Mitsubishi L200 User Manual

5 (1)

00-1

GROUP 00

GENERAL

CONTENTS

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

NOTES

00-1

GROUP 00

GENERAL

CONTENTS

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

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

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

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 GENERAL

HOW TO USE THIS MANUAL

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 inspections, adjustments, and the removal and installation procedures for major components. For detailed information 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 separate 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.

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 completed 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 tolerance. 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 overhead camshaft.

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

GENERAL

00-3

HOW TO USE THIS MANUAL

 

EXPLANATION OF MANUAL CONTENTS

 

 

 

Indicates the

 

 

 

 

 

 

section title.

 

 

 

 

Denotes tightening torque.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

For bolts and nuts which do

 

 

 

 

 

 

 

not have a tightening torque

 

 

 

 

 

 

 

listed, refer to the "Standard

Indicates the

 

Indicates the

Parts tightening-torque Table"

group title.

 

group number.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Maintenance and servicing procedures

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.

Mark N denotes nonreusable part.

Repair kit or parts sets are shown.

(Only very frequently used parts are shown.)

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 removal steps.

Disassembly steps :

The part designation number corresponds to the number in the illustration to indicate disassembly steps.

Installation steps :

Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps.

Reassembly steps :

Specified in case installation is impossible in reverse order of removal steps. Omitted if reassembly is possible in reverse order of disassembly steps.

AC311238AB

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

AC311239AB

GENERAL

00-5

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

 

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) disconnected. 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 systems 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

 

 

 

 

 

 

 

GENERAL

 

 

 

 

 

 

 

 

 

 

 

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

 

 

Diagnosis method

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gathering information

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

from the customer.

 

 

 

 

 

 

 

 

 

 

 

 

Reoccurs

 

 

 

 

 

 

 

 

 

 

 

 

Does not reoccur

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check trouble symptom.

 

 

 

 

 

 

 

 

 

 

 

 

 

NG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAN bus diagnosis*1

 

 

 

 

CAN bus diagnosis chart*2

 

 

 

 

 

 

 

 

 

OK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Diagnosis code

Diagnosis code

 

 

 

 

 

 

 

 

 

 

Read the diagnosis code.

displayed.

displayed.

 

 

 

Read the diagnosis code.

 

 

 

 

 

(Current trouble)*3

(Current trouble)*3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No diagnosis code

Diagnosis code

 

 

 

 

After taking note of the

 

 

 

 

 

Diagnosis code

No diagnosis

or communication

displayed.

 

 

 

 

malfunction code, erase the

 

 

 

displayed.

code.

with M.U.T.-III not

(Past trouble)*3

 

 

 

 

diagnosis code memory.

 

 

 

(Past trouble)*3

 

 

possible

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

How to treat past

 

Recheck trouble symptom.

 

How to treat past

 

 

 

 

 

 

trouble*4

 

 

 

 

 

 

 

 

 

 

trouble*4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Read the diagnosis codes.

 

No diagnosis

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Diagnosis code

 

 

 

 

code.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

displayed.

 

 

 

 

 

 

 

 

 

 

 

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

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES

(Refer to applicable group).

INTERMITTENT MALFUNCTIONS*5

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 are shown.

3. DIAGNOSIS FUNCTION

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

5. DIAGNOSIS CODE PROCEDURES

Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to Use Inspection Procedures P.00-8).

6. TROUBLE SYMPTOM CHART

If there are trouble symptoms even though the M.U.T.-III does not find any diagnosis codes, Inspection 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

00-7

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

 

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

CAUTION

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

Diagnosis

connector

MB991910

MB991824

MB991827

AC501413AB

 

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 colour.

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).

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

AC501413AB

 

00-8

GENERAL

 

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

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.

AC301964AB

 

 

 

GENERAL

00-9

 

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

 

 

 

 

 

 

 

 

 

 

Explains about the basic

 

Start of diagnosis

 

Describes

 

 

 

procedure

 

 

 

operation of the components.

 

 

inspection

 

 

 

 

 

 

 

 

 

 

 

procedure.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M.U.T.-III datalist

Explains about technical details.

Describes the conditions for that diagnosis code being set.

Describes possible causes(s) for that diagnosis code.

AC313955AC

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.

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 inspection 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 procedure 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) disconnected. 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.

