Pajero 2001
Pajero 2001
00
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 11
WORKSHOP Engine Lubrication . . . . . . . . . . . . . 12
MANUAL Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Cooling . . . . . . . . . . . . . . . . 14
SUPPLEMENT
Intake and Exhaust . . . . . . . . . . . . . 15
FOREWORD Engine Electrical . . . . . . . . . . . . . . . 16
Engine and Emission Control . . . 17
This manual outlines changes in servicing
procedures related to the chassis including Interior and Supplemental
vehicle inspections and adjustments in the Restraint System (SRS) . . . . . . . . 52
newly added models. Use the following
manuals in combination with this manual as Chassis Electrical . . . . . . . . . . . . . . 54
required.
<4-DOOR MODELS>
Model code Engine model Transmission model Fuel supply system
CHASSIS NUMBER
The chassis number is stamped on the side wall of the frame
near the right rear wheel.
1 2 3 4 5 6 7 8 9 10 11
11 Serial number - -
NOTE
*: Indicates changes.
5 8 4 9 6
1
Items V24W
NDGL6Y GNDGL6Y
Vehicle Overall length 1 4,075
di
dimensions
i
Overall width 2 1,695 1,785
mm
Overall height (unladen) 3 1,835 1,845
Wheelbase 4 2,420
Track-front 5 1,420 1,465
Track-rear 6 1,435 1,480
Ground clearance 7 205 215
(unladen)
Overhang-front 8 675
Overhang-rear 9 980
Vehicle Kerb weight 1,700 1,755
weight
i ht kg
k
Max. gross vehicle weight 2,510
Max. axle weight rating-front 1,070
Max. axle weight rating-rear 1,750
Seating capacity 5
Engine
g Model No. 4D56 Intercooler Turbocharger
Total displacement mL 2,477
Transmis- Model No. V5MT1
sion
i
Type 5-speed manual
Fuel system Fuel supply system Injection
4-DOOR MODELS
7
5 8 4 9
6
1
Items V44W
NDGL6Y GNDGL6Y
Vehicle Overall length 1 4,655
di
dimensions
i
Overall width 2 1,695 1,775
mm
Overall height (unladen) 3 1,890 1,900
Wheelbase 4 2,725
Track-front 5 1,420 1,465
Track-rear 6 1,435 1,480
Ground clearance 7 205 215
(unladen)
Overhang-front 8 650
Overhang-rear 9 1,280
Vehicle Kerb weight 1,875 1,930
weight
i ht kg
k
Max. gross vehicle weight 2,750
Max. axle weight rating-front 1,090
Max. axle weight rating-rear 1,780
Seating capacity 7
Engine
g Model No. 4D56 Intercooler Turbocharger
Total displacement mL 2,477
Transmis- Model No. V5MT1
sion
i
Type 5-speed manual
Fuel system Fuel supply system Injection
Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)
Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)
NO TE
1. Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
2. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the
greater the bolt strength.
ENGINE
CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
Items 4D56
Compression ratio 21
Exhaust 4
SERVICE SPECIFICATIONS
Items Standard value
Timing belt tension mm 4-5
Timing belt B tension mm 4-5
Idle speed r/min 750 ± 30
SPECIAL TOOLS
Tools Number Name Use
MD998727 Oil pan remover Removal of oil pan
MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt
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.
12
15
4 mm
(0.16 in.) 19 ± 3 N·m
diameter 14
Groove Hole of bolt
4
Sealant:
MITSUBISHI GENUINE Part No.
MD997110 or equivalent
9.0 ± 1.0 N·m 12 ± 1 N·m
8 9
7
(Engine oil)
12
7.0 ± 1.0
5 N·m
6
11
39 ± 5 N·m 10
35 ± 6 N·m
1
9.0 ± 1.0 N·m
13
110 ± 10 N·m
Removal steps
1. Vacuum hose connection 8. Oil level sensor connector
2. Bolt 9. Oil level sensor
3. Front suspension crossmember 10. Space rubber
4. Engine oil level gauge and guide 11. Bell housing cover
assembly AA" "AA. 12. Oil pan
5. Drain plug 13. Oil pan cover
"BA 6. Drain plug gasket 14. Oil screen
7. Alternator vacuum pump oil return 15. Oil screen gasket
hose connection
6
26 ± 3 N·m 8 9
1 7
26 ± 3 N·m
11 ± 1 N·m
5
(Engine oil) 4
18
3
26 ± 3 N·m
11 ± 1 N·m
17
177 ± 9 N·m 16
13 15 26 ± 3 N·m
12
26 ± 3 N·m 11 14 2
10
9.0 ± 1.0 N·m
Removal steps
"CA 1. Timing belt front upper cover 9. Timing belt tensioner
2. Tension pulley and tension pulley 10. Crank angle sensor
bracket assembly 11. Crankshaft sensing blade
3. Crankshaft pulley (for power steer- 12. Crankshaft sprocket
ing and A/C) 13. Flange
AA" "DA 4. Crankshaft pulley AC" "AA 14. Timing belt B
"CA 5. Timing belt front lower cover 15. Gasket
AB" "BA 6. Timing belt 16. Tensioner spacer B
7. Tensioner spacer 17. Tensioner spring B
8. Tensioner spring 18. Timing belt tensioner B
MD998721
Belt deflection
Crankshaft
sprocket B
Tension
side
Amount of belt 9. Press on the center of the bolt with an index finger to check
deflection the amount of deflection.
Standard value: 4 - 5 mm
C B 6×50
C 6×60
d=Nominal diameter
l=Nominal length
A
A
13 ± 2 N·m
8 5.9 ± 1.0 N·m
6
7
13
14
4
10 mm 10 mm 1
24 ± 4 N·m
10
15
11
Sealant:
3M ATD Part No. 8660 or
equivalent
Removal steps
1. Engine coolant temperature switch 8.
Boost sensor and bracket assembly
connector (for A/C) 9.
Vacuum hose and pipe assembly
2. Engine coolant temperature gauge 10.
Rocker cover
unit and sensor connector 11.
