Mitsubishi Pajero 2002 User Manual

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

00

WORKSHOP

MANUAL

SUPPLEMENT

FOREWORD

This manual outlines changes in servicing
procedures related to the chassis including
vehicle inspections and adjustments in the
newly added models. Use the following
manuals in combination with this manual as
required.

TECHNICAL INFORMATION MANUAL

PYJE9002

WORKSHOP MANUAL

ENGINE GROUP PWEE____

(Looseleaf edition)

CHASSIS GROUP PWJE9086(Basic)

PWJE9086-G(Supplement)

PWJE9086-H(Supplement)

PWJE9086-I(Supplement)

ELECTRICAL WIRING PHJE9026(Basic)

PHJE9026-D(Supplement)
PHJE9026-E(Supplement)

PHJE9026-F(Supplement)

PHJE9026-G(Supplement)

PHJE9026-H(Supplement)

PHJE9026-I(Supplement)

PARTS CATALOGUE B60356A2Aj

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

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

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

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

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

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

Engine and Emission Control . . .

Interior and Supplemental

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

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

11

12

13

14

15

16

17

52

54

All information, illustrations and product
descriptions contained in this manual are
current as at the time of publication. We,
however, reserve the right to make changes
at any time without prior notice or obligation.

E Mitsubishi Motors Corporation May 2001

GENERAL - How to Use This Manual/Vehicle Identification

ith

turboch

ith

turboch

00-1

GROUP 00

GENERAL

HOW TO USE THIS MANUAL

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.00-5.

VEHICLE IDENTIFICATION

MODELS

<2-DOOR MODELS>

Model code Engine model Transmission model Fuel supply system

V24W NDGL6Y 4D56 (2,477 mL)

w

GNDGL6Y

<4-DOOR MODELS>

Model code Engine model Transmission model Fuel supply system

V44W NDGL6Y 4D56 (2,477 mL)

GNDGL6Y

and inter-cooler

w
and inter-cooler

arger

arger

V5MT1 <5M/T> Injection

V5MT1 <5M/T> Injection

00-2

GENERAL - Vehicle Identification

CHASSIS NUMBER

The chassis number is stamped on the side wall of the frame
near the right rear wheel.

12 3 4

No. Items Contents

1 Fixed figure J Asia

2 Distribution channel M Japan channel

3 Destination B For Europe, left hand drive

4 Body style 0 4 or 2-door with tailgate(back door)

5 Transmission type N 5-speed manual transmission

6 Development order V2 PAJERO 2-door models

7 Engine 4 4D56: 2,477 mL diesel engine

8 Sort W Station wagon

9 Model year 2* 2002

5

6

V4 PAJERO 4-door models

7

89

10

11

10 Plant J Pajero Manufacturing Co., Ltd. *

11 Serial number - -

NOTE
*: Indicates changes.

GENERAL - Major SpecificationsGENERAL - Major Specifications

mm

g

MAJOR SPECIFICATIONS

2-DOOR MODELS

2

5

84 9

00-3

3

7

6

1

Items

Vehicle
dimensions

Vehicle
weight kg

Seating capacity 5

Engine Model No. 4D56 Intercooler Turbocharger

Transmis­sion

Fuel system Fuel supply system Injection

Overall length 1 4,075

Overall width 2 1,695 1,785

Overall height (unladen) 3 1,835 1,845

Wheelbase 4 2,420

Track-front 5 1,420 1,465

Track-rear 6 1,435 1,480

Ground clearance
(unladen)

Overhang-front 8 675

Overhang-rear 9 980

Kerb weight 1,700 1,755

Max. gross vehicle weight 2,510

Max. axle weight rating-front 1,070

Max. axle weight rating-rear 1,750

Total displacement mL 2,477

Model No. V5MT1

Type 5-speed manual

V24W

NDGL6Y GNDGL6Y

7 205 215

00-4

mm

g

4-DOOR MODELS

2

5

GENERAL - Major Specifications

84

1

3

7

9

6

Items

Vehicle
dimensions

Vehicle
weight kg

Seating capacity 7

Engine Model No. 4D56 Intercooler Turbocharger

Transmis­sion

Fuel system Fuel supply system Injection

Overall length 1 4,655

Overall width 2 1,695 1,775

Overall height (unladen) 3 1,890 1,900

Wheelbase 4 2,725

Track-front 5 1,420 1,465

Track-rear 6 1,435 1,480

Ground clearance
(unladen)

