Mitsubishi L200 User Manual

GROUP 00

GENERAL

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00

GENERAL<ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

00-1

NOTES

GROUP 00

GENERAL

CONTENTS

00-1

HOW TO USE THIS MANUAL. . . . . . 00-2

HOW TO USE TROUBLESHOOTING/INSPECTION

SERVICE POINTS . . . . . . . . . . . . . . . 00-5

CONTENTS OF TROUBLESHOOTING . . . 00-5

DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 00-7

HOW TO USE THE INSPECTION

PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 00-8

CONNECTOR MEASUREMENT SERVICE

POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10

CONNECTOR INSPECTION SERVICE

POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11

INSPECTION SERVICE POINTS FOR A

BLOWN FUSE . . . . . . . . . . . . . . . . . . . . . . 00-12

HOW TO COPE WITH INTERMITTENT

MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-12

HOW TO TREAT PAST TROUBLE . . . . . . 00-13

VEHICLE IDENTIFICATION . . . . . . . 00-13

INJECTOR IDENTIFICATION CODE

REGISTRATION PROCEDURE . . . . . . . . . 00-24

SMALL INJECTION QUANTITY LEARNING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-25

SUPPLY PUMP CORRECTION LEARNING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-26

LEARNING PROCEDURE FOR IDLING. . . 00-27

SERVICING ELECTRICAL SYSTEM . . . . . 00-27

VEHICLES WITH SEMI AUTOMATIC AIR

CONDITIONER . . . . . . . . . . . . . . . . . . . . . . 00-27

APPLICATION OF ANTI-CORROSION

AGENTS AND UNDERCOATS . . . . . . . . . . 00-27

VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-27

PRE-INSPECTION CONDITION . . . . . . . . . 00-27

MULTI USE TESTER (M.U.T.-III) SUB

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 00-28

HOW TO USE THE THROTTLE CONTROLLER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-28

IN ORDER TO PREVENT VEHICLES FROM

FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-29

ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 00-29

GENERAL DATA AND SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-17

PRECAUTIONS BEFORE SERVICE. 00-23

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-

TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . 00-23

WHAT THE COMMON RAIL ENGINE LEARNS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-24

SUPPLEMENTAL RESTRAINT SYSTEM

(SRS). . . . . . . . . . . . . . . . . . . . . . . . . . 00-30

SRS SERVICE PRECAUTIONS . . . . . 00-31

SUPPORT LOCATIONS FOR LIFTING

AND JACKING . . . . . . . . . . . . . . . . . . 00-33

STANDARD PART/TIGHTENING-

TORQUE TABLE . . . . . . . . . . . . . . . . 00-37

00-2

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspec tions, adjustments, and the removal and installation procedures for major components. For detailed infor mation concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to sepa rate manuals covering the engine and the transmission.

ON-VEHICLE SERVICE

"On-vehicle Service" is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.

INSPECTION

Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

DEFINITION OF TERMS STANDARD VALUE

Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.

LIMIT

Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.

GENERAL

M1001000101016

REFERENCE VALUE

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be com pleted in a shorter time).

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that

must be avoided. The differences among DANGER,

WARNING, and CAUTION are as follows:

• If a DANGER is not followed, the result is severe

bodily harm or even death.

• If a WARNING is not followed, the result could be

bodily injury.

• If a CAUTION is not followed, the result could be

damage to the vehicle, vehicle components or service equipment.

INDICATION OF TIGHTENING TORQUE

Tightening torques (units: N⋅ m) are set to take into account the central value and the allowable toler ance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to

P.00-37.

MODEL INDICATIONS

The following abbreviations are used in this manual for identification of model types. 2500:Indicates an engine with the 2,477mL <4D56>

diesel engine.

3200:Indicates an engine with the 3,200mL <4M41>

diesel engine.

DOHC: Indicates an engine with the double over-

head camshaft. M/T:Indicates the manual transmission. A/T:Indicates the automatic transmission. A/C:Indicates the air conditioner.

GENERAL

HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS

Indicates the

Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the "Standard Parts tightening-torque Table"

section title.

Indicates the group title.

00-3

Indicates the group number.

Indicates the page number.

Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished.

Component diagram

A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.

Maintenance and servicing procedures

The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures.

Removal steps : The part designation number corresponds to the number in the illustration to indicate remov al steps.

Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disas sembly steps.

Mark denotes nonreusable part.

Repair kit or parts sets are shown. (Only very frequently used parts are shown.)

Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of re moval steps.

Reassembly steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if reassembly is possible in reverse order of dis assembly steps.

AC311238

00-4

GENERAL

HOW TO USE THIS MANUAL

Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.). These are arranged together as major maintenance and service points and explained in detail.