Semi-circular packing
3. Glow plug terminal AC" 12.
Power steering oil pump assembly
AA" "DA 4. Radiator upper hose 13.
Power steering oil pump bracket
AB" "CA 5. Fuel injection pipe bolt
6. Heater hose or water by-pass hose AD" "BA 14. Cylinder head assembly
connection "AA 15. Cylinder head gasket
7. Fuel hose connection
MD998051
Front
B Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
C Therefore, 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.)
MD998051
17 13 9 5 1 3 7 11 15
14 10 6 4 12
18 2 8 16
Front of engine
Front of engine
GROUP 12
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
Engine oil quantity L Oil filter 0.8
Total 7.5
FUEL
CONTENTS
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.
Vacuum pump
l5 Throttle solenoid valve
l3 l7
EGR control Variable geometry Alternator
solenoid valve No. 1 solenoid valve
Throttle
actuator
To variable
geometry actuator L7 Control
Boost air sleeve
L6 l4 EGR control L4 Boost pressure
temperature sensor solenoid position L5 Fuel
sensor
valve No. 2 sensor temperature
L3 Engine coolant sensor
temperature sensor
L9 EGR L1 Pump speed
valve position l6 Fuel cut sensor
sensor solenoid
valve
EGR valve
Variable geometry
turbocharger
l1 GE actuator
L10 Variable geometry control
pressure sensor L8 Timer piston
To variable geome- l2 Timing control position
Variable try solenoid valve valve sensor
L2 Crank angle
geometry sensor
actuator
Catalytic converter
SEALANT
Item Specified sealant
Engine coolant temperature sensor 3M Nut Locking Part No. 4177 or equivalent
SPECIAL TOOL
Tool Number Name Use
MB991502 MUT-II sub Electronically controlled fuel in-
assembly jection system check
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
Engine warning lamp
(check engine lamp)
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.
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)
NG
Accelerator pedal position sensor check Replace
(Refer to P.13-59.)
OK
NG NG
Measure at C-134 accelerator pedal position Check the following connector: C-43 Repair
sensor connector OK
D Disconnect the connector and measure
at the harness side. Check the trouble symptoms.
D Voltage between 2 and earth NG
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V Check the harness between the Repair
D Continuity between 1 and earth engine-ECU and the accelerator pedal
OK: Continuity position sensor connector.
OK
OK
Replace the engine-ECU.
NG NG
Measure at C-43 engine-ECU connector Check the following connectors: Repair
D Connect the connector. C-43, C-134
D Voltage between 84 and the earth OK
(Ignition switch: ON)
OK: 0.9 - 1.1 V Check the trouble symptoms.
(Throttle lever idling position) NG
4.1 V or higher
(Throttle lever fully opened position) Replace the engine-ECU.
OK
NG
Check the following connector: C-43 Repair
OK
NG
Check the harness between the Repair
engine-ECU and the accelerator pedal
position sensor connector.
OK
NG NG
Measure at A-129 boost pressure Measure at A-129 boost pressure Checkthefollowing connector:C-130
sensor connector sensor connector
OK NG
D Connect the connector. D Disconnect the connector and Repair
(Test harness: MB991348 used) measure at the harness side.
D Voltage between 1 and the earth D Voltage between 3 and the earth Check the trouble symptoms.
(Engine: Idling) (Ignition switch: ON)
OK: 1.3 - 1.7 V OK: 4.5 - 5.5 V NG
D Voltage between 1 and the earth D Continuity between 2 and the
OK: When the accelerator pedal earth Check the harness between the
is suddenly pressed from OK: Continuity engine-ECU and the boost pressure
the idling condition, the OK sensor connector.
voltage temporarily in-
creases from 1.3 V to 1.7 OK NG
NG Repair
V. Check the following connector: Repair
A-129
OK Replace the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Fuel temperature sensor check (Refer to Replace the injection pump.
P.13-62.)
OK
NG NG
Measure at A-131 fuel temperature sensor Check the following connectors: Repair
connector C-43, C-130
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 11 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
Check the harness between the
D Continuity between 7 and the earth Repair
engine-ECU and the fuel temperature
OK: Continuity
sensor connector.
OK
OK
Check the following connector: A-131 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Engine coolant temperature sensor check Replace
(Refer to P.13-60.)
OK
NG NG
Measure at A-113 engine coolant temperature Check the following connectors: Repair
sensor connector C-43, C-130
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.1 - 4.9 V NG
D Continuity between 2 and the earth Check the harness between the Repair
OK: Continuity engine-ECU and the engine coolant
temperature sensor connector.
OK
OK
Check the following connector: A-113 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
Code No. 16 Boost air temperature sensor (intake air Probable cause
sensor) system
Range of Check D Boost air temperature sensor inoperative
D Ignition switch: ON, except for during engine cranking D Boost air temperature sensor open circuit, short
Set Conditions circuit, or connector contact inoperative
D The sensor output voltage for 3 seconds is 4.6 V or higher (the intake air D Engine-ECU inoperative
temperature is approximately - 45_C or lower).
or
D The sensor output voltage for 3 seconds is 0.3 V or lower (the intake air
temperature is approximately 110_C or higher).
NG
Boost air temperature sensor check Replace
(Refer to P.13-60.)
OK
NG NG
Measure at C-136 boost air temperature Check the following connectors: Repair
connector C-43, C-130
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.0 - 5.3 V NG
D Continuity between 2 and the earth
OK: Continuity NG
Check the harness between the Repair
OK engine-ECU and the boost air temperature
sensor connector.
OK
NG
Check the vehicle speed sensor. (Refer to GROUP54-Combination Replace
Meters.)
OK
1. NG NG
Measure at combination meter connector C-05, C-06. Check the following Repair
D Disconnect the connector and measure at the harness side. connector:
1. Voltage between 1 and earth (Ignition switch: ON) C- 75, C-24, C-43
OK: 4.8 - 5.2 V 2. NG OK
2. Continuity between 43 and earth
OK: Continuity Check trouble symptoms.