Overhang-front 8 650

Overhang-rear 9 1,280

Kerb weight 1,875 1,930

Max. gross vehicle weight 2,750

Max. axle weight rating-front 1,090

Max. axle weight rating-rear 1,780

Total displacement mL 2,477

Model No. V5MT1

Type 5-speed manual

V44W

NDGL6Y GNDGL6Y

7 205 215

GENERAL - Standard Part/Tightening-Torque Table

STANDARD PART/TIGHTENING-TORQUE TABLE

00-5

Each torque value in the table is a standard value
for tightening under the following conditions.
(1) Bolts, nuts and washers are all made of steel

and plated with zinc.

(2) The threads and bearing surface of bolts and

nuts are all in dry condition.

The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast

inserted nuts.

(4) If self-tapping screws or self-locking nuts are

used.

Standard bolt and nut tightening torque

Thread size Torque N·m

Bolt nominal
diameter (mm)

M5 0.8 2.50.5 5.01.0 6.01.0

M6 1.0 5.01.0 9.02.0 102

M8 1.25 122 224 254

M10 1.25 244 4410 537

M12 1.25 418 8312 9812

M14 1.5 7312 14020 15525

Pitch (mm) Head mark “4” Head mark “7” Head mark “8”

M16 1.5 11020 21030 23535

M18 1.5 16525 30040 34050

M20 1.5 22535 41060 48070

M22 1.5 30040 55585 64595

M24 1.5 39555 735105 855125

Flange bolt and nut tightening torque

Thread size Torque N·m

Bolt nominal
diameter (mm)

M6 1.0 5.01.0 102 122

M8 1.25 132 244 275

M10 1.25 264 499 587

M10 1.5 244 458 5510

M12 1.25 468 9515 10515

M12 1.75 438 8312 9812

Pitch (mm) Head mark “4” Head mark “7” Head mark “8”

NOTE

1. Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.

2. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the
greater the bolt strength.

NOTES

ENGINE

CONTENTS

11-1

ENGINE <4D5-Step III>2.............

GENERAL 2.................................

Outline of Changes 2...........................

GENERAL INFORMATION 2..................

SERVICE SPECIFICATIONS 2.................

SEALANT 3..................................

SPECIAL TOOLS 3...........................

ON-VEHICLE SERVICE 4.....................

Injection Timing Check and Adjustment 4.........

Idle Speed Check 4............................

OIL PAN AND OIL SCREEN 5................

TIMING BELT AND TIMING BELT B 7........

CYLINDER HEAD GASKET 11................

G

l/G

l

Inf

11-2

ENGINE <4D5-Step III>-

enera

Specifications

enera

ormation/Service

ENGINE <4D5-Step

III

>

GENERAL

OUTLINE OF CHANGES

Some service procedures have been revised as the following changes have been made to comply to
the Emission Regulation Step III.
D The injection timing check and adjustment procedure and the idle speed check procedure have been

changed.

D The oil pan has a cover in order to reduce noise due to an enhanced engine output.
D A crank angle sensor and crankshaft sensing blade have been added due to the introduction of

an electronic-controlled fuel injection pump. Due to this change, the timing belt front lower cover
has been reshaped.

D The tightening torque of the cylinder head bolts and the cylinder head gasket have been changed.