<<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or reassembly.

35A-21

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

Indicates (by symbols) where lubrication is necessary.

Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

Grease (Multi-purpose grease unless there is a brand or type specified)

Sealant or adhesive Brake fluid or automatic transmission fluid

Engine oil, gear oil or air conditioning compressor oil

Adhesive tape or butyl rubber tape

AC311239

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-5

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS

CONTENTS OF TROUBLESHOOTING

M1001013300211

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) discon nected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

WARNING

Since the radiator fan rotates during CAN bus line diagnostics, make sure that no one is servicing the engine compartment before diagnosing the CAN bus line. Since the CAN communication stops when diagnosing the CAN bus line, the ETACS-ECU detects the time-out of the engine-ECU, and activates the radiator fan to prevent overheating as fail-safe.

Troubleshooting of electronic control systems for which the M.U.T.-III can be used follows the basic outline described below. Even in systems for which the M.U.T.-III cannot be used, some of these sys tems still follow this outline.

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.

00-6

Diagnosis method

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Gathering information from the customer.

Reoccurs

CAN bus diagnosis*

Read the diagnosis code. Read the diagnosis code.

No diagnosis code or communication with M.U.T.-III not possible

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group).

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

Diagnosis code displayed. (Current trouble)*

Check trouble symptom.

CAN bus diagnosis chart*

After taking note of the malfunction code, erase the diagnosis code memory.

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code displayed.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group).

Diagnosis code displayed. (Current trouble)*

Does not reoccur

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

No diagnosis code.

INTERMITTENT MALFUNCTIONS*

No diagnosis code.

AC501888

• *1: For how to diagnose CAN bus lines, refer to GROUP 54C .

• *2: For the CAN bus diagnosis chart, refer to GROUP 54C .

• *3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem

currently exists or whether it existed before. The message for the former state identifies it as a "Active" and the message for the latter identifies it as a "Stored".

• *4: For how to treat past trouble, refer to P.00-13.

• *5: For how to cope with intermittent malfunctions, refer to P.00-12.

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms

5. DIAGNOSIS CODE PROCEDURES

Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to Use Inspection Procedures

P.00-8).

are shown.

6. TROUBLE SYMPTOM CHART

3. DIAGNOSIS FUNCTION

Details which are different from those in the "Diagnosis Function P.00-7" section are described.

If there are trouble symptoms even though the M.U.T.-III does not find any diagnosis codes, Inspec tion procedures for each trouble symptom will be found by means of this chart.

4. DIAGNOSIS CODE CHART

Diagnostic trouble codes and diagnostic items are shown.

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-7

7. SYMPTOM PROCEDURES

Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart (Refer to How to Use Inspection Procedures

P.00-8).

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have been provided in this chart as reference information.

9. ACTUATOR TEST TABLE

The Actuator Test item numbers, inspection items, and judgment values have been provided in this chart as reference information.

10. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspection items, and judgment values have been provided in this chart as reference information.

11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are described here.

DIAGNOSIS FUNCTION

M1001013400100

HOW TO READ DIAGNOSIS CODE

Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK"

(OFF).

2. Start up the personal computer.

3. Connect M.U.T.-III USB cable MB991827 to

special tool Vehicle Communication Interface (V.C.I.) MB991824 and the personal computer.

4. Connect M.U.T.-III main harness A MB991910 to

the V.C.I.

5. Connect the M.U.T.-III main harness A to the

diagnosis connector.

6. Turn the V.C.I. power switch to the "ON" position.

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col

our.

7. Start the M.U.T.-III system on the personal

computer and turn the ignition switch to the "ON" position.

8. Read the diagnosis code.

9. Disconnecting the M.U.T.-III is the reverse of the

connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF).

CAUTION

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

MB991910

MB991824

ERASING DIAGNOSIS CODE

CAUTION

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

MB991910

MB991824

MB991827

AC501413

MB991827

AC501413

00-8

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

GENERAL

Connect the M.U.T.-III to the diagnosis connector, and erase the diagnosis code. The procedure is the same as "How to Read Diagnosis Code

HOW TO USE THE INSPECTION PROCEDURES

M1001013500237

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

Relevant circuit(s) of the component which the Code No. indicates are described.

AC301964

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-9

Explains about the basic operation of the components.

Explains about technical details.

Describes the conditions for that diagnosis code being set.

Start of diagnosis procedure

Describes inspection procedure.

M.U.T.-III data list

Describes possible causes(s) for that diagnosis code.

CURRENT TROUBLE

Indicates that the status is "Active" and the trouble is currently present. Carry out troubleshooting as described in the applicable inspection procedure.