OK NG
NG NG
Check the following Repair Check the harness wire Repair
connectors: between theengine-ECU
C-05, C-06 and the combination me-
ter connector.
OK
OK
Check trouble symptom.
Replace the engine-ECU.
NG
NG
Check the harness wire Repair
between the engine-ECU Check the harness wire between the combination meter and the
and the combination meter earth, and repair if necessary.
connector.
OK
NG
Pump speed sensor check (Refer to Replace the injection pump.
P.13-63.)
OK
NG NG
Measure at engine-ECU connector C-130. Check the following connector: Repair
D Connect the connector. A-133, C-130
D Voltage between 51 - 61.
(Engine: idling and then raced) OK
OK: Voltage increases from the voltage
when engine is idling Check the trouble symptoms.
OK NG
NG (1) NG
Measure at crank angle sensor Measure at crank angle sensor Check the following connector:
connector A-112 connector A-112. C-126
D Connect the connector. D Disconnect the connector and
OK NG
(Test harness: MB998478 used) measure at the harness side.
D Voltage between 2 (black clip) (1) Voltage between 3 and the earth Repair
and the earth (Ignition switch: ON) Check the trouble symptoms.
OK: 0.4 - 4.0 V OK: System voltage
(Engine: cranking) (2) Continuity between 2 and the NG
1.5 - 2.5 V earth (Ignition switch: ON) (2) NG
(Engine: idling) OK: 4.6 - 5.4 V Check the harness between the
(3) Continuity between 1 and the crank angle sensor and the engine
OK earth control relay, and repair if necessary.
OK: Continuity
Check the following connector:
Replace the engine-ECU. (3) NG C-43
OK NG
OK Repair
Check the following connector: Check the trouble symptoms.
A-112
NG
OK NG
Repair Check the harness between the
engine-ECU and the crank angle
Check the trouble symptoms. sensor.
NG OK NG
Replace the crank angle sensor. Repair
Replace the engine-ECU.
NG
Idle switch check (Refer to P.13-59.) Replace
OK
NG NG
Measure at C-134 accelerator pedal position Check the following connectors: Repair
sensor connector C-24, C-42
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 4 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 5 and the earth NG
OK: Continuity Check the harness between the Repair
engine-ECU and the accelerator pedal
OK position sensor connector.
Check the following connector: C-134 OK
OK NG Replace the engine-ECU.
Repair
Check the trouble symptoms.
NG
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
NG
Timer piston position sensor check Replace injection pump assembly.
(Refer to P.13-63.)
OK
NG NG
Check the following connector: A-132 Check the following connector: C-43 Repair
OK OK
NG
MUT-II Data list Replace the engine-ECU.
19 Injection timing (command value)
(Refer to P.13-43.)
OK
OK
MUT-II Data list Replace the engine-ECU.
18 Actual injection timing (Refer to P.13-43.)
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
NG
Control sleeve position sensor check (Refer Replace injection pump assembly.
to P.13-62.)
OK
NG NG
Check the following connector: A-131 Check the following connector: C-43 Repair
OK OK
NG
Accelerator pedal position sensor check Replace
(Refer to P.13-59.)
OK
NG NG
Measure at C-134 accelerator pedal position Check the following connector: Repair
sensor connector C-24
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 8 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 7 and the earth NG
Check the harness between the Repair
OK: Continuity
engine-ECU and the accelerator pedal
OK position sensor connector.
OK
NG
Check the following connector: C-134 Repair
OK
Check the trouble symptoms.
NG
NG
Throttle solenoid valve check Replace
(Refer to P.13-63.)
OK
NG
Throttle actuator check Replace
(Refer to P.13-64)
OK
NG NG
Measure at A-128 throttle solenoid valve Check the following connector: C-126 Repair
connector OK
D Disconnect the connector and measure at
the harness side. Check the trouble symptoms.
D Voltage between 2 and the earth
(Ignition switch: ON) NG
OK: System voltage
Check and repair the harness between the
OK control relay and the solenoid valve
connector.
NG NG
Measure at C-41 engine-ECU connector Check the following connectors: Repair
D Disconnect the connector and measure at A-128, C-126
the harness side.
D Voltage between 14 and the earth OK
(Ignition switch: ON)
OK: System voltage Check the trouble symptoms.
OK NG
NG
Timing control valve check Replace injection pump assembly.
(Refer to P.13-62.)
OK
NG NG
Measure at A-131 injection pump assembly Check the following connector: C-126 Repair
connector. OK
D Disconnect the connector and measure at
the harness side. Check the trouble symptoms.
D Voltage between 5 and the earth
(Ignition switch: ON) NG
OK: System voltage
Check and repair the harness between the
OK control relay and the injection pump
assembly connector.
NG NG
Measure at C-41 engine-ECU connector. Check the following connector: A-131 Repair
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 3 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
OK: 11 V or higher NG
OK
Check and repair the harness between the
engine-ECU and the injection pump
assembly connector.
NG
Check the following connector: C-41 Repair
OK
NG
Fuel system blockage check Replace
D Fuel filter blocked
D Fuel hose blocked or bent
D Fuel tank filter blocked
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NG NG
Measure at A-134 injection volume adjusting Check the following connector: C-130 Repair
ROM connector.
OK
D Disconnect the connector and measure at
the harness side.
Check the trouble symptoms.
D Voltage between 3 and the earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
D Continuity between 4 and the earth Check the harness between the Repair
OK: Continuity engine-ECU and the injection volume
adjusting ROM connector.
OK
OK
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 circuit, or connector contact inoperative
D Engine-ECU inoperative
NG
GE actuator check (Refer to P.13-62.) Replace injection pump assembly.
OK
NG NG
Measure at A-131 injection pump assembly Check the following connector: C-126 Repair
connector.
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 6 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: System voltage
OK Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG NG
Measure at C-41 engine-ECU connector Check the following connector: A-131 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 9 V or higher NG
OK Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG
Check the following connector: C-41 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Variable geometry actuator check (Refer to Replace
GROUP 15 - On-vehicle Service.)