GENERAL INFORMATION

Items 4D56

Total displacement mL 2,477

Bore x Stroke mm 91.1 x 95.0

Compression ratio 21

Combustion chamber Vortex chamber type

Camshaft arrangement SOHC

Number of valve Intake 4

Exhaust 4

Valve timing Intake Opening BTDC 20_

Exhaust Closing ABDC 49_

Intake Opening BBDC 55_

Exhaust Closing ATDC 22_

Fuel system Electronically controlled type injection pump

Rocker arm Roller type

Adjusting screw Elephant foot type

SERVICE SPECIFICATIONS

Items Standard value

Timing belt tension mm 4-5

Timing belt B tension mm 4-5

Idle speed r/min 750 ± 30

ENGINE <4D5-Step III>-Sealant/Special Tools

SEALANT

Items Specified sealant Remarks

11-3

Oil pan MITSUBISHI GENUINE PART

MD970389 or equivalent

Semi-circular packing and rocker
cover seal, and cylinder head seal

3M ATD Part No. 8660 or equivalent

SPECIAL TOOLS

Tools Number Name Use

MD998727 Oil pan remover Removal of oil pan

MD998721 Crankshaft pulley

holder

MD998051 Cylinder head bolt

wrench

Semi-drying sealant

Holding the crankshaft pulley

Removal and installation of the cylinder head
bolt

MB991614 Angle gauge Tightening of the cylinder head bolts

11-4

Tachometer

ENGINE <4D5-Step III>-On-vehicle Service

ON-VEHICLE SERVICE

INJECTION TIMING CHECK AND
ADJUSTMENT

The cold start device (wax type) has been discontinued as
an electronically controlled injection pump has been used.
The other inspection and adjustment procedures are the same
as before.

IDLE SPEED CHECK

1. Set the vehicle to the pre-inspection condition.

2. Turn the ignition switch to “LOCK” (OFF) position, and
connect the diagnosis connector to the MUT-II.
If the MUT-II is not used, connect a tachometer to the
injection nozzle or the pipe.

3. Start the engine, and let it run at idle.

4. Check the idle speed.

Injection nozzle

Standard value: 750 ± 30 r/min

5. If the idle speed is not within the standard value, refer
to 13C - Troubleshooting to check the electronic controlled
fuel injection system.

NOTE
The idle speed is controlled by the engine-ECU.

ENGINE <4D5-Step III>-Oil Pan and Oil Screen

OIL PAN AND OIL SCREEN

REMOVAL AND INSTALLATION

11-5

Pre-removal and Post-installation Operation

D Skid Plate and Under Cover Removal and Installation.
D Front Exhaust Pipe Removal and Installation (Refer

to GROUP 15 - Exhaust Pipe and Muffler.)

12

4mm
(0.16 in.)
diameter

Hole of boltGroove

Sealant:
MITSUBISHI GENUINE Part No.
MD997110 or equivalent

9.0 ± 1.0 N·m

D Engine Oil Draining and Supplying.

15

19 ± 3 N·m

14

4

8

9

12 ± 1 N·m

7

(Engine oil)

12

1

110 ± 10 N·m

Removal steps

1. Vacuum hose connection

2. Bolt

3. Front suspension crossmember

4. Engine oil level gauge and guide
assembly

5. Drain plug

"BA 6. Drain plug gasket

7. Alternator vacuum pump oil return
hose connection

5

7.0 ± 1.0
N·m

6

11

39 ± 5 N·m

10

35 ± 6 N·m

9.0 ± 1.0 N·m

13

3

9.0 ± 1.0 N·m

2

110 ± 10 N·m

8. Oil level sensor connector

9. Oil level sensor

10. Space rubber

11. Bell housing cover

AA""AA. 12. Oil pan

13. Oil pan cover

14. Oil screen

15. Oil screen gasket

11-6

ENGINE <4D5-Step III>-Oil Pan and Oil Screen

MD998727

MD998727

φ 4mm

GrooveBolt hole

REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL

INSTALLATION SERVICE POINTS

"AA OIL PAN INSTALLATION

1. Remove sealant from oil pan and cylinder block mating
surfaces.

2. Degrease the sealant-coated surface and the engine
mating surface.

3. Apply a continuous bead of the specified sealant to the
oil pan mating surface as shown.

Specified sealant:

MITSUBISHI GENUINE PART No. MD970389 or
equivalent

NOTE
The sealant should be applied in a continuous bead
approximately 4 mm in diameter.

4. Assemble oil pan to cylinder block within 15 minutes after
applying the sealant.

Caution
After installing the oil pan, wait at least 1 hour before
starting the engine.

Drain plug
gasket

"BA DRAIN PLUG GASKET INSTALLATION

Install a new gasket in the direction so that it faces as shown
in the illustration.

Oil pan
side

ENGINE <4D5-Step III>-Timing Belt and Timing B

TIMING BELT AND TIMING BELT B

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Intercooler Removal and Installation

(Refer to GROUP 15.)

D Cooling Fan Removal and Installation.