PAST TROUBLE

Indicates that the status is "Stored" and the trouble is historic. Since the trouble may still be present, set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", observe the applicable inspection procedure with particular emphasis on connector(s) and wiring harness.

AC313955

HARNESS CHECK

Check for an open or short circuit in the harness between the terminals which are faulty according to the connector measurements. Carry out this inspec

tion while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between the power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse

P.00-12."

MEASURES TO TAKE AFTER REPLACING THE ECU

If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection proce dure from the beginning.

00-10

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR MEASUREMENT SERVICE POINTS

M1001013600223

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) discon

nected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR CONNECTED <WATERPROOF CONNECTORS>

CAUTION

Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool extra fine probe (MB992006).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A FEMALE PIN>

CAUTION

• Use special tool check harness (MB991219). If

the test bar is inserted forcibly, it will cause a poor contact.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

MB991219

Special tool

AC105597

Use the special tools such as test harness, harness connector or check harness.

IF INSPECTING WITH THE CONNECTOR CONNECTED <ORDINARY (NON-WATERPROOF) CONNECTORS>

MB992006

AC105598

AC105599

Use check harness (MB991219) of special tool harness set (MB991223).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A MALE PIN>

CAUTION

• Be careful not to short the connector pins

with the test bars. To do so may damage the circuits inside the ECU.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

AC105600

Touch the pin directly with the test bar.

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-11

CONNECTOR INSPECTION SERVICE POINTS

M1001013700189

VISUAL INSPECTION

•

Connector disconnected or improperly connected

Stretched or broken wires

• Low contact pressure between male and female

terminals

• Low connection pressure due to rusted terminals

or foreign matter lodged in terminals

CONNECTOR PIN INSPECTION

AC300898

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be per fect even if the connector body is connected, and the pins may pull out of the reverse side of the connec tor. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

Harness wire breakage at terminal section

Low contact pressure

Good

Bad

AC300896

Connector is disconnected or improperly connected

• Connector pins are pulled out

• Due to harness tension at terminal section

CONNECTOR ENGAGEMENT INSPECTION

MB991219

AC300899

Use special tool inspection harness (MB991219) (connector pin connection pressure inspection har ness of the inspection harness set) to inspect the engagement of the male pins and female pins. (Pin drawing force: 1 N or more)

00-12

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

M1001013800186

CAUTION

A diagnosis code may be stored due to a blown fuse.

Battery

Fuse

Short-circuit Load switch

occurrence

section

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

M1001013900183

Load

AC300900

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0

Ω

at this time, there is a short somewhere between these switches and the load. If the resistance is not 0

Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following.

• Harness being clamped by the vehicle body

• Damage to the outer casing of the harness due to

wear or heat

• Water getting into the connector or circuitry

• Human error (mistakenly shorting a circuit, etc.)

AC300901

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascer

tained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the cus

tomer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trou

ble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these con ditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which gen erates diagnosis codes or trouble symptoms).

GENERAL

VEHICLE IDENTIFICATION

00-13

• Gently shake the connector up, down and to the

left and right.

• Gently shake the wiring harness up, down and to

the left and right.

• Gently rock each sensor and relay, etc. by hand.

• Gently shake the wiring harness at suspensions

and other moving parts.

NOTE: If determining the cause is difficult, the drive recorder function of the M.U.T.-III can also be used. (For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual).

VEHICLE IDENTIFICATION

VEHICLE NAME PLATE

HOW TO TREAT PAST TROUBLE

M1001014100157

Since the trouble may still be present even the status is "Stored", set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", carry out the following procedure.

1. Establish from the customer whether a fuse or

connector has been replaced or disconnected.

2. If yes, erase the diagnosis code, and then check

that no diagnostic code is reset. If no diagnosis code is reset, the diagnosis is complete.

3. If no, follow the applicable Diagnostic Trouble

Code Chart. Then check the wiring harness and connector, and refer to "How to Cope with Intermittent Malfunction

P.00-12 ."

M1001000401255

AC501406

The name plate is riveted to the cowl top outer panel in the engine compartment.