OK
NG
Variable geometry solenoid valve check Replace
(Refer to GROUP 15 - On-vehicle Service.)
OK
NG
Measure at A-127 variable geometry solenoid Check and repair the harness between the
valve connector control relay and the solenoid valve
D Disconnect the connector and measure at connector.
the harness side.
D Voltage between 2 and earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at C-41 engine-ECU connector Check the following connector: A-127 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 17 and earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
NG
Check the following connector: C-41 Repair
OK
YES
Connect a boost gauge to the boost Replace the turbocharger assembly.
pressure sensor hose. When the vehicle is
driven at 1st gear with full throttle, does
boost pressure exceed 133 kPa
momentarily?
NO
NG
NG
EGR valve position sensor check Replace
(Refer to P.13-61.)
OK
NG NG
Measure at A-135 EGR valve position sensor Check the following connector: C-130 Repair
connector.
OK
D Disconnect the connector and measure at
the harness side.
Check the trouble symptoms.
D Voltage between 2 and earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
D Continuity between 3 and earth Check the harness between the Repair
OK: Continuity engine-ECU and the EGR valve position
sensor connector.
OK
OK
NG NG
Measure at A-130 variable geometry Measure at A-130 variable geometry Check the following connector:
control pressure sensor connector. control pressure sensor connector C-130
D Connect the connector. D Disconnect the connector, and OK NG
(Use the test harness: measure at the harness side. Repair
MB991348) D Voltage between 3 and earth Check the trouble symptoms.
D Voltage between 1 and earth (Ignition switch: ON)
(Ignition switch: ON) OK: 4.8 - 5.2 V NG
OK: Altitude 0 m: 3.7 - 4.3 V D Continuity between 2 and earth
Check the harness between the
Altitude 1,200 m: 3.2 - 3.8 OK: Continuity
engine-ECU and the variable
V
OK geometry control pressure sensor
OK: 0.5 - 1.2 V when 80 kPa
connector.
of negative pressure is ap-
plied to the sensor OK NG
Repair
OK
Replace the engine-ECU.
NG
Check the following connector: Repair
A-130
OK
NG
Check the trouble symptoms. Check the harness between the
engine-ECU and the variable
NG geometry control pressure sensor
Measure at C-42 engine-ECU Check the following connector: connector.
connector A-130
D Connect the connector. OK NG
OK NG Repair
D Voltage between 45 and earth.
Repair
(Ignition switch: ON) Check the vacuum hose and pipe
OK: Altitude 0 m: 3.7 - 4.3 V Check the trouble symptoms. between the variable geometry
Altitude 1,200 m: 3.2 - 3.8 control pressure sensor and
NG
V alternator.
OK: 0.5 - 1.2 V when 80 kPa Check the harness between the OK NG
of negative pressure is ap- engine-ECU and the variable Repair
plied to the sensor geometry control pressure sensor Replace the variable geometry
OK connector, if necessary. control pressure sensor.
NG
Check the following connector:
Repair
C-42
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NOTE
(1) If the ignition switches are close each other when starting the engine, radio interference may cause
this code to be displayed.
(2) This code may be displayed when registering the key encrypted code.
Yes
Is there another ignition key near the ignition key that is inserted Remove the extra ignition key
in the ignition switch?
No NG
Check the trouble symptoms.
OK
Check the harness between the engine-ECU and immobilizer-ECU. Replace the engine-ECU and immobilizer-ECU.
NG
Repair
Engine warning lamp Immediately after the ignition switch is “ON”, the engine 3 13-31
related warning lamp does not turn on.
The engine warning lamp keeps on and does not turn off. 4 13-31
Idling stability Low idling speed when the engine is cold (improper idling 8 13-33
(idling inoperative) speed)
Idling stability The engine halts after running for a while. 12 13-34
(idling sustainment in-
in
operative) The engine halts during idling. 13 13-35
NG NG
Measure at C-113 diagnosis Check the following connectors: Repair
connector. C-108, C-103, A-19X, C-101
D Voltage between 16 and the
earth OK
OK: System voltage
Check the trouble symptoms.
OK NG
NG
Measure at C-113 diagnosis Check and repair the earth line.
connector.
D Continuity between 4 and the
earth
D Continuity between 5 and the
earth
OK: Continuity
OK
Replace MUT-II.
INSPECTION PROCEDURE 2
No communication can be established between MUT-II Probable cause
and the engine-ECU.
Probable causes are shown in the following: D The power supply circuit of the engine-ECU
D The power is not supplied to the engine-ECU. inoperative
D The earth circuit of the engine-ECU inoperative D Engine-ECU inoperative
D The engine-ECU inoperative D Open circuit at the harness between the
D Communication between the engine-ECU and MUT-II inoperative engine-ECU and the diagnosis connector
NG
Check the following connectors: C-75, C-24, C-130 Repair
OK
NG
MUT-II Data list The engine-ECU power supply and
11 Engine-ECU power supply voltage the earth circuit check (Refer to
(Refer to P.13-43.) P.13-39, Inspection procedure 21.)
OK
OK NG
Measure at C-41 engine-ECU Check the following connector: Repair
connector. C-41
D Disconnect the connector and OK
measure at the harness side.
D Short circuit between 8 and the Check the trouble symptoms.
earth (Ignition switch: ON)
OK: The engine warning lamp turns NG
on.
NG Replace the engine-ECU.
INSPECTION PROCEDURE 4
The engine warning lamp keeps on and does not turn Probable cause
off.
The probable causes can be found in either the engine-ECU detecting the D Short circuit at the harness between the engine
malfunction in the sensor and/or the actuator, or the problem shown in the right warning lamp and the engine-ECU
takes place. D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
NG
Measure at C-12 combination meter connector. Check and repair the harness between the combination meter
D Disconnect the connector and measure at the harness and the engine-ECU connector.
side.
D Disconnect the engine-ECU connector C-41.
