Mitsubishi MOTORS Pajero 2001 Workshop Manual Supplement Download Page 1

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General . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . .

Engine and Emission Control . . .

Chassis Electrical . . . . . . . . . . . . . .

Mitsubishi Motors Corporation

May 2001

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

PYJE9002

WORKSHOP MANUAL

ENGINE GROUP

PWEE____

(Looseleaf edition)

CHASSIS GROUP

PWJE9086(Basic)

PWJE9086-G(Supplement)

PWJE9086-H(Supplement)

PWJE9086-I(Supplement)

ELECTRICAL WIRING PHJE9026(Basic)

PHJE9026-D(Supplement)

PHJE9026-E(Supplement)

PHJE9026-F(Supplement)

PHJE9026-G(Supplement)

PHJE9026-H(Supplement)

PHJE9026-I(Supplement)

PARTS CATALOGUE

B60356A2A

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.

Interior and Supplemental

Restraint System (SRS) . . . . . . . .

Summary of Contents for Pajero 2001

Page 1: ...as required TECHNICAL INFORMATION MANUAL PYJE9002 WORKSHOP MANUAL ENGINE GROUP PWEE____ Looseleaf edition CHASSIS GROUP PWJE9086 Basic PWJE9086 G Supplement PWJE9086 H Supplement PWJE9086 I Supplement ELECTRICAL WIRING PHJE9026 Basic PHJE9026 D Supplement PHJE9026 E Supplement PHJE9026 F Supplement PHJE9026 G Supplement PHJE9026 H Supplement PHJE9026 I Supplement PARTS CATALOGUE B60356A2Aj All inf...

Page 2: ...he checking range for tightening torques If bolts and nuts are not provided with tightening torques refer to P 00 5 VEHICLE IDENTIFICATION MODELS 2 DOOR MODELS Model code Engine model Transmission model Fuel supply system V24W NDGL6Y 4D56 2 477 mL with turbocharger V5MT1 5M T Injection GNDGL6Y with turbocharger and inter cooler 4 DOOR MODELS Model code Engine model Transmission model Fuel supply s...

Page 3: ...stribution channel M Japan channel 3 Destination B For Europe left hand drive 4 Body style 0 4 or 2 door with tailgate back door 5 Transmission type N 5 speed manual transmission 6 Development order V2 PAJERO 2 door models V4 PAJERO 4 door models 7 Engine 4 4D56 2 477 mL diesel engine 8 Sort W Station wagon 9 Model year 2 2002 10 Plant J Pajero Manufacturing Co Ltd 11 Serial number NOTE Indicates ...

Page 4: ... 4 2 420 Track front 5 1 420 1 465 Track rear 6 1 435 1 480 Ground clearance unladen 7 205 215 Overhang front 8 675 Overhang rear 9 980 Vehicle i ht k Kerb weight 1 700 1 755 weight kg Max gross vehicle weight 2 510 Max axle weight rating front 1 070 Max axle weight rating rear 1 750 Seating capacity 5 Engine Model No 4D56 Intercooler Turbocharger g Total displacement mL 2 477 Transmis i Model No ...

Page 5: ...20 1 465 Track rear 6 1 435 1 480 Ground clearance unladen 7 205 215 Overhang front 8 650 Overhang rear 9 1 280 Vehicle i ht k Kerb weight 1 875 1 930 weight kg Max gross vehicle weight 2 750 Max axle weight rating front 1 090 Max axle weight rating rear 1 780 Seating capacity 7 Engine Model No 4D56 Intercooler Turbocharger g Total displacement mL 2 477 Transmis i Model No V5MT1 sion Type 5 speed ...

Page 6: ...mm Head mark 4 Head mark 7 Head mark 8 M5 0 8 2 5 0 5 5 0 1 0 6 0 1 0 M6 1 0 5 0 1 0 9 0 2 0 10 2 M8 1 25 12 2 22 4 25 4 M10 1 25 24 4 44 10 53 7 M12 1 25 41 8 83 12 98 12 M14 1 5 73 12 140 20 155 25 M16 1 5 110 20 210 30 235 35 M18 1 5 165 25 300 40 340 50 M20 1 5 225 35 410 60 480 70 M22 1 5 300 40 555 85 645 95 M24 1 5 395 55 735 105 855 125 Flange bolt and nut tightening torque Thread size Tor...

Page 7: ...NOTES ...

Page 8: ...Outline of Changes 2 GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 2 SEALANT 3 SPECIAL TOOLS 3 ON VEHICLE SERVICE 4 Injection Timing Check and Adjustment 4 Idle Speed Check 4 OIL PAN AND OIL SCREEN 5 TIMING BELT AND TIMING BELT B 7 CYLINDER HEAD GASKET 11 ...

Page 9: ...trolled fuel injection pump Due to this change the timing belt front lower cover has been reshaped D The tightening torque of the cylinder head bolts and the cylinder head gasket have been changed GENERAL INFORMATION Items 4D56 Total displacement mL 2 477 Bore x Stroke mm 91 1 x 95 0 Compression ratio 21 Combustion chamber Vortex chamber type Camshaft arrangement SOHC Number of valve Intake 4 Exha...

Page 10: ... packing and rocker cover seal and cylinder head seal 3M ATD Part No 8660 or equivalent SPECIAL TOOLS Tools Number Name Use MD998727 Oil pan remover Removal of oil pan MD998721 Crankshaft pulley holder Holding the crankshaft pulley MD998051 Cylinder head bolt wrench Removal and installation of the cylinder head bolt MB991614 Angle gauge Tightening of the cylinder head bolts ...

Page 11: ...o the pre inspection condition 2 Turn the ignition switch to LOCK OFF position and connect the diagnosis connector to the MUT II If the MUT II is not used connect a tachometer to the injection nozzle or the pipe 3 Start the engine and let it run at idle 4 Check the idle speed Standard value 750 30 r min 5 If the idle speed is not within the standard value refer to 13C Troubleshooting to check the ...