Special tool

AC105597AB

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

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

MB992006

AC105598AH

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

AC105599AB

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

00-11

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

 

CONNECTOR INSPECTION SERVICE POINTS

M1001013700189

VISUAL INSPECTION

Connector disconnected or

improperly connected

Stretched or broken wires

Harness wire breakage

at terminal section

Low contact

pressure

Good

Bad

AC300896AB

Connector is disconnected or improperly connected

Connector pins are pulled out

Due to harness tension at terminal section

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 perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

CONNECTOR ENGAGEMENT

INSPECTION

MB991219

AC300899AB

Use special tool inspection harness (MB991219) (connector pin connection pressure inspection harness 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 occurrence switch section

Load

AC300900AB

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.)

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

M1001013900183

AC300901

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions 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 generates diagnosis codes or trouble symptoms).

GENERAL

00-13

VEHICLE IDENTIFICATION

 

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).

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 ."

VEHICLE IDENTIFICATION

VEHICLE NAME PLATE

AC501406AB

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

 

M1001000401255

1

2

 

AC501266AB

No.

Item

Content

 

1

MODEL

KA4

Vehicle model

 

 

 

 

 

 

KB4

 

 

 

 

 

 

 

KB8

 

 

 

 

 

2

ENGINE

4D56

Engine model

 

 

 

 

 

 

4M41

 

 

 

 

 

00-14

 

 

GENERAL

 

 

 

 

VEHICLE IDENTIFICATION

 

 

MODELS

 

 

 

 

 

<CLUB CAB>

 

 

 

 

 

 

 

 

 

 

 

 

Model code

Engine model

Transmission model

Fuel supply system

 

 

 

 

 

 

 

 

KA4T

NCNMFRU

4D56 IDI (Indirect

2WD

R5M21

Electrical fuel injection

 

 

 

Diesel Injection) SOHC

(rear axle

(5-speed manual

(distribution type

 

 

 

engine with Turbo

drive)

transmission)

injection pump system)

 

 

 

charger (2,477 mL)

 

 

 

 

 

 

 

 

 

 

 

 

NCNUZRU

4D56 DI-D (Direct

 

R5MB1

Electrical fuel injection

 

 

 

Injection-Diesel) DOHC

 

(5-speed manual

(common rail engine

 

 

 

engine with Turbo

 

transmission)

control system)

 

 

 

charger (2,477 mL)

 

 

 

 

 

NCRUZRU

 

R4AW4

 

 

 

 

 

 

(4-speed automatic

 

 

 

 

 

 

transmission)

 

 

 

 

 

 

 

 

 

KB4T

GCNHZRU

4D56 DI-D (Direct

4WD

V5MB1

 

 

 

 

Injection-Diesel) DOHC

(easy select

(5-speed manual

 

 

 

 

engine with Inter cooler,

4WD)

transmission)

 

 

 

 

Turbo charger (2,477

 

 

 

 

 

 

mL)

 

 

 

 

 

 

 

 

 

 

 

KB8T

GCNHZRU

4M41 DI-D (Direct

 

 

 

 

 

 

Injection-Diesel) engine

 

 

 

 

 

 

with Inter cooler, Turbo

 

 

 

 

 

 

charger (3,200 mL)

 

 

 

 

 

 

 

 

 

 

 

<DOUBLE CAB>

 

 

 

 

 

 

 

 

 

 

Model code

Engine model

Transmission model

Fuel supply system

 

KA4T

NJNMZRU

4D56 DI-D (Direct

2WD

R5MB1

Electrical fuel injection

 

 

 

Injection-Diesel) DOHC

(rear axle

(5-speed manual

(common rail engine

 

 

 

engine with Turbo

drive)

transmission)

control system)

 

 

 

charger (2,477 mL)

 

 

 

 

 

NJNUZRU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NJRUZRU

 

 

R4AW4

 

 

 

 

 

 

(4-speed automatic

 

 

 

 

 

 

transmission)

 

 

 

 

 

 

 

 

 

KB4T

GJNHZRU

4D56 DI-D (Direct

4WD

V5MB1

 

 

 

 

Injection-Diesel) DOHC

(easy select

(5-speed manual

 

 

 

 

engine with Inter cooler,

4WD)

transmission)

 

 

 

 

Turbo charger (2,477

 

 

 

 

 

 

mL)

 

 

 

 

 

 

 

 

 

 

 

KB8T

GJNHZRU

4M41 DI-D (Direct

 