11-7

(Engine oil)

3

11 ± 1 N·m

4

1

11 ± 1 N·m

5

26 ± 3 N·m

6

26 ± 3 N·m

18

8

9

7

26 ± 3 N·m

177 ± 9 N·m

26 ± 3 N·m

Removal steps

"CA 1. Timing belt front upper cover

2. Tension pulley and tension pulley
bracket assembly

3. Crankshaft pulley (for power steer­ing and A/C)

AA""DA 4. Crankshaft pulley

"CA 5. Timing belt front lower cover

AB""BA 6. Timing belt

7. Tensioner spacer

8. Tensioner spring

11

13

12

9.0 ± 1.0 N·m

10

17

16

15

26 ± 3 N·m

14

9. Timing belt tensioner

10. Crank angle sensor

11. Crankshaft sensing blade

12. Crankshaft sprocket

13. Flange

AC""AA 14. Timing belt B

15. Gasket

16. Tensioner spacer B

17. Tensioner spring B

18. Timing belt tensioner B

2

11-8

ENGINE <4D5-Step III>-Timing Belt and Timing B

REMOVAL SERVICE POINTS

Timing marks

MD998721

AA" CRANKSHAFT PULLEY REMOVAL

1. Turn the crankshaft clockwise, align the timing marks
to set No.1 cylinder to TDC of its compression stroke.

Caution
Never turn the crankshaft anticlockwise.

2. Use the special tool to keep crankshaft from turning and
remove the bolts.

Tilt to water pump side

Water pump

D

AB" TIMING BELT REMOVAL

1. When reinstalling timing belt, mark an arrow at the belt

A

to show rotation direction.

2. Loosen the tensioner mounting bolt A and B.

3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt A and B. Secure so that
tensioner will not move back.

B

AC" TIMING BELT B REMOVAL

1. When reinstalling timing belt B, mark an arrow at the
belt to show rotation direction.

C

2. Loosen the tensioner mounting bolt C and nut D.

3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt C and nut D. Secure so that
tensioner will not move back.

Timing
marks

ENGINE <4D5-Step III>-Timing Belt and Timing Belt BENGINE <4D5-Step III>-Timing Belt and Timing Belt B

INSTALLATION SERVICE POINTS

Timing mark

C

Deflection
side

D

Tension
side

"AA TIMING BELT B INSTALLATION

1. Align the timing marks of the 3 sprockets.

2. When reusing timing belt B, make sure the arrow mark
is pointing in the same direction as when the belt was
removed.

3. Install timing belt B and make sure there is no deflection
on the tension side.

4. Press the deflection side of timing belt B with the hand
and fully stretch the tensioner side.

5. Make sure that the timing marks are aligned.

6. Loosen the tensioner mounting bolt and nut so that only
the pressure of the spring is applied to timing belt B.

7. Tighten the tensioner mounting bolt C and nut D, tightening
the nut first. If the bolt is tightened first, the tensioner
will move and tension the belt.

Tightening torque: 26 ± 3 N·m

11-9

Counterbalance
shaft sprocket

Timing marks

Belt deflection

Crankshaft
sprocket B

Tension side

Water pump

8. Press in the direction of the arrow in the figure with the
index finger to check the amount of deflection.

Standard value: 4 - 5 mm

"BA TIMING BELT INSTALLATION

1. Align the timing marks of the 3 sprockets.

2. When reusing timing belt, make sure the arrow mark is
pointing in the same direction as when the belt was
removed.

3. Install the timing belt to the crankshaft sprocket, to injection
pump sprocket, to tensioner and to camshaft sprocket
in that order. Being careful not to allow deflection on
the tension side of the timing belt.

Caution
(1) Engage the belt on the various sprockets while

maintaining tension on the belt of tension side.

(2) Align the injection pump sprocket with the timing

mark, hold the sprocket so that is does not turn
and engage the belt.

4. Loosen the tensioner mounting bolts and apply tension
with the spring.

Tension
side

11-10

A

Tensioner

ENGINE <4D5-Step III>-Timing Belt and Timing Belt BENGINE <4D5-Step III>-Timing Belt and Timing Belt B

5. Turn the crankshaft clockwise and stop at the second

Camshaft sprocket

2 teeth

Tensioner
mounting bolt

Tensioner
mounting bolt

lobe of the camshaft sprocket.

Caution
(1) When turning the crankshaft in item (5), strictly

observe the specified amount of rotation (2 teeth
on the camshaft sprocket) in order to apply a

constant force to the tension side of the belt.
(2) Do not turn the crankshaft counterclockwise.
(3) Do not touch the belt during adjustment.