Page 12: ... N m 9 0 1 0 N m 39 5 N m 7 0 1 0 N m 35 6 N m Engine oil 2 9 0 1 0 N m 8 7 9 0 1 0 N m 12 4 110 10 N m Sealant MITSUBISHI GENUINE Part No MD997110 or equivalent 12 4 mm 0 16 in diameter Hole of bolt Groove Removal steps 1 Vacuum hose connection 2 Bolt 3 Front suspension crossmember 4 Engine oil level gauge and guide assembly 5 Drain plug BA 6 Drain plug gasket 7 Alternator vacuum pump oil return ...

Page 13: ...an mating surface as shown Specified sealant MITSUBISHI GENUINE PART No MD970389 or equivalent NOTE The sealant should be applied in a continuous bead approximately 4 mm in diameter 4 Assemble oil pan to cylinder block within 15 minutes after applying the sealant Caution After installing the oil pan wait at least 1 hour before starting the engine BA DRAIN PLUG GASKET INSTALLATION Install a new gas...

Page 14: ...26 3 N m 26 3 N m 10 11 9 0 1 0 N m 26 3 N m 26 3 N m Removal steps CA 1 Timing belt front upper cover 2 Tension pulley and tension pulley bracket assembly 3 Crankshaft pulley for power steer ing and A C AA DA 4 Crankshaft pulley CA 5 Timing belt front lower cover AB BA 6 Timing belt 7 Tensioner spacer 8 Tensioner spring 9 Timing belt tensioner 10 Crank angle sensor 11 Crankshaft sensing blade 12 ...

Page 15: ...arrow at the belt to show rotation direction 2 Loosen the tensioner mounting bolt A and B 3 Push timing belt tensioner to water pump side and tighten the tensioner mounting bolt A and B Secure so that tensioner will not move back AC TIMING BELT B REMOVAL 1 When reinstalling timing belt B mark an arrow at the belt to show rotation direction 2 Loosen the tensioner mounting bolt C and nut D 3 Push ti...

Page 16: ...ning torque 26 3 N m 8 Press in the direction of the arrow in the figure with the index finger to check the amount of deflection Standard value 4 5 mm BA TIMING BELT INSTALLATION 1 Align the timing marks of the 3 sprockets 2 When reusing timing belt make sure the arrow mark is pointing in the same direction as when the belt was removed 3 Install the timing belt to the crankshaft sprocket to inject...

Page 17: ...e elongated hole If the lower bolt is tightened first belt tension will become too tight 8 Turn the crankshaft anticlockwise and align the timing mark Next make sure that the timing marks of all sprockets are aligned 9 Press on the center of the bolt with an index finger to check the amount of deflection Standard value 4 5 mm CA TIMING BELT FRONT LOWER COVER TIMING BELT FRONT UPPER COVER INSTALLAT...

Page 18: ...12 11 11 3 2 6 4 7 1 15 14 13 10 5 29 2 N m 120 During cold engine 5 9 1 0 N m 4 9 1 0 N m 30 6 N m 30 6 N m 4 9 1 0 N m 4 9 1 0 N m 30 6 N m 22 4 N m 22 4 N m 24 4 N m 8 9 10 2 N m 13 2 N m Removal steps 1 Engine coolant temperature switch connector for A C 2 Engine coolant temperature gauge unit and sensor connector 3 Glow plug terminal AA DA 4 Radiator upper hose AB CA 5 Fuel injection pipe 6 H...

Page 19: ...ench and loosen nut Caution After disconnecting the injection pipe plug the opening so that no foreign particles get inside the pump or into the injection nozzle AC POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the bracket with the hose attached NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engi...

Page 20: ...refore if the piston or the connecting rod is replaced the protrusion amount may be changed Always select a correct gasket by measuring the protrusion amount For details refer to the Engine Workshop Manual BA CYLINDER HEAD INSTALLATION 1 Select a cylinder head gasket of correct specification 2 Clean the cylinder head assembly and the cylinder block mating surfaces with a scraper or a wire brush Ca...

Page 21: ...CA FUEL INJECTION PIPE INSTALLATION When tightening the nuts at both ends of the fuel injection pipe hold the delivery holder for pump side and the injection nozzle assembly for nozzle side with a wrench and tighten the nuts to the specified torque Tightening torque 30 6 N m DA RADIATOR UPPER HOSE CONNECTION To reuse the radiator upper hose align the mating marks that were made during removal and ...

Page 22: ...2 LUBRICATION GENERAL OUTLINE OF CHANGE D The engine oil quantity has been changed as variable geometry VG turbocharger has been used LUBRICANT Items 4D5 Step III Items 4D5 Step III Engine oil quantity L Oil filter 0 8 Oil cooler 0 4 Total 7 5 ...

Page 23: ...NOTES ...

Page 24: ...l Position Sensor APS Adjustment 58 Control Relay Continuity Check 59 Accelerator Pedal Position Sensor APS Check 59 Idle Switch Check 60 Boost Air Temperature Sensor Intake Air Temperature Sensor Check 60 Engine Coolant Temperature Sensor Check 61 EGR Valve Position Sensor Check 61 Fuel Injection Pump Check 62 Throttle Solenoid Valve Check 63 Throttle Actuator Check 64 Variable Geometry Solenoid ...

Page 25: ...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 ...

Page 26: ...ition 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 clut...

Page 27: ...lenoid valve No 2 l5 Throttle solenoid valve l6 Fuel cut solenoid valve l7 Variable geometry solenoid valve D Control relay D A C relay D Condenser fan relay D Intercooler fan relay D Glow indicator lamp D Glow plug relay D Engine warning lamp D Diagnosis output Engine ECU L8 Timerpiston position sensor L2 Crank angle sensor L9 EGR valve position sensor L10 Variable geometry control pressure senso...