D Continuity between 55 and the earth
OK: No continuity
OK
NG
Check the following connector: C-24 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
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
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Check the following items in order:
(Refer to P.13-42, 46.) D Glow plug, glow plug relay
D Battery
NG D Injection nozzle
D Throttle body assembly
Repair D Injection pump
D Compression pressure
D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 6
Starting performance is bad when the engine is cold Probable cause
(unable to start)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Glow plug, glow plug relay
D Injection nozzle, fuel filter
NG D Throttle body assembly
D Existence of starter switch signal input
Repair D Engine oil
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D Compression pressure
D Injection pump
Repair D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 8
Low idling speed when the engine is cold (improper Probable cause
idling speed)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel system. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection pump
D Fuel filter
NG
Repair
INSPECTION PROCEDURE 9
High idling speed (improper idling speed) Probable cause
Probable causes can be found in troubles with control system and injection D Control system inoperative
pump. D Injection pump inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection pump
D Starter switch signal
NG
Repair
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
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection nozzle
D Injection pump
NG
Repair
INSPECTION PROCEDURE 11
Idling instable (rough idling, hunting) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, glow system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Glow plug, glow plug relay
D EGR system
NG D Injection nozzle
D Compression pressure
Repair D Valve clearance
D Throttle body assembly
D Injection timing
D Fuel line bleeding
D Injection pump
INSPECTION PROCEDURE 12
The engine stalls after running for a while. Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and intake system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Throttle body assembly
D Fuel filter
NG D Injection pump
Repair
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Power supply system
D Throttle body assembly
NG D EGR system
D Injection pump
Repair
INSPECTION PROCEDURE 14
Lack of output power 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
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D EGR system
D Turbocharger
Repair D Compression pressure
D Injection timing
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 15
Occurrence of abnormal knocking Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection nozzle
D Injection timing
NG
D EGR system
D Injection pump
Repair
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
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Air cleaner
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
INSPECTION PROCEDURE 17
Abnormal white smoke Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, EGR system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Glow plug, glow plug relay
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
INSPECTION PROCEDURE 18
Hunting during driving Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel system. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13-9.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13-42, 46.) D Injection nozzle
D Injection pump
NG
Repair
NG
Measure at engine-ECU connector C-41. A/C condenser fan motor circuit check
D Disconnect the connector and measure at the harness (Refer to the wiring harness configuration diagram.)
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
OK
NG
Check the following connector: C-41 Repair
OK
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
NG
Measure at C-41 engine-ECU connector Intercooler fan circuit check
D Disconnect the connector and measure at the harness (Refer to the wiring harness configuration diagram.)
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
OK
NG
Check the following connector: C-41 Repair
OK
(1) NG NG
Measure at C-41, C-42, C-43 Check the following connectors: Repair
engine-ECU connectors. C-26, C-61
D Disconnect the connector and
(2), (3) NG OK
measure at the harness side.
(1) Voltage between 82 and the
earth (Ignition switch: ON) Check the trouble symptoms.
OK: System voltage NG
(2) Voltage between 46 and the NG
earth Check the harness between the Repair
OK: System voltage engine-ECU and the ignition switch.
(3) Voltage between 12, 25 and the (4) NG
OK
earth (Ignition switch: ON)
OK: System voltage
Ignition switch check
(When terminal 46 is short
circuited to the earth) (5) NG
(4) Continuity between 13, 26 and NG
Check the following connectors: Repair
the earth
C-126
OK: Continuity
(5) Voltage 80 and the earth OK
OK: System voltage NG
OK Check the trouble symptoms. Check and repair the harness
between the engine-ECU and the
control relay connector.
Check the following connectors:
Check and repair the harness
C-41, C-42, C-43
between the engine-ECU and the
OK NG earth.
Repair NG
Check the following connectors: Repair
Check the trouble symptoms. C-24, C-110, C-103, A-19X, C-101
NG OK
NG
Replace the engine-ECU. Check the trouble symptoms. Check and repair the harness
between the engine-ECU and the
battery.
INSPECTION PROCEDURE 22
Fuel cut solenoid valve circuit inspection
NG
Fuel cut solenoid valve check Replace the injection pump.
(Refer to P.13-61.)
OK
NG NG
Measure at fuel injection pump Check the following connector: Repair
assembly connector A-131. C-41
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK NG
Check the harness between the Repair
engine-ECU and the fuel cut
Check the fuel injection pump solenoid valve connector.
assembly connector A-131, and OK
repair if necessary.
Replace the engine-ECU.
INSPECTION PROCEDURE 23
EGR control solenoid valve No. 1 circuit inspection
NG
EGR control solenoid valve No. 1 Replace
check (Refer to GROUP 17 -
Service Adjustment Procedures.)
OK
NG
Measure at EGR control solenoid Check the harness between the
valve No. 1 connector A-89. control relay and the EGR control
D Disconnect the connector and solenoid valve No. 1 connector, and
measure at the harness side. repair if necessary.
D Voltage between 1 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-41. A-89
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 9 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK
Check the harness between the
Check the following connector: engine-ECU and the EGR control
C-41 solenoid valve No. 1 connector, and
repair if necessary.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
INSPECTION PROCEDURE 24
EGR control solenoid valve No. 2 circuit inspection
NG
EGR control solenoid valve No. 2 Replace
check (Refer to GROUP 17 -
Service Adjustment Procedures.)
OK
NG
Measure at EGR control solenoid Check the harness between the
valve No. 2 connector A-90. control relay and the EGR control
D Disconnect the connector and solenoid valve No. 2 connector, and
measure at the harness side. repair if necessary.
D Voltage between 1 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
C-41. A-90
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 5 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK
Check the harness between the
Check the following connector: engine-ECU and the EGR control
C-41 solenoid valve No. 2 connector, and
repair if necessary.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Glow plug relay check. (Refer to Replace
GROUP 16 - Glow System.)
OK
NG NG
Measure at glow plug relay Check the following connector: Repair
connector A-101. C-41
D Disconnect the connector and
OK
measure at the harness side.