6. Make sure that the part indicated by arrow A does not
float upward.

7. Tighten the tensioner mounting bolts, starting with the
bolt in the elongated hole. If the lower bolt is tightened
first, belt tension will become too tight.

8. Turn the crankshaft anticlockwise and align the timing
mark. Next, make sure that the timing marks of all
sprockets are aligned.

Amount of belt
deflection

9. Press on the center of the bolt with an index finger to check
the amount of deflection.

Standard value: 4 - 5 mm

"CA TIMING BELT FRONT LOWER COVER/TIMING

A

BELT FRONT UPPER COVER INSTALLATION

Install the bolts to the timing belt cover at the shown positions.

A

C

B

A

Name Symbols Size mm (d×l)

Flange bolt A 6×22

B 6×50

C 6×60

d=Nominal diameter
l=Nominal length

A

B

A

"DA CRANKSHAFT PULLEY INSTALLATION

Using the special tool to install the crankshaft pulley as same
as removal procedure.

A

A

ENGINE <4D5-Step III>-Cylinder Head Gasket

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

11-11

Pre-removal Operation

D Intake and Exhaust Manifold Removal

(Refer to GROUP 15.)

D Timing Belt Removal (Refer to P.11-4.)
D Engine Coolant Draining.

13 ± 2 N·m

10 ± 2 N·m

29 ± 2 N·m → +120°
(During cold engine)

22 ± 4 N·m

22 ± 4 N·m

12

10

Post-installation Operation

D Timing Belt Installation (Refer to P.11-4.)
D Intake and Exhaust Manifold Installation

(Refer to GROUP 15.)

D Fuel Line Air Bleeding

(Refer to GROUP 13 - On-vehicle Service.)

D Engine Coolant Filling

8

9

5.9 ± 1.0 N·m

4.9 ± 1.0 N·m

11

30 ± 6
N·m

4.9 ± 1.0
N·m

30 ± 6 N·m

4.9 ± 1.0 N·m

3

5

2

30 ± 6 N·m

10 mm

10 mm

10

11

Sealant:
3M ATD Part No. 8660 or
equivalent

Removal steps

1. Engine coolant temperature switch
connector (for A/C)

2. Engine coolant temperature gauge
unit and sensor connector

3. Glow plug terminal

AA""DA 4. Radiator upper hose
AB""CA 5. Fuel injection pipe

6. Heater hose or water by-pass hose
connection

7. Fuel hose connection

6

7

13

14

4

1

24 ± 4 N·m

15

8. Boost sensor and bracket assembly

9. Vacuum hose and pipe assembly

10. Rocker cover

11. Semi-circular packing

AC" 12. Power steering oil pump assembly

13. Power steering oil pump bracket
bolt

AD""BA 14. Cylinder head assembly

"AA 15. Cylinder head gasket

11-12

ENGINE <4D5-Step III>-Cylinder Head Gasket

REMOVAL SERVICE POINTS

AA" RADIATOR UPPER HOSE DISCONNECTION

After making mating marks on the radiator upper hose and
the hose clamp, disconnect the radiator upper hose.

AB" FUEL INJECTION PIPE REMOVAL

Delivery holder

Nut

When loosening nuts at both ends of injection pipe, hold
the delivery holder (for pump side) and the injection nozzle
assembly (for nozzle side) with wrench and loosen nut.

Caution
After disconnecting the injection pipe, plug the opening
so that no foreign particles get inside the pump or into
the injection nozzle.

MD998051

AC" POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump from the bracket with
the hose attached.

NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.

AD" CYLINDER HEAD ASSEMBLY REMOVAL

Use the special tool to tighten each bolt 2 - 3 times in the
order shown in the illustration.

Front

Identification mark

ENGINE <4D5-Step III>-Cylinder Head Gasket

INSTALLATION SERVICE POINTS

"AA CYLINDER HEAD GASKET INSTALLATION

When replacing the cylinder head gasket only, confirm the
gasket identification mark, and then select a replacement
part according to the table below:

Spec Identification mark (size) Parts num-

A D5 -774 (fitted thickness 1.45 ± 0.04) MD377774

11-13

ber

A

B

B D5 -775 (fitted thickness 1.50 ± 0.04) MD377775

C D5- 776 (fitted thickness 1.55 ± 0.04) MD377776

Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.