Page 28: ...nector terminals No 1 No 2 160 168 p p Connector terminals No 1 No 3 80 84 Connector terminals No 2 No 3 80 84 Control sleeve position sensor resistance Ω Connector terminals No 4 No 12 11 2 12 4 p Connector terminals No 4 No 8 5 6 6 2 Connector terminals No 8 No 12 5 6 6 2 GE actuator electronic governor resistance Ω Connector terminals No 6 No 10 0 64 0 72 Fuel temperature sensor resistance kΩ C...

Page 29: ...nt D Inspection using an analyzer MD998478 Test harness 3 pin square D Crank angle sensor check D Inspection using an analyzer MB990767 End yoke holder Holding the fuel injection pump sprocket MD998719 Crankshaft pulley holder pin MD998388 Injection pump sprocket puller Fuel injection pump sprocket removal ...

Page 30: ...ub Boost pressure sensor Boost sensor Crank angle sensor Control sleeve position sensor Timer piston position sensor Throttle solenoid valve GE actuator Variable geometry control pressure sensor Barometric pressure sensor Timing control valve Idle switch Engine ECU METHOD OF ERASING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points INSPECTION USING ...

Page 31: ...tem assumes the coolant temperature as 0_C when engine is started D Void EGR control Control sleeve position sensor D Engine controlled at low speed D Void EGR control D Void variable geometry turbocharger control Timer piston position sensor D Injection timing stabilizing control D Void EGR control Barometric pressure sensor ECU built in D Keep the barometric pressure at 101 kPa D Void EGR contro...

Page 32: ...ition sensor system 13 18 26 Control sleeve position sensor system 13 19 27 Accelerator pedal position sensor sub system 13 20 41 Throttle solenoid valve system 13 21 43 Timing control valve system 13 22 46 Injection volume adjusting ROM system 13 23 48 GE actuator in the middle of control sleeve position sensor inoperative system 13 24 49 Over boost variable geometry control pressure sensor syste...

Page 33: ...short circuit or connector contact inoperative D Engine ECU inoperative NG OK OK Measure at C 134 accelerator pedal position sensor connector D Disconnect the connector and measure at the harness side D Voltage between 2 and earth Ignition switch ON OK 4 5 5 5 V D Continuity between 1 and earth OK Continuity NG Check the following connector C 43 NG Repair OK OK Repair NG Accelerator pedal position...

Page 34: ... 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 Repair Check the following connector A 129 NG Measure at A 129 boost pressure sensor connector D Conne...

Page 35: ...anking Set Conditions D The sensor output voltage for 3 seconds is 0 2 V or lower the fuel temperature is approximately 125 C or higher or D The sensor output voltage for 3 seconds is 4 6 V or higher the fuel temperature is approximately 47 C or lower D Fuel temperature sensor inoperative D Fuel temperature sensor open circuit short circuit or connector contact inoperative D Engine ECU inoperative...

Page 36: ...30 Check the harness between the engine ECU and the engine coolant temperature sensor connector Check the trouble symptoms Replace Code No 16 Boost air temperature sensor intake air sensor system Probable cause Range of Check D Ignition switch ON except for during engine cranking Set Conditions D The sensor output voltage for 3 seconds is 4 6 V or higher the intake air temperature is approximately...

Page 37: ... NG Repair OK Measure at combination meter connector C 05 C 06 D Disconnect the connector and measure at the harness side 1 Voltage between 1 and earth Ignition switch ON OK 4 8 5 2 V 2 Continuity between 43 and earth OK Continuity Check the following connector C 75 C 24 C 43 NG Repair Check the vehicle speed sensor Refer to GROUP54 Combination Meters NG Check the harness wire between the combinat...

Page 38: ... circuit or poor sensor contact D Engine ECU inoperative NG Replace the engine ECU OK Check trouble symptoms NG Repair NG Check the harness between the engine ECU and the pump speed sensor connector and repair if necessary OK Replace the injection pump OK Measure at engine ECU connector C 130 D Connect the connector D Voltage between 51 61 Engine idling and then raced OK Voltage increases from the...

Page 39: ...ngle sensor connector A 112 D Connect the connector Test harness MB998478 used D Voltage between 2 black clip and the earth OK 0 4 4 0 V Engine cranking 1 5 2 5 V Engine idling NG Replace the crank angle sensor Replace the engine ECU Check the following connector C 126 NG NG Check the trouble symptoms OK Repair Check the following connector C 43 NG OK Repair NG Check the harness between the engine...

Page 40: ...osition sensor open circuit short circuit or connector contact inoperative D Idle switch ON inoperative D Idle switch signal line short circuit D Engine ECU inoperative OK Measure at C 134 accelerator pedal position sensor connector D Disconnect the connector and measure at the harness side D Voltage between 4 and the earth Ignition switch ON OK 4 5 5 5 V D Continuity between 5 and the earth OK Co...

Page 41: ...e input pulse signal converted in the engine ECU and cannot be measured Replace injection pump assembly timer piston fully closed opened position inoperative etc NG NG OK OK NG Check the following connector C 43 NG Repair OK Repair NG Timer piston position sensor check Refer to P 13 63 NG NG OK NG Check the trouble symptoms Replace injection pump assembly Check the following connector A 132 OK Rep...

Page 42: ...input pulse signal converted in the engine ECU and cannot be measured OK NG Check the following connector C 43 NG Repair OK Repair NG Control sleeve position sensor check Refer to P 13 62 NG NG OK NG Check the trouble symptoms Replace injection pump assembly Check the following connector A 131 OK Replace the engine ECU NG MUT II Data list 17 Control sleeve position sensor target value Refer to P 1...

Page 43: ... main output voltage is 1 875 V or higher D Accelerator pedal position sensor inoperative D Accelerator pedal position sensor open circuit short circuit or connector contact inoperative D Engine ECU inoperative OK Measure at C 134 accelerator pedal position sensor connector D Disconnect the connector and measure at the harness side D Voltage between 8 and the earth Ignition switch ON OK 4 5 5 5 V ...