D Voltage between 1 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
(Engine coolant temperature: NG
40_C or lower) NG
OK: System voltage (for 1 - 8 sec- Check the harness between the Repair
onds after ignition switch is engine-ECU and the glow plug relay
turned to ON) connector.
OK OK
Check glow plug relay connector Replace the engine-ECU.
A-101, and repair if necessary.
INSPECTION PROCEDURE 26
A/C switch and A/C relay inspection
OK NG
Measure at engine-ECU connector Check the following connectors: Repair
C-41 or C-42. C-41, C-42
D Disconnect the connector and
OK
measure at the harness side.
D Voltage between 21 and 32 and
Check the trouble symptoms.
the earth (Ignition switch: ON)
OK: 0 - 3 V (A/C switch: OFF) OK
System voltage (A/C
switch: ON) Replace the engine-ECU.
D Short out 21 and the earth
(Ignition switch: ON)
(A/C switch: ON)
OK: A/C compressor clutch
turns on
NG
31 EGR valve Engine: After warming Idling under no load 2.3 - 3.3 V Code No. 13-26
position up the engine 51
sensor (tar- Engine is suddenly Momentarily
get value) raced decreases
(0.3 - 0.7 V)
32 EGR valve Engine: After warming Idling under no load 2.3 - 3.3 V Code No. 13-26
position up the engine 51
sensor (ac- Engine is suddenly Momentarily
tual value) raced decreases
(0.3 - 0.7 V)
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.
02 Glow plug relay Turning the Ignition switch: Battery charge is Procedure 13-41
relay from ON energized to the glow No 25
No.
OFF to ON or plug when the glow
from ON to plug relay is ON.
ON
OFF
03 A/C compressor Turning the Ignition switch: The A/C compressor Procedure 13-41
relay relay from ON clutch makes an No 26
No.
OFF to ON or audible sound.
from ON to
OFF
11 Timing control Turn the D Ignition Makes an audible Code No. 13-22
valve timing control switch: ON sound 43
valve to ON D Engine:
Idling
12 Turn the D Timer piston
timing control position
valve to OFF sensor:
Normal
15 Glow lamp Turn the glow Ignition switch: The glow lamp turns – –
lamp on or off ON on.
16 Warning lamp Turn the Ignition switch: The warning lamp Procedure 13-31
warning lamp ON turns on. No. 3, 4
on or off
22 Condenser fan Turning the Ignition switch: The condenser fan Procedure 13-37
relay relay from ON rotates. No. 19
OFF to ON or
from ON to
OFF
23 Throttle solenoid Turn the D Ignition Makes an audible Code No. 13-21
valve solenoid switch: ON sound 41
valve from D Vehicle
OFF to ON or speed:
from ON to 0 km/h
OFF D Engine
speed:
1,000 r/min
or lower
Item Check item Drive Con- Inspection Value to be determined Code No. Reference
No. tents conditions as normal or inspec- page
tion proce-
dure No.
25 GE actuator Turn the GE D Ignition Measure the wave Code No. 13-24
actuator to switch: ON pattern between 48
ON D Engine engine-ECU connec-
speed: tor terminals No. 1
0 r/min or and No. 15 using an
lower analyzer and check
26 Turn the GE
D Control the change in the duty
actuator to
sleeve posi- ratio.
OFF
tion sensor:
Normal
34 Middle position Hold the D Ignition When the crankshaft Code No. 13-24
of GE actuator injection switch: ON is turned clockwise 48
governor in during the adjustment
its middle of the injection timing,
position. the injection pipes
spray out fuel.
35 Variable Turn the Ignition switch: Makes an audible Code No. 13-25
geometry solenoid ON sound 49
solenoid valve valve to ON
37 EGR control Turn the Ignition switch: Makes an audible Procedure 13-40
solenoid valve solenoid ON sound No. 23
No. 1 valve from
OFF to ON
from ON to
OFF
38 EGR control Turn the Ignition switch: Makes an audible Procedure 13-40
solenoid valve solenoid ON sound No. 24
No. 2 valve from
OFF to ON
from ON to
OFF
39 Intercooler fan Turn the Ignition switch: Makes an audible Procedure 13-38
relay solenoid ON sound No. 20
valve from
OFF to ON
from ON to
OFF
26 - Body earth
73 - 75 5.6 - 6.2 Ω
74 - 75 11.2 - 12.4 Ω
76 - 77 80 - 84 Ω
76 - 78 80 - 84 Ω
83 - 61 Engine coolant temperature sensor 5.1 - 6.5 kΩ (when the engine coolant temperature is
0_C)
87 - 61 Fuel temperature sensor 5.1 - 6.5 kΩ (when the fuel temperature is 0_C)
88 - 61 Boost air temperature sensor 5.3 - 6.7 kΩ (when the intake air temperature is 0_C)
Measurement Method
Analyzer
1. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MD998478) in between.
CHI 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.
TIME/DIV. 10 ms
VOLTS/DIV. 2V
AC - GND - DC DC
Other -
1 engine revolution
(V)
T
Crank angle
sensor output ATDC BTDC9_
wave pattern 90_ BTDC35_ ATDC
12_
5
TDC TDC
D Example 2
Cause of problem
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
Measurement Method
Analyzer
1. Disconnect the pump speed sensor connector and
Sensor side connector
connect the special 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.
AC - GND - DC DC
(V)
0.85
- 0.85 T
1 cranking
D Example 2
Cause of problem
Incorrect gap between sensor and sensing gear plate
Wave pattern characteristics
No signal is output even when engine is started, or signal
amplitude is small.
APS
ACCELERATOR PEDAL POSITION SENSOR
(APS) ADJUSTMENT
Caution
(1) APS is properly adjusted in the factory. Therefore,
Connector at APS should not be moved carelessly.
the equipment (2) If the adjustment is not done correctly, carry out
a new adjustment in the following procedure:
Accelerator
pedal
APS
ACCELERATOR PEDAL POSITION SENSOR
(APS) CHECK
1. Disconnect the APS connector.
2. Measure the resistance between APS connector terminal
Connector at the No. 2 [APS (main) power supply] and the terminal No.
equipment 1 [APS (main) earth] as well as the resistance between
terminal No. 8 [APS (sub) power supply] and terminal
No. 7 [APS (sub) earth].