C

Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)

"BA CYLINDER HEAD INSTALLATION

1. Select a cylinder head gasket of correct specification.

2. Clean the cylinder head assembly and the cylinder block
mating surfaces with a scraper or a wire brush.

Caution
Do not allow foreign material to enter the engine
coolant or oil passages and the cylinder.

Cylinder head
bolt washer

3. Install the cylinder head bolt washer to the cylinder head
bolt so that the washer chamfered side faces as shown.

4. Apply a small amount of engine oil to the cylinder head
bolt thread and the washer.

Chamfered
side

11-14

ENGINE <4D5-Step III>-Cylinder Head Gasket

5. Tighten the cylinder head bolts according to the following
procedure (angle-tightening procedure.)
(1) Use the special tool to tighten the cylinder head bolts

in the order of the illustrated numbers to 29 ± 2 N·m.

MD998051

13

13

14

14

9

10

9

10

17

18

Front of engine

MD998051

17

18

5

6

3

1

2

11

7

4

8

12

15

16

(2) Place the special tool in a wrench to tighten the

MB991614

cylinder head bolt in the order of the illustrated
numbers to 120_.

"CA FUEL INJECTION PIPE INSTALLATION

When tightening the nuts at both ends of the fuel injection
pipe, hold the delivery holder (for pump side) and the injection
nozzle assembly (for nozzle side) with a wrench, and tighten
the nuts to the specified torque.

Tightening torque: 30 ± 6 N·m

"DA RADIATOR UPPER HOSE CONNECTION

5

3

1

11

7

15

To reuse the radiator upper hose, align the mating marks
that were made during removal, and then install the hose
clamp.

6

4

2

12

8

16

Front of engine

LUBRICATION - General/Lubricant

It

4D5-St

III

12-1

GROUP 12

LUBRICATION

GENERAL

OUTLINE OF CHANGE

D The engine oil quantity has been changed as variable geometry (VG) turbocharger has been used.

LUBRICANT

ems

Engine oil quantity L Oil filter 0.8

Oil cooler 0.4

Total 7.5

ep

NOTES

FUEL

CONTENTS

13-1

FUEL SYSTEM <4D5-step III>2.......

GENERAL 2.................................

Outline of Changes 2...........................

GENERAL INFORMATION 2...................

SERVICE SPECIFICATIONS 5.................

SEALANT 5..................................

SPECIAL TOOLS 5...........................

TROUBLESHOOTING 7.......................

ON-VEHICLE SERVICE 57....................

Injection Timing Check and Adjustment 57.........

Idle Speed Check and Adjustment 57.............

Injection Nozzle Check and Adjustment 57.........

Accelerator Pedal Position Sensor (APS)

Adjustment 58.................................

Control Relay Continuity Check 59................

Accelerator Pedal Position Sensor (APS)

Check 59......................................

Idle Switch Check 60............................

Boost Air Temperature Sensor (Intake Air

Temperature Sensor) Check 60..................

Engine Coolant Temperature Sensor Check 61.....

EGR Valve Position Sensor Check 61.............

Fuel Injection Pump Check 62....................

Throttle Solenoid Valve Check 63.................

Throttle Actuator Check 64......................

Variable Geometry Solenoid Valve Check 64.......

EGR Control Solenoid Valve Check 64............

FUEL INJECTION PUMP 65..................

CRANKSHAFT POSITION SENSOR 66........

ACCELERATOR PEDAL 67...................

13-2

FUEL SYSTEM <4D5-step III> - General/General Information

FUEL SYSTEM <4D5-step III>

GENERAL

OUTLINE OF CHANGES

Some service procedures have been established as the following changes have been made due to the
compliance with the Emission Regulation Step III.

D An electronic-controlled fuel injection pump has been used.
D A crankshaft position sensor has been used as the electronic-controlled fuel injection pump has been

used.

D An engine-ECU has been used as the electronic-controlled fuel injection pump has been used.

Removal and installation procedure of the engine-ECU is the same as for vehicles with 4G6 engine
or 6G7 engine.

D Due to the introduction of the electronic-controlled injection pump, the accelerator cable has been

abolished, and the accelerator pedal position sensor has been added.