Page 44: ...k the following connector C 126 NG Repair OK Check and repair the harness between the control relay and the solenoid valve connector Check the trouble symptoms NG NG OK Measure at A 128 throttle solenoid valve connector D Disconnect the connector and measure at the harness side D Voltage between 2 and the earth Ignition switch ON OK System voltage OK Replace Throttle actuator check Refer to P 13 6...

Page 45: ...he following connector C 41 Check the trouble symptoms NG NG NG Check the following connector A 131 NG Repair OK Check the trouble symptoms NG NG Measure at C 41 engine ECU connector D Disconnect the connector and measure at the harness side D Voltage between 3 and the earth Ignition switch ON OK 11 V or higher OK Measure at A 131 injection pump assembly connector D Disconnect the connector and me...

Page 46: ...llowing connector C 130 NG Repair OK Check the trouble symptoms NG Measure at A 134 injection volume adjusting ROM connector D Disconnect the connector and measure at the harness side D Voltage between 3 and the earth Ignition switch ON OK 4 5 5 5 V D Continuity between 4 and the earth OK Continuity Check the harness between the engine ECU and the injection volume adjusting ROM connector OK Replac...

Page 47: ... check Refer to P 13 62 Replace the engine ECU OK Repair Check the following connector C 41 Check the trouble symptoms NG NG NG Check the following connector A 131 NG Repair OK Check the trouble symptoms NG NG Measure at C 41 engine ECU connector D Disconnect the connector and measure at the harness side D Voltage between 1 and the earth Ignition switch ON OK 9 V or higher OK Measure at A 131 inje...

Page 48: ... Check the following connector A 127 NG Repair OK Check the trouble symptoms NG NG Measure at C 41 engine ECU connector D Disconnect the connector and measure at the harness side D Voltage between 17 and earth Ignition switch ON OK System voltage OK Measure at A 127 variable geometry solenoid valve connector D Disconnect the connector and measure at the harness side D Voltage between 2 and earth I...

Page 49: ...U and the EGR valve position sensor connector EGR valve position sensor check Refer to P 13 61 OK Replace Check the following connector C 43 Check the trouble symptoms NG NG Check the following connector A 135 NG Repair OK Check the trouble symptoms NG NG Measure at C 43 engine ECU connector D Connect the connector D Voltage between 90 and earth OK 0 4 0 6 V Ignition switch ON 4 1 4 8 V When 60 kP...

Page 50: ... symptoms OK Replace the engine ECU OK Repair NG NG Check the harness between the engine ECU and the variable geometry control pressure sensor connector Check the trouble symptoms OK NG Repair Check the following connector C 42 NG Repair OK OK OK Check the following connector A 130 NG NG NG Check the following connector A 130 Measure at A 130 variable geometry control pressure sensor connector D C...

Page 51: ... the engine radio interference may cause this code to be displayed 2 This code may be displayed when registering the key encrypted code Is there another ignition key near the ignition key that is inserted in the ignition switch Yes Remove the extra ignition key No Check the following connectors C 120 C 124 C 130 NG Repair No Is a diagnosis code output from the immobilizer ECU Yes Check the immobil...

Page 52: ...mance is bad when the engine is cold difficult to start 6 13 32 Starting performance is bad regardless of when the engine is hot or cold difficult to start 7 13 33 Idling stability idling inoperative Low idling speed when the engine is cold improper idling speed 8 13 33 High idling speed improper idling speed 9 13 33 Low idling speed improper idling speed 10 13 34 Idling instable rough idling hunt...

Page 53: ...nnector D Continuity between 4 and the earth D Continuity between 5 and the earth OK Continuity Check and repair the earth line INSPECTION PROCEDURE 2 No communication can be established between MUT II and the engine ECU Probable cause Probable causes are shown in the following D The power is not supplied to the engine ECU D The earth circuit of the engine ECU inoperative D The engine ECU inoperat...

Page 54: ...e at C 41 engine ECU connector D Disconnect the connector and measure at the harness side D Short circuit between 8 and the earth Ignition switch ON OK The engine warning lamp turns on OK Check the following connector C 41 NG Repair MUT II Data list 11 Engine ECU power supply voltage Refer to P 13 43 NG The engine ECU power supply and the earth circuit check Refer to P 13 39 Inspection procedure 2...

Page 55: ...ressure D Existence of mixing foreign objects water kerosene with the fuel INSPECTION PROCEDURE 6 Starting performance is bad when the engine is cold unable to start Probable cause Probable causes can be found in troubles with control system injection pump fuel system intake system and glow system D Control system inoperative D Injection pump inoperative D Fuel system inoperative D Intake system i...

Page 56: ...ing speed when the engine is cold improper idling speed Probable cause Probable causes can be found in troubles with control system injection pump and fuel system D Control system inoperative D Injection pump inoperative D Fuel system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13 9 NO Conduct M...

Page 57: ... D Glow system inoperative D EGR system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13 9 NO Conduct MUT II Data list check and an actuator test Refer to P 13 42 46 OK Inspect the following items in order D Glow plug glow plug relay D EGR system D Injection nozzle D Compression pressure D Valve c...

Page 58: ...el system inoperative D Intake system inoperative D EGR system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13 9 NO Conduct MUT II Data list check and an actuator test Refer to P 13 42 46 OK Inspect the following items in order D Injection nozzle fuel filter D Throttle body assembly D EGR system ...

Page 59: ...system and glow system D Control system inoperative D Injection pump inoperative D Fuel system inoperative D Intake system inoperative D EGR system inoperative D Glow system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13 9 NO Conduct MUT II Data list check and an actuator test Refer to P 13 42 4...