Accelerator Standard value: 3.5 - 6.5 kΩ
pedal
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 Resistance smoothly
slowly. changes in proportion to the
travel of the accelerator
pedal.
4. If the APS is out of the range of the standard value or
the resistance does not change smoothly, replace APS.
NOTE
Make an adjustment on APS after replacement. (Refer
to P.13-58.)
APS
IDLE SWITCH CHECK
1. Disconnect the accelerator pedal position sensor (APS)
connector.
2. Check the continuity between the idle switch connector
Connector at the terminal No. 4 (idle switch) and terminal No. 5 (earth).
equipment Normal condition:
Accelerator pedal Continuity
Accelerator Step on None
pedal
Release Yes
3. Replace APS if it is inoperative.
NOTE
Make an adjustment on APS after replacement.(Refer
to P.13-58.)
Connector at the
GE ACTUATOR (ELECTRONIC GOVERNOR) CHECK
equipment (12 pin) 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
Connector at
TIMER PISTON POSITION SENSOR CHECK
the equipment 1. Disconnect the timer piston position sensor connector.
2. Measure the resistance between the following terminals.
Standard value:
Terminal No. 1 - Terminal No. 2 160 - 168 Ω
Terminal No. 1 - Terminal No. 3 80 - 84 Ω
Terminal No. 2 - Terminal No. 3 80 - 84 Ω
Timer piston position sensor
Battery
Standard value:
Jumper lead Nipple A Normal condition
Connected Open Negative pressure
leaks
Closed Negative pressure
maintained
Disconnected Open Negative pressure
maintained
30 ± 7 N·m
5.0 ± 1.0 N·m
30 ± 7 N·m 12 ± 1 N·m
7
2
4
10 ± 2 N·m
1 (Engine oil)
5
6 23 ± 3 N·m
19 ± 3 N·m
83 ± 5 N·m
Removal steps
1. Fuel injection pump connector AB" 5. Fuel injection pump sprocket
2. Fuel hoses connection 6. Flange
AA" 3. Fuel injection pipe 7. Fuel injection pump
4. Engine oil level gauge guide and
oil level gauge assembly
Nut
Delivery holder
MD998719
Crankshaft position
sensor
10
12 6 8
2
9
12 7
1
10
11
3 10
9
5
5.0 ± 1.0 N·m
10 ± 2 N·m 8
6
4 5
Removal steps
1. Accelerator pedal position sensor 8. Accelerator pedal
2. Accelerator pedal assembly 9. Spring
3. Hysteresis assembly 10. Accelerator arm
4. Push-on spring nut 11. Pedal stopper
5. Bushing 12. Accelerator pedal bracket
6. Spring
7. Accelerator arm and pedal
assembly
COOLING
CONTENTS
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.
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 Performance kJ/h 4D5-Step III 236,500
16
14 ± 1 N·m
15
13
14
11 ± 1 N·m
14 ± 1 N·m
8
22 ± 4 N·m
10 7
11
1
4
3 18 17
5
9 42 ± 7 N·m
12
14 ± 1 N·m
6
2
11 ± 1 N·m
Removal steps
D Injection pipe D Turbocharger heat protector (Refer to
1. Heater hose connection GROUP 15 - Intake and exhaust
2. Water hose manifold, turbocharger.)
D Air cleaner assembly 9. Water hose
3. Water pipe and hose assembly 10. Hose protector
"AA 4. Water hose 11. Water pipe A
5. Water pipe E 12. Gasket
"BA 6. O-ring 13. Water pipe B
"AA 7. Water hose 14. Gasket
8. Hose protector 15. Water hose
D EGR valve, EGR cooler 16. Hose protector
(Refer to GROUP 17.) 17. Water pipe C
18. Water pipe D
INTAKE AND
EXHAUST
CONTENTS
GENERAL
OUTLINE OF CHANGES
With the modification below by additional emission regulation step III compatible 4D5 engine, the service
procedure of the part that is different from previous service procedure has been established.
D The turbocharger has been changed to a Variable Geometry (VG) type.
D A catalytic converter has been added.
D The variable geometry turbocharger can not be disassembled, and must be always replaced as an
assembly.
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.
ON Approximately 80 Approximately 3
kPa kPa
18 ± 2 N·m
7 8 24 ± 4 N·m
3
6
14 ± 1 N·m 2 4
1 4
9 5 18 ± 2 N·m
10 14 ± 1 N·m
4 12
11
13
9.0 ± 1.0 N·m
17
14 20 ± 4 N·m
17 ± 2 N·m
14 ± 1 N·m 11 ± 1 N·m
15 18 ± 2 N·m
19 20
28
16 42 ± 7 N·m
12 ± 1 N·m
14 ± 1 N·m
22 21
42 ± 7 N·m
29
14 ± 1 N·m
27
18 23
30
26
24 25
14 ± 1 N·m 49 ± 10 N·m
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. Water pipe A and water hose
4. Vacuum hose connection assembly
5. Solenoid valve assembly 20. Gasket
6. Air temperature sensor 21. Water pipe B connection
7. Gasket 22. Gasket
8. Air intake fitting 23. VG actuator
9. Gasket 24. Turbocharger lower heat protector
10. Throttle body assembly 25. Front exhaust pipe connection
11. Gasket 26. Gasket
12. Engine hanger 27. Oil return hose connection
13. Turbocharger upper heat protector 28. Exhaust manifold and turbocharger
14. Oil pipe assembly assembly
15. Gasket 29. Intake and exhaust manifold gasket
16. Vacuum hose connection 30. Oil return hose
36
34
35
59 ± 10 N·m
32
31
14 ± 1 N·m
25 ± 4
N·m 35 ± 6 12
15 N·m 8 9
16 49 ± 10 N·m
13 ± 2 N·m
11 14 13
10
49 ± 10 N·m
49 ± 10 N·m 13 ± 2 N·m
13 ± 2 N·m
3
6 4
7
<Short wheelbase>
44 ± 5 N·m
1 13 ± 2
2 3 N·m
6 13 ± 2 N·m
7
5
25 ± 4 N·m
1
<Long wheelbase>
2 44 ± 5 N·m
25 ± 4 N·m
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. The other items are the same as before.