GENERAL INFORMATION

The electronically-controlled fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuators
which operate according to control commands from the engine-ECU.
The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing control
and idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions which
make troubleshooting easier in the event that a problem develops.

FUEL INJECTION RATE CONTROL

The fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure that
the optimum amount of fuel is supplied to the engine in accordance with gradual changes in the engine
running condition.
Before fuel injection starts, the solenoid-type spill valve is on (energized), so that the valve is closed.
As the plunger turns and rises, fuel is sent out under pressure, and when the fuel flow rate reaches
the target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spill
valve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamber
and fuel injection is completed.

FUEL INJECTION TIMING CONTROL

The position of the injection pump timer piston is controlled so that fuel injection is carried out at the
optimum timing in accordance with the engine running condition.
The timer piston position is determined by duty control of the timing control solenoid valve which is located
in the line between the high-pressure chamber and the low-pressure chamber of the timer piston.
The fuel injection timing is advanced by increasing the control duty of the timing control solenoid valve.

IDLE SPEED CONTROL

Controlling the fuel injection rate in accordance with the engine running condition maintains the idle speed
at the optimum condition.

FUEL SYSTEM <4D5-step III> - General Information

SELF-DIAGNOSIS FUNCTION

D When an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates

to warn the driver.

D When an abnormality is detected in any of the sensors or actuators, a diagnosis code number

corresponding to the problem which occurred is output.

D The RAM data relating to the sensors and actuators which is stored in the engine-ECU can be read

using the MUT-II. In addition, the actuators can be force-driven under certain conditions.

OTHER CONTROL FUNCTIONS

1. Power Supply Control
When the ignition switch is turned to ON, the relay turns on and power is supplied to components
such as the timing control solenoid valve.

2. Intake Air Throttle Control
When the engine-ECU detects an abnormality in any of the sensors or actuators, the throttle valve
is half opened to restrict the amount of intake air in order to prevent the vehicle from running away.

3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF

4. Condenser Fan Motor Relay Control
Controls the condenser fan motor relay based on the A/C switch, engine coolant temperature and
vehicle speed input signals.

5. Intercooler Fan Motor Relay Control
Controls the intercooler fan motor relay based on the boost air temperature and vehicle speed input
signals.

6. Glow Control
Refer to GROUP 16.

7. EGR Control
Refer to GROUP 17.

13-3

13-4

FUEL SYSTEM <4D5-step III> - General Information

CONTROL SYSTEM DIAGRAM

L1. Pump speed sensor
L2. Crank angle sensor
L3. Engine coolant temperature sensor
L4. Boost pressure sensor
L5. Fuel temperature sensor
L6. Boost air temperature sensor
L7. Control sleeve position sensor
L8. Timer piston position sensor
L9. EGR valve position sensor
L10. Variable geometry control pressure sensor

D Accelerator pedal position sensor (main)
D Accelerator pedal position sensor (sub)
D Idle switch
D Power supply
D Ignition switch-IG
D Ignition switch-ST
D Vehicle speed sensor
D A/C switch
D A/C relay switch
D Injection volume adjusting ROM
D Barometric pressure sensor (ECU built-in)

l5 Throttle solenoid valve

3

l

EGR control
solenoid valve No. 1

Throttle
actuator

Engine­ECU

7

l

Variable geometry
solenoid valve

l1. GE actuator (electronic governor)
l2. Timing control valve
l3. EGR control solenoid valve No. 1
l4. EGR control solenoid valve No. 2
l5. Throttle solenoid valve
l6. Fuel cut solenoid valve
l7. Variable geometry solenoid valve

D Control relay
D A/C relay
D Condenser fan relay
D Intercooler fan relay
D Glow indicator lamp
D Glow plug relay
D Engine warning lamp
D Diagnosis output