AC501266

No. Item Content

1 MODEL KA4 Vehicle model

KB4

KB8

2 ENGINE 4D56 Engine model

4M41

00-14

VEHICLE IDENTIFICATION

GENERAL

MODELS

Model code Engine model Transmission model Fuel supply system

KA4T NCNMFRU 4D56 IDI (Indirect

Diesel Injection) SOHC engine with Turbo charger (2,477 mL)

NCNUZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Turbo

NCRUZRU R4AW4

charger (2,477 mL)

2WD (rear axle drive)

R5M21 (5-speed manual transmission)

R5MB1 (5-speed manual transmission)

(4-speed automatic transmission)

Electrical fuel injection (distribution type injection pump system)

Electrical fuel injection (common rail engine control system)

KB4T GCNHZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Inter cooler, Turbo charger (2,477 mL)

KB8T GCNHZRU 4M41 DI-D (Direct

Injection-Diesel) engine with Inter cooler, Turbo charger (3,200 mL)

Model code Engine model Transmission model Fuel supply system

KA4T NJNMZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Turbo

NJNUZRU

NJRUZRU R4AW4

charger (2,477 mL)

4WD (easy select 4WD)

2WD (rear axle drive)

V5MB1 (5-speed manual transmission)

R5MB1 (5-speed manual transmission)

(4-speed automatic transmission)

Electrical fuel injection (common rail engine control system)

KB4T GJNHZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Inter cooler, Turbo charger (2,477 mL)

KB8T GJNHZRU 4M41 DI-D (Direct

Injection-Diesel) engine with Inter cooler, Turbo

GJNXZRU

GJRXZRU V4A5A

charger (3,200 mL)

4WD (easy select 4WD)

V5MB1 (5-speed manual transmission)

(4-speed automatic transmission)

GENERAL

VEHICLE IDENTIFICATION

MODEL CODE

1 2 3 4 5 6 7 8 9 10 11

No. Item Content

1 Development K TRITON

2 Drive system A 2WD

B 4WD

3 Engine type 4 2,477 mL

8 3,200 mL

4 Sort T Truck

5 Vehicle width N Standard

G Wide fender

6 Body style C Club cab

00-15

AC407365

J Double cab

7 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

8 Vehicle grade M GL

U GLX

H GLS

X GLS-S

9 Specification engine feature F Turbo charger

9 Specification engine feature Z Inter cooler, turbo charger

10 Steering wheel location R Right hand

11 Destination U For Thailand

00-16

GENERAL

VEHICLE IDENTIFICATION

CHASSIS NUMBER

The chassis number is stamped on the side wall of the frame near the rear wheel (RH).

Frame

AC501503

1234567891011 12

No. Item Content

1 Country of manufacture M Asia

2 Maker

(distribution channel)

M MMC Sittipol Co., Ltd.

(Thailand)

AC501425

3 Destination and steering wheel

T For Thailand, right hand

location

4 Body style C Club cab

J Double cab

5 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

6 Vehicle line K MITSUBISHI TRITON

7 Development order A 2-wheel drive

B 4-wheel drive

8 Engine type 4 2,477mL diesel engine

8 3,200mL diesel engine

9 MSC internal purpose 0 No meaning

10 Model year 7 2006

11 Plant D MMC Sittipol Co., Ltd.

12 Serial number

− −

GENERAL

GENERAL DATA AND SPECIFICATIONS

00-17

ENGINE MODEL STAMPING

<4D5-SOHC>

<4D5-DOHC, 4M4>

AC502319

AC502538

The engine model is stamped on the cylinder block. This engine model numbers is as shown as follow.

Engine model Engine displacement

4D56 2,477 mL

4M41 3,200 mL

The engine serial number is stamped near the engine model number.

Engine serial number AA0201 to YY9999

CLUB CAB

<2WD>

GENERAL DATA AND SPECIFICATIONS

M1001000900945

AC502183

00-18

Items KA4T

GENERAL DATA AND SPECIFICATIONS

GENERAL

NCNMFRU NCNUZRU NCRUZRU

Vehicle dimensions mm

Vehicle weight kgKerb weight 1,565 1,600 1,600

Seating capacity 2 2 2

Front track 1 1,505 1,505 1,505

Overall width 2 1,750 1,750 1,750

Front overhang 3 785 785 785

Wheel base 4 3,000 3,000 3,000

Rear overhang 5 1,325 1,325 1,325

Overall length 6 5,110 5,110 5,110

Ground clearance (unladen) 7 200 195 195

Overall height (unladen) 8 1,660 1,655 1,655

Rear track 9 1,500 1,500 1,500

BED interior length 10 1,805 1,805 1,805

BED interior width 11 1,470 1,470 1,470

BED interior height 12 405 405 405

Cargo floor height (unladen) 13 725 720 720

Max. gross vehicle weight 2,285 2,330 2,330

Max. axle weight rating-front 1,030 1,030 1,030

Max. axle weight rating-rear 1,500 1,500 1,500

Engine Model No. 4D56 IDI (Indirect

Diesel Injection) engine with Turbo charger

Total displacement mL 2,477 2,477 2,477

Max. output kW (SP)/rpm 66 (90)/4,000 81 (110)/4,000 81 (110)/4,000 Max. torque N⋅ m/rpm 196 (20)/2,000 240 (24.5)/2,000 240 (24.5)/2,000