Page 60: ...isconnect the connector and measure at the harness side D Check the A C condenser fan condition Ignition switch ON OK Fan stopped D Voltage between 7 and the earth Ignition switch ON OK System voltage D Short out 7 and the earth Ignition switch ON OK A C condenser fan turns NG A C condenser fan motor circuit check Refer to the wiring harness configuration diagram OK MUT II Data list 02 Engine cool...

Page 61: ...tive Check the following connector C 41 NG Measure at C 41 engine ECU connector D Disconnect the connector and measure at the harness side D Check the intercooler fan condition Ignition switch ON OK Fan stopped D Voltage between 6 and earth Ignition switch ON OK System voltage D Short out 6 and the earth Ignition switch ON OK Intercooler fan turns NG Intercooler fan circuit check Refer to the wiri...

Page 62: ...82 and the earth Ignition switch ON OK System voltage 2 Voltage between 46 and the earth OK System voltage 3 Voltage between 12 25 and the earth Ignition switch ON OK System voltage When terminal 46 is short circuited to the earth 4 Continuity between 13 26 and the earth OK Continuity 5 Voltage 80 and the earth OK System voltage 1 NG OK OK NG Repair Check the trouble symptoms Check the following c...

Page 63: ...ON OK System voltage NG Replace the engine ECU NG Check the trouble symptoms OK Repair Check the following connector C 41 OK INSPECTION PROCEDURE 24 EGR control solenoid valve No 2 circuit inspection NG Check the harness between the engine ECU and the EGR control solenoid valve No 2 connector and repair if necessary OK Check the trouble symptoms OK Measure at EGR control solenoid valve No 2 connec...

Page 64: ...ystem NG Replace Check glow plug relay connector A 101 and repair if necessary OK OK Check the harness between the engine ECU and the glow plug relay connector NG Repair INSPECTION PROCEDURE 26 A C switch and A C relay inspection Replace the engine ECU OK Check the trouble symptoms Measure at engine ECU connector C 41 or C 42 D Disconnect the connector and measure at the harness side D Voltage bet...

Page 65: ...20_C 20_C When the engine coolant temperature is 40_C 40_C When the engine coolant temperature is 80_C 80_C 03 Barometric Ignition switch ON Altitude 0 m 101 kPa Code No 13 13 12 pressure sensor g Altitude 600 m 95 kPa 13 sensor Altitude 1 200 m 88 kPa Altitude 1 800 m 81 kPa 04 Boost D Engine coolant t t Altitude 0 m 101 kPa Code No 12 13 11 pressure sensor g temperature 80 95_C Altitude 600 m 95...

Page 66: ...on 99 100 11 System volt age Ignition switch ON System volt age Procedure No 21 13 39 13 Timing t l Engine After warming th i Idling 70 90 Code No 25 N 13 18 g control valve 1 g g up the engine When engine is suddenly raced Changes 25 or No 43 13 22 17 Control sleeve posi Engine After warming up the engine Idling 2 1 2 5 V Code No 26 13 19 sleeve posi tion target value up the engine 2 500 r min no...

Page 67: ...y raced Momentarily increases 52 NOTE 1 The opening degree of the timing control valve is converted into percentage 0 timer non advanced angle 100 timer maximum advanced angle 2 The opening degree of the EGR solenoid valve is converted into percentage Item No Check item Inspection conditions Value to be determined as normal Code No or inspec tion proce dure No Reference page 41 Idle switch Ignitio...

Page 68: ...e stops OFF Code No 41 13 21 solenoid valve Engine main sensor or actuator is failed ON 41 55 Engine warning D Ignition switch ON S Engine warning lamp off OFF Procedure No 3 13 31 g lamp D Select actuator test item No 16 Engine warning lamp is forced on ON 56 Glow lamp D Ignition switch ON Glow lamp off OFF ON D Select actuator test item No 15 Glow lamp is forced on ON 60 Fuel cut relay D Ignitio...

Page 69: ...25 from ON to OFF plug relay is ON 03 A C compressor relay Turning the relay from Ignition switch ON The A C compressor clutch makes an Procedure No 26 13 41 relay relay from OFF to ON or from ON to ON clutch makes an audible sound No 26 from ON to OFF 11 Timing control valve Turn the timing control valve to ON D Ignition switch ON D Engine Idling Makes an audible sound Code No 43 13 22 12 Turn th...

Page 70: ...actuator Hold the injection governor in its middle position D Ignition switch ON When the crankshaft is turned clockwise during the adjustment of the injection timing the injection pipes spray out fuel Code No 48 13 24 35 Variable geometry solenoid valve Turn the solenoid valve to ON Ignition switch ON Makes an audible sound Code No 49 13 25 36 Turn the solenoid valve to OFF Engine Idling Operatin...

Page 71: ...r lower D Vehicle speed 176 km h or higher D The accelerator pedal is fully depressed D The accelerator pedal is released when engine speed is 2 700 r min or higher and vehicle speed is 140 km h or higher D Engine coolant temperature 112_C or higher System voltage 6 Intercooler fan relay Ignition switch ON Boost air temperature at 45_C or lower System voltage Boost air temperature at 60_C or highe...

Page 72: ... Idling Use a digital voltage meter to check 0 V 5 V repeat the change 55 Accelerator pedal position sensor sub Ignition switch ON Accelerator pedal Idling position 0 9 1 1 V Accelerator pedal Fully opened position 3 7 V or higher 60 Sensor power supply Ignition switch ON 4 6 5 4 V 71 Ignition switch ST Engine Cranking 8 V or higher 80 Back up power supply Ignition switch OFF System voltage 81 Pow...

Page 73: ... switch Ignition switch ON Engine stops Parking brake ON 0 1 V Engine stops Parking brake OFF System voltage CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1 Turn the ignition switch to LOCK OFF position 2 Disconnect the engine ECU connector 3 Measure the resistance and check for continuity between the terminals of the engine ECU harness side connector while referring to the check cha...