 

 

 

 

 

Injection-Diesel) engine

 

 

 

 

 

 

with Inter cooler, Turbo

 

 

 

 

 

 

charger (3,200 mL)

 

 

 

 

 

GJNXZRU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GJRXZRU

 

 

V4A5A

 

 

 

 

 

 

(4-speed automatic

 

 

 

 

 

 

transmission)

 

 

 

 

 

 

 

 

 

GENERAL

00-15

VEHICLE IDENTIFICATION

 

MODEL CODE

 

1

2

3

4

5

6

7

8

9

10

11

 

 

 

 

 

 

 

 

 

 

 

AC407365AB

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

AC501503AB

 

1

2

3

4

5

6

7

8

9

10

11

12

 

 

 

 

 

 

 

 

 

 

 

 

AC501425AB

 

 

 

 

 

 

 

 

 

 

 

 

No.

Item

 

 

 

 

 

 

Content

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

Country of manufacture

 

 

M

 

Asia

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

Maker

 

 

 

 

M

 

MMC Sittipol Co., Ltd.

 

 

(distribution channel)

 

 

 

 

 

(Thailand)

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Mitsubishi L200 User Manual

GENERAL

00-17

GENERAL DATA AND SPECIFICATIONS

 

ENGINE MODEL STAMPING

<4D5-SOHC>

AC502319AB

<4D5-DOHC, 4M4>

AC502538AB

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

 

 

GENERAL DATA AND SPECIFICATIONS

M1001000900945

CLUB CAB

<2WD>

 

 

 

 

 

 

 

 

11

 

 

 

10

12

 

 

 

 

 

 

 

 

8

 

 

 

 

13

1

3

4

5

7

2

 

6

 

9

 

 

 

 

AC502183AB

00-18

 

 

 

GENERAL

 

 

 

 

GENERAL DATA AND SPECIFICATIONS

 

 

 

 

 

 

 

Items

 

 

KA4T

 

 

 

 

 

 

 

 

 

 

 

 

 

NCNMFRU

NCNUZRU

NCRUZRU

Vehicle

 

Front track

1

1,505

1,505

1,505

dimensions

 

 

 

 

 

 

 

Overall width

2

1,750

1,750

1,750

mm

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

Vehicle weight

 

Kerb weight

 

1,565

1,600

1,600

kg

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

Seating capacity

 

 

 

2

2

2

 

 

 

 

 

 

 

Engine

 

Model No.

 

4D56 IDI (Indirect

4D56 DI-D

4D56 DI-D (Direct

 

 

 

 

Diesel Injection)

(Direct

Injection-Diesel)

 

 

 

 

engine with

Injection-Diesel)

engine with Turbo

 

 

 

 

Turbo charger

engine with

charger

 

 

 

 

 

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

 

 

 

 

 

 

automatic

 

 

 

 

 

 

 

Fuel system

 

Fuel supply system

 

Electrical fuel

Electrical fuel

Electrical fuel

 

 

 

 

injection

injection

injection

 

 

 

 

(distribution type

(common rail

(common rail

 

 

 

 

injection pump

engine control

engine control

 

 

 

 

system)

system)

system)

 

 

 

 

 

 

 

Max speed km/h

 

 

 

150

160

158

 

 

 

 

 

Turning radius m

 

5.7

5.7

5.7

 

 

 

 

 

 

 

GENERAL

00-19

GENERAL DATA AND SPECIFICATIONS

 

<4WD>

 

 

 

 

 

 

 

 

11

 

 

 

10

12

 

 

 

 

 

 

 

 

8

 

 

 

 

13

1

3

4

5

7

2

 

6

 

9

 

 

 

 

AC502184 AB

Items

 

 

KB4T

KB8T

 

 

 

 

GCNHZRU

GCNHZRU

 

 

 

 

 

 

Vehicle

 

Front track

1

1,520

1,520

dimensions

 

 

 

 

 

 

Overall width

2

1,800

1,800

mm

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

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

 

Kerb weight

 

1,795

1,840

kg

 

 

 

 

 

 

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

4M41 DI-D (Direct

 

 

 

 

Injection-Diesel) engine

Injection-Diesel) engine

 

 

 

 

with Inter cooler, Turbo

with Inter cooler, Turbo

 

 

 

 

charger

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

 

 

 