Transmission Model No. R5M21 R5MB1 R4AW4

Type 5-speed manual 5-speed manual 4-speed

Fuel system Fuel supply system Electrical fuel

injection (distribution type injection pump system)

Max speed km/h 150 160 158

Turning radius m 5.7 5.7 5.7

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

Electrical fuel injection (common rail engine control system)

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

automatic

Electrical fuel injection (common rail engine control system)

<4WD>

GENERAL

GENERAL DATA AND SPECIFICATIONS

00-19

1 2

Items KB4T KB8T

GCNHZRU GCNHZRU

Vehicle dimensions mm

Front track 1 1,520 1,520

Overall width 2 1,800 1,800

Front overhang 3 785 785

Wheel base 4 3,000 3,000

Rear overhang 5 1,325 1,325

Overall length 6 5,110 5,110

Ground clearance (unladen) 7 205 205

AC502184

Overall height (unladen) 8 1,780 1,780

Rear track 9 1,515 1,515

BED interior length 10 1,805 1,805

BED interior width 11 1,470 1,470

BED interior height 12 405 405

Cargo floor height (unladen) 13 860 860

Vehicle weight kgKerb weight 1,795 1,840

Max. gross vehicle weight 2,535 2,605

Max. axle weight rating-front 1,250 1,250

Max. axle weight rating-rear 1,600 1,600

Seating capacity 2 2

Engine Model No. 4D56 DI-D (Direct

Injection-Diesel) engine with Inter cooler, Turbo charger

4M41 DI-D (Direct Injection-Diesel) engine with Inter cooler, Turbo charger

Total displacement mL 2,477 3,200

Max. output kW (PS)/rpm 100 (136)/4,000 118 (136)/3,800 Max. torque N⋅ m/rpm 314 (32)/2,000 343 (35)/2,000

Transmission Model No. V5MB1

Type 5-speed manual

00-20

GENERAL DATA AND SPECIFICATIONS

GENERAL

Items KB4T KB8T

GCNHZRU GCNHZRU

Fuel system Fuel supply system Electrical fuel injection

(common rail engine control system)

Electrical fuel injection (common rail engine control system)

Max speed km/h 175 175

Turning radius m 5.9 5.9

DOUBLE CAB

<2WD>

1 2

AC502185

Items KA4T

NJNMZRU NJNUZRU NJRUZRU

Vehicle dimensions

Front track 1 1,505 1,505 1,505

Overall width 2 1,750 1,750 1,750

Front overhang 3 785 785 785

Wheel base 4 3,000 3,000 3,000

Rear overhang 5 1,210 1,210 1,210

Overall length 6 4,995 4,995 4,995

Ground clearance (unladen) 7 200 195 195

Overall height (unladen) 8 1,655 1,650 1,650

Rear track 9 1,500 1,500 1,500

BED interior length 10 1,325 1,325 1,325

BED interior width 11 1,470 1,470 1,470

BED interior height 12 405 405 405

Cargo floor height (unladen) 13 715 710 710

Vehicle weight kg

Kerb weight 1,640 1,640 1,640

Max. gross vehicle weight 2,330 2,330 2,330

Max. axle weight rating-front 1,030 1,030 1,030

Max. axle weight rating-rear 1,500 1,500 1,500

Seating capacity 5 5 5

GENERAL

GENERAL DATA AND SPECIFICATIONS

Items KA4T

NJNMZRU NJNUZRU NJRUZRU

00-21

Engine Model No. 4D56 DI-D

(Direct Injection-Diesel) engine with Turbo charger

Total displacement mL 2,477 2,477 2,477

Max. output kW (PS)/rpm 81 (110)/4,000 81 (110)/4,000 81 (110)/4,000 Max. torque N⋅ m/rpm 240 (24.5)/2,000 240 (24.5)/2,000 240 (24.5)/2,000

Transmission Model No. R5MB1 R5MB1 R4AW4

Type 5-speed manual 5-speed manual 4-speed

Fuel system Fuel supply system Electrical fuel

injection (common rail engine control system)

Max speed km/h 160 160 158

Turning radius m 5.7 5.7 5.7

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

Electrical fuel injection (common rail engine control system)

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

automatic

Electrical fuel injection (common rail engine control system)