Vacuum pump

Alternator

6 Boost air

L

temperature sensor

Catalytic converter

L9 EGR

valve position
sensor

EGR valve

Variable geometry
turbocharger

Variable
geometry
actuator

4 EGR control

l

solenoid
valve No. 2

L10 Variable geometry control

pressure sensor

To variable geome­try solenoid valve

To variable
geometry actuator

L4 Boost pressure

sensor

L3 Engine coolant

temperature sensor

l6 Fuel cut

l1 GE actuator

L2 Crank angle

sensor

L7 Control

sleeve
position
sensor

solenoid
valve

l2 Timing control

valve

L5 Fuel

temperature
sensor

L1 Pump speed

sensor

L8 Timerpiston

position
sensor

FUEL SYSTEM <4D5-step III>-Service Specifications/Sealant/Special Tools

p(p

g

p

p

p

p

SERVICE SPECIFICATIONS

Item Standard value

Fuel injection initial pressure kPa 14,710 - 15,490

Accelerator pedal position sensor reference voltage V 0.985 - 1.085

Accelerator pedal position sensor resistance kΩ 3.5 - 6.5

Boost air temperature sensor (Intake air temperature
sensor) resistance kΩ

Engine coolant temperature sensor resistance kΩ

Fuel cut solenoid valve resistance Ω 6.8 - 9.2

Timing control valve resistance Ω 10.8 - 11.2

Timer piston position sensor resistance Ω

Control sleeve position sensor resistance Ω

GE actuator (electronic governor) resistance Ω Connector terminals No. 6 - No. 10 0.64 - 0.72

Fuel temperature sensor resistance kΩ Connector terminals No. 7 - No. 11 1.4 - 2.6

Pump speed sensor resistance kΩ 1.36 - 1.84

Throttle solenoid valve resistance Ω 36 - 44

When the temperature is 20_C 2.3 - 3.0

When the temperature is 80_C 0.30 - 0.42

When the temperature is 20_C 2.1 - 2.7

When the temperature is 80_C 0.26 - 0.36

Connector terminals No. 1 - No. 2 160 - 168

Connector terminals No. 1 - No. 3 80 - 84

Connector terminals No. 2 - No. 3 80 - 84

Connector terminals No. 4 - No. 12 11.2 - 12.4

Connector terminals No. 4 - No. 8 5.6 - 6.2

Connector terminals No. 8 - No. 12 5.6 - 6.2

13-5

SEALANT

Item Specified sealant

Engine coolant temperature sensor 3M Nut Locking Part No. 4177 or equivalent

SPECIAL TOOL

Tool Number Name Use

MB991502 MUT-II sub

assembly

MB991529 Diagnosis code

check harness

MB991348 Test harness set D Boost pressure sensor check

Electronically controlled fuel in­jection system check

Diagnosis code reading

D Variable geometry control

pressure sensor check

13-6

Tool UseNameNumber

FUEL SYSTEM <4D5-step III> - Special Tools

MB991658 Test harness set D APS adjustment

D Inspection using an analyzer

MD998478 Test harness

(3-pin, square)

MB990767 End yoke holder Holding the fuel injection pump

MD998719 Crankshaft pulley holder

pin

MD998388 Injection pump sprocket

puller

D Crank angle sensor check
D Inspection using an analyzer

sprocket

Fuel injection pump sprocket
removal

FUEL SYSTEM <4D5-step III> - Troubleshooting

Engine warning lamp
(check engine lamp)

13-7

TROUBLESHOOTING

STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING

Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.

NOTE
When replacing the engine-ECU, replace immobilizer-ECU
and ignition key as well at the same time.

DIAGNOSIS FUNCTION

ENGINE WARNING LAMP (CHECK ENGINE LAMP)

Engine warning lamp is lit when any abnormality takes place
in the item related to electronically controlled fuel injection
system shown in the following table.
If the malfunction indicator lamp has been on and/or is lit
when the engine is in operation, check the diagnosis output.

Engine warning lamp check items

Accelerator pedal position sensor (main)

Accelerator pedal position sensor (sub)

Boost pressure sensor (Boost sensor)

Crank angle sensor

Control sleeve position sensor

Timer piston position sensor

Throttle solenoid valve

GE actuator

Variable geometry control pressure sensor

Barometric pressure sensor

Timing control valve

Idle switch

Engine-ECU

METHOD OF ERASING AND ERASING DIAGNOSIS
CODES

Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.

INSPECTION USING MUT-II DATA LIST AND
ACTUATOR TESTING

1. Carry out inspection by means of the data list and the
actuator test function.
If there is an abnormality, check and repair the chassis
harnesses and components.

2. After repairing, re-check using MUT-II and check that
the abnormal input and output have returned to normal
as a result of the repairs.

3. Erase the diagnosis code memory.

4. Remove the MUT-II.

5. Start the engine again and carry out a road test to confirm
that the problem has disappeared.