GENERAL DATA AND SPECIFICATIONS

 

 

 

 

 

Items

 

KB4T

KB8T

 

 

 

 

 

 

 

 

GCNHZRU

GCNHZRU

Fuel system

Fuel supply system

 

Electrical fuel injection

Electrical fuel injection

 

 

 

(common rail engine

(common rail engine

 

 

 

control system)

control system)

 

 

 

 

 

Max speed km/h

 

 

175

175

 

 

 

 

Turning radius m

 

5.9

5.9

 

 

 

 

 

DOUBLE CAB

<2WD>

 

 

 

 

 

 

 

 

11

 

 

 

10

12

 

 

 

 

 

 

 

 

8

 

 

 

 

13

1

3

4

5

7

2

 

6

 

9

 

 

 

 

AC502185AB

Items

 

 

KA4T

 

 

 

 

 

NJNMZRU

NJNUZRU

NJRUZRU

 

 

 

 

 

 

Vehicle

Front track

1

1,505

1,505

1,505

dimensions

 

 

 

 

 

Overall width

2

1,750

1,750

1,750

mm

 

 

 

 

 

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

Kerb weight

 

1,640

1,640

1,640

weight kg

 

 

 

 

 

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

 

00-21

 

GENERAL DATA AND SPECIFICATIONS

 

 

 

 

 

 

 

Items

 

 

KA4T

 

 

 

 

 

 

 

 

 

 

 

NJNMZRU

NJNUZRU

NJRUZRU

Engine

Model No.

 

4D56 DI-D

4D56 DI-D

4D56 DI-D (Direct

 

 

 

(Direct

(Direct

Injection-Diesel)

 

 

 

Injection-Diesel)

Injection-Diesel)

engine with Turbo

 

 

 

engine with

engine with

charger

 

 

 

Turbo charger

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

 

 

 

 

 

automatic

 

 

 

 

 

 

Fuel system

Fuel supply system

 

Electrical fuel

Electrical fuel

Electrical fuel

 

 

 

injection

injection

injection

 

 

 

(common rail

(common rail

(common rail

 

 

 

engine control

engine control

engine control

 

 

 

system)

system)

system)

 

 

 

 

 

 

Max speed km/h

 

160

160

158

 

 

 

 

 

Turning radius m

 

5.7

5.7

5.7

 

 

 

 

 

 

00-22

GENERAL

 

GENERAL DATA AND SPECIFICATIONS

<4WD>

 

 

 

 

 

 

 

 

11

 

 

 

10

12

 

 

 

 

 

 

 

 

8

 

 

 

 

13

1

3

4

5

7

2

 

6

 

9

 

 

 

 

AC502186AB

Items

 

 

KB4T

KB8T

 

 

 

 

 

GJNHZRU

GJNHZRU

GJNXZRU

GJRXZRU

 

 

 

 

 

 

 

Vehicle

Front track

1

1,520

1,520

1,520

1,520

dimensions

 

 

 

 

 

 

Overall width

2

1,800

1,800

1,800

1,800

mm

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

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

Kerb weight

 

1,860

1,920

1,930

1,940

weight kg

 

 

 

 

 

 

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

4M41 DI-D

4M41 DI-D

4M41 DI-D

 

 

 

(Direct

(Direct

(Direct

(Direct

 

 

 

Injection-Dies

Injection-Die

Injection-Die

Injection-Die

 

 

 

el) engine

sel) engine

sel) engine

sel) engine

 

 

 

with Inter

with Inter

with Inter

with Inter

 

 

 

cooler, Turbo

cooler, Turbo

cooler, Turbo

cooler, Turbo

 

 

 

charger

charger

charger

charger

 

 

 

 

 

 

 

 

Total displacement mL

 

2,477

3,200

3,200

3,200

 

 

 

 

 

 

 

 

Max. output kW (PS)/rpm

 

100

118

118

118

 

 

 

(136)/4,000

(160)/3,800

(160)/3,800

(160)/3,800

 

 

 

 

 

 

 

 

Max. torque N m/rpm

 

314

343

343

343

 

 

 

(32)/2,000

(35)/2,000

(35)/2,000

(35)/2,000

 

 

 

 

 

 

 

 

 

GENERAL

 

 

00-23

 

 

PRECAUTIONS BEFORE SERVICE

 

 

 

 

 

 

 

 

 

Items

 

 

KB4T

KB8T

 

 

 

 

 

 

 

 

 

 

 

 

GJNHZRU

GJNHZRU

GJNXZRU

GJRXZRU

Transmission

Model No.