Page 74: ...12 Timing control valve 10 8 11 2 Ω 5 12 EGR control solenoid valve No 2 36 44 Ω at 20_C 9 12 EGR control solenoid valve No 1 36 44 Ω at 20_C 13 Body earth Engine ECU earth Continuity 0 Ω 26 Body earth 14 12 Throttle solenoid valve 29 35 Ω at 20_C 31 61 Idle switch Continuity Replace the foot from the accelerator pedal No continuity when accelerator pedal is fully depressed 51 61 Pump speed sensor...

Page 75: ..._C 0 26 0 36 kΩ when the engine coolant temperature is 80_C 87 61 Fuel temperature sensor 5 1 6 5 kΩ when the fuel temperature is 0_C 2 1 2 7 kΩ when the fuel temperature is 20_C 0 9 1 3 kΩ when the fuel temperature is 40_C 0 26 0 36 kΩ when the fuel temperature is 80_C 88 61 Boost air temperature sensor 5 3 6 7 kΩ when the intake air temperature is 0_C 2 3 3 0 kΩ when the intake air temperature i...

Page 76: ...onnect the crank angle sensor connector and connect the special tool test harness MD998478 in between 2 Connect the analyzer probe to terminal No 2 of the crank angle sensor connector black clip of special tool NOTE When measuring at the engine ECU connector connect the analyzer probe to terminal No 89 Standard Wave Pattern Observation conditions Crank angle sensor Probe select switch 1 TIME DIV 1...

Page 77: ...n be calculated from the following formula Engine speed r min 2 4T sec 60 30 T sec Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is n...

Page 78: ... tool test harness MD991658 in between All terminals should be connected 2 Connect the analyzer probe to terminal No 1 of the pump speed sensor connector black clip of special tool NOTE When measuring at the engine ECU connector connect the analyzer probe to terminal No 51 Standard Wave Pattern Observation conditions Pump speed sensor Probe select switch Set according to the probe TIME DIV About 1...

Page 79: ...rmula Engine speed 2 4 T sec 60 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased Examples of Abnormal Wave Patterns D Example 1 Cause of problem Malfunction or open circuit in sensor Wave pattern characteristics No signal is output even when engine is started D Example 2 Cause of problem Incorrect gap between sen...

Page 80: ...ure 14 710 15 490 kPa 4 If the fuel injection initial pressure is outside the standard value disassembly the nozzle holder to clean it and then change the thickness of the shim to adjust the fuel injection initial pressure NOTE 1 For disassembly reassembly and adjustment of the nozzle holder refer to 91 PAJERO Workshop Manual Pub No PWJE9085 P 13B 8 2 There are 10 shims for adjustment with thickne...

Page 81: ...usted in the factory Therefore APS should not be moved carelessly 2 If the adjustment is not done correctly carry out a new adjustment in the following procedure 1 Connect MUT II to the diagnosis connector If MUT II is not used the following operation should be done 1 Disconnect APS connector and connect the special tool test harness MB991658 between two connectors Be careful not to take a wrong t...

Page 82: ...as the resistance between terminal No 8 APS sub power supply and terminal No 7 APS sub earth Standard value 3 5 6 5 kΩ 3 Measure the resistance between APS connector terminal No 2 APS main power supply and the terminal No 3 APS main output as well as the resistance between terminal No 8 APS sub power supply and terminal No 6 APS sub output Normal condition Step on the accelerator pedal slowly Resi...

Page 83: ...e the boost air temperature sensor 2 Measure the resistance at the boost air temperature sensor connector terminal Standard value 2 3 3 0 kΩ at 20_C 0 30 0 42 kΩ at 80_C 3 Measure the resistance at the sensor part being warmed up by a hair dryer Normal condition Temperature _C Resistance value kΩ Rising Become smaller 4 If the resistance is not within the range of the standard value or does not ch...

Page 84: ...alant 3M Nut Locking Part No 4171 or equivalent Tightening torque 36 6 N m EGR VALVE POSITION SENSOR CHECK 1 Disconnect the EGR valve position sensor connector 2 Measure the resistance between the EGR valve position sensor side connector terminal No 2 and terminal No 3 Standard value 3 5 6 5 kΩ 3 Install a hand vacuum pump to the EGR valve nipple 4 Measure the resistance between the EGR valve posi...

Page 85: ...t the injection pump connector 12 pin 2 Measure the resistance between terminal No 5 and terminal No 9 Standard value 10 8 11 2 Ω GE ACTUATOR ELECTRONIC GOVERNOR CHECK 1 Disconnect the injection pump connector 12 pin 2 Measure the resistance between terminal No 6 and terminal No 10 Standard value 0 64 0 72 Ω FUEL TEMPERATURE SENSOR CHECK 1 Disconnect the injection pump connector 12 pin 2 Measure t...

Page 86: ...o 2 Terminal No 3 80 84 Ω PUMP SPEED SENSOR CHECK 1 Disconnect the pump speed sensor connector 2 Measure the resistance between terminals No 1 and No 2 Standard value 1 36 1 84 kΩ THROTTLE SOLENOID VALVE CHECK INSPECTION PROCEDURE 1 Disconnect the vacuum hose black and yellow stripe from the solenoid valve 2 Disconnect the harness connector 3 Install a hand vacuum pump to solenoid valve nipple B 4...

Page 87: ...tandard value 29 35 Ω at 20_C THROTTLE ACTUATOR CHECK 1 Remove the vacuum hose yellow stripe from the throttle actuator and connect a hand vacuum pump to the throttle actuator nipple 2 Check that the actuator rod moves smoothly when applying vacuum gradually Also check that the vacuum is maintained when applying 53 kPa of vacuum VARIABLE GEOMETRY SOLENOID VALVE CHECK Refer to GROUP 15 On vehicle S...

