed to a Variable Geometry (VG) type. A catalytic converter has been added.

  • Page 98: Service Specifications <4D5-Step Iii

    15-3 INTAKE AND EXHAUST - General Information/Service Specifications/Sealant At starting and driving at low speed, the duty control Opening the nozzle allows the characteristic of value of the variable geometry solenoid valve is boost pressure to become a high speed type so increased to apply the vacuum pressure of the that the appropriate boost pressure can be vacuum pump to the variable geometry actuator.

  • Page 99: On-Vehicle Service

    15-4 INTAKE AND EXHAUST - On-vehicle Service ON-VEHICLE SERVICE TURBOCHARGER SUPERCHARGING CHECK Caution Conduct the driving test in a location where driving at full acceleration can be done with safety. Two person should be in the vehicle when the test is conducted; the person in the passenger seat should read the indications shown by the MUT-II.

  • Page 100: Variable Geometry Actuator Check

    15-5 INTAKE AND EXHAUST - On-vehicle Service NOTE (1) If the variable geometry actuator vacuum is not in a normal condition, the variable geometry actuator, variable geometry solenoid valve, variable geometry control pressure sensor, vacuum pump or hose may be faulty. (2) If the variable geometry actuator vacuum is in a normal condition but the supercharging pressure is not in a normal condition, the variable geometry turbocharger nozzle,...

  • Page 101: Intercooler <4D5-Step Iii

    15-6 INTAKE AND EXHAUST - On-vehicle Service/Intercooler Battery voltage Nipple condition Normal condition Applied Both nipples are Vacuum leaks. opened. Nipple A is closed. Vacuum is maintained. Not applied Both nipples are Vacuum leaks. opened. Nipple C is closed. Vacuum is maintained. 5.

  • Page 102: Intake Manifold And Exhaust

    Intake and Exhaust Manifold, Throttle 15-7 INTAKE AND EXHAUST - Body and Turbocharger <4D5-Step III> INTAKE AND EXHAUST MANIFOLD, THROTTLE BODY AND TURBOCHARGER <4D5-Step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Engine Coolant Draining and Refilling. Intercooler Removal and Installation Skid Plate and Under Cover Removal and Installation.

  • Page 103: Intake And Exhaust

    Intake and Exhaust Manifold, Throttle 15-8 INTAKE AND EXHAUST - Body and Turbocharger <4D5-Step III> Removal steps 1. Air temperature sensor connector 17. Intake manifold 2. Throttle solenoid valve connector 18. Exhaust manifold heat protector 3. VGT solenoid valve connector 19.

  • Page 104: Exhaust Pipe And Main Muffler <4D5-Step Iii

    15-9 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler <4D5-Step III> EXHAUST PIPE AND MAIN MUFFLER <4D5-Step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Under Cover Removal and Installation 25 ± 4 35 ± 6 N·m N·m 49 ±...

  • Page 105: Engine Electrical

    16-1 ENGINE ELECTRICAL - Glow System <4D5-Step III> GROUP 16 ENGINE ELECTRICAL GLOW SYSTEM <4D5-STEP III> GENERAL OUTLINE OF CHANGE Glow system control is now carried out by the engine-ECU to correspond to the adoption of an electronically-controlled fuel injection system. Refer to GROUP 13 - Troubleshooting for details on measuring the ECU terminal voltage as a result of this.
  • Page 106 17-1 ENGINE AND EMISSION CONTROL CONTENTS GENERAL <4D5-step III> ....EXHAUST GAS RECIRCULATION (EGR) SYSTEM <4D5-step III> ....Outline of Change .

  • Page 107: General <4D5-Step Iii

    General/General Information/Service 17-2 ENGINE AND EMISSION CONTROL - Specifications GENERAL <4D5-step III> OUTLINE OF CHANGES Some service procedures have been established as the following changes have been made due to the compliance with the Emission Regulation Step III. An electronic-controlled EGR valve and EGR cooler have been used. A catalytic converter has been added.

