1999-2006 Mitsubishi Pajero NM Service & Repair Manual

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

13E-1 DIESEL FUEL <4D5-STEP III> 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 .............................

DIESEL FUEL <4D5-step III>- General/General Information 13E-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 D When an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates to warn the driver. D When an abnormality is detected in any of the sensors or actuators, a diagnosis code number corresponding to the problem which occurred is output. D The 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.

DIESEL FUEL <4D5-step III>- General Information 13E-3 CONTROL SYSTEM DIAGRAM L1. Pump speed sensor L2. Crank angle sensor L3. Engine coolant temperature sensor L4. Boost pressure sensor L5. Fuel temperature sensor L6. Boost air temperature sensor L7. Control sleeve position sensor L8. Timer piston position sensor L9. EGR valve position sensor L10. Variable geometry control pressure sensor D Accelerator pedal position sensor (main) D Accelerator pedal position sensor (sub) D Idle switch D Power supply D Ignition switch-IG D Ignition switch-ST D Vehicle speed sensor D A/C switch D A/C relay switch D Injection volume adjusting ROM D Barometric pressure sensor (ECU built-in) l1. GE actuator (electronic governor) l2. Timing control valve l3. EGR control solenoid valve No. 1 l4. EGR control solenoid 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 Glow indicator lamp D Glow plug relay D Engine warning lamp D Diagnosis output Engine- ECU L8 Timer piston position sensor L2 Crank angle sensor L9 EGR valve position sensor L10 Variable geometry control pressure sensor L6 Boost air temperature sensor L4 Boost pressure sensor L3 Engine coolant temperature sensor L7 Control sleeve position sensor l7 Variable geometry solenoid valve l3 EGR control solenoid valve No. 1 l1 GE actuator l5 Throttle solenoid valve l6 Fuel cut solenoid valve Vacuum pump Alternator To variable geometry actuator l2 Timing control valve Catalytic converter Variable geometry actuator Variable geometry turbocharger Throttle actuator EGR valve To variable geometry solenoid valve L1 Pump speed sensor L5 Fuel temperature sensor l4 EGR control solenoid valve No. 2

DIESEL FUEL <4D5-step III>- Service Specifications/Sealant 13E-4 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 ) it kΩ When the temperature is 20_C 2.3 - 3.0 sensor) resistance kΩ When the temperature is 80_C 0.30 - 0.42 Engine coolant temperature sensor resistance kΩ When the temperature is 20_C 2.1 - 2.7 When the temperature is 80_C 0.26 - 0.36 Fuel cut solenoid valve resistance Ω 6.8 - 9.2 Timing control valve resistance Ω 10.8 - 11.2 Timer piston position sensor resistance Ω Connector terminals No. 1 - No. 2 160 - 168 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 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 Connector terminals No. 7 - No. 11 1.4 - 2.6 Pump speed sensor resistance kΩ 1.36 - 1.84 Throttle solenoid valve resistance Ω 36 - 44 SEALANT Item Specified sealant Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent

DIESEL FUEL <4D5-step III>- Special Tools 13E-5 SPECIAL TOOLS Tools Number Name Application MB991502 MUT-II sub assembly Electronically controlled fuel injection system check MB991529 Diagnosis code check harness Diagnosis code reading MB991348 Test harness set D Boost pressure sensor check D Variable geometry control pressure sensor check MB991658 Test harness set D APS adjustment 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

DIESEL FUEL <4D5-step III>- Troubleshooting 13E-6 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 in the item related to electronically controlled fuel injection system shown in the following table. If the malfunction indicator lamp has been on and/or is lit when the engine is in operation, check the diagnosis output. Engine warning lamp check items Accelerator pedal position sensor (main) Accelerator pedal position sensor (sub) 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 MUT -II DATA LIST AND ACTUATOR TESTING 1. Carry out inspection by means of the data list and the actuator test function. If there is an abnormality, check and repair the chassis harnesses and components. 2. After repairing, re-check using MUT-II and check that the abnormal input and output have returned to normal as a result of the repairs. 3. Erase the diagnosis code memory. 4. Remove the MUT-II. 5. Start the engine again and carry out a road test to confirm that the problem has disappeared. Engine warning lamp (check engine lamp)

DIESEL FUEL <4D5-step III>- Troubleshooting 13E-7 FAIL-SAFE, BACKUP FUNCTIONS When abnormalities in the major sensors are detected by diagnosis functions, pre-set control logic operates to maintain a safe driving condition for the vehicle. Diagnosis item Control features in malfunction Accelerator pedal position sensor D Accelerator pedal released (idle switch ON) Acceleration opening degree = 0 % D Accelerator pedal applied (idle switch OFF) Engine controlled at low speed Acceleration opening degree = 30 % fixed D Void EGR control Idle switch Void idling speed control. Engine speed sensor D Engine controlled at low speed D Void EGR control D Void variable geometry turbocharger control Boost air temperature sensor D Maintain the intake air temperature at 50_C. D Void EGR control Vehicle speed sensor D Void idling speed control. D Void EGR control Engine coolant temperature sensor D Maintain the engine coolant temperature at 80_C (However, the system assumes the coolant temperature as 0_C). 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 control D Void variable geometry turbocharger control Fuel temperature sensor Maintain the fuel temperature at 40_C. Boost pressure sensor D Keep the boost pressure as barometric pressure (101 kPa). D Void EGR control D Void variable geometry turbocharger control Injection volume adjusting ROM Void correction. GE actuator D Engine controlled at low speed D Void EGR control D Void variable geometry turbocharger control Over boost D Void variable geometry turbocharger control D Engine controlled at low fuel injection Timing control valve D Injection timing stabilizing control D Void EGR control EGR valve position sensor Void EGR control Variable geometry control pressure sensor D Void EGR control D Void variable geometry turbocharger control

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

DIESEL FUEL <4D5-step III>- Troubleshooting 13E-9 INSPECTION PROCEDURE FOR DIAGNOSIS CODE Code No. 11 Accelerator pedal position sensor (main) system Probable cause Range of Check D Ignition switch: ON, accelerator pedal position sensor (sub) operative, except for during engine cranking Set Conditions D Accelerator pedal position sensor output voltage is as below for 1 second: Sub side: 0.2 V or more, less than 2.5 V Main side: 4.5 V or more or Sub or main side: less than 0.2 V Range of Check D Ignition switch: ON, except for during engine cranking Set Conditions D The output voltage of accelerator pedal position sensor (main and sub) for 0.2 second is 0.2 V or higher, or lower than 4.5 V and the difference in sensor output voltage between the main and sub is 1 V or higher, or idle switch: ON, and sensor 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 NG OK OK Measure at D-135 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: D-113 NG Repair OK OK Repair NG Accelerator pedal position sensor check (Refer to P.13E-57.) Replace Check the trouble symptoms. Replace the engine-ECU. NG Check the trouble symptoms. NG Replace the engine-ECU. NG Repair Check the following connectors: D-113, D-135 OK NG NG Check the following connector: D-113 NG Repair OK Check the harness between the engine-ECU and the accelerator pedal position sensor connector. OK Measure at D-113 engine-ECU connector D Connect the connector. D Voltage between 84 and the earth (Ignition switch: ON) OK: 0.9 - 1.1 V (Throttle lever idling position) 4.1 V or higher (Throttle lever fully opened position) Check the harness between the engine-ECU and the accelerator pedal position sensor connector. NG Repair NG NG NG NG NG Check the trouble symptoms. OK Replace the engine-ECU.

1999-2006 Mitsubishi Pajero NM Service & Repair Manual

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