 

V5MB1

V5MB1

V5MB1

V4A5A

 

 

 

 

 

 

 

 

Type

 

5-speed

5-speed

5-speed

4-speed

 

 

 

manual

manual

manual

automatic

 

 

 

 

 

 

 

Fuel system

Fuel supply system

 

Electrical fuel

Electrical fuel

Electrical

Electrical

 

 

 

injection

injection

fuel injection

fuel injection

 

 

 

(common rail

(common rail

(common rail

(common rail

 

 

 

engine

engine

engine

engine

 

 

 

control

control

control

control

 

 

 

system)

system)

system)

system)

 

 

 

 

 

 

 

Max speed km/h

 

175

175

175

175

 

 

 

 

 

 

Turning radius m

 

5.9

5.9

5.9

5.9

 

 

 

 

 

 

 

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. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.

3.Warning labels must be heeded when servicing 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 disposing of the air bag module or disposing of a

vehicle equipped with an air bag (Refer to GROUP 52B Air Bag Module Disposal Procedures).

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 components.

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 ° C or more

Seat belt pre-tensioner: 90 ° C or more

00-24

GENERAL

 

PRECAUTIONS BEFORE SERVICE

WHAT THE COMMON RAIL ENGINE LEARNS

M1001012500018

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

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

Registration and

Operation type

 

 

learning item

 

 

 

Injector replacement

Supply pump

Engine-ECU

 

 

replacement

replacement

 

 

 

 

Injector identification

appricable

appricable

code registration

 

 

 

 

 

 

 

Small injection quantity

appricable

appricable

learning

 

 

 

 

 

 

 

Supply pump correction

appricable

learning

 

 

 

 

 

 

 

REGISTRATION AND LEARNING PROCE-

Small injection quantity learning

DURE

Refer to P.00-25, SMALL INJECTION QUANTITY

Injector identification code registration

LEARNING PROCEDURE.

 

Refer to P.00-24, INJECTOR IDENTIFICATION

Supply pump correction learning

CODE REGISTRATION PROCEDURE.

Refer to P.00-26, SUPPLY PUMP CORRECTION

 

 

LEARNING PROCEDURE.

INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE

CAUTION

1.If the injector identification code is not registered, 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, abnormal noise, and emission deterioration.

M1001012600015

PURPOSE

Identification code

AK501491 AB

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.

GENERAL

00-25

PRECAUTIONS BEFORE SERVICE

 

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 identification 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

 

 

 

 

 

 

Frame 2

 

 

(4 digits)

 

 

 

 

 

 

(4 digits)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Frame 3

 

 

 

 

 

 

Frame 4

 

 

 

 

 

 

(4 digits)

 

 

 

 

 

 

(4 digits)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Frame 6

 

 

Frame 5

 

 

 

 

 

 

 

 

 

(4 digits)

 

 

 

 

 

 

(4 digits)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Frame 7

 

 

 

 

 

 

Frame 8

 

 

(4 digits)

 

 

 

 

 

 

(2 digits)

 

 

 

 

 

 

 

 

 

AK501492 AB

 

 

 

 

 

 

 

 

(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 injection 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

M1001014300010

CAUTION

1.If small injection quantity learning has not been executed, the engine warning lamp blinks.

2.When the requirements for learning are satisfied by operation after replacement of the engine-ECU, learning is automatically executed even if no instruction is given from the M.U.T.-III. Accordingly, the malfunction indicator 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.

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 learning. 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

M1001014400017

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 volume.

The learning value is calculated from the suction control valve drive current and the rail pressure sensor 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.

GENERAL

00-27

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.

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.

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

AC300832AB

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 more

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 inspection can be carried out. If you see the words "Set the vehicle to the pre-inspection condition" in this manual. 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

Do not use

MB991911

M.U.T.-III measurement adapter

MB991825

M.U.T.-III trigger harness

MB991826

AC305090AI

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

CAUTION

Diagnosis

connector

MB991910

MB991824

MB991827

AC501413AB

 

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.

HOW TO USE THE THROTTLE CONTROLLER

M1001009300014

As for a vehicle with the electronic control throttle

valve*, engine operations such as racing can not be 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

AC103781AC

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