00-22

<4WD>

GENERAL

GENERAL DATA AND SPECIFICATIONS

1 2

Items KB4T KB8T

GJNHZRU GJNHZRU GJNXZRU GJRXZRU

Vehicle dimensions

Front track 1 1,520 1,520 1,520 1,520

Overall width 2 1,800 1,800 1,800 1,800

Front overhang 3 785 785 785 785

Wheel base 4 3,000 3,000 3,000 3,000

Rear overhang 5 1,210 1,210 1,210 1,210

Overall length 6 4,995 4,995 4,995 4,995

Ground clearance (unladen) 7 205 205 205 205

Overall height (unladen) 8 1,780 1,780 1,780 1,780

AC502186

Rear track 9 1,515 1,515 1,515 1,515

BED interior length 10 1,325 1,325 1,325 1,325

BED interior width 11 1,470 1,470 1,470 1,470

BED interior height 12 405 405 405 405

Cargo floor height (unladen) 13 850 850 850 850

Vehicle weight kg

Kerb weight 1,860 1,920 1,930 1,940

Max. gross vehicle weight 2,535 2,605 2,605 2,605

Max. axle weight rating-front 1,250 1,250 1,250 1,250

Max. axle weight rating-rear 1,600 1,600 1,600 1,600

Seating capacity 5 5 5 5

Engine Model No. 4D56 DI-D

(Direct Injection-Dies el) engine with Inter cooler, Turbo charger

4M41 DI-D (Direct Injection-Die sel) engine with Inter cooler, Turbo charger

Total displacement mL 2,477 3,200 3,200 3,200

Max. output kW (PS)/rpm 100

(136)/4,000

Max. torque N⋅ m/rpm 314

(32)/2,000

118 (160)/3,800

343 (35)/2,000

118 (160)/3,800

343 (35)/2,000

4M41 DI-D (Direct Injection-Die sel) engine with Inter cooler, Turbo charger

118 (160)/3,800

343 (35)/2,000

GENERAL

PRECAUTIONS BEFORE SERVICE

Items KB4T KB8T

GJNHZRU GJNHZRU GJNXZRU GJRXZRU

Transmission Model No. V5MB1 V5MB1 V5MB1 V4A5A

Type 5-speed

manual

Fuel system Fuel supply system Electrical fuel

injection (common rail engine control system)

Max speed km/h 175 175 175 175

Turning radius m 5.9 5.9 5.9 5.9

5-speed manual

Electrical fuel injection (common rail engine control system)

5-speed manual

Electrical fuel injection (common rail engine control system)

00-23

4-speed automatic

Electrical fuel injection (common rail engine control system)

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER

M1001011600238

CAUTION

Items to review when servicing SRS:

1. Be sure to read GROUP 52B − Supplemental

Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.

2. Wait at least 60 seconds after disconnecting

the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Seri ous injury may result from unintended air bag deployment if work is done on the SRS sys tem immediately after the battery cable is disconnected.

3. Warning labels must be heeded when servic-

ing or handling SRS components. Warning labels can be found in the following locations.

• SRS air bag control unit (SRS-ECU)

• Front impact sensor

• Clock spring

• Driver's and front passenger's air bag

modules

• Seat belt with pre-tensioner

4. Always use the designated special tools and

test equipment.

5. Store components removed from the SRS in a

clean and dry place. The air bag module should be stored on a flat surface and placed

so that the pad surface is facing upward. Do not place anything on top of it.

6. Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module and clock spring).

7. Whenever you finish servicing the SRS, check

the SRS warning lamp operation to make sure that the system functions properly.

8. Be sure to deploy the air bag before dispos-

ing of the air bag module or disposing of a vehicle equipped with an air bag (Refer to GROUP 52B dures).

Observe the following when carrying out operations on places where SRS components are

installed, including operations not directly

related to the SRS air bag.

1. When removing or installing parts, do not

allow any impact or shock to the SRS compo nents.

2. If heat damage may occur during paint work,

remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, and the seat belt pre-tensioner.

• SRS-ECU, air bag module, clock spring,

front impact sensor: 93

• Seat belt pre-tensioner: 90 ° C or more

− Air Bag Module Disposal Proce-

° C or more

00-24

PRECAUTIONS BEFORE SERVICE

GENERAL

WHAT THE COMMON RAIL ENGINE LEARNS

After fuel-related parts are replaced, the common rail engine must register their identification codes with the engine-ECU and execute learning. The table below shows what should be registered and learned after each type of operation.

Correspondence table

Registration and learning item

Injector identification code registration

Small injection quantity learning

Supply pump correction learning

Operation type

Injector replacement Supply pump

replacement

appricable

−

appricable

M1001012500018

NOTE: When the engine-ECU is replaced, collect in advance the injector identification code from the cur rent engine-ECU. Doing it makes registration easy.

Engine-ECU replacement

appricable

−

REGISTRATION AND LEARNING PROCEDURE

Injector identification code registration

Refer to P.00-24, INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE.