ENGINE AND
EMISSION
CONTROL
CONTENTS
SYSTEM DIAGRAM
Vacuum pump
Accelerator pedal position
EGR solenoid sensor
valve No. 1 (ON-
OFF control)
Crank angle sensor
Boost air temperature sensor
COMPONENT LOCATION
EGR solenoid valve No.1 EGR solenoid valve No.2
EGR valve
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.
Diaphragm
17 ± 2 N·m 6 17 ± 2 N·m
7
5
22 ± 4 N·m
22 ± 4 N·m
10
3
22 ± 4 N·m
1
14
8
2
4
12
15 13
9 17 ± 2 N·m
11
Removal steps
1. EGR valve connector "BA 9. O-ring
2. Vacuum hose connection 10. Water hose connection
3. EGR valve 11. EGR cooler and EGR lower pipe
4. EGR gasket assembly
5. EGR pipe gasket "AA 12. EGR pipe gasket
6. EGR upper pipe 13. EGR lower pipe
"AA 7. EGR pipe gasket "AA 14. EGR pipe gasket
"CA 8. Water pipe and hose assembly 15. EGR cooler
49 ± 10 N·m
1
2
49 ± 4 N·m
Removal steps
1. Catalytic converter
2. Gasket
<Short wheelbase>
<New> <Old>
<Long wheelbase>
<New> <Old>
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.
D The troubleshooting has been changed due to the addition to the 4D56 engine which complies with
emission regulation step III.
IMMOBILIZER SYSTEM
The troubleshooting and the ignition key registration method other than below are the same as before.
Refer to PAJERO ’97 Workshop Manual. (Pub. No. PWJE9086 - H)
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom Inspection pro- Reference
cedure No. page
Communication with MUT-II is not possible. 1 54-1
Encrypted code cannot be registered using the MUT-II. 2 54-2
Engine does not start (Cranking but no initial combustion). 3 54-2
Malfunction of the immobilizer-ECU power source and earth circuit. 4 54-3
NO NG
Can the MUT-II communicate with the Check the following connectors: Repair
engine-ECU? C-24, C-75, C-113, C-130
YES OK
NG
Check trouble symptoms. Check the harness wire between the
engine-ECU and diagnosis connector,
and repair if necessary.
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
C-130 and immobilizer-ECU connector C-24, C-120, C-130
C-120. OK
D Disconnect the connector and NG
measure at the harness side. Check trouble symptoms. Check the harness wire between the
D Continuity between the C-130 engine-ECU and immobilizer-ECU, and
terminal No. 52 and C-120 terminal repair if necessary.
No. 5
OK: Continuity
OK Check the harness between the
NG immobilizer-ECU power circuit and the
Check trouble symptoms.
earth circuit. (Refer to P.54-3,
Inspection Procedure 4.)
OK
NG
Check trouble symptoms. Replace the immobilizer-ECU.
NO
No ignition key can be registered. Replace the ignition key that cannot be Re-register the encrypted code.
registered.
YES
YES
Is a diagnosis code displayed? To INSPECTION CHART FOR DIAG-
NOSIS CODE.
NO
OK NG
Check the immobilizer-ECU power Check trouble symptom. Replace the immobilizer-ECU.
source and the earth circuit. (Refer to
P.54-3, Inspection Procedure 4.)
Register the password (secret code)
and the encrypted code.
Inspection Procedure 3
Engine does not start (Cranking but no initial combus- Probable cause
tion).
If no fuel injection, there might be a problem with the fuel injection system in addition D Malfunction of diesel fuel injection system
to a malfunction of the immobilizer system. D Malfunction of immobilizer-ECU
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.
NG
Check the system voltage during crank- Check the battery.
ing
OK: 8 V or more
OK
YES
Is a diagnosis code displayed from the To INSPECTION CHART FOR DIAG-
immobilizer-ECU? NOSIS CODE.
NO
NG NG
Measure at immobilizer-ECU connector Check the following connectors: Repair
C-120. C-24, C-120, C-126
D Disconnect the connector and OK
measure at the harness side.
NG
D Ignition switch: ON Check trouble symptoms. Check the harness wire between the
D Voltage between terminal No. 7 and immobilizer-ECU and engine control
body earth. relay, and repair if necessary.
OK: System voltage
OK
Checktheelectricallycontrolledsystem.
(Refer to GROUP 13 - Troubleshoot-
ing.)
OK
OK NG
Check the immobilizer-ECU power sup- Check trouble symptom. Replace the immobilizer-ECU.
ply and the earth circuit. (Refer to P.54-3
, Inspection Procedure 4.)
Register the password (secret code),
and encrypted code.
Inspection Procedure 4
Malfunction of the immobilizer-ECU power source and earth circuit
(1) NG NG
Measure at the immobilizer-ECU con- Check the following connectors: Repair
nector C-120. C-24, C-120, C-126
D Disconnect the connector and
OK
measure at the harness side.
D Ignition switch: ON NG
Check trouble symptom. Check the harnessbetween the immobi-
(1) Voltage between terminal No. 7 and lizer-ECU and engine control relay, and
body earth. repair if necessary.
OK: System voltage
(2) Continuity between terminal No. 3
and body earth.
OK: Continuity
(2) NG
NG
Check the following connector: Repair
C-77, C-120
OK
NG
Check trouble symptom. Check the harnessbetween the immobi-
lizer-ECU and body earth and repair if
necessary.
CHECK AT IMMOBILIZER-ECU
Terminal Voltage Check Chart
ELECTRICAL WIRING
FOREWORD
This manual integrates the WORKSHOP
MANUAL (CHASSIS) and ELECTRICAL
WIRING.