Page 88: ...Installation D Engine Coolant Supplying 1 3 4 5 6 7 2 10 2 N m 5 0 1 0 N m 5 0 1 0 N m 30 7 N m 30 7 N m 19 3 N m 23 3 N m 83 5 N m 12 1 N m Engine oil Removal steps 1 Fuel injection pump connector 2 Fuel hoses connection AA 3 Fuel injection pipe 4 Engine oil level gauge guide and oil level gauge assembly AB 5 Fuel injection pump sprocket 6 Flange 7 Fuel injection pump REMOVAL SERVICE POINTS AA FU...

Page 89: ... the fuel injection pump sprocket Caution 1 Do not hit pump drive shaft with hammer etc 2 When holding injection pump do not allow to dangle by holding accelerator lever or fast idle lever Do not remove these levers Removal will cause injection pump malfunction CRANKSHAFT POSITION SENSOR REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Timing Belt Cover Removal and Installati...

Page 90: ...stment Refer to P 13 58 3 5 1 0 N m 10 2 N m 1 2 3 4 5 6 7 12 8 9 10 11 5 0 1 0 N m 5 6 12 10 10 8 9 Removal steps 1 Accelerator pedal position sensor 2 Accelerator pedal assembly 3 Hysteresis assembly 4 Push on spring nut 5 Bushing 6 Spring 7 Accelerator arm and pedal assembly 8 Accelerator pedal 9 Spring 10 Accelerator arm 11 Pedal stopper 12 Accelerator pedal bracket ...

Page 91: ...NOTES ...

Page 92: ...14 1 COOLING CONTENTS GENERAL 2 Outline of Change 2 SPECIFICATIONS 2 General Specification 2 WATER HOSE AND WATER PIPE 4D5 3 ...

Page 93: ...s service procedure has been established D 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 has been changed D Heat release of the radiator has been enhanced to correspond to a newly introduced Variable Geometry VG turbocharger SPECIFICATIONS GENERAL SPECIFICATION Items Specifications Radiator Per...

Page 94: ...42 7 N m 16 8 10 Removal steps D Injection pipe 1 Heater hose connection 2 Water hose D Air cleaner assembly 3 Water pipe and hose assembly AA 4 Water hose 5 Water pipe E BA 6 O ring AA 7 Water hose 8 Hose protector D EGR valve EGR cooler Refer to GROUP 17 D Turbocharger heat protector Refer to GROUP 15 Intake and exhaust manifold turbocharger 9 Water hose 10 Hose protector 11 Water pipe A 12 Gask...

Page 95: ...E POINTS BA O RING INSTALLATION Rinse the mounting location of the O ring and water pipe with water and install the O ring and water pipe Caution 1 Care must be taken not to permit engine oil or other greases to adhere to the O ring 2 When inserting the pipe check to be sure that there is no sand dirt etc on its inner surface Water hose EGR cooler side Identification mark Hose protector Water pipe...

Page 96: ...4D5 Step III 3 ON VEHICLE SERVICE 4 Turbocharger Supercharging Check 4 Supercharging Pressure Control System Check 4 Variable Geometry Actuator Check 5 Variable Geometry Solenoid Valve Check 5 INTERCOOLER 4D5 Step III 6 INTAKE MANIFOLD AND EXHAUST MANIFOLD THROTTLE BODY AND TURBOCHARGER 4D5 Step III 7 EXHAUST PIPE AND MAIN MUFFLER 4D5 Step III 9 ...

Page 97: ...control the variable nozzle opening angle of the variable geometry turbocharger This allows to obtain the characteristic of boost pressure corresponding to the engine operation status At starting driving at low speed Nozzle vane fully closed Vacuum pressure increased rod activated Turbin wheel To vacuum pump Variable geometry solenoid valve Variable geometry control pressure sensor Variable geomet...

Page 98: ...wards the direction of opening the nozzle of the variable geometry turbocharger Opening the nozzle allows the characteristic of boost pressure to become a high speed type so that the appropriate boost pressure can be maintained Therefore boost pressure can be controlled by appropriate duty control of the variable geometry solenoid valve The engine ECU calculates the correct boost pressure based on...

Page 99: ...age of supercharging pressure D Malfunction of the turbocharger 5 When the indicated supercharger is 133 kPa or more supercharging control may be faulty therefore check the followings D Malfunction of the variable geometry actuator D Malfunction of the variable nozzle D Malfunction of the variable geometry solenoid valve D Malfunction of the boost pressure sensor D Malfunction of the variable geom...

Page 100: ...o nipple 2 While gradually applying vacuum check the vacuum that begins to active approximately 1 mm stroke the variable geometry actuator rod Standard value Approximately 10 5 12 5 kPa Caution In order to avoid damage to the diaphragm do not apply a vacuum of 59 kPa or higher 3 If there is a significant deviation from the standard value check the actuator or the variable nozzle replace if necessa...

Page 101: ...e the resistance between the terminals of the solenoid valve Standard value 29 35 Ω at 20_C INTERCOOLER 4D5 Step III The air temperature switch has been replaced with an air temperature sensor as an electronic controlled injection pump has been introduced The intercooler service procedure is the same as before except the air temperature sensor and reshaped hose B On new models the engine ECU contr...

Page 102: ...Cover Removal and Installation D Battery Battery Tray Removal and Installation D Air Cleaner Assembly Removal and Installation D Intercooler Removal and Installation Refer to P 15 2 D EGR valve and EGR cooler Removal and Installation Refer to GROUP 17 3 7 8 1 6 14 10 11 12 13 15 18 17 21 19 20 26 23 25 24 27 22 2 4 9 16 28 29 4 30 14 1 N m 4 5 14 1 N m 18 2 N m 24 4 N m 14 1 N m 18 2 N m 17 2 N m ...