Small injection quantity learning

Refer to P.00-25, SMALL INJECTION QUANTITY LEARNING PROCEDURE.

Supply pump correction learning

Refer to P.00-26, SUPPLY PUMP CORRECTION LEARNING PROCEDURE.

INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE

CAUTION

1. If the injector identification code is not regis-

tered, the engine warning lamp goes on and diagnosis code No. P1626 is logged.

2. Failure to register the injector identification

code correctly will cause rough idling, abnor mal noise, and emission deterioration.

PURPOSE

Identification code

Because individual injectors have different injection characteristics, the engine-ECU corrects injection time for each cylinder to improve injection accuracy. For this reason, when the injector or engine-ECU is replaced, injector correction data must be registered afterwards in the engine-ECU using the Multi Use Tester III (M.U.T.-III). Correction data is converted into an identification code consisting of 30 alphanumeric characters and printed on the injector connector.

AK501491

M1001012600015

GENERAL

PRECAUTIONS BEFORE SERVICE

00-25

REGISTRATION PROCEDURE

1. When replacing the engine-ECU, connect the current engine-ECU to the body harness.

NOTE: This operation is purposed to read the injector identification code stored in the engine-ECU. Reading the identification code in this way before replacement can eliminate manual input of the identi fication code after replacement.

2. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

3. Turn the ignition switch to "ON" position.

4. Select SPECIAL FUNCTION from the function menu.

5. When the current engine-ECU is still mounted, read and register the injector identification code as follows:

(1) Select Read Injector ID Code (for engine-ECU

replacement) from the SPECIAL FUNCTION menu.

(2) Select Write and Save Injector ID Code from

the menu to read data from the current engine-ECU and save the data if it could be

read normally. (3) Mount the new engine-ECU on the vehicle. (4) Select SPECIAL FUNCTION from the function

menu. (5) Select Write Injector ID Code (for engine-ECU

replacement) from the SPECIAL FUNCTION

menu. (6) Select SAVED INJECTOR ID WRITING from

the Write Injector ID Code menu to write the

data, which was saved previously, to the

engine-ECU.

6. If the injector has been replaced or data has not been read from the current engine-ECU, register the injector identification code as follows:

(1) Select Write Injector ID Code from the

SPECIAL FUNCTION menu.

(2) If the injector was replaced, specify whether to

write to every cylinder or a specific cylinder.

Frame 1 (4 digits)

Frame 2 (4 digits)

Frame 3 (4 digits)

Frame 5 (4 digits)

Frame 7 (4 digits)

Frame 4 (4 digits)

Frame 6 (4 digits)

Frame 8 (2 digits)

AK501492

(3) Select the write mode from the menu, enter

the identification code printed on the injector, and execute writing.

CAUTION

Even if the number of the cylinder to be registered does not match the actual injector mounting location, registration ends normally. Specify the cylinder number correctly.

NOTE: The identification code is displayed in order of the frame numbers when it is read.

7. Makes sure that the engine warning lamp that is on changes to blinking, indicating the registration is complete.

NOTE: When the injector is replaced, executing the write operation also clears the values of small injec tion quantity learning.

8. Execute small injection quantity learning.

Refer to P.00-25, the SMALL INJECTION QUANTITY LEARNING PROCEDURE for the learning procedure.

9. Confirm that the engine warning lamp is off.

Confirm also that the diagnosis code is not stored.

SMALL INJECTION QUANTITY LEARNING PROCEDURE

CAUTION

1. If small injection quantity learning has not

been executed, the engine warning lamp blinks.

2. When the requirements for learning are satis-

fied by operation after replacement of the engine-ECU, learning is automatically exe

cuted even if no instruction is given from the M.U.T.-III. Accordingly, the malfunction indica tor lamp goes off. However, the learning thus executed is tentative and limited. Be sure to complete leaning using the M.U.T.-III.

PURPOSE

To keep emission and noise level at adequate levels, the engine-ECU must learn injector fuel injection in idle mode. During learning, the engine-ECU calculates actual injection from each cylinder based on changes in engine speeds and corrects pilot injection control. It then keeps records of this amount of correction as a learned value.

For this reason, after the engine-ECU or injector is replaced, learning must be executed using the M.U.T.-III.

M1001014300010

00-26

GENERAL

PRECAUTIONS BEFORE SERVICE

NOTE: Engine friction changes or injector deterioration over time may cause fluctuation in pilot injection. After use over time, it may prevent injection of an accurate amount of fuel according to the indication by the engine-ECU. This is why learning must be executed again periodically. For this reason, the engine-ECU periodically leans injection according to the cumulative mileage. Note that making the M.U.T.-III learn again resets the cumulative mileage.