  • Page 108: Exhaust Gas Recirculation (Egr) System <4D5-Step Iii

    Engine and Emission Control System 17-3 ENGINE AND EMISSION CONTROL - <4D5-Step III> EXHAUST GAS RECIRCULATION (EGR) SYSTEM <4D5-step III> GENERAL INFORMATION The electronically-controlled EGR system consists Feedback control of the EGR solenoid valves No. of an EGR valve, a vacuum pump, EGR solenoid 1 and No.

  • Page 109: Engine And Emission Control

    Engine and Emission Control System 17-4 ENGINE AND EMISSION CONTROL - <4D5-Step III> EGR valve EGR valve position sensor FUNCTION CHECK 1. Start the engine and warm it up until the engine coolant temperature reaches 65_C or above. 2. Race the engine by suddenly depressing the accelerator pedal, then check that the EGR valve diaphragm lifts.
  • Page 110 Engine and Emission Control System 17-5 ENGINE AND EMISSION CONTROL - <4D5-Step III> EGR solenoid valve No.2 <EGR solenoid valve No.2> Battery voltage Normal condition When current is Vacuum is maintained flowing When current is not Vacuum leaks flowing EGR SOLENOID VALVE RESISTANCE CHECK Measure terminal resistance of EGR solenoid valves Nos.

  • Page 111: Egr Valve And Egr Cooler <4D5-Step Iii

    17-6 ENGINE AND EMISSION CONTROL - EGR Valve and EGR Cooler <4D5-step III> EGR VALVE AND EGR COOLER <4D5-step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying. 17 ± 2 N·m 17 ± 2 N·m 22 ±...
  • Page 112 17-7 ENGINE AND EMISSION CONTROL - EGR Valve and EGR Cooler <4D5-step III> INSTALLATION SERVICE POINT EGR pipe "AA EGR PIPE GASKET INSTALLATION The tab on the EGR pipe gasket should be positioned as shown. cooler or cylinder block Tab on EGR pipe gasket "BA O-RING INSTALLATION Thermostat housing...

  • Page 113: Catalytic Converter <4D5-Step Iii

    17-8 Catalytic Converter <4D5-step III> ENGINE AND EMISSION CONTROL - CATALYTIC CONVERTER <4D5-step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation 49 ± 10 N·m 49 ± 4 N·m Removal steps 1. Catalytic converter 2. Gasket...
  • Page 114 52A-1 INTERIOR - General GROUP 52A INTERIOR GENERAL OUTLINE OF CHANGE The headrestraints have been reshaped in order to comply with a regulation. The regulation (96/37/EC) is applicable for the vehicles which have been registered after October 1, 2001. Their service procedures are the same as before.

  • Page 115: Chassis Electrical

    54-1 CHASSIS ELECTRICAL - General/Immobilizer System GROUP 54 CHASSIS ELECTRICAL GENERAL OUTLINE OF CHANGE The following service procedure of the immobilizer system has been changed. The same procedures as before are applied except for the items shown below. The troubleshooting has been changed due to the addition to the 4D56 engine which complies with emission regulation step III.
  • Page 116 54-2 CHASSIS ELECTRICAL - Immobilizer System Inspection Procedure 2 Encrypted code cannot be registered using the MUT-II Probable cause The cause is probably that there is no encrypted code registered in the immobilizer-ECU D Malfunction of transponder or there is a malfunction of the immobilizer-ECU. D Malfunction of ignition key ring antenna D Malfunction of harness or connector D Malfunction of immobilizer-ECU...
  • Page 117 54-3 CHASSIS ELECTRICAL - Immobilizer System Inspection Procedure 4 Malfunction of the immobilizer-ECU power source and earth circuit (1) NG Repair Measure at the immobilizer-ECU con- Check the following connectors: nector C-120. C-24, C-120, C-126 D Disconnect the connector and measure at the harness side.
  • Page 118 WORKSHOP MANUAL ELECTRICAL WIRING FOREWORD This manual integrates the WORKSHOP MANUAL (CHASSIS) and ELECTRICAL WIRING. Mitsubishi Motors Corporation May 2001...

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