Page 103: ...21 Water pipe B connection 22 Gasket 23 VG actuator 24 Turbocharger lower heat protector 25 Front exhaust pipe connection 26 Gasket 27 Oil return hose connection 28 Exhaust manifold and turbocharger assembly 29 Intake and exhaust manifold gasket 30 Oil return hose 32 34 35 31 36 9 0 1 0 N m 59 10 N m 33 14 1 N m 31 Oil return pipe 32 Oil return pipe gasket 33 Exhaust fitting heat protector 34 Exha...

Page 104: ... m 13 2 N m 13 2 N m 25 4 N m 25 4 N m 49 10 N m 49 10 N m 35 6 N m 25 4 N m 49 10 N m Short wheelbase Long wheelbase Exhaust main muffler removal steps 1 Tail pipe 2 Gasket 3 Hanger 4 Hanger bracket Short wheelbase 5 Exhaust main muffler 6 Hanger 7 Heat protector Center exhaust pipe and catalytic converter removal steps 8 Catalytic converter 9 Gasket 11 Gasket 12 Center exhaust pipe 13 Hanger 14 ...

Page 105: ...RAL 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 The other items are the same as before ...

Page 106: ... GENERAL 4D5 step III 2 Outline of Change 2 GENERAL INFORMATION 4D5 step III 2 SERVICE SPECIFICATIONS 4D5 step III 2 EXHAUST GAS RECIRCULATION EGR SYSTEM 4D5 step III 3 EGR VALVE AND EGR COOLER 4D5 step III 6 CATALYTIC CONVERTER 4D5 step III 8 ...

Page 107: ... converter has been added GENERAL INFORMATION 4D5 step III The electronically controlled EGR system reduces the level of exhaust gases NOx Items Name Specification Exhaust emission control system Exhaust gas recirculation system D EGR valve D EGR solenoid valve No 1 D EGR solenoid valve No 2 D EGR valve position sensor Electronically controlled EGR system Single type ON OFF solenoid valve ON OFF s...

Page 108: ...opening of the EGR valve is calculated based on the input signal from each sensor Feedback control of the EGR solenoid valves No 1 and No 2 operation is carried out based on the signal from EGR valve position sensor so that the opening of the EGR valve can be quickly adjusted to the target angle In this way the EGR is controlled to reduce NOx emissions while maintaining good engine performance SYS...

Page 109: ...d vacuum hoses 2 Attach a vacuum pump to each nipple of the EGR solenoid valve Nos 1 and 2 and connect each connector of EGR solenoid valve to battery and apply negative pressure Check that the valves are airtight both when voltage is applied to each terminal of the EGR solenoid valve Nos 1 and 2 and when it is not applied EGR solenoid valve No 1 Battery voltage Normal condition When current is fl...

Page 110: ...SOLENOID VALVE RESISTANCE CHECK Measure terminal resistance of EGR solenoid valves Nos 1 and 2 with a circuit tester Standard value 36 44 Ω at 20_C ACCELERATOR PEDAL POSITION SENSOR APS ENGINE COOLANT TEMPERATURE SENSOR BOOST AIR TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR EGR VALVE POSITION SENSOR CHECK Refer to GROUP 13 On vehicle Service CHECK AT ENGINE ECU TERMINALS Refer to GROUP 13 Troublesho...

Page 111: ...22 4 N m 17 2 N m 1 2 3 6 8 10 12 7 4 5 17 2 N m 9 11 22 4 N m 22 4 N m 13 14 17 2 N m 15 Removal steps 1 EGR valve connector 2 Vacuum hose connection 3 EGR valve 4 EGR gasket 5 EGR pipe gasket 6 EGR upper pipe AA 7 EGR pipe gasket CA 8 Water pipe and hose assembly BA 9 O ring 10 Water hose connection 11 EGR cooler and EGR lower pipe assembly AA 12 EGR pipe gasket 13 EGR lower pipe AA 14 EGR pipe ...

Page 112: ...ution 1 Care must be taken not to permit engine oil or other greases to adhere to the O ring 2 When inserting the pipe check to be sure that there is no sand dirt etc on its inner surface CA WATER PIPE AND HOSE ASSEMBLY INSTALLATION If the water hose is separated from the water pipe for any reason the identification mark on the water hose end should face towards the EGR cooler EGR pipe EGR cooler ...

Page 113: ...c Converter 4D5 step III 17 8 CATALYTIC CONVERTER 4D5 step III REMOVAL AND INSTALLATION Pre removal and Post installation Operation Under Cover Removal and Installation 2 1 49 4 N m 49 10 N m 2 Removal steps 1 Catalytic converter 2 Gasket ...

Page 114: ...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 New Old New Old Short wheelbase Long wheelbase ...

Page 115: ...ure 1 Communication with MUT II is impossible Probable cause The cause is probably that a malfunction of the diagnosis line or the immobilizer ECU is not functioning D Malfunction of diagnosis line D Malfunction of harness or connector D Malfunction of immobilizer ECU Register the password secret code and the encrypted code Check trouble symptoms Check the harness between the immobilizer ECU power...

Page 116: ...ht be a problem with the fuel injection system in addition to a malfunction of the immobilizer system It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered D Malfunction of diesel fuel injection system D Malfunction of immobilizer ECU Check the system voltage duringcrank ing OK 8 V or more NG Check the battery OK Is a diagnosis c...

Page 117: ... trouble symptom NG Checktheharnessbetweentheimmobi lizer ECU and engine control relay and repair if necessary 2 NG Check the following connector C 77 C 120 NG Repair OK Check trouble symptom NG Checktheharnessbetweentheimmobi lizer ECU and body earth and repair if necessary CHECK AT IMMOBILIZER ECU Terminal Voltage Check Chart Terminal No Signal Checking requirements Terminal voltage 3 Immobilize...

Page 118: ...WORKSHOP MANUAL ELECTRICAL WIRING E Mitsubishi Motors Corporation May 2001 FOREWORD This manual integrates the WORKSHOP MANUAL CHASSIS and ELECTRICAL WIRING ...

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