NOTE: The engine sound may change or idling engine speeds may increase during injection learn ing. These are not abnormalities.

LEARNING PROCEDURE

1. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

2. Put the vehicle in the following idling stable conditions:

• Engine coolant temperature: 80 − 90°C

• Automatic transmission fluid temperature: 60° C

or higher

• Lamps, A/C condenser fan and all accessories:

OFF

• Transmission: Neutral <M/T>, "P" range <A/T>

• Power steering: Static state

3. Select SPECIAL FUNCTION from the function menu.

4. Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNCTION menu to execute learning.

CAUTION

If the vehicle conditions go out of the learning

conditions during idling, learning is interrupted.

To reexecute learning, the ignition switch

must once be turned off.

5. Continue idling for about 3 minutes before learning is completed.

6. Confirm that the engine warning lamp is off. If it still blinks, reexecute learning.

SUPPLY PUMP CORRECTION LEARNING PROCEDURE

PURPOSE

The engine-ECU learns the relation between the suction control valve (linear solenoid valve) of the supply pump drive current and the fuel injection vol ume.

The learning value is calculated from the suction control valve drive current and the rail pressure sen sor output voltage. When the supply pump is replaced, therefore, this

learning must be executed.

Re-learning is executed when the engine is idling after the learning value in the engine-ECU has been reset by the M.U.T.-III.

M1001014400017

GENERAL

PRECAUTIONS BEFORE SERVICE

LEARNING PROCEDURE FOR IDLING

After the ignition switch is in "LOCK" (OFF) position,

connect the M.U.T.-III to the diagnosis connector.

1. Turn the ignition switch to "ON" position. (Do not start the engine.)

2. Select SPECIAL FUNCTION from the function menu.

3. Select SUPPLY PUMP CORRECTION LEARNING from the SPECIAL FUNCTION menu and execute the initializing of the learning value.

4. After initializing, run the engine at idle in the following conditions.

• Accelerator pedal: OFF

• Engine coolant temperature: 60° C or higher

• Fuel temperature: 30° C or higher

5. Confirm that the item No. 65 High pressure pump learned status on M.U.T.-III Service Data is "2".

NOTE: "2" indicates that the learning has completed.

00-27

M1001014500014

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

M1001011000173

If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

VEHICLE WASHING

M1001012000206

Approximately 40 cm

SERVICING ELECTRICAL SYSTEM

M1001011900217

CAUTION

Before connecting or disconnecting the negative (

−) cable, be sure to turn off the ignition switch

and the lighting switch (If this is not done, there is the possibility of semiconductor parts being damaged).

AC300693

Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (

−) cable from the battery in

order to avoid damage caused by short-circuiting.

VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER

M1001011300055

CAUTION

Never start the engine with the refrigerant system empty as it will damage the A/C compressor.

AC300832

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc.

• Spray nozzle distance: Approximately 40 cm or

• Spray pressure: 3,900 kPa or less

• Spray temperature: 82°C or less

• Time of concentrated spray to one point: within

30 sec.

PRE-INSPECTION CONDITION

M1001012100117

"Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspec tion can be carried out. If you see the words "Set the vehicle to the pre-inspection condition" in this man ual. It means to set the vehicle to the following condition.

• Engine coolant temperature 80 to 90° C

• Lamps, electric cooling fan and all accessories:

OFF

• M/T: Neutral

• A/T: N range

00-28

GENERAL

PRECAUTIONS BEFORE SERVICE

MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY

M1001012400011

MULTI USE TESTER (M.U.T.-III) sub assembly

Vehicle communication interface (V.C.I.)

MB991824

M.U.T.-III USB cable

MB991827

M.U.T.-III main harness A

MB991910

M.U.T.-III main harness B

CAUTION

Diagnosis connector

MB991910

MB991824

MB991827

AC501413

Turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-III.

Connect the M.U.T.-III to the diagnosis connector as shown in the illustration.

Do not use

MB991911

M.U.T.-III measurement adapter

MB991825

M.U.T.-III trigger harness

MB991826

AC305090

Refer to the "M.U.T.-III OPERATION MANUAL" for instructions on handling the M.U.T.-III.

HOW TO USE THE THROTTLE CONTROLLER

M1001009300014

As for a vehicle with the electronic control throttle

, engine operations such as racing can not be

valve performed from outside the vehicle. Thus, the throttle valve controller (MB991791) is provided as a special tool to enable the engine operation from outside the vehicle.

NOTE: *: A vehicle with the accelerator pedal position sensor (APS) installed to the accelerator pedal

THE THROTTLE CONTROLLER CONNECTION

APS harness side connector

MB991894

MB991791

AC103781

+ 528 hidden pages